Coating apparatus – Control means responsive to a randomly occurring sensed... – Responsive to attribute – absence or presence of work
Reexamination Certificate
1999-03-17
2001-10-02
Crispino, Richard (Department: 1734)
Coating apparatus
Control means responsive to a randomly occurring sensed...
Responsive to attribute, absence or presence of work
C118S052000, C118S056000, C118S058000, C118S320000, C118S500000, C118S503000, C118S695000, C427S164000, C427S165000, C427S168000, C427S425000, C427S557000, C427S558000
Reexamination Certificate
active
06296707
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to equipment used in the manufacture of lenses and deals more particularly with an automated device for applying protective and other coatings to lens surfaces.
BACKGROUND OF THE INVENTION
Lenses, particularly those used in the manufacture of eyeglasses, are generally fabricated from a polymeric material, such as polycarbonate. While these materials are lightweight, making the eyeglasses more comfortable to wear, they are not overly scratch resistant. To address this problem, a scratch resistant coating is typically applied to the lens surfaces.
Sometimes, this coating is applied manually, subjecting the coating process to human error potentially resulting in the lens surface being unevenly coated causing distorted vision for the person wearing the eyeglasses incorporating these lenses. In addition to distorted vision, improperly applied coatings can also result in reduced scratch resistance on the lens surface. Often a dip coating process is employed where the lenses are immersed in a coating resin and then cured in an oven. This process is expensive and time consuming as the lens must be cured for several hours.
To minimize the possibility of human error, machinery has been developed to automate the lens coating process. However, these prior art machines are normally quite large and cumbersome, as well as expensive. These factors make it difficult for retail eyeglass suppliers to have such a machine in their establishments. Accordingly, in order to supply consumers with scratch resistant lenses, these retail outlets usually send the lenses to larger facilities possessing the coating machinery to have the coating applied to each lens. This increases the cost of, and the time a consumer must wait for the finished eyeglasses.
Based on the foregoing, it is the general object of the present invention to provide an apparatus that overcomes the difficulties and drawbacks of prior art lens coating techniques and machinery.
It is a more specific object of the present invention to provide a highly automated, cost effective apparatus sized for use in retail eyeglass outlets for applying a coating to a lens surface.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus for coating a surface of at least one lens having a pair of opposed major surfaces. The apparatus includes a frame having at least one lens support coupled thereto. Mounting means are provided for releasably retaining at least one lens on the lens support, leaving one of the major surfaces of the lens exposed. A mounting plate is coupled to the frame proximate to the lens support and is adapted to carry a plurality of work stations thereon for performing various different work operations on the exposed lens surface. Each of the work operations performed by each of the work stations involves a step related to coating a surface of at least one lens. Indexing means are also provided to effect relative motion between the mounting plate and the lens support to thereby facilitate the performance of the work operations on the exposed lens surface. A controller coordinates the sequence of the work operations to be performed on a lens in response to lens coating data stored therein.
In the preferred embodiment of the present invention, the abovedescribed work stations include a wash station for cleaning the exposed lens surface, a coating station for depositing and dispensing coating solution onto the exposed lens surface, and a curing station for solidifying the deposited coating solution. During operation of the apparatus, air is introduced between the mounting plate and the indexing means to maintain a positive pressure in the apparatus thereby minimizing the potential for foreign matter to find its way therein. The air is introduced via a fan, through a HEPA filter and flows laminarly between the mounting plate and the indexing means. In addition a pneumatic cylinder is mounted to the frame at one end and coupled to the mounting plate at an opposite end for moving the mounting plate between a working position wherein at least one of the plurality of work stations is positioned adjacent to the lens support for the performance of a particular work operation; and a non working position wherein the mounting plate is located away from the lens support to allow the lens support to be indexed relative to the mounting plate.
Preferably, the indexing means includes a turntable rotatably mounted to the frame and having two lens supports attached thereto. The turntable is rotationally indexable relative to the mounting plate by a suitable drive such as, but not limited to a servo motor or stepper motor. During operation, the controller coordinates the rotation of the turntable to position the lens supports proximate to the work stations facilitating the simultaneous performance of different work operations on each lens carried by each of the lens supports. For example, one of the lens supports can be positioned adjacent to the coating station while the other lens support is located adjacent to the washing station. Accordingly, a coating and washing operation, or, depending on the turntable position; a curing and coating operation can be accomplished simultaneously.
The lens supports each include a mounting adapter coupled thereto and defining a bore for carrying a resilient support member upon which the lens is seated. The support member has a plurality of perforations extending therethrough and is made from a suitable material such as silicone. Means are provided for drawing vacuum through the perforations in the support member for pulling the lens thereagainst, releasably retaining the lens on the lens support. In this manner the material of the support member and its resiliency allows a large areal portion of a lens surface to be supported, preventing any damage to the lens.
Preferably, the wash station includes a wash cup defining an interior area and having an opening adapted to receive the lens support and the exposed lens surface when the lens support is positioned proximate to the wash station. Means for depositing a quantity of high-pressure washing fluid onto the exposed lens surface are also included and are preferably in the form of a nozzle. The nozzle is located within the wash cup and in fluid communication with a reservoir filled with washing fluid, such as, but not limited to deionized water.
The lens supports are rotatably mounted to the turntable and spun in response to commands issued from the controller by suitable means such as, but not limited to a servo motor. During a washing operation, the servo motor causes the lens support and thereby the lens to rotate generating a centrifugal force that acts on the washing solution applied to the rotating, exposed lens surface, causing the washing solution to spread thereover. The washing solution is expelled from the exposed lens surface and collects in a gutter defined by the wash cup. The collected washing solution then drains into a collection basin supported by the frame. Subsequent to the removal of the washing solution, the rotation of the lens support is stopped and a drying solution is applied to the exposed lens surface via a second nozzle positioned in the wash cup and coupled to a pressurized reservoir containing the drying solution. Once the drying solution is applied, the lens support once again rotates the lens and excess drying solution is expelled from the lens surface collected in the gutter and drained into the collection basin.
The coating station includes a housing carried by the mounting plate and having an interior area defined by at least one housing wall. An opening is provided in the housing and in communication with the interior area for receiving one of the lens supports having a lens mounted thereon. Applicator means, preferably in the form of a nozzle, are located within the housing and are adjustable relative thereto for depositing a known quantity of at least one lens coating solution onto the exposed lens surface in response to commands issued from the contro
Adamczyk Anthony P.
Bowley Glenn E.
Dahill John
Edwards Richard
Hall Lonzell
Crispino Richard
Gerber Coburn Optical Inc.
Lorengo J. A.
McCormick Paulding & Huber LLP
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