Vacuum Coating Masking Arrangement for Gradient Lens Production
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Solution Overview
Problem
Existing vacuum coating technologies for gradient lenses require opening and re-establishing a vacuum to switch between coating steps with and without shadowing effects, making large-scale production inefficient.
Innovation Solution
A box coating apparatus with a masking arrangement that can selectively assume a screening or non-screening state, allowing for in-situ coating with or without shadowing effects under the same vacuum conditions, using a rotating dome and gradient sector portions that can be moved between open and closed positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the aperture ring is used for shadowing substrates during gradient coating, then the gradient effect is achieved, but the aperture ring must remain in position which prevents subsequent non-screened coating steps without requiring vacuum chamber opening
Solution Approach 1:
The masking arrangement is designed to be dynamically reconfigurable, allowing the aperture ring to move between a first position for gradient coating and a second position for non-screened coating. This dynamic capability enables the system to adapt to different coating requirements without requiring vacuum chamber opening, thereby improving productivity while managing device complexity through controlled movement mechanisms.
Solution Approach 2:
The masking arrangement is segmented into movable and fixed components. The aperture ring can be moved independently to different positions, allowing flexible configuration for different coating modes. This segmentation enables the system to switch between gradient and non-gradient coating by repositioning only the masking component rather than the entire system.
2Loss of time
If the aperture ring is moved to allow non-screened coating, then subsequent coating steps can be performed under vacuum, but the masking arrangement requires additional movement mechanisms
Solution Approach 1:
The masking arrangement incorporates movement mechanisms that allow the aperture ring to transition between positions during the coating process. This dynamic repositioning eliminates the need to open and close the vacuum chamber between different coating steps, significantly reducing time loss while the movement mechanisms are designed to be integrated into the existing vacuum system architecture.
3Manufacturing precision
If the aperture ring remains in position for gradient coating, then gradient effect is maintained, but the aperture ring blocks the evaporation path for non-screened coating
Solution Approach 1:
The masking arrangement is designed with movable components that can be repositioned between different coating modes. During gradient coating, the aperture ring remains in the first position to maintain precision. For non-screened coating, the aperture ring moves to the second position to clear the evaporation path, enabling the system to adapt to different manufacturing requirements while maintaining precision when needed.
Solution Approach 2:
The masking system is segmented to allow independent movement of the aperture ring relative to the substrate holder. This segmentation enables the aperture ring to be positioned precisely for gradient coating when required, and moved away when non-screened coating is needed, providing both precision and versatility.
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 coating of gradient spectacle lenses with layer thickness and color variations by eliminating the need to open and re-establish the vacuum, significantly reducing processing time.
Implementation Method 1
a vacuum coating apparatus for vacuum coating of substrates, in particular spectacle lens blanks
Implementation Method 2
the zones of the substrate which lie in the shadow or half-shadow of the screen are vapor-coated less intensely than the exposed zones
Implementation Method 3
screens have already been proposed which shadow regions of the substrate area to be coated with respect to the evaporator crucible
Data Source
AI summary
A box coating apparatus for vacuum coating of substrates has a vacuum chamber containing an evaporation source and a substrate holder formed as a dome related to the evaporation source and rotatable about an axis. A masking arrangement is located in between for partially shadowing the substrates on the substrate holder relative to the evaporation source. The masking arrangement comprises a fixed masking portion stationary in the vacuum chamber, and a plurality of gradient sector portions carrying gradient shields assigned to the substrates on the substrate holder, for forming a gradient mask. The gradient sector portions can be rotated about the axis between a gradient mask open position where they are stored behind the fixed masking portion, and a gradient mask closed position where they are spread like a fan between the evaporation source and the substrate holder.