Lens Coating Apparatus with Automated Drying and UV Curing
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Solution Overview
Problem
Current lens coating processes are labor-intensive and prone to contamination due to the use of compressed gases for drying, which can introduce particles and static charges, limiting production efficiency and quality.
Innovation Solution
A closed-system coating apparatus with a mechanical arm that automates the handling and orientation of lenses through a series of stations, using a spraying mechanism for coating and radiant energy for drying, eliminating the need for air drying and reducing operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If compressed gas is used for drying the coated lens, then the drying efficiency is improved, but particle contamination on the coating surface increases
Solution Approach 1:
The harmful compressed air drying step is completely removed from the coating process. The system extracts the drying function and replaces it with a passive evaporation environment, eliminating the source of particle contamination while maintaining productivity through optimized coating application and controlled environmental conditions for efficient solvent evaporation.
Solution Approach 2:
A controlled atmospheric environment acts as an intermediary between the coated lens and the external environment. This atmosphere, maintained at specific temperature and humidity levels, facilitates solvent evaporation without introducing contaminants, thereby mediating the drying process without the harmful effects of compressed gas.
2Manufacturing precision
If manual handling and repositioning of lenses is performed, then coating coverage is improved, but production time increases and contamination risk increases
Solution Approach 1:
The lens coating process is segmented into distinct automated zones: loading, coating application, and drying. The mechanical arm divides the workflow into discrete, programmable steps that eliminate manual intervention. Each segment is optimized for its specific function, with the mechanical arm precisely positioning the lens in each zone without requiring operator repositioning, thereby maintaining complete coating coverage while dramatically reducing production time.
Solution Approach 2:
The mechanical arm system provides self-service automation, where the programmable controller manages the entire coating process without human intervention. The system automatically loads lenses, positions them through the coating station, and manages the drying process, eliminating the need for manual handling and repositioning while ensuring consistent, complete coating coverage.
3Adaptability or versatility
If operator intervention is used for lens positioning and handling, then process flexibility is maintained, but labor intensity increases and contamination risk increases
Solution Approach 1:
The system incorporates dynamic adaptability through programmable control, where the mechanical arm and coating parameters can be adjusted via software to accommodate different lens types, sizes, and coating requirements. This dynamic programming approach maintains process flexibility while eliminating manual labor, allowing the system to adapt to various production needs without operator intervention.
Solution Approach 2:
Manual mechanical handling by operators is replaced with an automated mechanical arm system controlled by programmable logic. This substitution eliminates labor-intensive operations while maintaining flexibility through software programming, allowing the mechanical system to perform complex positioning and handling tasks that previously required human operators.
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
The solution significantly reduces contamination risks, increases production efficiency by minimizing manual handling, and enhances the quality of coated lenses by ensuring even coating and precise control over the coating and drying processes.
Implementation Method 1
a spraying mechanism that directs an upward spray toward a bottom surface of the lens
Implementation Method 2
a plurality of blowing devices configured to direct air toward the lens after the lens has been coated
Implementation Method 3
The programmable controller is configured to control the mechanical arm to move linearly and collect the lens from the loading station
Data Source
AI summary
A lens coating apparatus is provided. The apparatus includes a mechanical arm configured to receive and maintain lenses in a desired orientation, a loading station configured to receive and maintain the lenses within the enclosed area, and a combined washing and drying station including a spraying mechanism that directs an upward spray toward a bottom surface of the lens, and blowing devices configured to direct air toward the lens after the lens has been washed. The coating apparatus includes a coating station where liquid coating is sprayed toward the bottom surface of the lens and a curing station where the coated lens is exposed to the UV energy radiation. A programmable controller controls the mechanical arm to collect the lens from the loading station without operator intervention, and move along a linear track between the loading station and the combined washing and drying, coating and curing stations.