Sublimation Coating for Optical Lens Adhesion and Durability

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Solution Overview

Problem

Traditional methods for tinting and designing optical lenses, such as dip-dyeing and vapor-deposition, are time-consuming and result in poor adhesion, leading to unsatisfactory longevity and durability due to uneven dye deposition and susceptibility to scratches.

Innovation Solution

A method involving sublimation transfer ink on sublimation paper, aligned and secured onto the optical lens, followed by heating in a vacuum oven to transfer coatings onto the lens surfaces, allowing for precise and durable color and design application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional dip-dyeing method is used for lens tinting, then the process is simple to implement, but the dye coating has poor adhesion and is easily scratched

Engineering Contradiction:

Improveease of lens tintingVSAvoidadhesion of dye coating

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses sublimation phase transition to transfer the coating from the transfer medium to the lens surface. The coating material transitions from solid to gas phase and then deposits onto the lens, creating strong adhesion without the weaknesses of liquid dye applications.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent replaces the mechanical dip-dyeing process with a thermal sublimation process. Instead of physically dipping the lens in dye solution, the coating is transferred through controlled heating that causes sublimation, eliminating the adhesion problems associated with liquid dye application.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If traditional vapor-deposition method is used for lens tinting, then the coating can be applied evenly, but the process is time consuming and cannot deposit designs

Engineering Contradiction:

Improveuniformity of dye depositionVSAvoiddyeing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent uses a transfer medium that contains a pre-printed design or pattern. During sublimation, the coating material transfers the exact pattern from the transfer medium to the lens, enabling design deposition in 1:1 manner without requiring complex masking or multiple application steps.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent combines the advantages of vapor deposition (even coating application) with the capabilities of pattern transfer. The sublimation process simultaneously achieves uniform distribution of dye molecules and precise pattern replication, merging two previously separate functions into one process.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple coating layers are applied to achieve dual-sided color contrast, then the aesthetic quality is improved, but the process becomes more complex and time consuming

Engineering Contradiction:

Improveaesthetic quality with dual-sided colorsVSAvoidcomplexity of coating process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent divides the lens into multiple surfaces that can be independently coated. Each surface can receive a different color or design through separate sublimation applications, enabling dual-sided color contrast while maintaining process simplicity through repeated use of the same basic technique.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a universal coating system that can produce multiple colors and designs using the same sublimation process and equipment. By changing the transfer medium or coating material, the same process can generate various aesthetic effects without requiring different equipment or complex procedural changes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This method enhances the speed and convenience of lens tinting and design application, providing long-term retention of colors and designs under sunlight and chemical exposure, with an additional hardcoat layer for protection and enabling dual-sided color/design contrast in three dimensions.

Implementation Method 1

heating and vacuuming the chamber of the vacuum oven during about the predetermined time such that the first coating sublimates onto the first surface of the optical lens from the sublimation paper

Methodology Applied

Scientific EffectSublimation: Sublimation

Data Source

PatentUS11536875B2Method for sublimation coating on optical lens

Publication Date: 2022.12.27 KH9100 LLC

AI summary

A method to sublimate a wide variety of coatings onto optical lens includes printing a first coating using a sublimation transfer ink onto a sublimation paper, positioning the sublimation paper onto the optical lens to align the sublimation paper to a first surface of the optical lens, placing the sublimation paper thereon, preheating a chamber of a vacuum oven to a predetermined temperature, placing the optical lens into the chamber of the vacuum oven with the first surface of the optical lens facing upward, closing the vacuum oven and setting a predetermined time for heating, heating and vacuuming the chamber of the vacuum oven during about the predetermined time such that the first coating sublimates onto the first surface of the optical lens from the sublimation paper, removing from the vacuum oven and cooling the optical lens having the first coating on its first surface.