玻璃透鏡鍍膜的基本知識
大家知道，任何物體對光線都有反射作用，這也是我們能看到東西的原因。對于鏡片而言，為了使得光線能夠完全透過鏡頭，在底片上完全反映自然的真實(shí)情況，鏡頭盡量是各種光線完全穿過。優(yōu)質(zhì)的光學(xué)玻璃，其光線透過率可達(dá)到90%以上，
尚余的光損失就需要在透鏡表面鍍上膜來彌補(bǔ)。所以，在光學(xué)玻璃透鏡上主要是鍍減反射膜也叫增透膜。為了滿足各種要求，往往需要鍍多層膜。為了提高玻璃透鏡的抗劃傷能力，外面的一層往往是高硬度的膜。在實(shí)驗(yàn)室里，現(xiàn)代的工藝技術(shù)幾乎可以達(dá)到光線百分之百通過。之所以這么說，是因?yàn)樵趯?shí)際使用中，透鏡上會或多或少地受灰塵、臟物等的影響，使得透過鏡頭的光線減少。鍍膜的方法很多，但常規(guī)的方法也就那么幾種。
(一)、化學(xué)方法，包括溶膠—凝膠法、化學(xué)氣相沉積等方法。根據(jù)膜的性質(zhì)配制一定成分的溶液，然后：
1、浸鍍。把潔凈的玻璃加熱到一定溫度，然后放入配置好的化學(xué)溶液里，拿出，烘干。這種膜顯然是雙面膜。
2、噴鍍。把配置好的膜溶液裝在噴槍上，噴到潔凈的、熱的玻璃表面。烘干。玻璃體可以是移動或旋轉(zhuǎn)，以增加膜的均勻性?？慑冸p面或單面。 (以前鏡頭鍍膜有采用所謂的甩膠法，但由于不經(jīng)濟(jì)，現(xiàn)代工藝鍍無機(jī)膜時(shí)已將其淘汰，但它仍然是鍍有機(jī)膜的一種常用、成本低廉的方法)。
以上是玻璃透鏡鍍膜常用的方法，隨著LED照明廣泛的發(fā)展，對玻璃透鏡的要求也越來越高，越來越多的公司要求給玻璃透鏡鍍膜，來增強(qiáng)透鏡的實(shí)用性。
光學(xué)玻璃透鏡的生產(chǎn)流程
近年來由于科技的發(fā)展與進(jìn)步，光學(xué)玻璃透鏡的制造過程，從熔融原料到押胚成型，多采用自動化生產(chǎn)方式的一貫作業(yè)，以提高品質(zhì)及生產(chǎn)量而降低成本。光學(xué)玻璃制造廠商通常著重于開發(fā)新產(chǎn)品、生產(chǎn)技術(shù)及效率的提升、品質(zhì)的改善以及制造成本的降低等等，而不擴(kuò)張生產(chǎn)設(shè)備。因此，從接單到出貨，往往費(fèi)時(shí)數(shù)月。光學(xué)玻璃的制造程式大約如下:
一、制造熔解爐：熔解爐有黏土爐及白金爐兩種。近年來，滲入稀有元素的光學(xué)玻璃都使用小型白金爐，以維持品質(zhì)的穩(wěn)定。
二、放入光學(xué)玻璃原材料：熔解爐（尤其是黏土爐）經(jīng)過長時(shí)間的干燥后，放入按照特殊配方以及經(jīng)過選別的原材料于熔解爐中，準(zhǔn)備熔融。
三、加熱、熔解、攪拌：加熱條件，視材質(zhì)而定。但是，各種材質(zhì)務(wù)必?cái)嚢杈鶆?，以求均質(zhì)。
四、冷卻：長時(shí)間予以「徐冷」。但是，時(shí)間的長短也因材質(zhì)而異，這是能保證優(yōu)良品質(zhì)的最重要的過程。
五、劈爐、選別：劈開黏土爐（注四），取出塊狀粗胚并且選別它。
六、檢查、測試、整型：逐項(xiàng)檢查或測試其各項(xiàng)性能，確保優(yōu)良品質(zhì)。
七、切斷、倒角（修邊）：將塊狀粗胚按照用途及規(guī)格，予以切斷成小塊并且倒角。
八、押胚成型：將粗胚加熱軟化后，按照工程圖的各項(xiàng)規(guī)格，押胚成型。但是，要事先制造或準(zhǔn)備各種模具、工具及副料等。
九、燒鈍：退火鈍化，消除內(nèi)部應(yīng)力。
十、測試、檢查：測試押胚的光學(xué)性能及外觀。該成品將成為下游工業(yè)（光學(xué)元件制造加工廠）的毛胚，繼續(xù)加工研磨后，成為光學(xué)元件。
Basic Knowledge of Coating for Glass Lenses
As we all know, all objects reflect light, which is why we can see them. For lenses, to allow light to pass completely through and accurately reflect the natural scene onto film or sensors, it is ideal for lenses to let as much light as possible pass through. High-quality optical glass can achieve a light transmittance of over 90%. The remaining light loss is addressed by applying coatings to the lens surface.
On optical glass lenses, anti-reflective coatings, also known as anti-glare coatings, are primarily applied. To meet different requirements, multiple layers of coatings are often used. To improve scratch resistance, the outermost layer is typically a high-hardness coating.
In laboratories, modern technology can achieve nearly 100% light transmission. However, in practical applications, lenses are often affected by dust, dirt, and other contaminants, which reduce the amount of light passing through the lens.
There are many coating methods, but only a few are commonly used in the industry. These methods are designed to enhance lens performance and meet the diverse needs of various applications.
(1) Chemical Methods
Chemical methods for coating include the sol-gel method and chemical vapor deposition (CVD). These techniques involve preparing a solution with specific components based on the desired properties of the coating. The process generally includes the following steps:
1. Dip Coating:
Clean the glass thoroughly and heat it to a specific temperature.
Immerse the heated glass into the prepared chemical solution.
Remove the glass and allow it to dry.
This method typically results in a double-sided coating on the glass surface.
2. Spray Coating
? The prepared coating solution is loaded into a spray gun and sprayed onto the clean, heated surface of the glass.
? After spraying, the glass is dried.
? To improve the uniformity of the coating, the glass can be rotated or moved during the process.
? This method allows for coatings on one or both sides of the glass.
(Note: In the past, the "spin-coating method" was used for lens coating, but it has been replaced in modern processes for inorganic coatings due to inefficiency. However, it remains a common and cost-effective method for organic coatings.)
With the widespread development of LED lighting, the demand for coated glass lenses is increasing. Many companies now require coatings on glass lenses to enhance their practicality and performance.
Production Process of Optical Glass Lenses
In recent years, advancements in technology have revolutionized the manufacturing process of optical glass lenses. From melting raw materials to press molding, automation has been widely adopted to improve quality and production efficiency while reducing costs. Optical glass manufacturers focus on developing new products, enhancing production techniques, improving quality, and reducing manufacturing costs, rather than expanding production facilities. As a result, the lead time from order to shipment often takes several months.
Typical Manufacturing Steps for Optical Glass:
1. Furnace Construction:
Furnaces are categorized as clay furnaces or platinum furnaces.
In recent years, rare-element-doped optical glass is manufactured in small platinum furnaces to maintain stable quality.
2. Loading Raw Materials:
After prolonged drying, the selected raw materials, based on specific formulations, are loaded into the furnace for melting.
3. Heating, Melting, and Stirring:
Heating conditions depend on the material.
Uniform stirring is essential to ensure homogeneity across different materials.
4. Cooling:
The molten material undergoes prolonged annealing to cool gradually.
Cooling time varies depending on the material and is critical for ensuring high-quality output.
5. Furnace Opening and Sorting:
The furnace is opened, and solidified glass chunks are extracted and sorted.
6. Inspection and Testing:
Various properties of the glass are inspected and tested to ensure quality.
7. Cutting and Chamfering:
The glass chunks are cut into smaller pieces according to the required specifications and chamfered for refinement.
8. Press Molding:
The glass is heated and softened, then pressed into shapes as per engineering specifications.
Molds, tools, and auxiliary materials must be prepared in advance.
9. Annealing:
The glass undergoes annealing to remove internal stress and stabilize its structure.
10. Final Testing and Inspection:
The pressed blanks are tested for optical performance and appearance.
These blanks are then supplied to downstream industries (such as optical component manufacturers) for further processing, grinding, and polishing into finished optical components.
