Patent Description:
With optical articles, such as lenses, one or more surfaces may be subjected to a treatment to enhance the overall performance and function of the optical articles. Examples of such treatments include the formation of one or more coatings on a surface of an optical substrate.

In order to manufacture a coated optical article from an uncoated optical substrate, a variety of manufacturing techniques have been developed. In some processes, an uncoated optical substrate is first washed and dried, after which a coating is applied on at least one surface of the substrate. With coatings that require curing with ultraviolet light, the coated substrate is passed through a curing device having an ultraviolet radiation source. In large scale operations, optical substrates may be processed on an automated production line. Such a production line may have a plurality of processing stations for performing the various operations, including washing, drying, coating, and curing. It would be desirable to develop a new ultraviolet curing apparatus for curing coated optical substrates.

<CIT> relates to an apparatus and process for curing conformal coatings on circuit boards being conveyed through a curing chamber within a UV oven. Warm air, exhausted from a lamp housing containing UV lamps for curing the coatings, is directed into a flash zone chamber through which the coated circuit boards are conveyed prior to entering the UV oven for flashing volatile constituents from the coatings and raising the temperature of the circuit boards.

<CIT> concerns an ultraviolet curing apparatus for curing of coated articles. The ultraviolet curing apparatus is configured for use with a production line having a guideway positioned outside of a housing of the ultraviolet curing apparatus.

According to the present invention, provided is a curing apparatus that includes a housing having a loading portion open to ambient atmosphere, a curing portion having a curing chamber with a controlled atmosphere, and a transition portion extending between the loading portion and the curing portion. The curing apparatus further comprises a carrier movable between the loading portion and the curing chamber via the transition portion. The curing apparatus further includes at least one ultraviolet radiation source operative for transmitting ultraviolet radiation into the curing chamber. The transition portion includes a plurality of baffles protruding from a sidewall of the transition portion and configured for minimizing mixing between the ambient atmosphere and the controlled atmosphere during movement of the carrier between the loading portion and the curing chamber.

In some non-limiting examples or aspects of the present disclosure, each of the plurality of baffles may be angled toward the loading portion. Each of the plurality of baffles may include a first end connected to the sidewall of the transition portion and a second, free end protruding toward a transition guideway of the transition portion. The plurality of baffles may include a first set of baffles extending from a first sidewall of the transition portion and a second set of baffles extending from a second sidewall of the transition portion. The plurality of baffles may be aligned such that a terminal end of the first set of baffles is positioned across from a terminal end of the second set of baffles.

In some non-limiting examples or aspects of the present disclosure, the loading portion may include a door for enclosing the loading portion. A transfer mechanism may be provided for moving the carrier between the loading portion and the curing portion. The transfer mechanism may include a motor, a linear actuator, or a rotary actuator.

In some non-limiting examples or aspects of the present disclosure, the carrier may include a rotatable holder configured to rotate about a rotation axis when the carrier is positioned in the curing chamber. The rotatable holder may include a vacuum chuck configured for securing an article to the rotatable holder using vacuum.

In some non-limiting examples or aspects of the present disclosure, at least one sensor may be provided in the curing chamber and may be configured for measuring oxygen content in the curing chamber. At least one nozzle may be in fluid communication with the curing chamber and may be configured for delivering an inert gas to the curing chamber. The at least one nozzle may be configured for delivering the inert gas to the curing chamber at a constant pressure and constant flow rate.

In some non-limiting examples or aspects of the present disclosure, a diffuser may be provided between the at least one nozzle and the curing chamber. The diffuser may be configured for diffusing a flow of the insert gas into the curing chamber. An ultraviolet radiation filter may be disposed between the at least one ultraviolet radiation source and the curing chamber.

A curing apparatus may be characterized by one or more of the following aspects.

In a first aspect, a curing apparatus according to the present invention configured for curing optical articles comprises: a housing having a loading portion open to ambient atmosphere, a curing portion having a curing chamber with a controlled atmosphere, and a transition portion extending between the loading portion and the curing portion; a carrier movable between the loading portion and the curing chamber via the transition portion; and at least one ultraviolet radiation source operative for transmitting ultraviolet radiation into the curing chamber, wherein the transition portion comprises a plurality of baffles protruding from a sidewall of the transition portion and configured for minimizing mixing between the ambient atmosphere and the controlled atmosphere during movement of the carrier between the loading portion and the curing chamber.

In a second aspect, in the curing apparatus in accordance with the first aspect, each of the plurality of baffles is angled toward the loading portion.

In a third aspect, in the curing apparatus in accordance with the first aspect or the second aspect, each of the plurality of baffles comprises a first end connected to the sidewall of the transition portion and a second, free end protruding toward a transition guideway of the transition portion.

In a fourth aspect, in the curing apparatus in accordance with any one of the first aspect to the third aspect, the plurality of baffles comprises a first set of baffles extending from a first sidewall of the transition portion and a second set of baffles extending from a second sidewall of the transition portion.

In a fifth aspect, in the curing apparatus in accordance with the fourth aspect, the plurality of baffles are aligned such that a terminal end of the first set of baffles is positioned across from a terminal end of the second set of baffles.

In a sixth aspect, in the curing apparatus in accordance with any one of the first aspect to the fifth aspect, the loading portion comprises a door for enclosing the loading portion.

In a seventh aspect, in the curing apparatus in accordance with any of one of the first aspect to the sixth aspect, a transfer mechanism is provided for moving the carrier between the loading portion and the curing portion.

In an eighth aspect, in the curing apparatus in accordance with the seventh aspect, the transfer mechanism comprises a motor, a linear actuator, or a rotary actuator.

In a ninth aspect, in the curing apparatus in accordance with any one of the first aspect to the eighth aspect, the carrier comprises a rotatable holder configured to rotate about a rotation axis when the carrier is positioned in the curing chamber.

In a tenth aspect, in the curing apparatus in accordance with the ninth aspect, the rotatable holder comprises a vacuum chuck configured for securing an article to the rotatable holder using vacuum.

In an eleventh aspect, in the curing apparatus in accordance with any one of the first aspect to the tenth aspect, at least one sensor is provided in the curing chamber and configured for measuring oxygen content in the curing chamber.

In a twelfth aspect, in the curing apparatus in accordance with any one of the first aspect to the eleventh aspect, at least one nozzle is in fluid communication with the curing chamber, wherein the at least one nozzle is configured for delivering an inert gas to the curing chamber.

In a thirteenth aspect, in the curing apparatus in accordance with the twelfth aspect, the at least one nozzle is configured for delivering the inert gas to the curing chamber at a constant pressure and constant flow rate.

In a fourteenth aspect, in the curing apparatus in accordance with any one of the first aspect to the thirteenth aspect, a diffuser is provided between the at least one nozzle and the curing chamber, the diffuser being configured for diffusing a flow of the insert gas into the curing chamber.

In a fifteenth aspect, in the curing apparatus in accordance with any one of the first aspect to the fourteenth aspect, an ultraviolet radiation filter is disposed between the at least one ultraviolet radiation source and the curing chamber.

The features that characterize the present invention are pointed out with particularity in the claims, which are annexed to and form a part of this disclosure. These and other features of the invention, its operating advantages, and the specific objects obtained by its use will be more fully understood from the following detailed description in which non-limiting examples of the invention are illustrated and described.

As used herein, the singular form of "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

Spatial or directional terms, such as "left", "right", "inner", "outer", "above", "below", and the like, relate to the invention as shown in the drawing figures and are not to be considered as limiting as the invention can assume various alternative orientations.

All numbers used in the specification and claims are to be understood as being modified in all instances by the term "about". By "about" is meant plus or minus twenty-five percent of the stated value, such as plus or minus ten percent of the stated value. However, this should not be considered as limiting to any analysis of the values under the doctrine of equivalents.

Unless otherwise indicated, all ranges or ratios disclosed herein are to be understood to encompass the beginning and ending values and any and all subranges or subratios subsumed therein. For example, a stated range or ratio of "<NUM> to <NUM>" should be considered to include any and all subranges or subratios between (and inclusive of) the minimum value of <NUM> and the maximum value of <NUM>; that is, all subranges or subratios beginning with a minimum value of <NUM> or more and ending with a maximum value of <NUM> or less. The ranges and/or ratios disclosed herein represent the average values over the specified range and/or ratio.

The terms "first", "second", and the like are not intended to refer to any particular order or chronology, but refer to different conditions, properties, or elements.

The term "at least" is synonymous with "greater than or equal to".

The term "not greater than" is synonymous with "less than or equal to".

As used herein, "at least one of" is synonymous with "one or more of'. For example, the phrase "at least one of A, B, or C" means any one of A, B, or C, or any combination of any two or more of A, B, or C. For example, "at least one of A, B, or C" includes A alone; or B alone; or C alone; or A and B; or A and C; or B and C; or all of A, B, and C.

The term "adjacent" means proximate to but not in direct contact with.

As used herein, the terms "parallel" or "substantially parallel" mean a relative angle as between two objects (if extended to theoretical intersection), such as elongated objects and including reference lines, that is from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, inclusive of the recited values.

As used herein, the terms "perpendicular" or "substantially perpendicular" mean a relative angle as between two objects at their real or theoretical intersection is from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, inclusive of the recited values.

As used herein, the term "baffle" or "baffles" refers to a physical structure configured to restrain a flow of gas within an interior of a curing apparatus.

The term "optical" means pertaining to or associated with light and/or vision. For example, an optical element, article, or device can be chosen from ophthalmic elements, articles, and devices; display elements, articles, and devices; visors; windows; and mirrors.

The term "ophthalmic" means pertaining to or associated with the eye and vision. Non-limiting examples of ophthalmic articles or elements include corrective and non-corrective lenses, including single vision or multi-vision lenses, which may be either segmented or non-segmented multi-vision lenses (such as, but not limited to, bifocal lenses, trifocal lenses, and progressive lenses), as well as other elements used to correct, protect, or enhance (cosmetically or otherwise) vision, including without limitation, contact lenses, intra-ocular lenses, magnifying lenses, and protective lenses or visors.

As used herein, the terms "lens" and "lenses" mean and encompass at least individual lenses, lens pairs, partially formed (or semi-finished) lenses, fully formed (or finished) lenses, and lens blanks.

As used herein, the term "transparent", such as used in connection with a substrate, film, material, and/or coating, means that the indicated substrate, film, material, and/or coating has the property of transmitting visible light without appreciable scattering so that objects lying beyond are visibly observable.

As used herein, the terms "ultraviolet", "UV", "ultraviolet light", or "ultraviolet radiation" mean electromagnetic radiation having a wavelength in the range of <NUM> to <NUM>.

As used herein, the term "coating" means a supported film derived from a flowable coating material, which can optionally have a uniform thickness, and specifically excludes polymeric sheets. The terms "layer" and "film" each encompass both coatings (such as a coating layer or a coating film) and sheets, and a layer can include a combination of separate layers, including sub-layers and/or over-layers. The verb "coating" means, within appropriate context, the process of applying a coating material (or materials) to the substrate to form a coating (or coating layer).

As used herein, the terms "cure", "cured", and related terms, mean that at least a portion of the polymerizable and/or crosslinkable components that form a curable composition are at least partially polymerized and/or crosslinked. In accordance with some examples, the degree of crosslinking can range from <NUM>% to <NUM>% of complete crosslinking. In accordance with some further examples, the degree of crosslinking can range from <NUM>% to <NUM>%, such as <NUM>% to <NUM>%, or <NUM>% to <NUM>%, or <NUM>% to <NUM>% of complete crosslinking. The degree of crosslinking can range between any combination of these recited lower and upper values, inclusive of the recited values.

As used herein, the terms "communication" and "communicate" may refer to the reception, receipt, transmission, transfer, provision, and/or the like, of information (e.g., data, signals, messages, instructions, commands, and/or the like).

As used herein, a "graphical user interface" or "GUI" refers to a generated display with which a user may interact, either directly or indirectly (e.g., through a button, keyboard, mouse, touchscreen etc.).

The discussion of the invention may describe certain features as being "particularly" or "preferably" within certain limitations (e.g., "preferably", "more preferably", or "even more preferably", within certain limitations). It is to be understood that the invention is not limited to these particular or preferred limitations but encompasses the entire scope of the disclosure.

The invention comprises, consists of, or consists essentially of the following examples of the invention, in any combination. Various examples of the invention may be discussed separately. However, it is to be understood that this is simply for ease of illustration and discussion. In the practice of the invention, one or more aspects of the invention described in one example can be combined with one or more aspects of the invention described in one or more of the other examples.

With reference to <FIG>, the curing apparatus <NUM> is shown in accordance with some examples or aspects of the present disclosure. In various examples or embodiments, the curing apparatus <NUM> may be configured for curing a coating applied to at least one surface of an article. In some examples or aspects, the article may be an opaque article, a translucent article, and/or a transparent article. In some examples or aspects, the transparent article may be an optical article. The curing apparatus <NUM> may be configured for emitting ultraviolet radiation for curing the coating applied to the at least one surface of the article. While the following disclosure describes the curing apparatus <NUM> configured to cure a single optical article at a time, one of ordinary skill in the art would readily understand that the curing apparatus <NUM> may be scaled for curing any number of coated articles, including non-optical articles. Accordingly, the following disclosure is to be construed as exemplary only and is not intended to limit the configuration of the curing apparatus <NUM>.

The curing apparatus <NUM> has a housing <NUM> defining a loading portion <NUM> that is open to ambient atmosphere, a curing portion <NUM> having a controlled atmosphere, and a transition portion <NUM> extending between the loading portion <NUM> and the curing portion <NUM>. In some examples or aspects, the loading portion <NUM>, the curing portion <NUM>, and the transition portion <NUM> may be defined by a common housing. In other examples or aspects, the loading portion <NUM>, the curing portion <NUM>, and the transition portion <NUM> may have discrete housings that are combined together end-to-end to define the overall housing <NUM> of the curing apparatus <NUM>.

With continued reference to <FIG>, the housing <NUM> has an upper portion or sidewall <NUM> spaced apart from a lower portion or sidewall <NUM>. An interior <NUM> of the housing <NUM> (shown in <FIG>) is defined between the upper portion or sidewall <NUM> and the lower portion or sidewall <NUM>, and between a pair of longitudinal portions or sidewalls <NUM>. In some examples or aspects, the pair of longitudinal portions or sidewalls <NUM>, the upper portion or sidewall <NUM>, and/or the lower portion or sidewall <NUM> are discrete elements that are removably or non-removably connected to each other. In other examples, the pair of longitudinal portions or sidewalls <NUM>, the upper portion or sidewall <NUM>, and/or the lower portion or sidewall <NUM> may be monolithically formed with each other.

With reference to <FIG>, the loading portion <NUM>, the curing portion <NUM>, and the transition portion <NUM> define separate chambers within the interior <NUM> of the housing <NUM>. The loading portion <NUM> has a loading chamber <NUM> configured for receiving an optical article <NUM> during loading and loading. The loading portion <NUM> is open to ambient atmosphere and may be enclosed by a door <NUM>. The curing portion <NUM> has a curing chamber <NUM> having the controlled atmosphere for curing the optical article <NUM>. The loading chamber <NUM> and the curing chamber <NUM> are connected to each other via a transition chamber <NUM> of the transition portion <NUM>.

With reference to <FIG>, the curing apparatus <NUM> includes a carrier <NUM> movable between the loading chamber <NUM> and the curing chamber <NUM> via the transition chamber <NUM>. The carrier <NUM> is movable between the loading chamber <NUM> and the curing chamber <NUM> on a rail <NUM> in a direction of arrow A in <FIG>. In some examples or aspects, the rail <NUM> may be linear or curvilinear. The carrier <NUM> is supported on an upper portion of the rail <NUM> and is movable between the loading chamber <NUM> and the curing chamber <NUM> via a transfer mechanism <NUM>. As described herein, the carrier <NUM> is configured for supporting an optical article for moving the optical article between the loading portion <NUM> and the curing portion <NUM>. In some examples or aspects, the transfer mechanism <NUM> includes a drive element <NUM>, such as motor, a linear actuator, or a rotary actuator that is operatively connected to the carrier <NUM>. The carrier <NUM> may be operatively connected to the drive element <NUM> via a belt, chain, rod, or other mechanical connection. Actuation of the transfer mechanism <NUM> may be controlled by a controller, as described hereinafter, and results in movement of the carrier <NUM>. Operation of the transfer mechanism <NUM> may be controlled by the controller to control the starting and stopping positions and speed at which the carrier <NUM> moves between the loading chamber <NUM> and the curing chamber <NUM>. In some embodiments or aspects, the speed at which the carrier <NUM> moves may be different when moving from the loading chamber <NUM> into the curing chamber <NUM> compared to the speed when moving from the curing chamber <NUM> to the loading chamber <NUM>.

With reference to <FIG>, the carrier <NUM> has a rotatable holder <NUM> configured to rotate about a rotation axis <NUM>. In some examples or aspects, the rotatable holder <NUM> is configured to be rotatable about the rotation axis <NUM> when the carrier <NUM> is positioned in the curing chamber <NUM>. The carrier <NUM> further has a support platform <NUM> configured for supporting an optical article <NUM> thereon. The support platform <NUM> may have a vacuum chuck <NUM> configured for securing the optical article <NUM> on the carrier <NUM> using vacuum. In this manner, the optical article <NUM> may be supported on its lower surface without any additional mechanical fixturing that may contact a coated surface of the optical article <NUM>.

With continued reference to <FIG>, the optical article <NUM> has a forward or top surface <NUM>, a rearward or bottom surface <NUM>, and a side surface <NUM> extending between the top surface <NUM> and the bottom surface <NUM>. When the optical article <NUM> is an ophthalmic lens, the bottom surface <NUM> is opposed to the eye of an individual wearing the optical article <NUM>, the side surface <NUM> typically resides within a supportive frame, and the top surface <NUM> faces incident light (not shown), at least a portion of which passes through the optical article <NUM> and into the individual's eye. With some examples or aspects, at least one of the top surface <NUM>, the bottom surface <NUM>, and the side surface <NUM> may have various shapes including, but not limited to, round, flat, cylindrical, spherical, planar, substantially planar, plano-concave and/or plano-convex, and curved, including, but not limited to, convex, and/or concave. The optical article <NUM> is configured to be supported on the support platform <NUM> of the carrier <NUM>, such as by the bottom surface <NUM>. In some examples or aspects, the optical article <NUM> may be supported on the support platform <NUM> of the carrier <NUM> by the side surface <NUM>.

The optical article <NUM> can be selected from ophthalmic articles or elements, display articles or elements, visors, windows, mirrors, active liquid crystal cell articles or elements, and passive liquid crystal cell articles or elements. Examples of ophthalmic articles or elements include, but are not limited to, corrective and non-corrective lenses, including single vision or multi-vision lenses, which can be either segmented or non-segmented multi-vision lenses (such as, but not limited to, bifocal lenses, trifocal lenses, and progressive lenses), as well as other elements used to correct, protect, or enhance (cosmetically or otherwise) vision, including without limitation, contact lenses, intra-ocular lenses, magnifying lenses, and protective lenses or visors. Examples of display articles, elements and devices include, but are not limited to, screens, monitors, and security elements, including without limitation, security marks and authentication marks. Examples of windows include, but are not limited to, automotive and aircraft transparencies, filters, shutters, and optical switches. The optical article <NUM> can comprise a polymeric organic material chosen from thermosetting polymeric organic materials, thermoplastic polymeric organic materials, or a mixture of such polymeric organic materials.

With reference to <FIG>, the curing apparatus <NUM> has at least one ultraviolet radiation source <NUM> (hereinafter referred to "UV source <NUM>") operative for transmitting ultraviolet (UV) radiation into the curing chamber <NUM>. In some examples or aspects, the curing apparatus <NUM> may have a plurality of UV sources <NUM>. The at least one UV source <NUM> may be mounted in an upper portion <NUM> of the housing <NUM> such that the at least one UV source <NUM> directs UV radiation into the curing chamber <NUM> from the upper portion <NUM> of the housing <NUM>. The at least one UV source <NUM> is positioned such that at least a portion of the UV radiation emitted therefrom is incident on at least one surface of the optical article <NUM> when the optical article <NUM> is positioned in the curing chamber <NUM>. In some examples, the at least one ultraviolet radiation source <NUM> may be an ultraviolet lamp having at least one bulb, such as a mercury bulb, configured for emitting radiation within the ultraviolet spectrum. The specifications of the at least one ultraviolet radiation source <NUM> may be selected depending on a type of coating to be cured.

With continued reference to <FIG>, a filter <NUM> may be positioned between the at least one UV source <NUM> and the curing chamber <NUM>. The filter <NUM> may be configured for filtering the UV radiation from the at least one UV source <NUM>, such as filtering radiation of a desired wavelength. The filtering characteristics of the filter <NUM> may be selected depending on a desired wavelength of ultraviolet radiation to be filtered. The curing apparatus <NUM> may have at least one reflective element positioned within the curing chamber <NUM> to reflect at least a portion of UV radiation emitted from the at least one UV source <NUM> in a direction toward the optical article <NUM>. In some examples, the at least one reflective element may be a reflective mirror, or a mirror-like film.

With reference to <FIG>, the curing apparatus <NUM> includes a plurality of baffles <NUM> configured for minimizing mixing between the ambient atmosphere in the loading chamber <NUM> and the controlled atmosphere in the curing chamber <NUM>. In some examples or aspects, the plurality of baffles <NUM> may be provided in the transition chamber <NUM>. Each of the plurality of baffles <NUM> may be connected to one more sidewalls of the housing <NUM>, such as one or more of the sidewalls of the transition chamber <NUM>. For example, each of the plurality of baffles <NUM> may be connected to one or more of the upper portion or sidewall <NUM>, the lower portion or sidewall <NUM>, and the longitudinal portions or sidewalls <NUM> of the housing <NUM>. <FIG> show the plurality of baffles <NUM> protruding from the longitudinal portions or sidewalls <NUM> of the housing <NUM> in the transition chamber <NUM>. The plurality of baffles <NUM> may be removably or non-removably connected to one or more of the upper portion or sidewall <NUM>, the lower portion or sidewall <NUM>, and the longitudinal portions or sidewalls <NUM> of the housing <NUM>. In some embodiments or aspects, the plurality of baffles <NUM> may be connected to an intermediate element that is connected to one or more of the upper portion or sidewall <NUM>, the lower portion or sidewall <NUM>, and the longitudinal portions or sidewalls <NUM> of the housing <NUM>.

With continued reference to <FIG>, each of the plurality of baffles <NUM> comprises a first end <NUM> connected to one or more of the upper portion or sidewall <NUM>, the lower portion or sidewall <NUM>, and the longitudinal portions or sidewalls <NUM> of the housing <NUM> and a second, free end <NUM> protruding toward a transition guideway <NUM> of the transition portion <NUM>. Each of the plurality of baffles <NUM> is angled toward the loading portion <NUM>. Each of the plurality of baffles <NUM> may be angled toward the loading portion <NUM> at a same angle. In some examples, the plurality of baffles <NUM> may be angled toward the loading portion <NUM> at different angles.

With continued reference to <FIG>, the plurality of baffles <NUM> are arranged in two rows on opposing sides of the transition guideway <NUM>. The plurality of baffles <NUM> may include a first set of baffles 158a extending from a first sidewall <NUM> of the transition portion <NUM> and a second set of baffles 158b extending from a second sidewall <NUM> of the transition portion <NUM>. The first set of baffles 158a is separated from the second set of baffles 158b by a distance D sufficient to allow for unobstructed passage of the carrier <NUM> carrying the optical article <NUM> through the transition portion <NUM>. The plurality of baffles <NUM> may be aligned such that the second end <NUM> of each of the first set of baffles 158a is positioned across from the second end <NUM> of each of the second set of baffles 158b.

With reference to <FIG>, the curing chamber <NUM> of the curing apparatus <NUM> may have an atmosphere that is different from the atmosphere outside the curing chamber <NUM>. In some examples or aspects, the curing chamber <NUM> may have an inert atmosphere due to increased concentration of an inert gas, such as nitrogen or one or more noble gases. Without intending to be bound by theory, it has been found that curing of the coating covering the optical article <NUM> can be significantly improved when the coating is cured in a controlled and inert atmosphere that is different from ambient atmosphere. The plurality of baffles <NUM> are configured to act as a barrier to a flow of ambient air from the loading chamber <NUM> into the curing chamber <NUM> during movement of the optical article <NUM> from the loading chamber <NUM> into the curing chamber <NUM>, and to act as a barrier to a flow of the inert atmosphere out of the curing chamber <NUM> during movement of the optical article <NUM> from the curing chamber <NUM> toward the loading chamber <NUM>. For example, during movement of the optical article <NUM> between the loading chamber <NUM> and the curing chamber <NUM>, the optical article <NUM> causes the air surrounding it to move. The plurality of baffles <NUM> are configured to minimize the movement of air around the optical article <NUM> so as to minimize an exchange between the ambient air in the loading chamber <NUM> and the inert gas in the curing chamber <NUM>. In this manner, introduction of the ambient atmosphere (i.e., oxygen) from the loading chamber <NUM> into the inert atmosphere in the curing chamber <NUM> can be minimized in order to conserve the use of inert gas.

With continued reference to <FIG>, at least one nozzle <NUM> may be provided for delivering the inert gas into the curing chamber <NUM>. The at least one nozzle <NUM> is in communication with a vessel <NUM> containing the inert gas. In some examples, a plurality of nozzles <NUM> may be provided. The at least one nozzle <NUM> extends into the curing chamber <NUM> through one or more of the upper portion or sidewall <NUM>, the lower portion or sidewall <NUM> of the housing <NUM> to deliver the inert gas into the curing chamber <NUM>. In some examples or aspects, the at least one nozzle <NUM> may be configured for delivering the inert gas into the interior chamber <NUM> at a fixed flow rate and pressure. In other examples or aspects, the at least one nozzle <NUM> may be adjustable to control the flow rate and pressure at which the inert gas is delivered to the curing chamber <NUM>. In such examples or aspects, a proportioning valve <NUM> may be provided for controlling the flow rate and pressure of the at least one nozzle <NUM>. The proportioning valve <NUM> may be manually or electronically adjustable. Flow rate and pressure of the inert gas flowing through the at least one nozzle <NUM> may be controlled by a controller, as described herein.

At least one sensor <NUM> may be provided for detecting a concentration of oxygen in the curing chamber <NUM>. By determining a concentration of oxygen in the curing chamber <NUM>, a controller associated with the at least one sensor <NUM> may determine a concentration of the inert gas in the curing chamber <NUM>. Output from the at least one sensor <NUM> may be used for adjusting a flow rate of the inert gas through the at least one nozzle <NUM> to maintain the concentration of the inert gas at a predetermined level.

With reference to <FIG>, the curing apparatus <NUM> may have at least one diffuser plate <NUM> disposed between the at least one nozzle <NUM> and the curing chamber <NUM>. The at least one diffuser plate <NUM> may have a plurality of openings <NUM> configured for flowing the inert gas therethrough and into the curing chamber <NUM>. The openings <NUM> may have a small diameter, such as around <NUM>, in order to evenly diffuse the inert gas within the curing chamber <NUM>.

With reference to <FIG>, the curing apparatus <NUM> has at least one controller <NUM> operatively connected to at least one component of the curing apparatus <NUM>. In some examples or aspects, the at least one controller <NUM> may be configured to control operation of at least one of the drive element <NUM> of the transfer mechanism <NUM>, the rotatable holder <NUM> of the carrier <NUM>, the UV source <NUM>, and the valve <NUM> of the nozzle <NUM>. In other examples or aspects, separate controllers <NUM> may be provided for each of the drive element <NUM> of the transfer mechanism <NUM>, the rotatable holder <NUM> of the carrier <NUM>, the UV source <NUM>, and the valve <NUM> of the nozzle <NUM>.

In some examples or aspects, the at least one controller <NUM> may be a microprocessor controller. The at least one controller <NUM> may be configured for pulse width modulated (PWM) operation, wherein analog operation of at least one of the drive element <NUM> of the transfer mechanism <NUM>, the rotatable holder <NUM> of the carrier <NUM>, the UV source <NUM>, and the valve <NUM> of the nozzle <NUM> can be achieved using digital control signals. In some examples or aspects, the at least one controller <NUM> may be configured for continuously modulated control of at least one of the drive element <NUM> of the transfer mechanism <NUM>, the rotatable holder <NUM> of the carrier <NUM>, the UV source <NUM>, and the valve <NUM> of the nozzle <NUM>. The at least one controller <NUM> may have memory configured for storing one or more predetermined automated curing processes, as discussed herein. In some examples or aspects, the at least one controller <NUM> may be configured for operating on a 110V or a 220V AC power circuit, and/or on battery power. In other examples or aspects, the at least one controller <NUM> may be configured for operating on a 12V DC power circuit.

Having described the curing apparatus <NUM> with reference to <FIG>, an exemplary method <NUM> of using the curing apparatus <NUM> to cure a coating applied on the optical article <NUM>, will now be described with reference to <FIG>. In some examples or aspects, the curing apparatus <NUM> may be configured for curing the coating applied on a single optical article <NUM>. In other examples or aspects, the curing apparatus <NUM> may be configured for curing the coating applied to a plurality of optical article <NUM> in a batch process.

With reference to <FIG>, at step <NUM>, a coated but uncured optical article <NUM> is loaded into the curing apparatus <NUM>. For example, the optical article <NUM> can be loaded into the curing apparatus <NUM> by opening the door <NUM> to the loading portion <NUM> and loading the optical article <NUM> onto the carrier <NUM> positioned in the loading chamber <NUM>. The optical article <NUM> is secured to the carrier <NUM> by actuating the vacuum chuck <NUM>.

At step <NUM>, the inert atmosphere in the curing chamber <NUM> is controlled to a desired level. For example, the inert gas from the vessel <NUM> is delivered into the curing chamber <NUM> via the at least one nozzle <NUM>. The at least one sensor <NUM> is used to determine the oxygen content in the inert atmosphere and flow of the inert gas can be adjusted via the valve <NUM> in order to reach a predetermined threshold inside the curing chamber <NUM>.

At step <NUM>, the optical article <NUM> is moved from the loading chamber <NUM> into the curing chamber <NUM>. For example, the drive element <NUM> of the transfer mechanism <NUM> is actuated to move the carrier <NUM> from the loading chamber <NUM> into the curing chamber <NUM> via the transition chamber <NUM>. During movement of the carrier <NUM> through the transition chamber <NUM>, the plurality of baffles <NUM> are configured to minimize an exchange between an ambient atmosphere in the loading chamber <NUM> and the inert atmosphere in the curing chamber <NUM>.

After positioning the carrier <NUM> in the curing chamber <NUM>, the UV source <NUM> is actuated in step <NUM> to initiate the curing process. The optical article <NUM> may be rotated about the rotation axis <NUM> of the rotatable holder <NUM> of the carrier <NUM>.

After the curing process is completed, the optical article <NUM> is moved in step <NUM> from the curing chamber <NUM> back into the loading chamber <NUM>. For example, the drive element <NUM> of the transfer mechanism <NUM> is actuated to move the carrier <NUM> from the curing chamber <NUM> into the loading chamber <NUM> via the transition chamber <NUM>. During movement of the carrier <NUM> through the transition chamber <NUM>, the plurality of baffles <NUM> are configured to minimize an exchange between an ambient atmosphere in the loading chamber <NUM> and the inert atmosphere in the curing chamber <NUM>.

At step <NUM>, the cured optical article <NUM> is unloaded from the curing apparatus <NUM>. For example, the optical article <NUM> can be unloaded from the curing apparatus <NUM> by opening the door <NUM> to the loading portion <NUM> and unloading the optical article <NUM> from the carrier <NUM> positioned in the loading chamber <NUM>. The vacuum chuck <NUM> is deactivated to permit the optical article <NUM> to be removed from the carrier <NUM>.

Claim 1:
A curing apparatus (<NUM>) comprising:
a housing (<NUM>) having a loading portion (<NUM>) open to ambient atmosphere, a curing portion (<NUM>) having a curing chamber (<NUM>) with a controlled atmosphere, and a transition portion (<NUM>) extending between the loading portion (<NUM>) and the curing portion (<NUM>);
a carrier (<NUM>) movable between the loading portion (<NUM>) and the curing chamber (<NUM>) via the transition portion (<NUM>); and
at least one ultraviolet radiation source (<NUM>) operative for transmitting ultraviolet radiation into the curing chamber (<NUM>),
wherein the transition portion (<NUM>) comprises a plurality of baffles (<NUM>) protruding from a sidewall of the transition portion (<NUM>) and configured for minimizing mixing between the ambient atmosphere and the controlled atmosphere during movement of the carrier (<NUM>) between the loading portion (<NUM>) and the curing chamber (<NUM>).