Microstructured Laminate Coating for Ophthalmic Lens Thermoforming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing ophthalmic lenses with microstructured surfaces often damage the microstructures during post-processing due to heat and pressure application.
Innovation Solution
A laminate is created with a substrate having a microstructure and a coating layer where the glass transition temperature of the substrate is higher than that of the coating layer, ensuring the microstructure is protected during post-processing by encapsulating it with the coating layer, which remains intact under the applied heat and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heat and pressure are applied during post processing to manufacture ophthalmic lenses, then the lens can be formed and shaped, but the microstructure on the lens surface is destroyed
Solution Approach 1:
The microstructure is formed on the lens surface before the post-processing heating and shaping operations. By preparing the microstructure in advance and protecting it through the coating layer during subsequent manufacturing steps, the lens can be formed and shaped without destroying the microstructure
Solution Approach 2:
A coating layer is applied over the microstructured surface to protect it during heat and pressure application. The coating layer acts as an intermediary barrier that allows the lens to undergo necessary thermal and mechanical processing while preserving the underlying microstructure
2Manufacturing precision
If a coating layer is applied to protect the microstructure, then the microstructure integrity is maintained, but the complexity of the manufacturing process increases
Solution Approach 1:
The coating layer application is combined with the lens manufacturing process itself, rather than being a separate protective step. The coating is applied and then the entire lens-coating assembly undergoes the necessary heating and shaping operations in an integrated process flow
Solution Approach 2:
The glass transition temperatures of the substrate and coating layer are specifically selected and differentiated. The substrate has a higher glass transition temperature than the coating layer, allowing the coating to remain protective during processing while the substrate can be properly formed
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 laminate method effectively preserves the microstructure integrity during thermoforming and injection molding, enabling the production of ophthalmic lenses with high fidelity microstructures.
Implementation Method 1
A glass transition temperature T1 of the substrate is higher than a glass transition temperature T2 of the coating layer
Implementation Method 2
The coating layer is in a glassy state at a temperature of lower than T2 and is in a rubbery state at a temperature of T2 to lower than T1
Implementation Method 3
the laminate is deformed by thermoforming, and/or injection molding a hot melt polymer over the laminate at a temperature of lower than T1
Implementation Method 4
deforming the laminate of the substrate and the coating layer by applying heat, pressure, or both
Data Source
AI summary
A laminate, including a substrate having a microstructure on a surface thereof; and a coating layer formed on the substrate and encapsulating the microstructure of the substrate. A glass transition temperature T1 of the substrate is higher than a glass transition temperature T2 of the coating layer. A method of producing an ophthalmic lens, including deforming the laminate into a shape of the ophthalmic lens by applying heat and/or pressure at a temperature of lower than T1.