Resilient Support Transfer for Curved Polarizing Layers
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Solution Overview
Problem
Current methods for applying polarizing films on curved surfaces, such as eyeglasses, result in reduced polarizing efficiency due to misalignment of dichroic compounds, making commercially available polarized eyeglasses non-existent or excessively expensive to produce.
Innovation Solution
A method involving a resilient support with a preformed polarizing layer, which is warped and then transferred onto a curved optical element, maintaining the orientation of dichroic compounds and ensuring high polarizing efficiency through an adhesive layer and controlled stress absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polarizing film is applied onto a curved surface, then the optical element gains polarizing effect, but the polarizing efficiency is significantly degraded due to misalignment of dichroic compounds
Solution Approach 1:
The polarizing film is preformed on a planar resilient support before application to the curved optical element. This preliminary formation allows the dichroic compounds to be properly oriented and aligned while the support is still planar, preventing misalignment that would occur if the film were applied directly to the curved surface.
Solution Approach 2:
A resilient support acts as an intermediary carrier between the polarizing film and the curved optical element. The support maintains the film in a planar state during handling and application, then transfers it to the curved surface where it conforms to the shape without compromising the orientation of dichroic compounds.
2Adaptability or versatility
If the polarizing film is stretched to conform to a curved surface, then the film adapts to the surface shape, but the dichroic compounds become misaligned and polarizing efficiency decreases
Solution Approach 1:
The resilient support is made of a flexible material that can conform to curved surfaces while maintaining its ability to support the polarizing film in a planar state. This flexibility allows the support to adapt to the curved optical element without causing the dichroic compounds to misalign.
Solution Approach 2:
The film is preformed on the planar support before application, establishing proper orientation of dichroic compounds while the support is still planar. The support then conforms to the curved surface during application, but the film's orientation is already established and protected by the resilient support.
3Ease of manufacture
If traditional methods are used to apply polarizing films on curved surfaces, then the process can be completed, but the production cost becomes excessively high and quality requirements cannot be met
Solution Approach 1:
The resilient support serves as an intermediary that enables the polarizing film to be applied to curved surfaces using standard planar processing techniques. This intermediary approach simplifies the manufacturing process, reduces costs, and maintains high quality by preventing defects associated with direct application methods.
Solution Approach 2:
The polarizing film is prepared and preformed on a planar resilient support using standard planar processing techniques before application to the curved surface. This preliminary action allows for quality control and defect prevention in a controlled environment, then the preformed film is transferred to the curved optical element.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method allows for reliable, cost-effective production of polarized optical elements with maintained polarizing efficiency, as indicated by an order parameter of 0.8 or higher, ensuring defect-free and high-quality polarizing effects.
Implementation Method 1
The resilient support acts for preventing that disordered stresses modify a structure of the polarizing layer
Implementation Method 2
the optical element surface is coated with an adhesive layer prior to step /c/
Implementation Method 3
Such films may contain dichroic compounds which are capable of absorbing a light radiation when a polarization direction of the light is parallel to an angular orientation of the compounds
Data Source
Figure 1
Figure 2~4
AI summary
A method for providing a polarizing layer (32) on a curved optical element (20) comprises using a support for temporarily carrying the polarizing layer. The support is resilient so that it can conform with the curved surface of the optical element. An adhesive layer is first deposited on the optical element surface, and the polarizing layer is applied on the adhesive layer by pressing the support. Then, the support is peeled so that the polarizing layer remains on the optical element. The method is compatible with high efficiency polarizing layer based on dichroic compounds.