PVD Coated Eyeglass Lens Support Body for Uniform Mirror Finish
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Solution Overview
Problem
Existing methods for producing mirrored eyeglass lenses using physical vapor deposition (PVD) often result in non-uniform coating distribution, leading to a faded edge effect due to random particle flow and interference with support structures, which complicates production and affects aesthetic appeal.
Innovation Solution
A method and intermediate assembly that utilize a support body with specifically designed through openings and centering references to orient and shape the coating layer on the lens blank, allowing for controlled deposition of a coating layer with a desired profile and orientation, thereby achieving a uniform and aesthetically pleasing design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If physical vapor deposition (PVD) is used to coat eyeglass lenses, then a mirrored coating layer can be deposited on the lens, but the coating distribution becomes non-uniform with a faded edge effect due to random particle flow and interference with support structures
Solution Approach 1:
The patent introduces a support body with a through opening as an intermediary structure between the PVD source and the lens. This support body controls the particle flow path, allowing uniform coating deposition while preventing the random particle flow that causes the faded edge effect. The through opening acts as a mediator that directs the coating material uniformly across the lens surface.
Solution Approach 2:
The support body is designed with a through opening that creates localized control over the coating deposition area. By defining a specific geometric path for particle flow through the opening, the system achieves uniform coating quality in the desired region while preventing harmful deposition patterns at the edges.
2Ease of manufacture
If traditional PVD coating methods are used, then the coating process is simple, but the production process becomes complicated due to the need to manage and compensate for non-uniform coating distribution
Solution Approach 1:
The support body with through opening serves as a built-in control mechanism that simplifies the overall production process. Instead of requiring complex post-coating operations to correct non-uniformity, the support body pre-controls the particle flow to achieve uniform deposition directly during the coating process, reducing production complexity.
3Manufacturing precision
If the lens is coated with a coating layer using conventional methods, then the coating can be applied, but the orientation and shape control of the coating layer is poor, affecting aesthetic appeal
Solution Approach 1:
The support body is designed with an asymmetric through opening configuration that is specifically tailored to produce the desired coating pattern and orientation on the lens. The asymmetric geometry of the opening controls the particle flow direction and distribution, enabling precise orientation control of the coating layer for aesthetic purposes.
Solution Approach 2:
The through opening creates a localized deposition zone with controlled geometry, allowing the coating to be applied with specific orientation and shape characteristics in the desired area of the lens, thereby improving aesthetic quality.
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 method enables the production of eyeglass lenses with a uniformly coated, oriented design that minimizes the faded edge effect, allowing for precise shaping and cutting to achieve desired aesthetic effects, improving the marketability of eyeglass lenses.
Implementation Method 1
coating the eyeglass lens with a coating layer by means of physical vapor deposition, known in the technical jargon of the field also by its acronym PVD
Implementation Method 2
the support body (2) itself with the flow of particles in vapor phase... determining a faded perimeter edge (11) of the coating layer (10)
Data Source
Figure 1A
Figure 2
Figure 3~4
AI summary
Method for making an eyeglass lens coated by means of physical vapor deposition PVD, such method comprising a step of arranging a lens blank (1), provided with a first centering reference (15), a step of arranging a support body (2), provided with a first abutment seat (3) for the lens blank (1) and with at least one first shaped and through opening (4) oriented with respect to a second centering reference (25) thereof, and a step of arranging a centering template (5) provided with a second abutment seat (6) for the support body (2) and with a second through opening (7). The present method then comprises an assembly step, in which the lens blank (1) is housed in the first abutment seat (3), orienting the first centering reference (15) with respect to the second centering reference (25), and in which the support body (2) is housed in the second abutment seat (6) with the first and the second through opening (4, 7) aligned. Subsequently, the present method comprises a step of coating the lens blank (1) by means of physical vapor deposition PVD, in which at least one coating layer (10) is deposited on the lens blank (1), such layer (10) provided with an exposed profile (20) coinciding with the first shaped and through opening (4), and finally comprises a cutting step in which the lens blank (1) is cut along a cutting profile (23) shaped in eyeglass lens form and oriented with respect to the first centering reference (15).