Differentiate Coating Deposition for Optical Lenses with Microstructures
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Solution Overview
Problem
Existing methods for coating optical articles with microstructures often result in shape distortion and impaired optical effects, as standard coating techniques do not account for local effects induced by microstructures.
Innovation Solution
A method involving differentiate coating deposition, where the parameters of coating deposition, such as presence, composition, and thickness of the coating, are varied according to the location relative to optical elements, allowing for selective modification of optical and mechanical properties without distorting the shape of the microstructures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standard coating methods (spin coating or dip coating) are used to coat the lens surface, then the coating process is simple and fast, but the coating exhibits thickness variation and distorts the shape of microstructures
Solution Approach 1:
The coating process is divided into multiple sequential steps: first applying a base coating layer, then selectively removing coating material from microstructure regions, and finally applying additional coating layers only where needed. This segmentation allows different regions of the lens to receive appropriate coating treatment, preserving microstructure shapes while achieving uniform overall coverage.
Solution Approach 2:
The patent applies different coating parameters (thickness, material composition, application method) to different regions of the lens surface. Specifically, microstructure regions receive minimal or no coating to preserve their shape, while surrounding areas receive full coating for protective and optical properties. This local differentiation resolves the contradiction between uniform coating and microstructure preservation.
2Strength
If a continuous coating layer is applied over the entire lens surface, then the mechanical properties of the lens are improved, but the optical effect of microstructures is impaired or disappears
Solution Approach 1:
The patent selectively removes coating material from regions containing microstructures after initial coating application. This extraction ensures that microstructures remain exposed and functional while the surrounding lens surface maintains protective coating for mechanical strength. The result is a coating distribution that preserves optical functionality while providing mechanical protection where needed.
Solution Approach 2:
The patent performs preliminary coating application followed by selective removal rather than attempting direct precise coating. This preliminary action allows the coating to be applied uniformly first, then the excess material in microstructure regions is removed, ensuring both mechanical strength from the base coating and optical function from the exposed microstructures.
3Manufacturing precision
If coating parameters are varied according to location relative to optical elements, then the optical and mechanical properties can be selectively modified without distorting microstructures, but the coating process becomes more complex
Solution Approach 1:
The patent employs dynamic adjustment of coating parameters during the coating process. The coating system dynamically modifies application speed, coating thickness, and material flow based on real-time detection of microstructure locations. This dynamic control enables precise selective coating while maintaining process automation, balancing complexity with manufacturing precision.
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 method effectively improves the mechanical properties of lenses with optical elements while preserving their optical properties, and allows for selective modification of optical properties of the base lens substrate without affecting the optical elements.
Implementation Method 1
a method involving differentiate coating deposition, where the parameters of coating deposition, such as presence, composition, and thickness of the coating, are varied according to the location relative to optical elements
Data Source
Figure 1a~1c
Figure 2
Figure 3a~3c
AI summary
It is disclosed a method for manufacturing an optical article, comprising: - providing a base-lens substrate (10) having opposite first and second lens surfaces, and at least one optical element (20) disposed on the second lens surface or embedded within the base-lens substrate, each optical element having a maximum height that is less than or equal to 0.5 mm, and a maximum width that is less than or equal to 2.0 mm, and - performing a differentiate coating deposition on the second lens surface, wherein the second lens surface comprises at least two areas (Z1, Z2) defined according to their relative position with respect to at least one optical element, and the differentiate coating deposition comprises changing at least one parameter of the coating deposition according to the considered area.