Lens Spin Coating With Two-Step Edge Liquid Pool Removal
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Solution Overview
Problem
Existing spin coating methods for lens base materials result in non-uniform coating thickness due to liquid pools forming on the peripheral edge and side surfaces, leading to reduced effective lens area and complex manufacturing processes.
Innovation Solution
A coating method involving a two-step removal process using an adsorption member, first through lens rotation and then contact with an adsorption member, particularly a sponge containing an organic solvent, to effectively remove liquid pools from the peripheral edge and side surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spin coating is used to form a coating layer on a lens base material, then a relatively thin and uniform coating layer can be formed on the surface, but liquid pools are generated on the peripheral edge portion and side surface portion, causing non-uniform thickness and deteriorating appearance
Solution Approach 1:
The patent extracts and removes the harmful liquid pool from the coating process by introducing a removal mechanism that specifically targets and eliminates the liquid pool formed on the peripheral edge and side surface portions, thereby resolving the contradiction between achieving uniform coating thickness and preventing liquid pool formation
Solution Approach 2:
The patent introduces an intermediary substance or mechanism that mediates between the coating agent and the lens base material surface, preventing the liquid pool from forming or stabilizing its state, thus maintaining both coating uniformity and preventing harmful liquid pool effects
2Manufacturing precision
If a flange portion is added to the lens base material to prevent liquid pool formation, then coating uniformity is improved, but the shape becomes complicated and additional removal steps are required
Solution Approach 1:
Instead of adding a flange portion to prevent liquid pool formation, the patent extracts and removes the liquid pool after coating using a specific removal mechanism, thereby achieving coating uniformity without complicating the lens base material shape or requiring additional removal steps
Solution Approach 2:
Rather than modifying the lens base material shape to prevent liquid pool formation, the patent inverts the approach by allowing the liquid pool to form and then removing it, thus achieving the same coating uniformity result without adding structural complexity
3Manufacturing precision
If a spatula is used to remove liquid pools, then coating uniformity is improved, but the removal state becomes unstable due to variations in contact state and holding posture
Solution Approach 1:
The patent employs a removal mechanism that does not require manual operation or precise human control, allowing the system to automatically and consistently remove liquid pools without variations in contact state or holding posture, thereby achieving both coating uniformity and removal stability
Solution Approach 2:
The patent replaces the manual mechanical operation of a spatula with an automated or controlled mechanism that consistently removes liquid pools, eliminating the variability associated with human operation and achieving stable, reliable coating uniformity
4Manufacturing precision
If suction is used to remove liquid pools, then coating uniformity is improved, but the suction pressure may adversely affect the uniformity of the coating liquid on the surface
Solution Approach 1:
The patent introduces an intermediary mechanism or substance that removes liquid pools without requiring direct suction contact with the coating liquid surface, thereby achieving coating uniformity without disturbing the coating liquid uniformity through suction pressure
Solution Approach 2:
The patent replaces the suction mechanism with an alternative removal method that does not involve pressure application, thus eliminating the harmful effect of suction pressure on coating liquid uniformity while still achieving the desired coating thickness uniformity
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 ensures a high-quality, uniformly coated lens by stabilizing the removal of liquid pools, simplifying the manufacturing process and improving yield.
Implementation Method 1
a method called spin coating is known in which a coating agent is supplied onto a lens base material and the lens base material is rotated to spread the coating agent on the surface of the lens base material
Implementation Method 2
a technique has been proposed in which a liquid pool formed on the peripheral edge portion and/or the side surface portion of a base material when a coating agent is spread is removed by suction
Data Source
AI summary
The present invention provides a coating method including: a step of supplying a coating agent to a surface of a lens base material; a spreading step of spreading the coating agent supplied to the surface by rotation of the lens base material; a first removal step of removing at least a part of a liquid pool of the coating agent generated on a peripheral edge portion and/or a side surface portion of the lens base material by rotation of the lens base material after the spreading step; and a second removal step of removing the liquid pool remaining on the peripheral edge portion and/or the side surface portion of the lens base material by bringing an adsorption member into contact with at least the side surface of the lens base material after the first removal step. According to the present invention, it is possible to provide a coating method capable of obtaining a base material having a coating layer excellent in uniformity of film thickness by reducing the liquid pool of the coating agent generated on the peripheral edge portion and/or the side surface portion of the lens base material when the coating layer is formed on the surface of the base material by spin coating the coating agent.