Lenslet Coating Thickness Control via Dynamic Withdrawal Speed
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Solution Overview
Problem
Existing methods for coating optical lenses with lenslets struggle to control the thickness of the coating layer accurately, leading to inconsistent optical power shifts, which complicates the manufacturing process and affects the reliability of the final product.
Innovation Solution
A method involving controlled withdrawal speed during the dip-coating process, with real-time thickness measurement and adjustment, using a coating assembly that includes a dipping system, a measuring system, and a controlling system to determine and adjust the withdrawal speed based on measured thickness, ensuring precise control over the coating layer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dip-coating method is used to coat optical lenses, then coating process is simple and efficient, but controlling the thickness of the coating layer becomes difficult
Solution Approach 1:
The patent implements a feedback control system where the withdrawal speed is continuously adjusted based on real-time thickness measurements. A sensor measures the actual thickness of the coating layer, and this measurement feeds back to the control system which automatically adjusts the withdrawal speed to maintain the desired thickness, resolving the contradiction between simple dip-coating process and precise thickness control
Solution Approach 2:
The patent transforms the static withdrawal speed into a dynamic parameter that can be adjusted in real-time. By making the withdrawal speed variable rather than fixed, the system can adapt to changing conditions during the coating process to maintain consistent thickness, thereby improving manufacturing precision while preserving the efficiency of the dip-coating method
2Manufacturing precision
If withdrawal speed is adjusted to control coating thickness, then coating thickness control improves, but process complexity increases
Solution Approach 1:
The system performs self-adjustment by automatically modifying the withdrawal speed based on thickness measurements without requiring external intervention. The control system autonomously regulates the coating process parameters, simplifying operation while achieving precise thickness control, thus improving manufacturing precision without proportionally increasing process complexity
3Loss of time
If thickness measurement is performed early in the process, then adjustment response speed increases, but measurement accuracy may be reduced
Solution Approach 1:
The patent performs preliminary thickness measurements during or immediately after the coating deposition, before the drying and hardening steps are complete. This early measurement allows for rapid feedback and adjustment of withdrawal speed, minimizing loss of time. The system accepts that early measurements may require subsequent verification but gains significant speed advantage for real-time process control
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 significantly reduces the variability of the coating layer thickness and corresponding optical power shifts, enhancing the reliability and efficiency of the final product by allowing for faster and more accurate adjustments during the coating process.
Implementation Method 1
withdrawing the at least one first optical lens from the coating fluid at a controlled withdrawal speed
Implementation Method 2
a coating assembly for coating optical lenses having at least one main surface at least partly covered with lenslets
Data Source
AI summary
A method for coating a plurality of optical lenses having at least one main surface at least partly covered with lenslets, the method comprising: —dipping (DIP) at least one first optical lens from the plurality of optical lenses into a coating fluid, —withdrawing (WDW) the at least one first optical lens from the coating fluid at a controlled withdrawal speed, —measuring (MEAS) a thickness of a coating layer deposited on the at least one first optical lens, —determining (ADJ) an adjusted withdrawal speed based on the measured thickness, and —repeating the steps of dipping (DIP), withdrawing (WDW), measuring (MEAS) and determining (ADJ) on at least other optical lenses from the plurality of optical lenses, using the adjusted withdrawal speed during the withdrawing step (WDW).