Vacuum Nebulization Coating Machine for Optical Articles
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Solution Overview
Problem
Existing methods for coating ophthalmic lenses, such as spectacle lenses, are complex, require removal of the lens from the frame, and often damage underlying coatings, limiting the range of usable coating compositions and increasing costs.
Innovation Solution
A compact machine using vacuum nebulization and plasma treatment within a single vacuum chamber allows for controlled deposition of a wide range of liquid coating compositions without removing the lenses from the frame, ensuring the underlying coatings are not damaged and enabling easy operation by opticians.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If existing coating methods are used, then coating can be applied to lenses, but the process is complex and requires removal of lenses from frames
Solution Approach 1:
The patent combines the vacuum chamber, plasma treatment system, and coating deposition system into a single integrated device. The lens remains in the frame throughout the entire process, with the frame itself serving as the mounting structure during treatment. This merging of functions eliminates the need for separate lens removal and mounting steps, directly resolving the contradiction between operational ease and device complexity.
2Adaptability or versatility
If plasma treatment is used to remove initial coating, then coating replacement is enabled, but underlying coatings may be damaged
Solution Approach 1:
The plasma treatment is applied selectively and controllably to the lens surface through the vacuum chamber system. The plasma parameters (power, duration, gas composition) are optimized to remove only the outermost coating layer while preserving the underlying anti-reflective and other functional coatings. This localized and controlled approach enables coating replacement without damaging the lens structure or underlying coatings.
3Manufacturing precision
If vacuum nebulization is used for coating deposition, then controlled deposition is achieved, but specialized equipment is required
Solution Approach 1:
The vacuum nebulization system is integrated into the existing vacuum chamber infrastructure. The same vacuum pump and chamber used for plasma treatment also support the nebulization coating process. This merging of vacuum infrastructure eliminates the need for separate specialized equipment, achieving precise controlled deposition while reducing overall device complexity and cost.
4Ease of manufacture
If lenses are removed from frames for coating, then coating application is possible, but handling complexity increases
Solution Approach 1:
The vacuum chamber is designed to accommodate lenses in their frames, with the frame serving multiple functions: structural support, lens mounting, and direct placement within the treatment chamber. This universal approach allows the same device to handle both coated and uncoated lenses, and to process lenses in various frame types, eliminating the need for special handling procedures and reducing operational complexity.
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 solution provides a simple, economic, and efficient method for applying or replacing anti-soiling or anti-fogging coatings on spectacle lenses, allowing for a broader range of coating compositions and reducing the need for specialized equipment and handling.
Implementation Method 1
a vacuum pump (20) configured to suck gases from the interior space (31) of the vacuum chamber (8)
Implementation Method 2
a nebulizer (40) configured to nebulize the predetermined coating composition which is liquid into a mist of aerosol droplets
Implementation Method 3
a plasma generator (11) configured to carry out a vacuum plasma treatment of the optical article (28) in the vacuum chamber (8)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention provides a machine for coating an optical article with a predetermined coating composition, comprising a vacuum chamber (8) having an interior space (31) configured to receive said optical article, a vacuum pump (20) connected to said vacuum chamber (8), a nebulizer (40) configured to carry out a vacuum nebulization treatment of said composition for depositing it on said optical article in said vacuum chamber, and a control unit (2) configured to control said vacuum pump; said control unit being configured to cause the vacuum pump to suck gases from said vacuum chamber to bring it to a predetermined required pressure for said vacuum nebulization treatment, and said control unit and said nebulizer are configured to nebulize said predetermined coating composition which is liquid into a mist of aerosol droplets and to direct said droplets towards at least a surface of said optical article.