Ophthalmic Lens Wetting Profile for Coating Uniformity
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Solution Overview
Problem
Existing optical lens coating systems face challenges with coating quality due to factors like dust, coating thickness, and uniformity issues, which can lead to defects and inconsistencies, and prior systems lack automated inspection and feedback mechanisms to adjust the coating process in real-time.
Innovation Solution
An automated system for wetting and quality control of optical lenses that includes an inspection system to detect flaws and a feedback mechanism to adjust the wetting profile, allowing for closed-loop feedback to correct defects and maintain process tolerances, with the ability to vary the speed and timing of lens submersion and withdrawal based on surface geometry and liquid properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated inspection and feedback mechanisms are added to detect and correct coating defects, then coating quality and consistency are improved, but device complexity increases
Solution Approach 1:
The patent implements a feedback mechanism where an inspection system detects coating defects and communicates this information to a control system, which automatically adjusts coating parameters to correct the defects. This closed-loop feedback system continuously monitors and refines the coating process, ensuring high manufacturing precision through automated defect correction rather than manual intervention.
Solution Approach 2:
The patent replaces manual inspection and adjustment mechanisms with automated optical inspection systems and computer-controlled parameter adjustment. The inspection system uses optical sensors and imaging to detect coating defects, while the control system uses software algorithms to analyze the defect data and automatically modify coating parameters, substituting mechanical and human operations with automated electronic systems.
2Strength
If the curing time is extended to ensure complete solidification of lens coatings, then coating durability is improved, but productivity decreases due to continuous in-process requirements
Solution Approach 1:
The patent applies preliminary action by implementing real-time defect detection and correction during the coating process, before the curing stage. The inspection system identifies potential defects early, and the feedback mechanism adjusts parameters to prevent defect development. This proactive approach ensures coating quality without requiring extended curing times, as defects are prevented rather than corrected after curing.
Solution Approach 2:
The patent maintains continuity of useful action by enabling overlapping processing cycles where multiple lenses are at different stages of the coating and curing process simultaneously. The automated inspection and feedback system operates continuously without interruption, allowing the production line to maintain steady flow and throughput while each individual lens receives the necessary curing time for durability.
3Device complexity
If manual inspection and adjustment of coating parameters are used, then system complexity is reduced, but manufacturing precision and defect detection capability deteriorate
Solution Approach 1:
The patent implements self-service by enabling the system to automatically monitor its own performance through the inspection system and correct its own deviations through the feedback mechanism. The control system autonomously adjusts coating parameters based on real-time defect detection, without requiring external manual intervention. This self-regulating capability maintains high manufacturing precision while reducing the need for complex manual monitoring and adjustment procedures.
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 system ensures uniform and defect-free optical lens coatings by dynamically adjusting the wetting process, preventing defects from propagating and maintaining coating quality within acceptable tolerances, even when contamination or molding issues arise.
Implementation Method 1
apparatus for wetting and coating ophthalmic lenses
Data Source
Figure 1a~1c
Figure 2
Figure 3
AI summary
An apparatus (200) for wetting and coating ophthalmic lenses having a tank with a cleaning or coating solution and a handling system (212) for sequentially moving a lens and the solution in relation to each other, to wet the lens. A master control module (232) is coupled to the handling system and configured execution a wetting profile. The wetting profile moves the lens to obtain a generally consistent lens surface wetting speed so that the lens coating has a more uniform thickness. According to a method, lenses are wetted in a liquid bath. The lens is placed in a handling system which moves the lens with respect to the bath according to a wetting profile. The wetting profile is based on the incremental vertical lens surface slope with respect to the surface of the solution.