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PMMA lenses",{"_85":817,"_811":818},"hardBreak",[819],{"_85":814},{"_85":810,"_811":821,"_810":823},[822],{"_85":814},"are coated with a scratch",{"_85":817,"_811":825},[826],{"_85":814},{"_85":810,"_811":828,"_810":830},[829],{"_85":814},"-resistant coating in an",{"_85":817,"_811":832},[833],{"_85":814},{"_85":810,"_811":835,"_810":837},[836],{"_85":814},"inline process to produce",{"_85":817,"_811":839},[840],{"_85":814},{"_85":810,"_811":842,"_810":844},[843],{"_85":814},"high-quality optical goods",{"_85":817,"_811":846},[847],{"_85":814},{"_85":810,"_811":849,"_810":851},[850],{"_85":814},"at Eschenbach GmbH.",{"_85":817,"_811":853},[854],{"_85":814},{"_85":810,"_811":856,"_810":858},[857],{"_85":814},"An inline coating process uses a new hard coating to give optical PMMAlenses a high scratch resistance. Developed jointly over a period of fouryears by a producer of optical components and a research institute, thecoating is applied immediately after the lenses have been injection moulded.After production had been started up, IMI was taken on a guided tour ofthe injection moulding and coating plant by Christian Wengrzik, head ofthe Technical Centre at manufacturer Eschenbach.",{"_85":817,"_811":860},[861],{"_85":814},{"_85":817,"_811":863},[864],{"_85":814},{"_85":810,"_811":866,"_810":868},[867],{"_85":814},"Project Partners",{"_85":817,"_811":870},[871],{"_85":814},{"_85":817,"_811":873},[874],{"_85":814},{"_85":810,"_811":876,"_810":878},[877],{"_85":814},"Eschenbach Optik GmbH & Co. of Nuremberg, Germany, was foundedin 1913 and currently produces spectacle frames, microscopes, binoculars,optical instruments, and high-grade lenses and optical systems for magnifyingglasses and seeing aids (Figure 1). The company has a payroll of 350, achievedsales of more than DM 127 million (US$ 71 million) in 1996, and sells itsproducts to 27,000 opticians in 60 countries. Eschenbach has its own branchesin the principal ultimate consumer markets of Europe. The growth in itsforeign business, which is currently running at 12 percent per annum, hasdriven its export share up to 32 percent. The niche market for magnifyingglasses and seeing aids accounts for approximately 80 percent of the productsmanufactured by Eschenbach itself. More than 1 million of these were soldin 1996. Eschenbach has invested DM 15 million (US$ 8.4 million) in itsnew Technical Centre, which was completed in 1997.",{"_85":817,"_811":880},[881],{"_85":814},{"_85":817,"_811":883},[884],{"_85":814},{"_85":810,"_811":886,"_810":888},[887],{"_85":814},"The Fraunhofer Institute of Silicate Research (ISC) in Wurzburg, Germanyis one of the 47 research facilities run by the Fraunhofer Society. Witha staff of more than 8,000 and annual expenditure of DM 1.3 billion (US$726 million), the Fraunhofer Society is Europe's biggest applied researchorganization, conducting contract research for industry and the governmentin virtually all fields of technology and natural science. The ISC is primarilyengaged in the wet chemical synthesis of inorganic, hybrid inorganic, andhybrid inorganichttps://www.plasticstoday.com/organic substances and ceramics from soluble precursors.The ISC is also engaged in the technological conversion of these into suchproducts as powders, fibers, compact materials, and coatings. Coatingsdeveloped at the ISC can be applied to workpieces and components to givethem such highly specific properties as scratch resistance, reduced reflection,and corrosion proofing. The services provided by the Institute range fromadvice on material and technology development, via prototype production,right through to transfer into industry. Obtaining protection for resultsand developments through patent rights also forms part of the Institute'swork.",{"_85":817,"_811":890},[891],{"_85":814},{"_85":817,"_811":893},[894],{"_85":814},{"_85":810,"_811":896,"_810":898},[897],{"_85":814},"Patented Development",{"_85":817,"_811":900},[901],{"_85":814},{"_85":817,"_811":903},[904],{"_85":814},{"_85":810,"_811":906,"_810":908},[907],{"_85":814},"The basic patents for the process developed by Eschenbach are alsoheld by the Fraunhofer Society. Eschenbach, however, has been granted theexclusive use of the jointly developed technology through license agreements.Interlinking of both the injection moulding process and the coating applicationconstituted the most important process-engineering constraint.",{"_85":817,"_811":910},[911],{"_85":814},{"_85":817,"_811":913},[914],{"_85":814},{"_85":810,"_811":916,"_810":918},[917],{"_85":814},"Apart from scratch resistance, the lenses coated by the new technique displaya clearly improved chemical resistance. The hard coating was speciallytailored to the basic material of polymethyl methacrylate (PMMA). The coating,which is only 3 m thick, does not impair either the transmission factoror the refractive index of the substrate. It can be readily wetted withliquids, and other coating materials also adhere well to the lacquer. Itis similarly relatively scratch and abrasion resistant, as well as resistantto the standard forms of chemical stressing imposed by alcohol, cleaningagents, sweat, and moisture.",{"_85":817,"_811":920},[921],{"_85":814},{"_85":817,"_811":923},[924],{"_85":814},{"_85":810,"_811":926,"_810":928},[927],{"_85":814},"The coating is an inorganichttps://www.plasticstoday.com/organic compound material and belongs to theso-called ormocer material class. It unites the toughness, functionality,and processibility of organic polymers with the thermal and mechanicalstability of inorganic glass and ceramics. Since the individual componentsare linked via chemical bonds, this leads to an extremely homogeneous material.These ormocer coatings can be used for a wide variety of applications andhave become established in such everyday products as scratch-resistantcoatings.",{"_85":817,"_811":930},[931],{"_85":814},{"_85":817,"_811":933},[934],{"_85":814},{"_85":810,"_811":936,"_810":938},[937],{"_85":814},"Lens Moulding",{"_85":817,"_811":940},[941],{"_85":814},{"_85":817,"_811":943},[944],{"_85":814},{"_85":810,"_811":946,"_810":948},[947],{"_85":814},"The injection moulding shop operates at full load with three shifts,two of which are unstaffed. The coating unit, which is located immediatelydownstream, has to be constantly staffed, but one or two shifts of thecoating unit will suffice to coat all the lenses that are produced in threeinjection moulding shifts.",{"_85":817,"_811":950},[951],{"_85":814},{"_85":817,"_811":953},[954],{"_85":814},{"_85":810,"_811":956,"_810":958},[957],{"_85":814},"The production shop contains machines mainly from Demag Ergotech with clampingforces of between 250 and 2,500 kN. An Arburg machine (1,500 kN) roundsoff the machine fleet. Robots from Neureder of Schwaig near Munich andA.S.S. Machinenbau of Overath are used to remove the moulded parts.",{"_85":817,"_811":960},[961],{"_85":814},{"_85":817,"_811":963},[964],{"_85":814},{"_85":810,"_811":966,"_810":968},[967],{"_85":814},"The unusually long cycle times of between 2 and 25 minutes that are requiredfor lenses mean that it is sufficient to have a single handling unit toremove the moulded parts from two injection moulding machines. The grippertakes the demoulded parts past showers of ionized air to prevent particlesof dust or dirt from sticking to them on account of static charges. Thefour-chamber unit for granule drying and the material supply system wereproduced by Helios GmbH, Rosenheim. The lenses are injection moulded fromdifferent types of PMMA made by Röhm, in Darmstadt, Germany, whilemany of the other plastic parts required are produced in PS or ABS.",{"_85":817,"_811":970},[971],{"_85":814},{"_85":817,"_811":973},[974],{"_85":814},{"_85":810,"_811":976,"_810":978},[977],{"_85":814},"The injection moulds for the lenses, which were designed by Eschenbachusing Prohttps://www.plasticstoday.com/Engineer 3-D design software, are manufactured in the company'sown mouldbuilding shop. A cold runner mould of this type costs betweenDM 20,000 and DM 200,000 (US$ 11,500 to US$ 115,000). The moulds do nothave any particular servicing requirements, but a great deal of time andattention goes into mould changing. Setting up the two mould halves onthe injection moulding machine and performing the subsequent process startupand optimization operations takes between 5 and 15 hours for all the mouldingsproduced on a multicavity mould to display the perfect optical qualityrequired. The entire injection moulding shop, including the mould storagecells, is kept at the same temperature so as to eliminate any negativeinfluences due to temperature fluctuations right from the start.",{"_85":817,"_811":980},[981],{"_85":814},{"_85":817,"_811":983},[984],{"_85":814},{"_85":810,"_811":986,"_810":988},[987],{"_85":814},"The finished lenses are not separated from the sprue but cool down in adefined manner while still attached to it. These parts, which are referredto as trees, are subsequently sent to the coating plant on a batch-by-batchbasis.",{"_85":817,"_811":990},[991],{"_85":814},{"_85":817,"_811":993},[994],{"_85":814},{"_85":817,"_811":996},[997],{"_85":814},{"_85":463,"_787":999,"_811":1001},{"_796":797,"_150":801,"_152":-5,"_106":-5,"_802":1000},{"_804":805},[1002],{"_85":814},{"_85":810,"_811":1004,"_810":1006},[1005],{"_85":814},"Figure 2. After moulding,lenses are",{"_85":817,"_811":1008},[1009],{"_85":814},{"_85":810,"_811":1011,"_810":1013},[1012],{"_85":814},"conveyed through ionized air",{"_85":817,"_811":1015},[1016],{"_85":814},{"_85":810,"_811":1018,"_810":1020},[1019],{"_85":814},"to reduce static attraction of dust",{"_85":817,"_811":1022},[1023],{"_85":814},{"_85":810,"_811":1025,"_810":1027},[1026],{"_85":814},"and dirt and are coated.",{"_85":817,"_811":1029},[1030],{"_85":814},{"_85":810,"_811":1032,"_810":1034},[1033],{"_85":814},"Coating",{"_85":817,"_811":1036},[1037],{"_85":814},{"_85":817,"_811":1039},[1040],{"_85":814},{"_85":810,"_811":1042,"_810":1044},[1043],{"_85":814},"The moulded parts then arrive in the cleanroom according to the firstin, first out principle. This accommodates the coating unit together withthe dipping and drying section (Figure 2). The cleanroom has a rating ofbetween 10,000 and 100,000.",{"_85":817,"_811":1046},[1047],{"_85":814},{"_85":817,"_811":1049},[1050],{"_85":814},{"_85":810,"_811":1052,"_810":1054},[1053],{"_85":814},"The coating is applied by dip coating with a transparent lacquer, whichcontains no toxic solvents or chlorinated hydrocarbons and can be storedin solution for three weeks. A batch of moulded parts is dipped into thelacquer every 2 minutes and then allowed to air dry for a number of minutes.The lacquer is then irradiated with UV light for just a few seconds toinitiate the photo-hardening of the lacquer (Figure 3). The low applicationtemperature of below 80 C prevents any thermal damage to the PMMA.",{"_85":817,"_811":1056},[1057],{"_85":814},{"_85":817,"_811":1059},[1060],{"_85":814},{"_85":810,"_811":1062,"_810":1064},[1063],{"_85":814},"Finishing and Assembly",{"_85":817,"_811":1066},[1067],{"_85":814},{"_85":817,"_811":1069},[1070],{"_85":814},{"_85":810,"_811":1072,"_810":1074},[1073],{"_85":814},"After being given their scratch-resistant coating, all the lenses aresubjected to a quality inspection. The coated lenses are essentially usedin magnifying glasses, reading spectacles, and seeing aids (Figure 4).These lenses are produced with the aid of a large number of special-purposewelding stations and automatic rotary welding units, most of which arefitted with units from Branson and Kiefel, and also assembly equipment.",{"_85":817,"_811":1076},[1077],{"_85":814},{"_85":817,"_811":1079},[1080],{"_85":814},{"_85":810,"_811":1082,"_810":1084},[1083],{"_85":814},"The sprues, which are quite large in some cases (see Figure 1, for example),are detached, granulated, and sold to the jewelry industry, which furtherprocesses the PMMA. The thin coating, which is also applied to the sprues,does not impair the production of fashion jewelry, but Eschenbach wouldnot run the risk of optical imperfections by using recyclate.",{"_85":817,"_811":1086},[1087],{"_85":814},{"_85":817,"_811":1089},[1090],{"_85":814},{"_85":810,"_811":1092,"_810":1094},[1093],{"_85":814},"Even now that the coating plant has been installed and has been seen towork successfully, Eschenbach and the ISC remain in constant contact. 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