Spectacle Lens Coating via Laser Masking

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Solution Overview

Problem

Existing methods for producing coatings on spectacle lenses, such as antireflection layers, are not cost-effective for small series production and require expensive printing plates or self-adhesive masks, limiting their economic viability for custom or low-volume lens manufacturing.

Innovation Solution

A method using matrix printing to apply masking and layers on spectacle lenses, allowing for the creation of defined reflection images without mechanical loading, enabling cost-effective and automated production of spectacle lenses with customized reflection patterns using conventional apparatuses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If printing plates or self-adhesive masks are used to produce reflection images on spectacle lenses, then the manufacturing precision and quality of the reflection image are improved, but the production cost increases and mechanical damage to the lens surface may occur

Engineering Contradiction:
Improvereflection image qualityVSAvoidproduction cost
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical printing plates and self-adhesive masks with a laser-based direct writing system. The laser beam is modulated according to the desired reflection image pattern and directly writes onto the lens surface, eliminating the need for physical contact with printing plates or masks. This substitution of mechanical systems with optical fields resolves the contradiction by maintaining manufacturing precision through laser control while eliminating the high costs and mechanical damage risks associated with traditional methods.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If printing plates are used for producing reflection images, then the precision of the reflection image is improved, but the device complexity and production setup requirements increase

Engineering Contradiction:
Improvereflection image precisionVSAvoidproduction setup complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts and removes the printing plate from the production system entirely. Instead of using a physical printing plate that requires storage, handling, and mounting on production lines, the reflection image pattern is stored as digital data and directly transferred to the lens surface via laser writing. This extraction of the printing plate eliminates the associated device complexity and setup requirements while maintaining reflection image precision through digital control of the laser beam.

Inventive Principle:
Principle #2Taking out (Extraction)

3Ease of operation

If self-adhesive masks are used for coating application, then the ease of operation is improved, but the mechanical durability of the lens surface deteriorates due to mechanical loading

Engineering Contradiction:
Improvemasking application easeVSAvoidlens surface mechanical durability
Core Design Contradiction:
Ease of operationVSStrength

Solution Approach 1:

The patent replaces the mechanical masking process with a laser-based direct writing process. Instead of applying physical self-adhesive masks that require manual handling and adhesion to the lens surface, the reflection image pattern is directly written onto the lens surface using a controlled laser beam. This substitution eliminates mechanical contact and loading on the lens surface, preserving mechanical durability while maintaining ease of operation through automated laser writing.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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

Enables the production of spectacle lenses with targeted, multicolored reflection images and improved mechanical durability, comparable to fully coated lenses, while reducing production costs and avoiding mechanical damage, thus addressing the limitations of existing methods.

Implementation Method 1

a laser beam is used for writing a masking on a spectacle lens

Methodology Applied
Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

applying at least one layer on the at least one surface and on the at least one masking

Methodology Applied
Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS11747649B2Method for producing a coating on a spectacle lens, and spectacle lens
Publication Date: 2023.09.05 CARL ZEISS VISION INTERNATIONAL GMBH
  • US11747649B2 patent drawing
  • US11747649B2 patent drawing
  • US11747649B2 patent drawing

AI summary

A method for producing a coating on a surface of a coated or uncoated spectacle lens includes: applying a masking on a partial region of the surface of the coated or uncoated spectacle lens, applying at least one layer on the surface, and removing the masking and the at least one layer applied on the masking from the partial region of the surface. The masking is applied with a matrix printing method. A spectacle lens produced by the method is also disclosed.