WO2008099061A1 - Nouveau procede de fabrication de produits optiques - Google Patents

Nouveau procede de fabrication de produits optiques Download PDF

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Publication number
WO2008099061A1
WO2008099061A1 PCT/FI2008/050059 FI2008050059W WO2008099061A1 WO 2008099061 A1 WO2008099061 A1 WO 2008099061A1 FI 2008050059 W FI2008050059 W FI 2008050059W WO 2008099061 A1 WO2008099061 A1 WO 2008099061A1
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WO
WIPO (PCT)
Prior art keywords
coating
piezo
product
layer
lens
Prior art date
Application number
PCT/FI2008/050059
Other languages
English (en)
Inventor
Olavi Nieminen
Original Assignee
Olavi Nieminen
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Olavi Nieminen filed Critical Olavi Nieminen
Publication of WO2008099061A1 publication Critical patent/WO2008099061A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
    • B05D7/26—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials synthetic lacquers or varnishes
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/11—Anti-reflection coatings
    • G02B1/118—Anti-reflection coatings having sub-optical wavelength surface structures designed to provide an enhanced transmittance, e.g. moth-eye structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00865—Applying coatings; tinting; colouring
    • B29D11/00923—Applying coatings; tinting; colouring on lens surfaces for colouring or tinting
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/02—Pretreatment of the material to be coated
    • C23C16/0227—Pretreatment of the material to be coated by cleaning or etching
    • C23C16/0245—Pretreatment of the material to be coated by cleaning or etching by etching with a plasma
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/40—Oxides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
    • C23C16/50—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges
    • C23C16/515—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges using pulsed discharges
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/11—Anti-reflection coatings
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/12—Optical coatings produced by application to, or surface treatment of, optical elements by surface treatment, e.g. by irradiation
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/20—Filters
    • G02B5/208—Filters for use with infrared or ultraviolet radiation, e.g. for separating visible light from infrared and/or ultraviolet radiation

Definitions

  • the invention relates to a method for coating an optical product made of a viscous material, the method employing an integrated automated apparatus for manufacturing a surface component which is hard, scratch-free and comprises an Anti Reflection function, in which method at least one surface of an optical product is plasma-etched and a layer comprising the antireflection function is produced using Chemical Vapor Deposition.
  • Optical products are required to have different special char- acteristics depending on their purpose of use. Commonly required characteristics include antireflection, hereinafter AR (antireflective), scratch-freeness, hereinafter SF 1 UV (Ultra Violet) light blocking, IR (Infra Red) light blocking, reflective coating, anti-fogging surface quality, etc.
  • AR antireflective
  • SF 1 UV (Ultra Violet) light blocking hereinafter SF 1 UV (Ultra Violet) light blocking
  • IR (Infra Red) light blocking IR (Infra Red) light blocking
  • reflective coating anti-fogging surface quality
  • PICVD Plasma Impulse Chemical Vapor Deposition
  • the method of the invention is characterized by manufactur- ing a hard, scratch-free adhesion layer by piezo spraying varnish onto a plasma-etched surface of an optical product, and producing said layer comprising the antireflection function onto the piezo-sprayed layer.
  • An advantage of the invention is that it allows coating expenditure to be cut significantly.
  • Figure 1 is a schematic view of a method of the invention
  • Figure 2 is a schematic view of a device used in the method of the invention.
  • Figure 3 is a schematic view of a second method of the invention.
  • Figure 4 is a schematic view of a third method of the invention.
  • Figure 5 is a schematic view of a fourth method of the invention.
  • Figure 6 is a schematic side view of an optical product, with its coat- ing layers drawn apart, manufactured using the method of the invention
  • Figure 7 is a schematic view of a second device used in the method of the invention.
  • Figure 8 is a schematic view of an end product manufactured with the method of the invention.
  • Figure 9 is a schematic side view of a fifth method of the invention;
  • Figure 10 is as schematic top view of the method of Figure 9;
  • Figure 11 is a schematic view of an end product manufactured with the method of Figure 9;
  • Figure 12 is a schematic side view of a sixth method of the inven- tion.
  • Figure 13 is a schematic view of a seventh method of the invention.
  • Figure 14 is a schematic front view of a lens preform
  • Figure 15 is a schematic side view of a lens preform
  • Figure 16 is a schematic side view of an eight method of the inven- tion
  • Figure 17 is a schematic view of a prior art method
  • Figure 18 is a schematic side view of ninth method of the invention.
  • Figure 19 is a schematic view of a tenth method of the invention. [0011] For the sake of clarity, some of the embodiments shown in the figures have been simplified.
  • the new method differs from those mentioned above in that it contains at least two different coating methods applied to the same product. Further, the method may contain not only two different coating methods, such as piezo varnishing, one application of which is inkjet printing, and PICVD, but also other work phases, which are typically significant for the good functioning of the coating methods and in which some other function, such as a decorative coating, is produced.
  • Figure 1 illustrates plasma etching.
  • the method applied is preferably one known as the open space plasma method, carried out by equipment manufactured by plasma.de, for example.
  • the coating may still be acted on chemically, for example by means of an alkali wash, which is preferably carried out by means of inkjet printing.
  • Piezo varnishing may be applied to produce other functions as well, for example a hard coating and the method may be carried out using a Xaar 1001 printing head, for example.
  • the piezo varnishing method may be applied to produce the following functional coatings, for example:
  • a photochromatic coating which may be mono-, bi- or trichro- matic and deposited either onto an optical area or a decorative area, the latter being an eyeglass frame or a mobile phone cover, for example;
  • An electrochromatic coating which may be mono-, bi- or trichromatic and deposited either onto an optical area or a decorative area, the latter being an eyeglass frame or a mobile phone cover, for example;
  • C A sol-gel coating;
  • Multi-layer coating compositions of two or more coatings or coating layers one on top of the other may be a first coating to be deposited onto the product surface may be a polyurethane varnish, which is photochromatic, and a siloxane-based hard coating may be deposited thereon. Both may be spread using an inkjet printer.
  • a decorative metal, oxide, nitride or other similar coating is produced using a laser direct write method.
  • the method allows extremely small and detailed decorative or functional coatings to be prepared both onto the optical and the non-optical area of the product.
  • Laser direct write employs a clear plastic film provided with a substance to be evaporated, such as titanium nitride, cobalt oxide or some other suitable substance to be evaporated. When the laser beam hits the plastic film, the evaporating substance in the film evaporates therefrom.
  • Figure 1 illustrates one application of the new method used primarily for coating products such as eyeglasses, sunglasses or protective eyewear, protective windows for mobile phone displays, camera lenses and displays.
  • the first actual work process is plasma cleaning of the lens and its etching 1. Cleaning and surface activation are indispensable in view of the hard varnishing or other functional coating to be carried out in the next work phase.
  • Functional coating 2 is based on piezo spraying, one application of which is inkjet printing. This is an advantageous method for coating a product with an organic coating, such as varnishes, polymers or other substances that can be brought into a flowing form.
  • InkJet printing is one of the digitally controllable methods and it allows to control the thickness of the coating and also images, logos, etc. to be produced with the coating.
  • One of the advantages of a digitally controlled process is that photochromatic and electrochromatic functional coatings, for example, may be spread in a controlled manner on only some parts of the work piece, while part of the work piece surface remains uncoated.
  • electrically conductive coating material it is possible to produce elec- trically conductive circuits or areas. Masks or other similar structures for covering areas that are to be left uncoated are not needed.
  • InkJet printing may be carried out in a normal room atmosphere, although it is often advantageous to do it in a gaseous space with no humidity.
  • the gaseous space may contain any known protective gas, dry air, nitrogen gas, etc.
  • inkjet printing the coating is formed of droplets, the volume of which is typically 2 to 100 pi. What is essential is that the surface to be coated is clean and has a suitable surface tension to allow the droplets to join together but not to move. If the droplets move, sagging is formed, the coating becomes uneven and unhomogeneous, etc.
  • a preferred coating agent, such as an organic varnish, to be used for the coating preferably contains an extremely rapidly volatile diluent, such as acetone.
  • the varnish thus adheres very quickly to the surface to be coated.
  • a 30 ⁇ m thick polyurethane varnish for example, which has a solid matter content of 33% and in which over 55% of the diluent is based on acetone or a similar extremely volatile diluter or solvent, adheres in less than 10 seconds to the extent that 50%, i.e. half, of the diluent has evapo- rated.
  • a varnish coating may be hardened in a number of ways: for example thermally, by means of infra red radiation and ultra violet radiation.
  • two principles will be disclosed in order to achieve a hardening process as rapid as possible.
  • the first one is based on providing the varnish with a material absorbing IR radiation, known as an IR absorber, which works on a specific wavelength, such as 1064 nm or 3200 nm, etc.
  • the source of radiation applicable in this case is an IR radiation source functioning on the wavelength in question.
  • the idea is that the IR radiation penetrates the actual plastic product but absorbs into the varnish.
  • the temperature of the plastic product does not rise to the extent as that of the varnish; the varnish may have a temperature of 180 0 C, for example, whereas the temperature of the plastic product may be less than 100 0 C.
  • the other principle is based on providing the varnish with material-absorbing microwaves, known as a microwave absorber, which reacts to a microwave radiation of a specific frequency, such as 2.56, 6 or 10 GHz.
  • a microwave absorber material-absorbing microwaves
  • Varnishes to be hardened by microwaves are not commercially available yet, but the inventor has developed such varnishes. It has been observed that varnishes to be hardened with microwaves may be hardened even in half the time it takes to harden varnishes with infrared radiation.
  • electrically conductive optical coatings such as electrochromatic coatings, from ITO (indium tin oxide), for example, may be challenging to produce if PICVD is used.
  • One of the embodiments of the new method comprise a third coating method based on vacuum coating methods, such as sputtering, e-beam or laser ablation.
  • vacuum coating methods such as sputtering, e-beam or laser ablation.
  • the vacuum process to be used is not restricted to any specific alternative or work order. These are determined separately on the basis of the product to be prepared and the desired functions to be provided therein.
  • One of the methods that may be used is the one known as the sol-gel method.
  • FIG. 1 According to the operating principle of Figure 1 , one or more products (a lens) are placed to jigs.
  • a jig is denoted in Figure 2 with reference numeral 14 and in Figure 7 with reference numeral 59.
  • the products are arranged so as to allow them to be taken through the system in a controlled manner into separate work process spaces 1, 2, 3, 4, 5, 6 and 12.
  • the jig 14 leaves 11 the system and the actual products 13 may be removed and placed into their correct packaging.
  • Reference numeral 9 denotes a protected intermediate space between the different work points.
  • Figure 2 shows an application of the jig 14 with lenses 15 and 16 arranged thereto.
  • the lenses are eyeglass lenses, for example, this application consisting of two lenses in one jig 14, although it is naturally also possible to have one or more of them.
  • What is essential is that the jig 14 taken through the whole system.
  • Figure 2 shows a function in which the jig 14 may be rotated about its own central axis 18. This is an essential procedure especially when both surfaces of the product 15 and 16 are to be piezo-printed, because the printing of the product is preferably carried out from above 19 towards the surface of the product.
  • a typical rotation/turning angle is 180°, which is extremely simple to achieve by using a mechanical gripping means 17, or a linear manipulator.
  • the new method includes three main ways of carrying out the piezo varnishing.
  • Figure 3 shows what is known as the grey-zone coating principle.
  • Figure 4 illustrates a three-axle linear varnish system which has a rotating piezo nozzle 75 and in which the product remains immobile.
  • Figure 18 illustrates an application in which the product rotates about its own central axis 85 and piezo varnishing is carried out by moving the end from the centre of the product to the edge thereof.
  • Figure 3 illustrates a grey-zone piezo varnish application, in which either a piezo nozzle 20 or a lens 22, 23, 26 moves in such a way that they overlap.
  • the lens is advantageously in a horizontal position so that a varnish spray 21 is directed downwards from above, gravity providing a natural explanation for why this happens. Otherwise the piezo varnishing could be carried out in any position whatsoever.
  • An advantageous way to use a piezo comb 24 is to hold it in place and take the product 23 underneath 25 the comb.
  • Grey-zone piezo printing means that an extremely precise amount of varnish, for example 3 pi per spray droplet, may be applied with extreme precision. This would be most simple if the lens surface were absolutely even, but that is exactly what it is not.
  • the piezo comb 24 is pre-programmed to place the varnish droplets according to a predetermined geometry onto a specific 3D surface.
  • a lens 66 is placed to a jig 77 enabling convenient rotation thereof, i.e. both sides of the lens 66 are very easy to coat, i.e. the jig 77 may be rotated 180° very rapidly without touching the lens 66.
  • a piezo spray head 70 is arranged to a holder 75 that may rotate ⁇ 40°, for example, about its central axis.
  • the holder 75 in turn is at- tached to a linear axis 69 and 74 forming a travel path in a Z form, the path being in turn linked to a linear axis 74 of a Y-formed movement via a holder 67.
  • the lens is rotated at a constant speed about 84 its own central axis 83, the dispensing rate of the piezo spray head 70 may be changed as the spray head moves towards the outer side 86.
  • Figure 5 illustrates the operating principle of the new method and shows plasma etching 49, hard coating 50 carried out by means of piezo printing, AR coating by means of CVD, most preferably using precisely PICVD 51 , while finishing may be carried out using an extremely hard coating, such as aluminium oxide or some other functional coating, such as an electromagnetic coating provided by laser ablation 52.
  • an extremely hard coating such as aluminium oxide or some other functional coating, such as an electromagnetic coating provided by laser ablation 52.
  • Schott AG as well as Satisloh AG and Carl Zeiss AG, disclose a product attached to a jig, and a holder, both being placed into a PICVD vacuum chamber typically by means of a manipulator.
  • the product is not even entirely in the PICVD chamber, as shown in Figures 9, 10 and 11 , but in the form of a film or a plate, a part of the piece being left between the blocking surfaces of the chamber.
  • the AR function is arranged to the rear surface of the protective window, i.e. to the surface closest to the display. This is particularly essential in applications in which the protective window does not come into contact with the display itself, i.e. in applications, in which a void is left between the protective window and the display.
  • the antireflection function may be produced onto the rear surface of the plastic plate or film in a number of ways, for example: by providing the rear surface with a "moth eye” structured surface function, by vacuum evaporation of the coating containing the antireflection, by providing the rear surface with a coating made of varnish or plastic that is in a flowing form or with a coating made by the sol-gel method.
  • the thickness of the plastic plate or film is typically 30 ⁇ m to 4 mm, and it forms part of the end product.
  • a product typi- cally a plate or a band
  • it also allows the rear surface to be kept clean and speeds up the entire process significantly.
  • a lens for a mobile phone may be manufactured ( Figure 5) in such a way that at least plasma treatment 49, piezo printing with varnish 50 and creation of AR surfaces using the PICVD method are included in the production process.
  • Mobile phone lenses (Figure 11), which typically are sub- jected not only to the processes shown in Figure 5 but also to decorative printing or metallization, are not separate products; instead, they are joined into a plate form accommodating at least two product items.
  • Figure 6 shows the different surfaces 53 to 57 and the technological level used for producing them onto the surface of the lens 52.
  • the first coating is an organic or a non-organic varnish substrate 53, typically 100 nm to 100 urn thick and produced onto the surface of the lens 52 by the piezo spray method.
  • Layers 54 and 55 are not indispensable, but an IR and LJV blocking coatings may be included among those that are and they may be pro- prised using for example e-beam, sputtering or laser ablation.
  • the agent used for the coating may be ITO (Indium Tin Oxide), ATO (Aluminium Tin Oxide) or some other oxide or oxide composite.
  • the varnish substrate 53 of the piezo varnish process of the first work phase may itself be provided with nanofillers added thereto and having the same functionality, i.e. the IR/UV blocking feature.
  • a further essential coating is represented by the AR functional coatings 56 produced by a CVD method, preferably by PICVD, and with Si ⁇ 2 and TiU2 used as agents.
  • an anti-fogging coating 57 for example, may be used as the final coating.
  • Figure 7 shows a lens 60 placed to the jig 59 to a holder provided with a memory 61 , 62 or coding 63, such as a data matrix, RF-id (Radio Frequency ID), i.e. each lens 60 is always identifiable irrespective of where it is located.
  • the product is kept in the same jig throughout the work process.
  • a jig 59 with clear gripping areas 65 shaped in such a way that they are easy to grab mechanically is preferred.
  • Figures 8 to 11 relate to each other and illustrate an application of the new method, in which the work process is directed to a band, film or plate (reference numerals 114 and 116 in Figure 11 , reference numerai 126 in Figure 12 and reference numeral 138 in Figure 13).
  • the band, film or plate is taken through the disclosed work processes ( Figure 5) in such a way that the end product, such as a mobile phone lens (reference numeral 146 in Figure 13), is cut off from a larger plate, band, film in question to produce the end product, such as a finished mobile phone lens.
  • Figures 8, 9, 10 and 11 illustrate how to produce not 1 million but more than 50 million lenses per production unit annually, and this with a manufacturing apparatus that is less expensive than Satisloh PiCoat-8R, for example, the maximum production volume of which is 1 million items/year and the amount of human resources needed is not higher than two persons per work shift.
  • Figure 10 shows an end product, such as a mobile phone lens 111 , in which on top of the basic lens material 105, such as PC, PMMA 1 PA or other viscous material, there is provided a decorative printing 109, hard printing 106 produced by means of piezo spray varnishing, AR coatings 107 provided using PICVD and possibly some other coating 108 produced by laser ablation, e-beam, sputtering, sol-gel, or some other way.
  • the basic lens material 105 such as PC, PMMA 1 PA or other viscous material
  • the lens 111 is to be coated separately, two lenses are placed against each other 110 in such a way that the structured surfaces 112 remain facing each other when they travel through the different work proc- esses.
  • Figures 8 to 11 form a series illustrating a solution to the capacity problem, i.e. they show how to obtain a considerably higher production capacity without having to build more physical capacity.
  • the basic idea of the application is that (Figure 13, reference numeral 138) there is no separate, de- tached lens 146, but a predefined area to which lenses 139 to be detached later may be placed.
  • a single surface area of an A4 size accommodates 20 lenses of 40 x 60 mm.
  • This area is either an independent plastic plate of the A4 size, for example, (reference numeral 138 in Figure 13), or a corresponding area may be arranged onto a larger plastic plate or film (refer- ence numeral 126 in Figure 12).
  • the piezo spray printing 128 in Figure 12 comprises a hard varnishing or a functional coating (reference numeral 106 in Figure 10), and a decorative portion (reference numerals 101 and 129 in Figure 12).
  • CVD coating is carried out in a vacuum chamber (reference numeral 131 in Figure 12), most preferably by means of PICVD onto the same area that was earlier subjected to hard, functional and/or decorative coating 128.
  • the plate/film 130 is advanced stepwise to allow any final work phases 137 to be carried out, such as coatings required by touch- sensitive screen functions, soil repellent coating, etc., or a decorative coating, produced by means of laser direct write method, for example, which is one of the laser ablation applications.
  • the lenses 139 are cut off from the A4 surface area by means of laser, high-pressure water jet cutter, grinding, sawing or piercing, after which the product is completed.
  • the entire area is cut off 175 and moved 176 with the coated side facing up 177.
  • two identical pieces 175 of A4 size, for example, are cut off, one of them being rotated 180 c 178 and the pieces being arranged in such a way that the structured surfaces, which are not coated, of both plates 177, 179 face each other.
  • the plate pack 177, 179 is then placed into a CVD vacuum chamber in such a way that the outer surfaces, i.e. the surfaces that were piezo-varnished earlier, become aligned with the vacuum spaces 187 and 188 of the chambers.
  • the coating is then carried out using the CVD method, for example, only those plate surfaces that are facing the vacuum space 187, 188 are coated, whereas the area between the plates 177 and 179 does not become coated at all, because it does not relate in any way to the vacuum spaces 187 and 188.
  • the chamber walls 180 of the vacuum space 187, 188 are moved 189 and 190 away from each other, thus allowing the lens plate pack with both its plates 177 and 179 to be removed, spread onto the working platform with their front side 184, 185 up and cut off by means of laser, water cutting, grinding, sawing or some other way. As an end result, a lens 111 according to Figure 8 is obtained.
  • the new method represents two applications, in the first one of which separate products, such as eyeglass lenses, are handled in the basic form in which they normally appear, i.e. in a standard round shape prior to the adjustment and shaping of the lens.
  • separate products such as eyeglass lenses
  • specific holders, jigs are used to which one or more eyeglass lenses may be placed.
  • the lenses are attached to jigs, which are then taken through all desired work processes in an automated manufacturing method.
  • the coating is always applied to both sides.
  • the method of coating eyeglasses differs from the coating of protective lenses for mobile phone dis- plays, for example, in that the latter is always subjected to a planar surface that has usually already been subjected to other work processes, such as decorative printing carried out by piezo printing, for example, and typically also vacuum metallization.
  • the first application is meant for the treatment of piece goods, different lenses.
  • the second application of the new method Is as follows:
  • the method involves a surface area of a predetermined size, such as A4 of 225 x 280 mm to which 24 lens areas of 50 x 60 mm in size may be placed.
  • a surface area such as the disclosed A4 size, to which all the work processes are subjected. This means that there would be 24 lens areas, from which 24 separate lenses would be produced simultaneously, in one and the same work process. Further, this would mean that a 24-fold number of end products, i.e. production capacity.
  • display covers whether a display cover lens of 50 x 60 mm for a mobile phone, or a plasma, led, oled or some other display technology of 50 inches, only on one side of the display cover may be touched, i.e. on the side facing outwards. Normally the side of the display cover facing the display itself may not be touched, i.e. it is completely protected from contact.
  • the plate surface in question (Figure 11) is provided with at least 20 lenses of 50 x 60 mm, at least one side of which ⁇ Figure 9) has been subjected to all coating work processes; decorative printing 101 , functional coating and hard coating by means of piezo varnishing 106, AR surfaces by means of the PICVD method and eventually some other coating 108 produced by means of laser ablation or laser direct write method, for ex- ample.
  • the size of the work piece is of an order corresponding to a paper of A4 size, the end products being then cut off from this plate by means of laser A, water cutting B or grinding C, whereby independent products are obtained.
  • the hard coating D and the adhesion or gripping coating E are not produced using PICVD but by means of piezo var- nishing.
  • the fact that the new method does not employ the PICVD work process for producing adhesion coating E and hard coating D provides a number of advantages.
  • Coating thicknesses may vary according to application.
  • a simple varnish coating, such as a siloxane-based hard varnish coating applied directly onto the surface of the plastic piece typically has a thickness of 3 to 30 ⁇ m, for example 6 ⁇ m.
  • Coatings comprising a plural number of layers may have even hundreds of layers one on top of the other, trichromatic graphic and photochromattc coating serving as an example.
  • the thickness of a single coat- ing layer may be in the order of 100 nm, although a layer thickness as high as 3 to 30 ⁇ m is naturally also possible.
  • a coating composition comprising a photochromatic function of a polyurethane varnish base may have a total thickness of 5 to 500 ⁇ m, for example.
  • a basic idea of an embodiment of this new method is that PICVD is used for manufacturing only the antireflective coating onto the optical area and possibly also the IR and UV blocking coatings.
  • Other coatings are made of an organic varnish that may contain functional additives, such as photochromatic molecules.
  • the capacity required of the PICVD equipment is not as great as it would be if all the coatings were produced using the PICVD method.
  • the thickness of coatings made by PICVD is typically not more than 50 to 500 nm, whereas the thickness of organic varnish coatings produced by inkjet printing is typically over 5 ⁇ m.
  • a further point to be noted is that it is extremely difficult to use inorganic materials, such as Si ⁇ 2 or Ti ⁇ 2 , to produce all the coatings, i.e. also supporting coatings, which the new method enables to manufacture from organic varnish by means of inkjet printing.
  • the optical product to be coated is made of plastic, such as CR39, PMMA, PC, PA, etc., whose thermal expansion coefficient is many times higher than that of the inorganic materials mentioned.
  • plastic such as CR39, PMMA, PC, PA, etc.
  • the CVD method involves some weaknesses, such as the contamination of the walls of the vacuum chamber; in other words, they receive a surface layer. This complicates significantly serial manufacture for a number of reasons. Firstly, the walls with a surface layer substantially slow down the suction of the vacuum, i.e. the cycle length increases considerably. Secondly, the composition and stability of the gas mixture are disturbed. These are the essential reasons for why CVD is, on the whole, rarely used for manufacturing large series.
  • the new method allows any known CVD method to be applied, although the PICVD (Plasma Impulse Chemical Vapor Deposition) method of Schott AG would be the simplest one to apply, particularly because of it enables the growth mechanism of the surface thickness to be controlled.
  • the PICVD method of Schott AG has been applied to coating inner surfaces of plastic packages, such as PET bottles, to which the method suits excellently. All processes in the method take place within one and the same closed space and thus the coating chamber is not contaminated at all.
  • a product such as a plastic plate, film, band, of which there are two in the most preferred form, is placed between a moving mould frame 241 , 251 and a fixed chamber body 250.
  • the method differs from the PICVD method of the Schott AG type in that when the microplasma 255 is torched, over 90% of the coating is directed to where it is meant to, i.e. to the surface 258 of the product.
  • the other surface 257 in turn remains completely clean, i.e. it is not coated at all. Thus contamination is not directed to anything else but to the inner surface 256 of the chamber body 250.
  • the new method thus allows problems related to known CVD applications, such as the application of the Schott AG, to be largely eliminated.
  • the product/work piece 259 and 260 is placed in such a way that it forms a part of the blocking surface at the same time as the moving walls 241 and 251 of the chamber body block the plates, the product surfaces 259 and 260 against the static body 250.
  • the suction process of the vacuum is carrier out such that an identical pressure level is provided in the main chamber 262, in the actual process chamber and in the secondary vacuum spaces 261 by means of vacuum suction conduits 243 and 246.
  • the front side of the movable secondary chambers 241 and 251 i.e. the planar surface 248 and 252, from where the microwaves are di- rected to the actual process space 262, is typically made of glass, for example quartz glass or plastic, or generally of a substance that does not prevent the propagation of microwaves.
  • the frequency of the radiation is typically between 500 MHz and 500 GHz, although other frequencies, generally from 2.5 to 13.5 GHz, are also possible.
  • the embodiment of Figure 13 employs a jig 282, i.e. a holder, to which a lens 277 is placed. However, a holder is not necessary.
  • Figures 14 and 15 illustrate a lens preform characterized in that in addition to a conventional lens surface or optical area 290 it has a frame area 291 , which is constant in all parts, whatever the 3D geometry of the lens area.
  • frame area 291 which is constant in all parts, whatever the 3D geometry of the lens area.
  • sidewall of the lens may be used as the contact area, the rest of product surface being cosmetic and not to be touched at any stage of the work process. This is why jigs/holders of different types in one respect or another are always used in vacuum coating steps.
  • a frame 291 of standard dimensions is dis- closed, the dimensions being always standard irrespective of the geometry of the actual lens area 290.
  • the method provides the following advantages: use of an automated coating system is significantly easier, automation is simpler, jigs/holders can be totally disposed of, the production cycle becomes significantly speedier and thereby production volumes per production unit are greater, and the production equipment required is less complex/less expensive.
  • the coating may consist of oxides or oxide composites, such as ITO (Indium Tin Oxide) or ATO (Aluminium Tin Oxide) etc., in the form of reflective or mirror coatings, a coating regulating darkness according to the interference of light and produced around the world by the Eastman-Kodak method.
  • ITO Indium Tin Oxide
  • ATO Alluminanium Tin Oxide
  • the problem is that the more complicated the coating, the greater the likelihood that a plural number of different production technologies must be applied and therefore the optical product must be transferred from one manufacturing apparatus to another. It is therefore a major advantage if the product to be coated always has a same size or shape, like the frame 291 in Figure 24, that may be touched during the process and at the same be used as a part of the production process.
  • the frame may be provided with a number of production control codes, such as an RF-ID, a data matrix, a bar code, a mechanical shape or some other code or identifier.
  • production control codes such as an RF-ID, a data matrix, a bar code, a mechanical shape or some other code or identifier.
  • the work piece is thus easy to move and to hold by the lens 297, and the frame may further act as a sealing surface to the edge of the chamber wall, whereby no jig or holder needs to be inserted into the vacuum.
  • the work piece 308, i.e. the lens 308, provided with a standard frame 309 is placed, unlike in Figure 13, into a vacuum chamber of two parts 301 and 302 in such a way that the product itself, the lens 308 forms an interface, whereby two substantially separate process spaces 306 and 307 are formed. Both sides of the lens 308 are coated simultaneously in the CVD process, although the volumes of the process spaces 306 and 307 as such are only a fraction of a normal CVD vacuum space in which the work piece is attached to a jig or a holder.
  • FIG. 16 discloses a new application, in which the vacuum spaces 306 and 307 are minimal, whereby the supply of different gases 310 and 311 is extremely efficient and rapid and, likewise, residual gases 312 are extremely efficiently and rapidly discharged.
  • the PICVD method functions like a two-stroke engine: gas 310 is supplied into the vacuum chambers 306 and 307, the gas is torched to form plasma by means of microwaves 303 and 304, whereby a surface layer of a predetermined thickness is produced onto the surface of the work piece 308.
  • gas 310 is supplied into the vacuum chambers 306 and 307, the gas is torched to form plasma by means of microwaves 303 and 304, whereby a surface layer of a predetermined thickness is produced onto the surface of the work piece 308.
  • more gas must be fed into the chambers 306 and 307 and, prior to this, the previous gas must be removed, the volume of the vacuum thus being of a great importance as regards the time taken up by the production process.
  • FIG. 13 illustrates the operating principle of this new application, in which an essential aspect is that only one side of the lens 275 and 276 is placed facing inward 277 into the process chamber 271.
  • the CVD method such as one of the Schott AG type, produces the best possible efficiency when the surface not associated with the product, such as the lenses 275 and 276, is minimized.
  • the smaller the volume of the CVD vacuum chamber the more efficient is the gas supply 272 and 273 into the chamber 271 , i.e. its cycle rate is higher, and the faster is the gas discharge 274.
  • the shape of the vacuum chamber 271 is relevant to the end result.
  • a round cylindrical shape is the best, and the lower the vacuum space cylinder is, the better, because tests have shown that a cylinder height between 20 and 200 mm is optimal. If an eyeglass lens 275 and 276 of 070 mm is to be coated and the height of the vacuum chamber 271 is 50 mm, the volume is ⁇ 2 dl, which is 1/30 of the chambers used in prior art methods.
  • Another advantage in the use of a process space, or vacuum, of an extremely small volume is that the amount of process gas used is considerably less, which in turn is a cost factor.
  • the CVD vacuum coating chamber 271 is cylindrical and its diameter corre- sponds to that of the work piece to be coated, and the vacuum chamber is open at both ends.
  • the work pieces, such as the two lenses 275 and 276, to be coated in the chamber are placed at opposite ends of the chamber.
  • the vacuum level/gas pressure is lowered/raised to correspond to ambient val- ues, the lenses 275 and 276 are reversed 281 180° and placed so that the other side faces the coating chamber. After the other side has also been coated similarly, the product is finished.

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  • Optics & Photonics (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
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  • Health & Medical Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
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  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Surface Treatment Of Optical Elements (AREA)
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  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

L'invention concerne un procédé de revêtement d'un produit optique fabriqué à partir d'un matériau visqueux. Ce procédé met en œuvre un appareil automatisé intégré pour fabriquer un composite de surface dur, exempt de rayures et doté d'une fonction anti-reflet. Selon ce procédé, au moins une surface du produit optique (52) est gravée au plasma et une couche dotée de la fonction anti-reflet (56) est obtenue par un procédé de dépôt chimique en phase vapeur (DCPV). Le procédé selon l'invention consiste à fabriquer une couche d'adhérence dure et exempte de rayures (53) par piézo-pulvérisation de vernis sur la surface gravée au plasma du produit optique (52) ; et à produire la couche dotée de la fonction anti-reflet (56) sur la couche piézo-pulvérisée (53).
PCT/FI2008/050059 2007-02-14 2008-02-13 Nouveau procede de fabrication de produits optiques WO2008099061A1 (fr)

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FI20070131 2007-02-14
FI20070131A FI20070131L (fi) 2007-02-14 2007-02-14 Uusi menetelmä valmistaa optisia tuotteita

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2170589A1 (fr) * 2007-07-04 2010-04-07 Theta Optics LTD OY Procédé et équipement de production d'une pièce optique
DE102014013528A1 (de) 2014-09-12 2016-03-17 Schott Ag Beschichtetes Glas-oder Glaskeramiksubstrat mit beständigen multifunktionellen Oberflächeneigenschaften, Verfahren zu dessen Herstellung und dessen Verwendung
EP2891905A4 (fr) * 2012-08-31 2016-05-25 Hoya Corp Procédé de fabrication de lentille optique
EP3982558A1 (fr) * 2015-02-02 2022-04-13 Wi-Charge Ltd. Récepteur de puissance optique

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US6051310A (en) * 1994-06-27 2000-04-18 Essilor International-Compagnie Generale D'optique Ophthalmic lens made of organic glass with a shockproof intermediate layer, and method for making same
EP1136973A1 (fr) * 1999-09-06 2001-09-26 Seiko Epson Corporation Verre de recouvrement
WO2003066307A1 (fr) * 2002-02-06 2003-08-14 Jari Ruuttu Procede permettant d'ameliorer la qualite d'un produit, par exemple d'un produit optique, tel qu'une lentille de telephone portable
US20040142105A1 (en) * 2002-08-02 2004-07-22 Kazuaki Sakurada Application method, applicator, optical member, and optical device
US20040156983A1 (en) * 2002-12-17 2004-08-12 Vision-Ease Lens, Inc. Rapid, thermally cured, back side MAR resistant and antireflective coating for ophthalmic lenses
US20060182901A1 (en) * 2003-12-24 2006-08-17 Konica Minolta Opto, Inc. Stretched cellulose ester film, hard coat film, antireflective film, and optical compensation film, and polarizing plate, and display device using them
WO2006090000A1 (fr) * 2005-02-23 2006-08-31 Pintavision Oy Piece comprenant des elements optiques detachables et procede de fabrication de celle-ci

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6051310A (en) * 1994-06-27 2000-04-18 Essilor International-Compagnie Generale D'optique Ophthalmic lens made of organic glass with a shockproof intermediate layer, and method for making same
EP1136973A1 (fr) * 1999-09-06 2001-09-26 Seiko Epson Corporation Verre de recouvrement
WO2003066307A1 (fr) * 2002-02-06 2003-08-14 Jari Ruuttu Procede permettant d'ameliorer la qualite d'un produit, par exemple d'un produit optique, tel qu'une lentille de telephone portable
US20040142105A1 (en) * 2002-08-02 2004-07-22 Kazuaki Sakurada Application method, applicator, optical member, and optical device
US20040156983A1 (en) * 2002-12-17 2004-08-12 Vision-Ease Lens, Inc. Rapid, thermally cured, back side MAR resistant and antireflective coating for ophthalmic lenses
US20060182901A1 (en) * 2003-12-24 2006-08-17 Konica Minolta Opto, Inc. Stretched cellulose ester film, hard coat film, antireflective film, and optical compensation film, and polarizing plate, and display device using them
WO2006090000A1 (fr) * 2005-02-23 2006-08-31 Pintavision Oy Piece comprenant des elements optiques detachables et procede de fabrication de celle-ci

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2170589A1 (fr) * 2007-07-04 2010-04-07 Theta Optics LTD OY Procédé et équipement de production d'une pièce optique
EP2170589A4 (fr) * 2007-07-04 2014-04-09 Theta Optics Ltd Oy Procédé et équipement de production d'une pièce optique
EP2891905A4 (fr) * 2012-08-31 2016-05-25 Hoya Corp Procédé de fabrication de lentille optique
DE102014013528A1 (de) 2014-09-12 2016-03-17 Schott Ag Beschichtetes Glas-oder Glaskeramiksubstrat mit beständigen multifunktionellen Oberflächeneigenschaften, Verfahren zu dessen Herstellung und dessen Verwendung
DE102014013528B4 (de) 2014-09-12 2022-06-23 Schott Ag Beschichtetes Glas-oder Glaskeramiksubstrat mit beständigen multifunktionellen Oberflächeneigenschaften, Verfahren zu dessen Herstellung und dessen Verwendung
EP3982558A1 (fr) * 2015-02-02 2022-04-13 Wi-Charge Ltd. Récepteur de puissance optique
US11855705B2 (en) 2015-02-02 2023-12-26 Wi-Charge Ltd. Distributed optical resonator with thin receiver unit

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FI20070131A0 (fi) 2007-02-14

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