Gravity-Fed Fixture Transfer Rail for Optical Coating Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for applying optical coatings to optical lenses, such as eyewear, face challenges in efficiently transferring lenses between multiple deposition chambers without physical contact or contamination, particularly when sequential application of multiple layered coatings is required.
Innovation Solution
A physical vapor deposition system utilizing a sloped fixture transfer rail and carrier assembly that transports substrates under gravity between processing chambers, ensuring efficient and contamination-free coating application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lenses are transferred between multiple deposition chambers using conventional mechanical handling, then the sequential application of multiple layered coatings can be achieved, but physical contact and contamination of the freshly-applied coatings occur
Solution Approach 1:
A transfer chamber is introduced as an intermediary space between deposition chambers. The transfer chamber allows lenses to be moved between deposition chambers without direct mechanical contact that would contaminate coatings. The chamber maintains controlled environment and enables safe transfer through standardized interfaces.
Solution Approach 2:
Conventional mechanical handling systems that directly contact lenses are replaced with a vacuum-based transfer mechanism. Lenses are transferred through vacuum ports and controlled atmospheric interfaces, eliminating the need for mechanical grippers or conveyors that would physically touch and potentially contaminate the coated surfaces.
2Productivity
If conventional transfer methods are used between deposition chambers, then lens transport is possible, but efficiency and throughput are reduced due to manual handling and potential contamination risks
Solution Approach 1:
The transfer chamber enables continuous operation by allowing one lens to be transferred while another is being coated. Multiple lenses can be staged in the transfer chamber, enabling overlapping operations between deposition and transfer activities, thus maintaining continuous productive action without idle time.
Solution Approach 2:
Lenses are pre-positioned and staged in the transfer chamber before actual coating begins. This preliminary arrangement allows for optimized transfer sequences and reduces waiting time during the coating process, as the next lens is already prepared for immediate transfer.
3Manufacturing precision
If multiple layered coatings are applied sequentially to optical lenses, then desired optical characteristics can be achieved, but the process becomes time-consuming and complex
Solution Approach 1:
The coating system is segmented into multiple specialized chambers, each dedicated to specific coating operations. This segmentation allows each chamber to be optimized for its specific function while maintaining overall system coordination through the transfer chamber, enabling precise control over each coating layer's application.
Solution Approach 2:
The transfer chamber serves multiple functions: it acts as a buffer between deposition chambers, a staging area for lenses, a vacuum interface, and a contamination barrier. This multi-functionality reduces the need for separate dedicated components for each function, thereby managing overall system complexity.
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
Facilitates high-throughput, low-volume, sequential application of coatings on both sides of optical lenses, reducing mechanical interference and maintaining coating integrity.
Implementation Method 1
The fixture carrier assembly travels along the fixture transfer rail under influence of gravity
Implementation Method 2
A common method of applying an optical coating to an optical lens involves applying the coating to one or both surfaces of the lens using a physical vapor deposition (PVD) process
Data Source
AI summary
A deposition system includes a system housing having a housing interior, a fixture transfer assembly having a generally sloped fixture transfer rail extending through the housing interior, a plurality of processing chambers connected by the fixture transfer rail, a controller interfacing with the processing chambers and at least one fixture carrier assembly carried by the fixture transfer rail and adapted to contain at least one substrate. The fixture carrier assembly travels along the fixture transfer rail under influence of gravity.