Self-Stratified Lens Coating Preserves Microlens Power Against Abrasion
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Solution Overview
Problem
Existing optical articles with microstructures, such as microlenses, suffer from a reduction or impairment of their optical effects when covered by conventional abrasion-resistant coatings due to changes in curvature, leading to altered light paths and reduced mechanical protection.
Innovation Solution
A self-stratified coating composed of two distinct layers, each with specific refractive indices, is applied to encapsulate the microstructures, maintaining the original curvature and providing abrasion resistance without impairing optical functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional abrasion-resistant coating is applied to cover the microlenses, then the lens surface is protected against scratches, but the optical power of the microlenses is reduced or impaired due to changes in curvature
Solution Approach 1:
The patent changes the refractive index parameter of the coating material to match or exceed that of the microlens material. This parameter change allows the coating to protect the microlens surface without altering the light refraction pattern, thereby maintaining the optical power while providing scratch resistance.
Solution Approach 2:
The patent uses composite coating materials that combine high refractive index properties with abrasion resistance. By selecting materials with specific optical and mechanical properties, the coating simultaneously protects against scratches and maintains the microlens optical characteristics.
2Manufacturing precision
If the thickness of the abrasion-resistant coating is reduced to minimize alteration of microlens power, then the optical effect is better preserved, but the protection against scratching is highly reduced
Solution Approach 1:
Instead of reducing thickness, the patent changes the refractive index parameter of the coating material. This allows the use of a sufficiently thick coating for mechanical protection while minimizing optical interference, as the matched refractive indices reduce refraction at the coating-microlens interface.
3Object-affected harmful factors
If a coating is applied over the microlenses, then the surface is protected, but the free surface of the coating exhibits local deformations that alter light paths
Solution Approach 1:
The patent changes the refractive index of the coating material to match the microlens material. This parameter change eliminates refraction at the interface, preventing light path alterations even when the coating surface has deformations over the microlenses.
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 solution ensures that the optical elements retain their original power and shape while offering enhanced protection against scratches and abrasions, facilitating the application of additional functional coatings.
Implementation Method 1
the first layer LSSC1 being constituted of one of the at least two resins resin compositions, resin composition 1 after curing, cured resin 1, said cured resin 1: showing a refractive index nSSC1 being lower than the refractive index nm of the at least one or each optical element such that the difference nm−nSSC1 is greater than 0.045
Data Source
AI summary
Optical articles comprising a base-lens substrate having at least one optical element or a plurality of optical elements protruding from a surface thereof, and the method for forming such optical articles. The optical articles comprise the base-lens substrate, a protective layer protecting said substrate, and at least one optical element or a plurality of optical elements, wherein the protective layer does not reduce or suppress the optical effect of the optical element and ensures abrasion resistance.