Resin Diffusing Component Imprinting to Prevent Delamination
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Solution Overview
Problem
Conventional diffusing components face issues such as delamination between dissimilar materials, poor fluidity of thermoplastic materials, difficulty in forming larger sizes, residual air in microstructures, uneven shrinkage, and poor optical properties due to high temperature processes, leading to instability and increased costs.
Innovation Solution
An integrally formed resin diffusing component manufactured through a light-curable liquid resin material using imprinting without high temperature injection molding, ensuring stable bonding and high replication capability, with a manufacturing process that avoids delamination and maintains optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass substrate with adhesion-promoting layer and resin microlens layer is used, then optical properties are achieved, but delamination occurs due to bonding force instability between dissimilar materials
Solution Approach 1:
The patent uses a resin substrate instead of glass substrate, making the substrate material and microlens layer material both resin-based. This homogeneity ensures stable bonding between layers without delamination, while maintaining the required optical properties for diffusing light.
Solution Approach 2:
The patent employs a composite structure where the substrate and microlens layer are both made of resin materials with complementary properties. The substrate provides mechanical support and optical transmission, while the microlens layer provides light diffraction, creating a stable composite that avoids the bonding issues of dissimilar materials.
2Ease of manufacture
If conventional injection molding process is used to form microlens layer, then integration is achieved, but poor fluidity of molten resin material makes it difficult to form larger sizes
Solution Approach 1:
The patent changes the physical state parameter of the resin material from molten (liquid) to liquid-curable state. This allows the material to maintain fluidity for easy molding while avoiding the temperature-related issues of conventional injection molding, enabling formation of larger components without difficulty.
Solution Approach 2:
The patent replaces the thermal-mechanical injection molding process with a chemical-curing based forming process. The liquid-curable resin material is poured into the mold and cured in place, eliminating the need for high-temperature melting and injection, thus solving the fluidity problem for larger components.
3Ease of manufacture
If molten resin material is used in injection molding, then forming process is achieved, but residual air remains in microstructures due to poor replication ability
Solution Approach 1:
The patent changes the material state from molten to liquid-curable, allowing the material to flow more effectively into fine microstructures without air entrapment. The liquid-curable resin maintains good fluidity to fill complex mold cavities completely, ensuring high-quality replication of micro-lens structures without residual air.
4Productivity
If high temperature injection molding is used, then forming speed is improved, but material yellowing and optical property degradation occur
Solution Approach 1:
The patent replaces the high-temperature thermal process with a ambient-temperature chemical curing process. The liquid-curable resin material cures at room temperature through chemical reaction, eliminating the high-temperature exposure that causes yellowing and optical degradation, while maintaining efficient forming speed.
Solution Approach 2:
The patent changes the process temperature parameter from high temperature to ambient temperature. This parameter change eliminates thermal damage to the resin material, preventing yellowing and optical property degradation, while the curing process maintains sufficient forming speed for production.
5Strength
If glass substrate is used for diffusing component, then structural strength is achieved, but fragility requires additional sensors for safety detection, increasing cost
Solution Approach 1:
The patent uses resin substrate instead of glass, creating a material system that is inherently tougher and less fragile. This eliminates the need for additional safety sensors to detect breakage, simplifying the device while maintaining sufficient structural strength for the application.
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 resin diffusing component achieves reliable transmittance and optical properties, reduces material breakage, and lowers production costs by eliminating the need for additional sensors, while maintaining energy efficiency and high replication capability.
Implementation Method 1
performing a light-curing treatment on the resin material in a liquid state to obtain the light-cured resin material as the diffusing component
Data Source
AI summary
An integrally formed resin diffusing component, a diffractive optical element (DOE), and a manufacturing method thereof. A resin material in a liquid is spread between a supporting plate and a mold of a manufacturing apparatus, pressed, and light-cured, thus producing the light-cured resin diffusing component or the DOE. The diffusing component or the DOE is integrally formed, the phenomenon of delamination is prevented from occurring, and the need for high-temperature injection molding and cooled forming is obviated.