Variable-Focus Lens Manufacturing via Adhesive Ring Formation
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Solution Overview
Problem
Conventional manufacturing methods for varifocal lenses risk damaging the lens and creating spaces within the varifocal section due to local stress and inadequate adhesive distribution, leading to decreased performance.
Innovation Solution
A method involving inkjet application of non-overlapping liquid crystal grains and adhesive agent coating with an adhesive agent-free region around the liquid crystal holder, allowing the adhesive agent to be drawn to the boundary periphery without pressing force, ensuring proper bonding without damaging the liquid crystal holder or generating spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the upper substrate is tightly pressed to the varifocal section to prevent adhesive from entering the varifocal section, then adhesive contamination is avoided, but local stress damages the lens and creates spaces within the varifocal section
Solution Approach 1:
The substrate surface is divided into two distinct regions: an adhesive application region where adhesive is applied, and a varifocal section where no adhesive is applied. This segmentation prevents adhesive from entering the varifocal section while eliminating the need for tight pressing that would damage the lens.
Solution Approach 2:
Different surface regions are given different properties: the adhesive application region is prepared to receive adhesive, while the varifocal section is kept adhesive-free. This local differentiation allows adhesive to be contained in specific areas without compromising the varifocal section integrity.
2Strength
If adhesive agent is introduced through holes in the upper substrate to ensure complete coverage, then bonding is improved, but adhesive enters the varifocal section and damages the lens
Solution Approach 1:
The problematic feature of introducing adhesive through holes that could lead to the varifocal section is removed. Instead, adhesive is applied only to the adhesive application region, which is spatially separated from the varifocal section, eliminating the risk of adhesive intrusion while maintaining bonding strength.
3Manufacturing precision
If pressure is applied during substrate joining to ensure adhesive distribution, then bonding uniformity is improved, but local stress damages the liquid crystal holder
Solution Approach 1:
Adhesive is pre-applied to the adhesive application region before substrate joining, eliminating the need for pressure-induced adhesive distribution. This preliminary action ensures uniform adhesive placement without requiring pressing forces that would damage the liquid crystal holder.
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
Prevents performance degradation by ensuring the adhesive agent forms a ring-shaped region around the liquid crystal holder, maintaining the integrity of the varifocal lens without damaging the liquid crystal holder or creating internal spaces, thus maintaining lens functionality.
Implementation Method 1
After this, pressure is restored to the sealed vessel, so that the adhesive agent is drawn in to the boundary at the outer periphery of the liquid crystal holder
Data Source
AI summary
This manufacturing method comprises an adhesive agent coating step of coating the front of a first substrate (13) and/or the rear of a second substrate (15) with an adhesive agent (43), leaving an adhesive agent-free region (47) that surrounds a liquid crystal holder (19); a pressure reduction step of reducing the pressure inside a sealed vessel that holds the first substrate (13) and the second substrate (15), with respect to atmospheric pressure; an affixing step of affixing the second substrate (15) over the front of the first substrate (13) under the reduced pressure produced in the pressure reduction step; a standby step of continuing the affixed state between the first substrate (13) and the second substrate (15) for a specific length of time under the reduced pressure produced in the pressure reduction step after the substrates have been affixed; and a pressure restoration step of restoring the pressure of the sealed vessel after the standby step.