Substrate Deposition System for Optical Lens Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing substrate deposition systems face challenges in efficiently and effectively applying multiple layered coatings to optical lenses without physical contact or contamination, particularly in sequential applications where precise transfer and uniform coating are crucial.
Innovation Solution
A substrate deposition system featuring a system frame with processing tanks for different light refractive index coatings, actuators for sequential immersion and transfer, and a coating system for applying antireflective coatings, along with a lens surface location measuring system to ensure precise positioning and uniform deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layered coatings are sequentially applied to optical lenses using multiple deposition chambers, then coating functionality and performance are improved, but the risk of physical contact or contamination during transfer between chambers increases
Solution Approach 1:
The system is divided into multiple independent deposition chambers (first, second, third chambers) that can operate in sequence. Each chamber is a self-contained unit with its own deposition source and processing environment, allowing coatings to be applied in discrete stages without exposing the lens to external contamination between chambers.
Solution Approach 2:
A transfer mechanism serves as an intermediary device that moves the optical lens between chambers without requiring the lens to be manually handled or exposed to the external environment. This intermediary transfer system maintains the lens within a controlled atmosphere throughout the multi-step coating process.
2Adaptability or versatility
If multiple deposition chambers are used for sequential coating application, then coating versatility is improved, but system complexity increases
Solution Approach 1:
Each deposition chamber is designed as a multi-functional unit that can accommodate different deposition sources (such as electron beam, sputtering, or thermal evaporation) and process different types of coatings (hard coatings, anti-reflective coatings, mirror coatings). This universal design allows the same chamber structure to perform multiple coating functions, reducing overall system complexity while maintaining versatility.
Solution Approach 2:
The deposition sources and processing components are nested within the chamber structure in a compact arrangement. The transfer mechanism is integrated into the chamber assembly, and the vacuum system components are nested within the overall chamber configuration. This nested layout reduces the physical footprint and simplifies the interconnections between components.
3Adaptability or versatility
If optical lenses are transferred among multiple deposition chambers, then sequential coating application is enabled, but transfer efficiency and throughput are reduced
Solution Approach 1:
The deposition chambers are arranged in a continuous linear sequence with an automated transfer mechanism that moves lenses from one chamber to the next without interruption. The transfer process is integrated into the deposition workflow, allowing the lens to move continuously through the coating stages without removal or manual handling, thereby maintaining continuous productive action throughout the coating process.
Solution Approach 2:
The transfer mechanism is pre-positioned and pre-aligned between chambers, and the deposition sources are pre-configured with appropriate parameters before the lens arrives. This preliminary preparation ensures that when the lens enters each chamber, the coating process can begin immediately without setup delays, maximizing throughput.
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 efficient, contamination-free sequential application of coatings on optical lenses, ensuring uniformity and high throughput in coating processes, particularly suitable for optical lenses in eyewear.
Implementation Method 1
dipping the lens in a solution which adheres to one or both surfaces of the lens upon removal of the lens from the solution
Implementation Method 2
applying the coating to one or both surfaces of the lens using a physical vapor deposition (PVD) process
Data Source
AI summary
A substrate deposition system includes a system frame; a plurality of processing tanks carried by the system frame, the plurality of processing tanks adapted to contain liquid coating materials of different light refractive indexes; at least one actuator disposed in proximity to the plurality of processing tanks, the at least one actuator adapted to sequentially immerse at least one substrate in the liquid coating materials and transfer the at least one substrate between the plurality of processing tanks; and at least one coating system located in a process flow downstream direction from the plurality of processing tanks, the at least one coating system adapted to apply an antireflective coating to the at least one substrate. A lens surface location measuring system is also disclosed.