Coated Lens Manufacturing Using Electromagnetic Pulse Curing
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Solution Overview
Problem
Conventional methods for curing coating precursor materials on optical lens substrates are either time-consuming or require adjustments specific to each material, leading to suboptimal mechanical, optical, and functional properties, and often involve the use of photo-initiators that can affect the properties of the coating.
Innovation Solution
A method using a single electromagnetic pulse to rapidly convert coating precursor materials into coatings, allowing for adjustable mechanical, optical, and functional properties within a short process duration, without the need for thermal precuring and with reduced process time compared to conventional thermal curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermal curing methods are used to convert coating precursor materials into coatings, then the coating can be cured and hardened, but the process duration is extended and the temperature must be maintained below the threshold temperature of the optical lens substrate
Solution Approach 1:
The patent replaces the conventional thermal curing system with an electromagnetic radiation system. Instead of using heat (thermal energy) to cure the coating precursor material, the invention applies electromagnetic radiation (such as UV light or other wavelengths) to initiate and accelerate the curing process. This substitution allows the coating to be converted into a hardened state without prolonged exposure to temperatures that could affect the optical lens substrate, thereby reducing process duration while maintaining coating quality.
Solution Approach 2:
The patent changes the curing parameters by using electromagnetic radiation with specific wavelengths and intensities rather than thermal parameters. By adjusting the electromagnetic radiation parameters (wavelength, intensity, exposure time), the curing process can be optimized to achieve complete hardening of the coating precursor material in a shorter time frame, without exceeding the threshold temperature of the optical lens substrate.
2Object-affected harmful factors
If mild baking conditions are applied to cure the coating precursor material below the threshold temperature, then the lens properties are preserved, but the time required to dry and cure the coating is increased
Solution Approach 1:
The patent substitutes the thermal curing mechanism with electromagnetic radiation curing. This replacement eliminates the need for prolonged mild baking conditions, as electromagnetic radiation can initiate rapid photopolymerization or other curing reactions in the coating precursor material. The process achieves complete curing without subjecting the optical lens substrate to extended thermal exposure, thus preserving lens properties while significantly reducing curing time.
Solution Approach 2:
The patent employs periodic or pulsed electromagnetic radiation to cure the coating precursor material. By delivering radiation in controlled pulses or cycles, the system achieves thorough curing through cumulative energy input while allowing brief intervals that prevent excessive heat buildup. This periodic action ensures the optical lens substrate remains within safe temperature limits throughout the process, avoiding property deterioration while maintaining efficient curing times.
3Productivity
If photo-initiators are added to enable UV curing, then the curing process can be initiated by UV light, but the photo-initiators may affect the properties of the coating
Solution Approach 1:
The patent extracts or eliminates the photo-initiator component from the coating precursor material formulation. By removing the need for photo-initiators, the invention avoids the potential negative effects these additives may have on coating properties such as optical clarity, mechanical strength, or chemical stability. The curing process is instead initiated through alternative mechanisms that do not require foreign chemical agents, thereby maintaining the intrinsic properties of the coating material while still achieving rapid curing through electromagnetic radiation.
Solution Approach 2:
The patent changes the chemical composition parameters of the coating precursor material by formulating it to be curable without photo-initiators. This may involve using monomers or oligomers with inherent photoreactivity, or designing the coating chemistry to undergo curing through direct electromagnetic radiation absorption by the coating material itself rather than through photo-initiator mediation. This parameter change eliminates the compromise between curing speed and coating quality.
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 significantly reduces the total process duration for achieving desired mechanical, optical, and functional properties of coated lenses, offering a broader range of target values and flexibility in property adjustment without compromising the lens's properties, and eliminates the need for photo-initiators.
Implementation Method 1
converting the at least one coating precursor material into at least one coating by applying at least one electromagnetic pulse to the at least one coated optical lens substrate
Data Source
AI summary
A method for manufacturing a coated lens by applying at least one single electromagnetic pulse to convert a coating precursor material into at least one coating. The electromagnetic pulse is delivered to the coating precursor material applied on a surface of an uncoated or precoated optical lens substrate. The at least one single electromagnetic pulse is applied from an electromagnetic source such as a flash lamp, a halogen lamp, a directed plasma arc, a laser, a microwave generator, an induction heater, an electron beam, a stroboscope, or a mercury lamp.