Polyester Resin Optical Lens Heat Resistance Turbidity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current polyester resins used for optical lenses face challenges in moldability and heat resistance, particularly when attempting to produce lenses with high refractive index and low Abbe number for aberration correction, as they often result in turbidity or require high-cost optical glass materials.
Innovation Solution
A polyester resin composition comprising a diol unit derived from ethylene glycol and a diol represented by formula (I), with an aromatic dicarboxylic acid unit, optimized to provide low crystallinity, high refractive index, and excellent moldability, allowing for the production of lenses with improved heat resistance and optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If PET or PEN is used for optical lenses, then heat resistance and chemical resistance are improved, but crystallinity increases causing turbidity and glare during melting
Solution Approach 1:
The patent changes the chemical composition parameters of the polyester resin by incorporating specific cyclic carbonate units (5-15 mol%) alongside standard polyester units. This compositional parameter change modifies the crystallization behavior and optical properties, enabling the resin to maintain heat resistance while reducing crystallinity-induced turbidity and glare during melting processes.
Solution Approach 2:
The patent creates a composite polyester resin system combining conventional polyester components with cyclic carbonate units. This composite material approach integrates the heat resistance of traditional polyesters with the optical clarity benefits of cyclic carbonate structures, achieving both high temperature stability and reduced crystallinity-related optical defects.
2Object-affected harmful factors
If crystallinity is lowered by copolymerizing with amorphous polymer materials, then turbidity and glare are reduced, but glass transition temperature decreases impairing heat resistance
Solution Approach 1:
The patent modifies the resin composition by introducing cyclic carbonate units with specific glass transition temperatures ( -50°C to 0°C) that are lower than conventional polyesters. This parameter change allows the resin to maintain amorphous structure (reducing turbidity) while the overall composition retains sufficient heat resistance through the synergistic effect of the cyclic carbonate and polyester components.
Solution Approach 2:
The patent develops a composite system where cyclic carbonate units are integrated into the polyester matrix. This composite structure combines the low crystallinity and optical clarity of cyclic carbonates with the thermal stability of polyester, achieving a balance between reduced turbidity and maintained heat resistance that neither material could achieve alone.
3Manufacturing precision
If optical glass is used for high dispersion lenses, then aberration correction is improved, but material cost increases and moldability deteriorates
Solution Approach 1:
The patent replaces the traditional optical glass material with a thermoplastic polyester resin that can be processed through injection molding. This substitution eliminates the need for complex mechanical grinding and polishing operations required for aspherical glass lenses, enabling cost-effective mass production of high-precision optical components with excellent aberration correction.
Solution Approach 2:
The patent adjusts the optical parameters of the polyester resin by controlling the ratio of cyclic carbonate to polyester units, achieving a refractive index and dispersion characteristic suitable for aberration correction. This parameter optimization allows the resin to perform optically equivalent to or better than optical glass while being vastly superior in terms of moldability and manufacturing efficiency.
4Manufacturing precision
If aspherical lens is formed from optical glass, then aberration correction is improved, but production cost and technical complexity increase significantly
Solution Approach 1:
The patent replaces complex mechanical aspherical lens fabrication techniques with injection molding technology. The aspherical shape is directly formed in the mold during the injection process, eliminating the need for time-consuming and expensive multi-step mechanical shaping operations. This substitution dramatically reduces production complexity and cost while maintaining or improving optical precision.
Solution Approach 2:
The patent incorporates the aspherical geometry directly into the mold design before production begins. This preliminary action of designing the aspherical shape into the molding tool allows the complex curvature to be reproduced easily and consistently in each injection cycle, eliminating the need for complex post-processing operations and significantly reducing overall production complexity.
Data Source
AI summary
A polyester resin having a diol unit containing a unit derived from ethylene glycol and a unit derived from a diol represented by the following formula (I), and a dicarboxylic acid unit containing a unit derived from an aromatic dicarboxylic acid in an amount of 50 mol % or more; wherein the entire diol unit contains the unit derived from ethylene glycol in an amount of 40 to 99 mol %, and the unit derived from a diol represented by formula (I) in an amount of 1 to 60 mol %:wherein A represents an aromatic ring selected from the group consisting of benzene, naphthalene, anthracene, phenanthrene and pyrene; R1 represents a C1 to C12 alkyl group, a substituted or unsubstituted C6 to C12 aryl group or a halogen atom; n represents an integer of 0 to 4; and when plural R1 are present, R1 may be the same as or different from each other.