Spectacle Lens Top Coating Adhesion via Temporary Protection Layer
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Solution Overview
Problem
The existing methods for manufacturing spectacle lenses face challenges in ensuring sufficient adhesion between the lens blank and the block piece during processing, particularly with hydrophobic and oleophobic coatings, which can lead to the lens blank unintentionally coming off the block piece, and also struggle with maintaining the integrity of the top coating.
Innovation Solution
A method involving a temporary protection layer with higher surface energy than the top coating, applied between the blocking and processing steps, which is selectively removed after processing to protect the antireflection coating and ensure a standardized interface, allowing for secure holding without damaging the top coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a hydrophobic and/or oleophobic top coating is applied to the lens blank before blocking, then the lens blank gains stain resistance properties, but the adhesion between the blocking material and the lens blank is reduced
Solution Approach 1:
The patent applies the top coating TC to the lens blank before the blocking step, in advance of when the adhesion issue would normally occur. This preliminary action allows the lens to gain stain resistance while the blocking material BM is subsequently applied on top of the coating, creating a new interface for adhesion between the blocking material and the coated surface
Solution Approach 2:
The patent segments the coating application process by applying the top coating TC first, then adding the blocking material BM as a separate layer on top. This segmentation creates distinct functional layers where the top coating provides stain resistance and the blocking material provides adhesion, eliminating the conflict between these two properties
2Object-affected harmful factors
If the top coating is applied before blocking, then the lens blank gains protective properties, but the top coating may be damaged during processing
Solution Approach 1:
The top coating TC is applied in advance before blocking and processing, allowing it to be established as a permanent protective layer on the lens. The blocking material serves as a temporary protective layer during processing, and is subsequently removed to reveal the intact top coating
Solution Approach 2:
The blocking material BM acts as an intermediary protective layer during processing. It temporarily protects the top coating TC from damage during machining operations, and is then removed to reveal the undamaged top coating, serving as a sacrificial protective barrier
3Reliability
If the lens blank is held securely during processing, then manufacturing reliability is improved, but the adhesion interface must withstand higher forces
Solution Approach 1:
The patent changes the adhesion interface by creating a new bonding surface between the blocking material and the top-coated lens blank. This parameter change in the interface composition allows for optimized adhesion properties that can withstand processing forces while maintaining holding stability
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 ensures that the spectacle lenses are produced with high optical quality, quickly and at lower costs, without the risk of the lens blank detaching from the block piece, and with an intact, undamaged top coating.
Implementation Method 1
blocking with the aid of a blocking material the lens blank on a block piece
Implementation Method 2
a temporary protection layer with higher surface energy than the top coating
Data Source
AI summary
A method for manufacturing spectacle lenses includes the steps of: providing a lets blank having a first face that possesses a final curvature and is coated with an antireflection coating as an outer layer, a second face, and an edge; blocking with a blocking material the lens blank with its first face on a block piece; processing the blocked lens blank on the second face and to obtain a processed lens; deblocking the processed lens from the block piece; and applying on top of the first face antireflection coating of the processed lens a top coating selected from at least one of hydrophobic, oleophobic or dust repelling coatings.