OPTICAL ELEMENTS HOLDER DEVICE FOR A COATING STATION

Abstract

An optical elements holder device for a coating station is provided, including: a sheet carrier having holes and presenting a shape of a dome or a part of a dome; and elastic blocking means fixed to the sheet carrier associated with each hole and including at least three elastic contact portions distributed on a circumference of each hole and configured to block a block piece carrying a lens blank to hold the lens blank in a predetermined position for coating. A coating station for optical elements and a method for coating an optical element in a coating station are also provided.

Claims

1.-15. (canceled)

16. An optical elements holder device for a coating station, comprising: a sheet carrier having holes and presenting a shape of a dome or a part of a dome; and elastic blocking means fixed to the sheet carrier associated with each hole and comprising at least three elastic contact portions distributed on a circumference of said each hole and configured to block a block piece carrying a lens blank to hold the lens blank in a predetermined position for coating.

17. The optical elements holder device according to claim 16, wherein the elastic contact portions are regularly distributed on the circumference of said each hole.

18. The optical elements holder device according to claim 16, wherein the elastic blocking means further comprises an O-ring made of elastic material.

19. The optical elements holder device according to claim 18, wherein the O-ring is made of fluoroelastomer.

20. The optical elements holder device according to claim 19, wherein the O-ring is housed in an annular ring housing of the optical element holder device, the annular ring housing being disposed in a hole.

21. The optical elements holder device according to claim 20, wherein the annular ring housing is welded to the sheet carrier.

22. The optical elements holder device according to claim 20, wherein the annular ring housing is detachably fixed to the sheet carrier.

23. The optical elements holder device according to claim 22, wherein the annular ring housing presents clipping fastening means for clipping the annular ring housing into a hole of the sheet carrier.

24. The optical elements holder device according to claim 20, wherein the annular ring housing presents an alignment bar configured to cooperate with a transverse central groove on a backside of the block piece.

25. The optical elements holder device according to claim 16, wherein the elastic blocking means further comprises a metallic cylinder welded in a centered position, with respect to an associated hole, to the sheet carrier and presents at least three elastic inwardly bent cutouts tongues configured to cooperate with a backside of the block piece and to fix the latter in a centered position with respect to the associated hole.

26. The optical elements holder device according to claim 25, wherein the metallic cylinder presents an alignment bar configured to cooperate with a transverse central groove on a backside of the block piece.

27. A coating station for optical elements, comprising at least one optical elements holder device according to claim 16.

28. A method for coating an optical element in a coating station according to claim 27, the method comprising: picking up a block piece carrying a lens blank having a face to be coated; inserting the block piece into a hole of a sheet carrier, thereby automatically blocking the block piece in a removable way in a centered position to hold the lens blank (SFB) in a predetermined position for coating; coating the lens blank; and extracting the block piece from the hole of the sheet carrier.

29. The method for coating an optical element according to claim 28, wherein the steps of picking up, inserting, and extracting of the block piece are carried out robotically.

30. The optical elements holder device according to claim 16, wherein the elastic contact portions are made of elastic material.

Description

BRIEF DESCRIPTIONS OF THE DRAWINGS

[0053] Other advantages and characteristics will appear with the reading of the description of the following figures:

[0054] FIG. 1 is a schematic view in cross-section of an optical element fixed on a block piece,

[0055] FIG. 2 is a schematic cross section of a coating station according to the invention,

[0056] FIG. 3 is a schematic view in perspective of an optical elements holder device according to the invention,

[0057] FIG. 4 is a schematic view in cross section of a part of a sheet carrier and an optical element fixed on a block piece shown according to a first embodiment of the invention,

[0058] FIG. 5 is a another schematic view in cross section of a part of the sheet carrier according to the first embodiment,

[0059] FIG. 6 is a schematic view in perspective of a part of the sheet carrier according to the first embodiment and an elastic blocking means,

[0060] FIG. 7 is a schematic view in perspective of a part of the sheet carrier of an optical elements holder device according to a second embodiment,

[0061] FIG. 8 is a schematic view in perspective of a part of the sheet carrier of an optical elements holder device according to a third embodiment,

[0062] FIG. 9 is a schematic view in perspective of a part of the sheet carrier of an optical elements holder device according to a fourth embodiment,

[0063] FIG. 10 is a schematic view in perspective of a side receiving the block piece with the optical element fixed thereon and of a part of the sheet carrier according to the fourth embodiment,

[0064] FIG. 11 is a schematic view in cross section of a part of the sheet carrier according to the fourth embodiment, with a block piece received into a hole of the sheet carrier,

[0065] FIG. 12 is a schematic view in perspective of FIG. 11,

[0066] FIG. 13 is a larger schematic view in perspective of an example of a sheet carrier of the optical elements holder device according to the fourth embodiment receiving a block piece with an optical element mounted thereon,

[0067] FIG. 14 is a schematic view in perspective of an elastic blocking means to be fixed to the sheet carrier of an optical elements holder device according to a fifth embodiment,

[0068] FIG. 15 is a schematic view of the elastic blocking means of FIG. 14 cooperating with the backside of a block piece.

DETAILED DESCRIPTION

[0069] The embodiment(s) in the following description are only to be considered as examples. Although the description refers to one or several embodiments, this does not mean inevitably that every reference concerns the same embodiment, or that the characteristics apply only to a single embodiment. Simple characteristics of various embodiments can be also combined to new embodiments that are not explicitly described.

[0070] In the present description, the terms “upstream” and “downstream” are used according the following meaning: a first station for a certain processing operation of an optical element is placed upstream with respect to a second station when the optical element undergoes first the operation in the first station and then another operation in the second station.

[0071] And a first station for processing a certain processing operation of an optical element is placed downstream with respect to a second station when the optical element undergoes first the operation in the second station and then another operation in the first station.

[0072] In the figures is shown a reference triad X-Y-Z, where X and Y are two horizontal axes perpendicular to each other and Z is a vertical axis perpendicular to X and Y.

[0073] Block pieces as used in the present description satisfy for example the standard DIN 58766 of 1998 for manufacturing of optical elements in optical engineering and related DIN 58739-5 defining collets for block pieces for manufacturing optical lenses. Both standards are incorporated by reference.

[0074] In FIG. 1 is shown an optical element 3 which is for example a lens blank, in particular a semi-finished lens blank SFB which is fixed to a block piece B.

[0075] A semi-finished lens blank SFB comprises for example a first face cx, a second face cc opposite said first face cx, and an edge E between the first face cx and the second face cc.

[0076] The first face cx possesses a final curvature (not shown in the drawing) and is already coated, starting from a substrate comprised of, e.g., mineral glass, polycarbonate, PMMA, CR 39, Trivex<®>, HI index, etc., as the case may be, with a standard hard coating HC, a standard antireflection coating AR on top of the hard coating HC, a standard top coating TC on top of the antireflection coating AR, and a special temporary grip coating GC on top of the top coating TC.

[0077] As is known per se, the antireflection coating AR comprises for example a stack of alternating antireflection layers of high index HIL and low index LIL with an outermost, in FIG. 1 lowest layer. The top coating TC is selected from a group comprising hydrophobic, oleophobic and dirt repelling coatings, as known.

[0078] The thickness of the temporary grip coating GC may range from 1 to 500 nm, preferably from 5 to 100 nm, and more preferably from 10 to 20 nm, in particular 15 nm.

[0079] Further, in FIG. 1 reference sign CB designates a combination of the above semi-finished lens blank SFB and a block piece B for holding the semi-finished lens blank SFB for processing thereof, in particular for coating process in a coating station 5 (see FIG. 2).

[0080] As to the structure and function of a currently preferred block piece B explicit reference is being made at this point to document EP 2 093 018 A1 of the present applicant which is incorporated by reference.

[0081] Such block piece B, which can be used in thin film coating processes under vacuum conditions, typically has a basic body made from a plastic material, with a workpiece mounting face F for attachment of the lens blank SFB with the aid of a blocking material M on one side, and a clamping portion C on the other side which is configured to be grasped by an elastic blocking means (detailed later on in the description) during coating. Clamping portion C has a cylindrical portion CY and a frustoconical shape (truncated cone) CF.

[0082] Generally speaking, during lens processing, the lens blank SFB is blocked on the basic body of the block piece B in a machine or apparatus for processing of the lens blank SFB, and to provide in particular for reliable and secure mounting to the processing equipment throughout the whole process while avoiding damage and/or deformation to the lens blank SFB.

[0083] As far as a presently preferred blocking material M is concerned, which is applied directly onto the temporary grip coating GC of the lens blank SFB and preferably comprises an adhesive curable by UV or visible light that is liquid in an un-polymerized state, explicit reference is being made at this point to document EP 2 011 604 A1 of the present applicant which is incorporated by reference. In order to enhance the bonding effect, the workpiece mounting face F of the block piece B may be plasma treated prior to applying the blocking material M onto the workpiece mounting face F.

[0084] During manufacturing of spectacle lenses, the second face cc of the semi-finished lens blank SFB needs to be coated in the coating station 5 as shown in FIG. 2.

[0085] However, in alternative embodiments, one may consider that face cc possesses a final curvature and is already coated. In this case the semi-finished lens blank SFB is fixed and blocked with its face cc on the block piece B and the cx face shall receive an AR coating.

[0086] FIG. 2 shows a cross sectional view of an example of a coating station 5 for application in particular of an AR coating to the face cc of the semi-finished lens blank SFB.

[0087] In a manufacturing process of spectacle lenses, the coating station 5 is generally disposed downstream a lens surfacing station (not shown) which gives a desired surface contour to face cc and downstream one or more cleaning stations and an hard coating station needed to prepare the surfaced face cc of the semi-finished lens blank SFB for coating under vacuum.

[0088] By “lens surfacing”, it is understood in particular polishing, grinding or fine grinding and the overall object is to yield a finished spectacle lens so that the curvature of the first (in this instance convex) face cx and the curvature of the machined second (in this instance concave) face cc cooperate to yield desired optical properties according to a prescription of the user of the spectacle lenses.

[0089] The coating station 5 comprises a vacuum chamber 7 that is connected to a vacuum pump system 8. On the bottom of the vacuum chamber 7 is disposed a vaporization source 9.

[0090] During coating, a not shown vaporization material is heated, for example by an electric heating device or an electron beam source in order to vaporize or sublimate the vaporization material (schematically shown by arrows 10) that will be deposited on the optical elements 3, in particular the face cc of the semi-finished lens blank SFB.

[0091] The coating station 5 further comprises an optical elements holder device 11 which is hanging from the top wall 13 of the vacuum chamber 7 and is connected, through a rotation axis 15, to a drive motor 17 configured to rotate (arrows 19) the optical elements holder device 11.

[0092] Rotation of the optical elements holder device 11 during coating ensures averaging spatial inhomogeneity of the vaporization cone during coating.

[0093] As can be seen on FIG. 3, the optical elements holder device 11 comprises one or several sheet carrier(s) 21 for example metal sheet carrier(s) having a plurality of holes 23, such as circular holes, and presenting the shape of a dome or a part of a dome in order to put all optical elements 3 to the same distance with respect to the vaporization source 9.

[0094] In FIG. 3 is shown in dotted lines a dome frame 22 configured to support four different sheet carriers 21, only one them having circular holes 23.

[0095] As can be seen on FIG. 4, the optical elements 3 are mounted in a releasable manner upside down in the optical elements holder device 11. Thus in FIG. 2, one can see the backside of the block piece B, the semi-finished lens blank SFB pointing in direction towards the vaporization source 9.

[0096] In order to allow easy mounting of the optical elements 3 blocked on the block piece B, an elastic blocking means 24 associated to each hole 23 is fixed to the sheet carrier 21.

[0097] This can be seen more in detail in FIG. 4 which is a schematic view in cross section of a part of a sheet carrier 21 and an optical element 3 fixed on a block piece B of a first embodiment according to the invention.

[0098] According to this embodiment, the elastic blocking means 24 comprises an O-ring 25 of elastic material, like i.e. a fluoroelastomer like VITON (registered trademark) by the company DuPont.

[0099] A fluoroelastomer as elastic material has the advantage to withstand the vacuum conditions during coating and not to contaminate the coating process.

[0100] In order to mount the optical element 3 with its associated block piece B into a hole 23, one only has to grasp or to picking up the block piece B on its lateral sides and to insert it by pushing along arrow 27 into the hole 23. The movement to insert the block piece B into the hole 23 is quite simple so that it may be carried out by a robot programmed to realize the mounting instead of a human operator.

[0101] As the internal diameter of the O-ring 25 is slightly smaller than the largest diameter of the clamping portion C, the O-ring 25 will be radially compressed and will hold the block piece B by friction regularly contacting the block piece B on all the circumference of the hole 23. The O-ring 25 will then clamp the block piece B in a releasable manner and block the block piece B in a centered position such that the semi-finished lens blank SFB is hold in a predetermined position for coating.

[0102] As can be seen in FIGS. 4 and 5, the thickness of the sheet carrier 21 is large enough to allow creation of an inner circumferential groove 29 in the wall of the hole 23 receiving the O-ring 25.

[0103] According to one aspect, the O-ring 25 may be hold only through mechanical clamping though the form of the inner circumferential groove 29. This allows changing the O-ring 25 when worn for example.

[0104] According to another aspect, the O-ring 25 may be bond through adapted glue to the sheet carrier 21.

[0105] A mounted O-ring 25 is shown in FIG. 6.

[0106] In this first embodiment, the O-ring 25 will be in contact over its entire internal diameter with the block piece B, more specifically with the entire cylindrical portion CY of the clamping portion C. Therefore the O-ring 25 has infinity of elastic contact portions in contact with the clamping portion C of the block piece B to block the latter in a centered position in order that the semi-finished lens blank SFB may be hold in a predetermined position for coating.

[0107] According to a not shown alternative, the O-ring may be replaced by, for example three, four or five elastic protuberances fixed to the inside of the hole 23, protruding towards the center of the latter one, and in particular regularly distributed on the circumference of the hole 23. Each elastic protuberance forms an elastic contact portion with the block piece B when the latter is inserted into the hole 23. Thus the elastic contact portion is made of an elastic material.

[0108] By regularly distributed, it is meant that the angular distance between the protuberances is equal. In case of three protuberances, the angular distance between the center of the protuberance is 120°, in case of four 90° etc.

[0109] In a specific variant, for example for three protuberances, the latter are not regularly distributed, but for example according to a “Y” configuration.

[0110] According to a second embodiment shown in FIG. 7, the O-ring 25 is housed in a separate annular ring housing 31 of the optical elements holder device 11, the annular ring housing 31 being arranged in a hole 23.

[0111] The annular ring housing 31 has for example a stepped outer side wall 33 formed by a first ring portion 33A having a smaller diameter than the one of the hole 23 and a second ring portion 33B having a larger diameter than the one of the hole 23. As in the previous embodiment, the annular ring housing 31 presents an inner circumferential groove 29 receiving the O-ring 25.

[0112] For fixing the annular ring housing 31 in the hole 23, one may consider the possibility to weld the annular ring housing 31 to the sheet carrier 21, in particular when made of metal.

[0113] The third embodiment shown in FIG. 8 is similar to the second embodiment but differs in particular by the fact that the annular ring housing 31 is detachably fixed to the sheet carrier 21. For this purpose, the annular ring housing 31 is formed by a cover ring 35 comprising for example bayonet fitting means, such as three axial fixing lugs 37 that cooperate via bayonet coupling with correspondent recesses 39 (or cutouts) of the hole 23 of the sheet carrier 21.

[0114] In this embodiment, the cover ring 35 also compresses the O-ring 25 along a direction perpendicular to the sheet carrier 21. This contributes to fix the annular ring housing 31 to the sheet carrier 21.

[0115] According to a not shown alternative to this third embodiment, the annular ring housing 31 presents clipping fastening means for clipping the annular ring housing 31 into the hole 23 of the metal carrier sheet 21. This may be realized for example by particular axial fixing lugs 37 of a cover ring 35 that not rotate. Those axial fixing lugs 37 are elastic and present an insertion ramp at their tips. They can snap outwardly when inserted axially into the recesses 39 of the hole 23.

[0116] FIG. 9 relates to a fourth embodiment having some similarities with both the second embodiment shown in FIG. 7 and the third embodiment shown in FIG. 8.

[0117] Indeed, the fourth embodiment is similar to the second embodiment because the O-ring 25 is housed in a separate annular ring housing 31, having a stepped outer side wall 33 formed by a first ring portion 33A having a smaller diameter than the one of the hole 23 and a second ring portion 33B having a larger diameter than the one of the hole 23. As in the previous embodiment, the annular ring housing 31 presents, in the first ring portion 33A, an inner circumferential groove 29 receiving the O-ring 25.

[0118] Similar to the third embodiment, the annular ring housing 31 presents three axial fixing lugs 37 (only one of them is visible in FIG. 9).

[0119] Furthermore, the outer skirt of the first ring portion 33A presents three ramps 41 (only two are visible in FIG. 9) disposed between the axial fixing lugs 37 and configured to cooperate with the border of the hole 23. The ramps 41 may be realized by a sheet metal strip welded to the outer skirt of the first ring portion 33A, or may be realized by machining or milling operations or additive production methods.

[0120] According to another aspect, the annular ring housing 31 comprises an alignment element like for example an alignment bar 43 configured to cooperate with the backside of the block piece B in particular with a transverse central groove 45 (FIGS. 11 and 12) on the backside of the block piece B. As shown later on, this alignment bar 43 serves as a stop during insertion of the block piece B and allows fixing the angular position of the block piece B in the hole 23. It is understood that also other alignment elements supported by the annular ring housing 31 may be foreseen like a protrusion pointing for example in direction of the center axis of the annular housing 31. The basic principle behind is to get a well-defined mounting of the block piece B into the annular ring housing 31 according to the Poka Yoke principle.

[0121] For cooperation with this annular ring housing 31, the hole 23 of the sheet carrier 21 has three notches 47 for inserting the axial fixing lugs 37 and three peripheral cutouts 49, each in connection to a notch 47, for insertion of the ramps 41.

[0122] For releasable mounting the annular ring housing 31 on the sheet carrier 21, an axial insertion movement inserting the axial fixing lugs 37 in the correspondent notches 47 followed by a rotation like a screw movement has to be operated.

[0123] FIG. 10 shows the annular ring housing 31 of FIG. 9 mounted in a hole 23 of a sheet carrier 21. The axial fixing lugs 37 cooperate with the underside of the sheet carrier 21 which faces the vaporization source 9.

[0124] FIGS. 11 to 13 show respectively in a cross sectional view and two views in perspective the annular ring housing 31 of FIGS. 9 and 10 mounted in a hole 23 of a sheet carrier 21 and a block piece B supporting a semi-finished lens blank SFB inserted into the annular ring housing 31. These figures also show the alignment bar 43 as alignment element cooperating with the backside of the block piece B for angular orientation within the hole 23 and for acting as a stopper.

[0125] FIGS. 14 and 15 show a fifth embodiment where the elastic blocking means 24 comprises a metallic cylinder 51 and presenting at least three, regularly distributed elastic inwardly bent cutouts tongues 53 for cooperation with the backside of the block piece B and fixing the latter in a centered position with respect to the associated hole 23 of the sheet carrier 21.

[0126] The metallic cylinder 51 furthermore presents an alignment bar 43 similar to that of other embodiments described above and configured to cooperate with a transverse central groove 45 on the backside of the block piece B.

[0127] The metallic cylinder 51 is for example welded in a centered position with respect to an associated hole 23, to the sheet carrier 21 on the side of the latter opposing the vaporization source 9.

[0128] In inserting the block piece B into the metallic cylinder 51, elastic inwardly bent cutouts tongues 53 form three elastic contact portions which are i.e. regularly distributed on the circumference of the hole 23 and configured to block in a centered position the block piece B. The elastic inwardly bent cutouts tongues 53 will press against the clamping portion C, in particular cylindrical portion CY, of the block piece B and fix thus the optical element 3 in position, ready for a coating process. This embodiment is also quite simple in construction because the tongues are functioning as a spring to contact and to press the block piece B and they do not need further/other elastic means.

[0129] The present invention also relates to a method for coating an optical element 3 in a coating station 5 as described above and comprising the following steps: [0130] picking up a block piece B carrying a lens blank, in particular a semi-finished lens blank SFB having a face cc to be coated, [0131] inserting the block piece B into a hole 23 of the sheet carrier 21 thereby automatically blocking the block piece B in a removable way for example in a centered position in order that the lens blank SFB may be hold in a predetermined position for coating, [0132] coat the lens blank SFB, [0133] extract the block piece B from the hole 23 of the sheet carrier 21.

[0134] The steps of picking up, inserting and extracting the block piece B may be carried out manually or preferentially by a not shown robot.

[0135] As already mentioned above, face cc and cx may be inverted in the sense that face cx needs to be coated and not face cc of the semi-finished lens blank SFB.

[0136] One can understand easily that the optical elements holder device 11 according to the invention eases the manipulation of the semi-finished lens blanks SFB and even allows robotizing of the coating method.

[0137] In addition, in particular with regard to the embodiments shown on the figures, back-deposition on the clamping portion C of block piece B is avoided, allowing therefore multiple re-use of the block piece B.

LIST OF REFERENCES

[0138] SFB—Semi-finished lens blank [0139] B—Block piece [0140] Cx—First face (i.g. convex) [0141] Cc—Second face (i.g. concave) [0142] E—Edge [0143] HC—Hard coating [0144] AR—Anti-reflection coating [0145] TC—Top coating [0146] GC—Grip coating [0147] HIL—High index anti-reflection layer [0148] LIL—Low index anti-reflection layer [0149] CB—Combination of SFB and B [0150] M—Blocking material [0151] C—Clamping portion [0152] CY—Cylindrical portion of the clamping portion [0153] CF—Frustoconical portion of the clamping portion [0154] F—Workpiece mounting face [0155] A—Rotation axis [0156] OA—Optical axis [0157] 3—Optical element [0158] 5—Coating station [0159] 7—Vacuum chamber [0160] 8—Vacuum pump system [0161] 9—Vaporization source [0162] 10—Arrow [0163] 11—Optical elements holder device [0164] 13—Top wall [0165] 15—Rotation axis [0166] 17—Drive motor [0167] 19—Arrows [0168] 21—Sheet carrier [0169] 22—Dome frame [0170] 23—Holes [0171] 24—Elastic blocking means [0172] 25—O-ring [0173] 27—Arrow [0174] 29—Circumferential groove [0175] 31—Annular ring housing [0176] 33—Outer side wall [0177] 33A—First ring portion [0178] 33B—Second ring portion [0179] 35—Cover ring [0180] 37—Axial fixing lugs [0181] 39—Recesses [0182] 41—Ramps [0183] 43—Alignment bar [0184] 45—Transverse central groove [0185] 47—Notches [0186] 49—Peripheral cutouts [0187] 51—Metallic cylinder [0188] 53—Elastic inwardly bent cutout tongues