Coating Mask Rib Structure for Mark-Free Lens Black Films
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Solution Overview
Problem
Existing coating devices with ribbed plates cause ribbed marks on black films coated on lenses, leading to incomplete coatings and unsolved imaging issues like speckles from stray light.
Innovation Solution
A coating device with a modified coating mask featuring a bearing unit with ribbed plates of specific dimensions and configurations, including annular grooves and through holes, reduces the ribbed area and allows for a second coating step to minimize ribbed marks, ensuring a complete and mark-free coating film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rib plate is used in the coating device, then the coating structure is simple and easy to manufacture, but ribbed marks are caused on the black film leading to incomplete coating
Solution Approach 1:
The bearing unit is divided into multiple segments including a first bearing portion, a second bearing portion, and multiple ribbed plates. This segmentation allows the coating area to be divided into multiple sub-areas with different ribbed plate configurations, enabling precise control over coating deposition while maintaining structural simplicity.
Solution Approach 2:
Different regions of the coating area have different ribbed plate configurations. The first ribbed plate has a first width while the second ribbed plate has a second width different from the first. This local variation in ribbed plate dimensions allows different parts of the coating area to receive appropriate coating thickness, eliminating ribbed marks while maintaining overall coating completeness.
2Strength
If a ribbed plate with large width is used, then the structural strength is improved, but the ribbed area increases causing more visible ribbed marks
Solution Approach 1:
The ribbed plates are designed with varying widths at different locations. The first ribbed plate has a first width and the second ribbed plate has a second width, creating local variations in structural strength distribution. This allows each region to have sufficient strength while the overall ribbed area is optimized to minimize visible marks on the coating film.
Solution Approach 2:
The solution addresses the width issue by introducing a second dimension - the longitudinal position along the coating area. Instead of uniformly increasing width throughout, the ribbed plates have different widths at different longitudinal positions, allowing strength optimization in critical areas while minimizing ribbed area in other regions.
3Manufacturing precision
If the ribbed area is reduced to minimize ribbed marks, then the coating smoothness is improved, but the structural support may be insufficient
Solution Approach 1:
The bearing unit employs ribbed plates with different widths at different locations to achieve local optimization. Areas requiring structural support have wider ribbed plates, while areas where smooth coating is critical have narrower or no ribbed plates. This local differentiation maintains structural integrity while minimizing overall ribbed area to achieve coating smoothness.
Solution Approach 2:
The bearing unit is segmented into multiple functional zones with different ribbed plate configurations. This segmentation allows the structure to provide support where needed while presenting minimal ribbed area to the coating process in critical regions, thereby maintaining both structural support and coating smoothness.
Data Source
AI summary
A coating mask for bearing and covering a portion of a to-be-plated component includes at least one bearing unit. Each bearing unit includes a first bearing portion, a second bearing portion, and at least two ribbed plates. An annular groove is defined between the first bearing portion and the second bearing portion. The at least two ribbed plates are formed in the annular groove. Each of the at least two ribbed plates includes a first ribbed portion and a second ribbed portion connected to the first ribbed portion. The first ribbed portion is connected to the second bearing portion; the second ribbed portion is connected to the first bearing portion. An included angle θ1 is defined by the first ribbed portion and the second ribbed portion, and θ1 is an obtuse angle. The disclosure also relates to a coating device.