Thin Glass Lens Press Forming Fusion Prevention
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Solution Overview
Problem
Conventional press forming methods struggle to produce thin lenses with high shape accuracy and low surface roughness due to glass fusion bonding to forming dies, which complicates the production of lenses thinner than 0.5 mm, leading to shape and surface accuracy issues and increased costs.
Innovation Solution
A glass composition containing 20-22% B2O3, 30-40% La2O3, and 19-25% ZnO, expressed as wt %, is used to prevent glass fusion bonding during press forming, allowing for the stable production of thin lenses with improved shape accuracy and reduced surface roughness, eliminating the need for additional pretreatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional press forming methods are used to produce thin lenses, then lens thickness is reduced, but glass fusion bonding occurs on the forming die
Solution Approach 1:
The patent changes the chemical composition parameters of the glass material by specifying precise ranges of B2O3 (20-22%), La2O3 (30-40%), and ZnO (19-25%). This compositional parameter change fundamentally alters the glass's interaction with the forming die, preventing fusion bonding while enabling thin lens production without requiring additional pretreatment layers or processes.
2Manufacturing precision
If glass fusion bonding is prevented by surface treatments, then shape accuracy is improved, but the number of production steps increases
Solution Approach 1:
The patent extracts and eliminates the need for separate surface treatment steps (such as applying release agents or creating protective layers) by incorporating the anti-fusion properties directly into the base glass composition. The specified glass formula inherently prevents fusion bonding, allowing the process to proceed directly to press forming without additional pretreatment operations.
Solution Approach 2:
The patent merges the function of preventing fusion bonding with the base glass material itself, rather than treating it as a separate requirement. The glass composition integrates multiple oxides that work together to provide both optical performance and anti-fusion properties, combining material functionality into a single unified composition.
3Manufacturing precision
If glass fusion bonding is prevented by surface treatments, then surface roughness is reduced, but production cost increases
Solution Approach 1:
The patent removes the need for separate surface treatment processes (such as applying release coatings or performing surface modifications) by embedding the anti-fusion and surface quality properties directly into the glass composition. The specified oxide ratios create a glass that naturally resists fusion bonding and produces low surface roughness, eliminating additional cost-intensive steps.
4Manufacturing precision
If forming die surface accuracy is maintained, then lens shape accuracy is improved, but forming die maintenance frequency increases
Solution Approach 1:
The glass composition acts as its own protective agent during forming. The specific combination of B2O3, La2O3, and ZnO creates a glass that inherently prevents fusion bonding to the forming die surface, eliminating the need for external protective layers or frequent die maintenance. The glass itself provides the necessary anti-adhesion properties.
Solution Approach 2:
By changing the chemical composition parameters of the glass to include specific ranges of B2O3 (20-22%), La2O3 (30-40%), and ZnO (19-25%), the patent fundamentally alters how the glass interacts with the forming die. This compositional change reduces adhesion and fusion bonding, thereby preserving forming die surface accuracy and reducing maintenance frequency.
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 glass composition effectively prevents glass fusion bonding to forming dies, enabling the mass production of thin lenses with high shape accuracy and low surface roughness, reducing the size of image pickup optical systems and maintaining forming die integrity, thus enhancing productivity and reducing maintenance needs.
Implementation Method 1
use of the glass containing components within the range as mentioned above can prevent the glass from fusion bonding to a forming die
Implementation Method 2
transferring the surface shape of the forming die to the preformed body by heating and pressing the preformed body
Implementation Method 3
transferring the surface shape of the forming die to the preformed body by heating and pressing the preformed body
Data Source
AI summary
A concave lens as an optical component is made of glass containing 20 to 22% of B2O3, 30 to 40% of La2O3, and 19 to 25% of ZnO, expressed as wt %. The concave lens has a thickness t1 in its center portion of 0.5 mm or less, and a ratio (W/t1) of a diameter W with respect to the thickness t1 of 24 or more. The concave lens can be produced suitably by press forming.