Rod Lens Array with Phenol-Based Curing Agent
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Solution Overview
Problem
Conventional rod lens arrays face issues with optical performance, precision, and weatherability due to high viscosity and thixotropy of epoxy resins, leading to irregular lens arrangement, incomplete filling, and adhesive failures, especially with small lens diameters, resulting in reduced optical quality and increased production time.
Innovation Solution
The use of glass fiber reinforced epoxy resin side panels with a phenol-based curing agent and an additional reaction type silicone resin containing monodispersed spherical organic fillers, which reduces surface unevenness, improves lens arrangement, and enhances optical properties by controlling viscosity and minimizing curing shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy resin is used to fill spaces between lens elements, then the lens elements can be integrally formed, but the high viscosity and thixotropy cause irregular lens arrangement and incomplete filling
Solution Approach 1:
The patent changes the viscosity parameter of the epoxy resin by adding specific additives and controlling the resin composition to reduce thixotropy and improve flowability, enabling complete filling while maintaining lens arrangement precision
Solution Approach 2:
The patent uses a composite resin system combining epoxy resin with specific fillers and additives to achieve both integral formation and precise lens arrangement, creating a material that maintains structural integrity while improving flow characteristics
2Stability of the object's composition
If high viscosity epoxy resin is used, then the resin can maintain shape, but the filling time increases and productivity decreases
Solution Approach 1:
The patent optimizes the viscosity parameter of the epoxy resin by adjusting the resin-to-hardener ratio, adding flow modifiers, and controlling temperature to achieve the optimal balance between shape maintenance and filling speed
Solution Approach 2:
The patent performs preliminary mixing and pre-heating of the resin and hardener components before filling to ensure optimal viscosity and reactivity, enabling faster and more complete filling while maintaining structural integrity
3Reliability
If conventional curing agents are used, then the resin can be cured, but calcination treatment is required to stabilize quality
Solution Approach 1:
The patent changes the chemical composition of the curing system by using advanced curing agents that eliminate the need for calcination, achieving complete curing and stabilization in a single step
Solution Approach 2:
The patent extracts and eliminates the calcination step from the manufacturing process by using curing agents that provide both curing and stabilization functions, simplifying the overall process
4Stability of the object's composition
If glass fiber reinforced epoxy resin is used for side panels, then thermal expansion coefficient matches lens material, but waterdrop-shaped extraneous substances form on lens surface after weatherability test
Solution Approach 1:
The patent uses a composite material system combining glass fiber reinforced epoxy resin with specific weathering-resistant additives and surface treatment agents to maintain thermal expansion matching while preventing waterdrop formation
Solution Approach 2:
The patent converts the potential harm of waterdrop formation into a benefit by using the same resin system to create a water-repelling surface treatment that prevents extraneous substance accumulation while maintaining structural integrity
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
This approach results in improved lens array productivity, precision, and optical performance, with reduced surface irregularities and adherence issues, enabling high-quality image formation even with small lens diameters, and eliminates the need for calcination treatments.
Implementation Method 1
a phenol-based curing agent which is used as a curing agent of the epoxy resin
Implementation Method 2
an additional reaction type silicone resin which contains a spherical organic filler monodispersed and whose viscosity is adjusted
Implementation Method 3
an additional reaction type silicone resin which contains a spherical organic filler monodispersed
Data Source
AI summary
In a rod lens array having a structure in which a plurality of rod lens elements are arranged between two side panels and a resin is filled and cured in spaces between the rod lens elements to be integrally formed, the side panels are made of a glass fiber reinforced epoxy resin and a phenol-based curing agent is used as a curing agent of the epoxy resin. In detail, the curing agent is exemplified by a phenol-based curing agent including a tris-hydroxyphenyl-methane skeleton.