Coated Spectacle Lens Structuring via Digital Twin Laser Curing
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Solution Overview
Problem
Existing methods for structuring spectacle lenses require masking layers or local melting of materials, which can be inefficient and limiting in terms of precision and flexibility.
Innovation Solution
A method involving a digital twin of a coated spectacle lens is designed using laser process parameters based on curing characteristics of a coating composition to achieve predefined structures, allowing for precise and flexible manufacturing without the need for masking layers or local melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If masking layers or local melting methods are used to structure spectacle lenses, then structural precision can be achieved, but manufacturing complexity and process time increase
Solution Approach 1:
The patent removes the masking layer step from the manufacturing process by directly applying curable coating material to specific zones on the lens surface. The coating is applied only where structures are needed, eliminating the need for masks and subsequent removal steps, thus reducing manufacturing complexity while maintaining precision.
Solution Approach 2:
The curable coating material is applied in advance to the specific zones where structures are to be formed, before the laser curing step. This preliminary positioning of material eliminates the need for masking and allows direct structuring, simplifying the overall manufacturing process.
2Manufacturing precision
If masking layers are used for structuring, then precise pattern formation is possible, but the number of manufacturing steps increases
Solution Approach 1:
The masking layer application and removal steps are completely eliminated from the manufacturing process. The curable coating material is applied directly to the desired pattern areas, and then cured by laser, reducing the number of steps from multiple (mask application, coating, mask removal, cleaning) to just two (coating application, laser curing).
Solution Approach 2:
The curable coating material itself serves as the intermediary that defines the pattern, replacing the masking layer's function. By making the coating material curable, it provides both the pattern definition and the final structural material, eliminating the need for separate masking and coating steps.
3Manufacturing precision
If traditional coating methods are used, then complete surface coverage is achieved, but flexibility in creating specific structures is reduced
Solution Approach 1:
The coating material is applied with locally varying properties - it is curable in specific zones where structures are desired and non-curable in other zones. This local differentiation allows precise control over where structures form, providing both high precision and flexibility for creating different patterns on different lenses.
Solution Approach 2:
The coating material's curability is made dynamic and controllable - it can be cured or not cured based on laser exposure. This dynamic property allows the same coating material to serve different functions in different areas, enabling flexible pattern creation while maintaining complete surface coverage where needed.
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 precise and flexible manufacturing of spectacle lenses with predefined structures, enhancing manufacturing efficiency and precision.
Implementation Method 1
determining laser process parameters based on curing characteristics of a coating composition to achieve (i) the one predefined structure or (ii) the plurality of predefined structures
Data Source
AI summary
A method for designing a digital twin of a coated spectacle lens with a computer for the purpose of a use of the digital twin for manufacturing a coated spectacle lens and a method for manufacturing a coated spectacle lens are provided. The spectacle lens contains a predefined structure or a plurality of predefined structures. The predefined structure or structures are formed by selectively curing the coating composition with a laser beam.