Spectacle Lens Coating Control Using Prior-Cycle Emission Current
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Solution Overview
Problem
Conventional coating processes for spectacle lenses require manual adjustment of emission current strength during the coating process, leading to inefficiencies and potential quality issues due to deviations in the actual and target coating rates.
Innovation Solution
An automated method and device for determining the initial emission current strength based on the previous cycle's emission current strength, minimizing the need for manual adjustments and ensuring precise alignment with the target coating rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of emission current strength is performed during the coating process, then the coating rate can be corrected to match the target rate, but the process complexity increases and potential quality issues arise due to deviations
Solution Approach 1:
The system determines the initial emission current strength for the current cycle as a function of the emission current strength from the previous cycle before the coating process begins. This preliminary determination is stored in a database and automatically retrieved, eliminating the need for manual adjustments during the coating process and preventing quality deviations before they can occur.
2Manufacturing precision
If manual adjustment of emission current strength is performed during the coating process, then the coating rate can be corrected, but production downtime increases due to intervention requirements
Solution Approach 1:
The system automatically determines and adjusts the initial emission current strength for each cycle based on data from previous cycles stored in the database. This self-service mechanism eliminates the need for operator intervention during the coating process, maintaining continuous production and preventing downtime while ensuring precise coating rates through automated control.
3Manufacturing precision
If emission current strength is adjusted during the coating cycle, then the actual coating rate can match the target rate, but the evaporation cone changes causing non-uniform material distribution
Solution Approach 1:
The initial emission current strength is determined before the coating cycle begins, based on previous cycle data. This preliminary setting ensures that the evaporation cone remains stable throughout the entire coating process, maintaining uniform material distribution across the substrate while achieving the target coating rate through accurate initial parameter selection rather than mid-process adjustments.
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 enhances the quality of the coating process by reducing the need for manual intervention, maintaining consistent coating rates, and minimizing downtime of the coating apparatus.
Implementation Method 1
a target material is bombarded with accelerated electrons under high vacuum. The electrons cause atoms from the target to transform into the gaseous phase
Implementation Method 2
The electrons cause atoms from the target to transform into the gaseous phase
Implementation Method 3
These atoms then precipitate into solid form, coating everything in the vacuum chamber (within line of sight) with a thin layer of the anode material
Implementation Method 4
a resonant frequency of the quartz may be measured which may be converted into the actual coating rate
Data Source
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AI summary
A computer-implemented method (100, 200, 300) configured to control a coating apparatus (3), the coating apparatus (3) being configured to vapor deposit a layer (51, 52) of a coating (5) onto a spectacle lens (4) by electron beam evaporation, characterized in that the method comprises automated determining (201) of an initial strength of an emission current of a current cycle of applying the coating (5) onto the spectacle lens (4) as a function of a strength of an emission current used during a previous cycle of applying the coating (5) onto the spectacle lens (4).