Spectacle Lens Spin Coating for Uniform Films on Microprotrusions
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Solution Overview
Problem
Existing methods for applying a coating film on spectacle lenses with microprotrusions result in uneven film thickness due to the formation of liquid pools around the microprotrusions.
Innovation Solution
A method involving spin coating of a curable composition on lens substrates with microprotrusions, using a curable compound and metal oxide particles, to form a uniform coating film by controlling the viscosity and rotation speed during application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional free-form molding is used for manufacturing aspheric spectacle lenses, then manufacturing complexity is reduced, but manufacturing precision deteriorates due to inability to control surface accuracy in both meridians simultaneously
Solution Approach 1:
The patent divides the aspheric surface manufacturing process into two separate sequential molding operations instead of attempting to mold the entire complex aspheric surface in a single step. The first molding process creates an intermediate surface with controlled accuracy in one meridian, and the second molding process refines the surface to achieve final accuracy in both meridians. This segmentation resolves the contradiction by making the complex manufacturing process manageable while maintaining high precision.
2Productivity
If single molding process is used for aspheric lenses, then productivity is improved, but manufacturing precision deteriorates due to inability to achieve required surface accuracy
Solution Approach 1:
The first molding process performs a preliminary shaping operation that creates an intermediate aspheric surface with controlled accuracy in the first meridian. This preliminary action prepares the substrate for the second molding operation, allowing the final high-precision aspheric surface to be achieved more efficiently than attempting complete precision in a single step.
3Device complexity
If traditional molding methods are used, then device complexity is minimized, but manufacturing precision deteriorates due to lack of control over aspheric surface in both meridians
Solution Approach 1:
The manufacturing process is segmented into two distinct molding operations, each optimized for controlling surface accuracy in specific meridians. The first molding process controls the first meridian, and the second molding process controls the second meridian, allowing precise control of the complex aspheric surface without requiring excessively complex single-step molding equipment.
Data Source
Figure 1
AI summary
Provided is a method for manufacturing a spectacle lens, wherein: the spectacle lens includes a lens substrate having microprotrusions on at least one surface, and a coating film formed on the surface of the lens substrate that has the microprotrusions; and the method includes forming the coating film by applying an application liquid, through spin-coating, to the surface of the lens substrate that has the microprotrusions.