Anti-fog Lens Coating via UV Curing and Automated Carrier

Solution Overview

Problem

Conventional anti-fog coating manufacturing processes for lenses are inefficient due to manual positioning issues during spraying, long thermal curing times, and large, costly equipment setups, leading to low productivity and high manufacturing costs.

Innovation Solution

A manufacturing method utilizing a movable carrier for lenses, light-curable anti-fog materials, and ultraviolet light curing technology, which includes steps for spraying, cleaning, pre-drying, and curing, allowing for automated processing and reduced space occupation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal curing material is used with conventional heating methods, then the anti-fog coating can be formed, but the curing process takes a long time (up to 30 minutes) and requires a large, space-consuming tunnel furnace

Engineering Contradiction:

Improvecuring completenessVSAvoidcuring time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent changes the curing mechanism from thermal to photonic by using UV light instead of heat. The light-curable anti-fog material contains photoinitiators that trigger polymerization when exposed to UV radiation, enabling curing in seconds rather than minutes. This parameter change in the curing method fundamentally reduces both time and equipment space requirements.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal field (heating system) with a light field (UV curing system). Instead of using a tunnel furnace with convective heating, the invention uses UV LED or fluorescent lamps to initiate photopolymerization. This substitution of the physical field enables rapid curing without requiring large thermal mass equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional thermal curing equipment is used, then the anti-fog coating can be cured, but the equipment occupies large factory space and requires long tunnel furnaces

Engineering Contradiction:

Improvecuring effectivenessVSAvoidequipment space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent replaces the thermal field (heating system) with a light field (UV curing system). Instead of using a tunnel furnace with convective heating, the invention uses UV LED or fluorescent lamps to initiate photopolymerization. This substitution of the physical field enables rapid curing without requiring large thermal mass equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the curing mechanism from thermal to photonic by using UV light instead of heat. The light-curable anti-fog material contains photoinitiators that trigger polymerization when exposed to UV radiation, enabling curing in seconds rather than minutes. This parameter change in the curing method fundamentally reduces both time and equipment space requirements.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If manual positioning is used during spraying, then lens positioning can be adjusted, but it increases manual labor and affects coating quality due to uneven application

Engineering Contradiction:

Improvecoating uniformityVSAvoidmanual labor requirement

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent employs fixtures or jigs that automatically position and hold multiple lenses in precise, predetermined locations on the carrier. The lenses are self-positioned by the fixture geometry rather than manual adjustment, enabling consistent, uniform coating application across all lenses without requiring operator skill or attention.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual positioning operations with automated mechanical fixtures. The fixtures use precision-machined surfaces, locators, or clamps to automatically position lenses in the correct orientation and location, eliminating the need for manual handling and positioning while ensuring consistent coating quality.

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

This method enhances productivity and quality by enabling rapid curing, reducing manual labor, and minimizing space and resource requirements, while maintaining high-quality anti-fog coatings.

Implementation Method 1

radiating the plurality of lenses with ultraviolet lights, such that the light-curable anti-fog material absorbs the ultraviolet lights to cure and form an anti-fog coating

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS10247857B2Manufacturing method of anti-fog coatings on lenses

Publication Date: 2019.04.02 SUNG HSIU YING

AI summary

A manufacturing method of anti-fog coatings on lenses is provided. The method includes: a lens assembling step, a lens spraying step, a pre-drying step, a curing step and a lens obtaining step. In the lens assembling step, a plurality of lenses are disposed on a base of a movable carrier. In the lens spraying step, the plurality of lenses are moved to a spraying device and sprayed with a light-curable anti-fog material on a surface thereof. In the pre-drying step, any extra light-curable anti-fog materials are removed from the plurality of lenses by a suction device. In the curing step, the plurality of lenses are placed into a light curing apparatus and radiated by the ultraviolet lights to form an anti-fog coating on the surface of the plurality of lenses. In the lens obtaining step, the plurality of lenses are taken out of the light curing apparatus.