Systems, methods, and frameworks for manufacturing articles

Abstract

A system and method of manufacturing an article are disclosed. The method includes providing a submersion liquid to at least one first portion and at least one second portion of a chamber separated by a partition, opening a valve between the at least one first portion and the at least one second portion, providing a solidifiable liquid to an article frame included in the partition, closing the valve, adjusting a volume or a pressure of the submersion liquid in the at least one first portion using a pump to control a curvature of the article, and solidifying the solidifiable liquid to form the article.

Description

[0001] Cross-references to related applications This application claims priority to U.S. Provisional Application No. 63 / 536,714, filed September 6, 2023, entitled “SYSTEM, METHOD, AND FRAME FORFABRICATING AN ARTICLE”. The contents of the foregoing are incorporated herein by reference in their entirety, as if fully set forth herein. Technical Field

[0002] This invention generally relates to systems and methods for manufacturing articles. More specifically, this invention relates to systems, methods, and frameworks for manufacturing articles using fluid forming methods. Background Technology

[0003] Many items require highly polished surfaces, which are difficult and costly to achieve. Polishing curved surfaces is even more challenging. For example, the manufacture of optical items such as lenses and curved mirrors relies on machining processes such as grinding and machining, followed by polishing of the optical surface. The requirement for high-quality surfaces necessitates specialized and expensive equipment, and the manufacture of non-standard optical surfaces remains a challenge.

[0004] Even in the 21st century, limited access to corrective eyeglasses remains a significant medical, social, and economic challenge. More than one billion people suffer from uncorrected vision impairment, the vast majority of whom live in developing countries. Decades of philanthropic efforts have failed to meet even a small fraction of the demand, and local manufacturing using standard machining techniques remains a distant prospect due to insufficient resources.

[0005] It is impossible and impractical to manufacture custom lenses at the point of sale (such as an optometrist's shop) using known mechanical methods.

[0006] Therefore, a simple manufacturing method is needed that can be implemented at the point of sale or in rural areas, which will ensure a high-quality surface for any desired morphology. Summary of the Invention

[0007] Some aspects of the present invention may relate to an article manufacturing system comprising: a chamber configured to contain an immersion liquid; a partition including a through-hole opening dividing the chamber into at least one first portion and at least one second portion, the partition including an article frame and a liner located between the partition and the frame; an immersion liquid hydraulic system including at least one control valve and at least one bidirectional immersion liquid pump, wherein the immersion liquid hydraulic system is configured to: allow pressure equalization between at least one first portion and at least one second portion; and regulate the volume or pressure of the immersion liquid in at least one first portion; a curable liquid supply unit including a curable liquid reservoir configured to supply curable liquid to the article frame; and a controller configured to: control the immersion liquid hydraulic system to equalize the pressure between the first and second portions; control the immersion liquid hydraulic system to block flow between the first and second portions; control the curable liquid supply unit to supply curable liquid to the article frame; and control the immersion liquid hydraulic system to increase or decrease the amount or pressure of the immersion liquid in the first portion.

[0008] In some embodiments, the immersion liquid hydraulic system further includes: at least one control valve is a pressure control valve fluidly connected between at least one first portion and at least one second portion, and configured to allow pressure equalization between at least one first portion and at least one second portion; and wherein at least one bidirectional pump is fluidly connected to the first portion and configured to control the volume or pressure of the immersion liquid in at least one first portion.

[0009] In some embodiments, the immersion liquid hydraulic system includes two bidirectional pumps fluidly connected to a first portion, wherein a first bidirectional pump of the two bidirectional pumps is configured to provide a solvent solution, and a second bidirectional pump of the two bidirectional pumps is configured to provide at least one solute solution, and wherein a controller is configured to control the first and second bidirectional pumps to provide solvent and solute in a predetermined ratio to form an immersion liquid.

[0010] In some embodiments, the system further includes a first mixer for mixing the solvent solution and the solute solution before providing the immersion liquid into the first portion. In some embodiments, the system further includes a second mixer for mixing the solvent solution and the solute solution within the chamber.

[0011] In some embodiments, the density of the solvent solution is less than the density of the curable liquid, and the density of the solute solution is greater than the density of the curable liquid. In some embodiments, the bidirectional pressure control valve is fluidly connected to a first portion, a second portion, and at least one bidirectional pump.

[0012] In some embodiments, the curable liquid supply unit further includes: a port configured to supply curable liquid from a curable liquid reservoir to an article frame; and at least one curable liquid bidirectional pump fluidly connected to the port and the curable liquid reservoir.

[0013] In some embodiments, the separator further includes a separator plate having a through-hole opening; and a frame retainer that hermetically secures the gasket and frame to the separator ring. In some embodiments, the system further includes at least one imaging device configured to capture light transmitted through or reflected from the curable liquid. In some embodiments, the at least one imaging device is at least one of a camera and a wavefront sensor. In some embodiments, a controller is configured to: receive an image from the at least one imaging device; and control at least one of a curable liquid supply unit, an immersion liquid hydraulic system, and at least one light source based on the image.

[0014] In some embodiments, the system further includes at least one light source configured to illuminate the article. In some embodiments, the at least one light source is located at at least one of the following locations: an end of a first portion opposite to the article frame, or an end of a second portion opposite to the article frame, on a wall of the first portion or the second portion, and outside a closed chamber, wherein the closed chamber includes at least one transparent window located between the light source and the article. In some embodiments, the controller is also configured to control the at least one light source to provide light to the curable liquid. In some embodiments, the light source includes at least one of a light-emitting diode (LED) array, a gas discharge lamp, and an incandescent bulb. In some embodiments, the system further includes a diffuser configured to diffuse light onto the article.

[0015] In some embodiments, the system further includes a pressure sensor fluidly connected to at least one first portion, and wherein the controller is configured to also control the immersion liquid hydraulic system based on pressure measurements received from the pressure sensor. In some embodiments, the curable liquid and the immersion liquid are immiscible. In some embodiments, the density of the immersion liquid is... ρ im Density of curable liquid ρ The difference is less than 15%. In some embodiments, the article is a curved article. In some embodiments, the article is an optical article, and the curable liquid is at least partially transparent. In some embodiments, the article is a mold for optical manufacturing.

[0016] Additional aspects of the invention may include a kit for article manufacturing. The kit may include an article manufacturing system according to any of the embodiments disclosed herein; an immersion liquid; and a curing liquid.

[0017] Some additional aspects of the invention relate to a method of manufacturing an article, the method comprising: providing an immersion liquid to at least one first portion and at least one second portion of a chamber separated by a partition; opening a valve between at least one first portion and at least one second portion; providing a curable liquid to an article frame included in the partition; closing the valve; using a pump to regulate the volume or pressure of the immersion liquid in at least one first portion to control the curvature of the article; and curing the curable liquid to form the article.

[0018] In some embodiments, the method further includes receiving a measurement of the pressure of the immersion liquid in at least one first portion, and wherein the volume or pressure of the immersion liquid in the first portion is adjusted based on the pressure measurement and the desired characteristics of the article.

[0019] In some embodiments, curing a curable liquid includes regulating the volume or pressure of the immersion liquid in at least one first portion during curing. In some embodiments, regulation includes passively releasing the incoming immersion liquid if the pressure in the first portion exceeds a predetermined threshold, and actively operating a pump to regulate the volume or pressure of the immersion liquid in at least one first portion.

[0020] In some embodiments, the article is a curved article. In some embodiments, the article is an optical article, and the curable liquid is at least partially transparent. In some embodiments, the article is a mold for optical manufacturing.

[0021] Some additional aspects of the invention relate to a frame for manufacturing articles, the frame comprising: a housing having walls having a variable height along the contour of the housing. In some embodiments, the contour of the housing is determined based on a receiving device for receiving the article. In some embodiments, the article is a lens or mirror, and the receiving device is selected from eyeglass frames, microscopes, telescopes, binoculars, and laser cavities. In some embodiments, the frame is an integral part of the receiving device.

[0022] In some embodiments, the variability of the height is determined based on the intersection of the shell profile with the surface having the desired shape of the article. In some embodiments, the desired surface shape satisfies the following fluid forming equation: Where r is the normalized radius variable, h is the normalized surface height variable, the subscript indicates the spatial derivative of h with respect to the radial or azimuth direction, and A and B are free parameters.

[0023] In some embodiments, at least a portion of the frame's surface forms a connector for connecting at least one of the frame and the article to a receiving device. In some embodiments, the inner surface of the frame includes one or more connector forming elements to form at least one connector on the contour of the article for connecting the article to the receiving device. In some embodiments, the at least one connector forming element is selected from recesses and protrusions and any combination thereof. In some embodiments, the outer surface of the frame includes a connector for connecting the frame to the receiving device.

[0024] Some additional aspects of the present invention relate to a method of manufacturing a frame for making articles, the method comprising: receiving a profile in a receiving device; determining a shell profile of the frame to fit the profile in the receiving device; receiving a desired shape of the articles; determining the height of the shell wall along the profile based on the intersection of the shell profile with a surface having the desired shape; and manufacturing the shell wall.

[0025] In some embodiments, the method further includes adding at least one external connecting element to the outer surface of the frame, wherein the at least one external connecting element is configured to form a connector for connecting at least one of the frame and the article to the contour of a space in the receiving device.

[0026] In some embodiments, the desired morphology of the surface satisfies the following fluid forming equation. Where r is the normalized radius variable, h is the normalized surface height variable, the subscript indicates the spatial derivative of h with respect to the radial or azimuth direction, and A and B are free parameters. Attached Figure Description

[0027] The subject matter considered to be the present invention is specifically pointed out and explicitly claimed in the concluding section of the specification. However, both the organization and operation of the invention, as well as its objects, features, and advantages, can be best understood by referring to the following detailed description when read in conjunction with the accompanying drawings, in which: Figure 1A , Figure 1B and Figure 1C This is an illustration of an article manufacturing system according to some embodiments of the present invention, and a block diagram of controllable components of the article manufacturing system; Figure 2A , Figure 2B and Figure 2C These are illustrations and flowcharts of steps in a method of manufacturing an article according to some embodiments; Figure 3 This includes models of frames according to some embodiments and examples of frames for manufacturing articles; Figure 4Simulations of two frames according to some embodiments and results of curved lenses fabricated using these frames are shown; Figure 5 Examples of two additional frames according to some embodiments and corresponding lenses made using these frames are shown; Figure 6 This is a flowchart of a method for manufacturing a framework according to some embodiments; Figure 7A , Figure 7B , Figure 7C and Figure 7D This is based on the illustration of lenses in some embodiments and the analysis results of the lens's optical power as a function of the frame geometry and injection volume; Figure 7E This is a flowchart illustrating calculations based on some embodiments to determine the frame geometry and liquid volume used in manufacturing the desired lens; and Figure 8A , Figure 8B , Figure 8C and Figure 8D These are experimental results and characterizations of eyeglass lenses manufactured using fluid forming methods according to some embodiments.

[0028] It should be understood that, for the sake of simplicity and clarity, the elements shown in the figures are not necessarily drawn to scale. For example, for clarity, the dimensions of some elements may be exaggerated relative to others. Furthermore, where deemed appropriate, reference numerals may be repeated in the figures to indicate corresponding or similar elements. Detailed Implementation

[0029] Those skilled in the art will recognize that the invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the foregoing embodiments should be considered illustrative in all respects and not limiting of the invention described herein. The scope of the invention is therefore indicated by the appended claims rather than by the foregoing description, and thus all variations within the meaning and equivalent scope of the claims are intended to be included therein.

[0030] Articles with curved surfaces are always more difficult to manufacture, and those requiring high-quality curved surfaces (e.g., optical-grade quality) are even more difficult. One promising technique for manufacturing such articles is the use of fluid forming methods. In these methods, a curable liquid is injected into a frame immersed in the liquid. The curable liquid fills the spaces between the walls of the frame that form the article. When cured (within the immersion liquid), the curable liquid solidifies while retaining the properties of the liquid / liquid interface, thus achieving a very high-quality (e.g., optical-grade) surface.

[0031] The systems, methods, and frames according to embodiments of the present invention allow for precise control of the curvature of an article from both sides. In a non-limiting example, the systems, methods, and frames can allow the manufacture of optical lenses at an optometrist's shop based on a specific optometric prescription provided in real time by an optometrist. In some embodiments, a first unit (e.g., a 3D printer, a small CNC machine, etc.) can manufacture the frame according to, for example, an optometric prescription. According to some embodiments of the present invention, the manufactured frame can then be inserted into an article manufacturing system. In a non-limiting example, the article can be an optical lens.

[0032] In some embodiments, at least one surface of the article (e.g., a lens) has a desired morphology, characterized by Equation 1: in r Represents the normalized radius variable. h This represents the normalized surface height variable, with the subscript indicating... h The spatial derivative with respect to the radial or azimuth direction, and A and B are free parameters. In some embodiments, at least one optical surface of the lens is characterized by Equation 1. In some embodiments, each point on at least one surface is described by Equation 1, where A and B are surface-specific constants.

[0033] As used herein, the term "surface height" is defined as the vertical distance between the highest and lowest points on the surface of an article. As used herein, the term "radius" is defined as the horizontal distance between the highest and lowest points on the surface of an article. In some embodiments, the surface is the optical surface of a lens.

[0034] In the non-limiting example, density ρ lens Curable liquid injected into radius R 0 and height d Within a cylindrical frame, suspended in density ρ im The liquid in which it is submerged. In the examples section below, regarding... Figures 7A to 7D Another non-limiting example of an elliptical frame is given. It can be assumed that the lens liquid wets the inner wall of the cylinder, forming two separate interfaces with the immersed liquid, namely the upper surface. u ( r , θ (also known as) h top ( x , y )) and lower surface l ( r , θ (also known as) h bot ( x, y (See also) Figure 3 and Figure 7A The shapes of these surfaces are determined by the balance between surface tension and gravity, a balance that can be expressed by Bond numbers. Characterization, in which It is capillary length. ρ = ρ lens - ρ im It's a difference in density. γ It is the interfacial energy between two liquids, and g It refers to negative The direction of Earth's gravity. For Bo << 1. Surface forces dominate relative to gravity, and both surfaces exhibit a spherical cap shape. For Bo >> 1. Gravity dominates over surface forces, leading to unstable configurations and ruling out steady-state solutions. Therefore, we should consider... Bo The parameter domain is approximately 1, which is the case where gravity and surface forces are of equal importance.

[0035] The upper and lower surfaces can be described by minimizing the free energy functional given by Equation 2. Under the constraint that the volume of the liquid in the lens is constant, where F(r,θ) As given by Equation 3, The first three terms under the integral sign represent surface energy and gravitational potential energy, respectively, while the last term utilizes the Lagrange multiplier. λ This indicates a volume constraint.

[0036] When the first change in energy potential disappears, equilibrium is reached, i.e., δΠ=0, which gives rise to the standard Euler-Lagrange equations given in equation 4. It can be explicitly written as Equation 5 The following normalized variables are defined by Equation 6. in h 0 is the characteristic deformation length scale, and After replacing the variables in Equation 1.4 with normalized variables, we obtain Equation 7: Equation 7 and Equation 1 are equivalent. For a given (e.g., measured) surface... U , L and dimensionless numbers Bo a fixed value, P 0 is determined by Equation 1.6. For surfaces created by the method of the present invention, there exists Bo The value of makes, within their domain, P 0 remains constant while R And Θ changes. On the other hand, if the surface is created via different methods, then regardless of Bo How does the value of [value] affect [the outcome]? R Both Θ and Θ will change. P The value of 0. Bo The reasonable range for its value is between 0 and 100.

[0037] In some embodiments, the article has the property defined by Equation 1 or Equation 7. Figure 3 The non-spherical surface is represented.

[0038] In a non-limiting example, the lens has an optical axis and a predetermined focal length.

[0039] Now for reference Figure 1A and Figure 1B These are examples of article manufacturing systems according to some embodiments of the present invention, and Figure 1B This is a block diagram of controllable components of an article manufacturing system according to some embodiments of the present invention.

[0040] The article manufacturing system 100 may include a chamber 110 configured to contain an immersion liquid and a partition 120 dividing the chamber 110 into at least one first portion 112 and at least one second portion 114. In some embodiments, the partition 120 may include an article frame 122 connected to an opening in the partition 120. Figure 1A In the illustrated non-limiting example, the separator 120 may include a separator plate 124 with an opening and a frame retainer 126, which, for example, uses a gasket 128 to secure and seal a frame 122 to the separator plate 124. In some embodiments, the separator 120 may consist only of the separator plate 124 and the frame 122, and the frame 122 may be directly attached (e.g., bonded) to the separator plate 124 using a gasket made of a sealing adhesive (e.g., a silicone-based adhesive), a metal gasket, a composite gasket, etc. The following discussion... Figure 3 , Figure 4 , Figure 5 and Figure 6 Further disclosures related to framework 122 are provided.

[0041] In some embodiments, the immersion liquid is sufficient to submerge at least one surface of the curable liquid. In some embodiments, the volume of the immersion liquid is sufficient to provide buoyancy to the curable liquid. In some embodiments, the volume of the immersion liquid is sufficient to contact the surface of the curable liquid. In some embodiments, the density of the immersion liquid is determined according to the desired morphology.

[0042] In some embodiments, the immersion liquid of the present invention is characterized by sufficient rheological properties, such as viscosity, to be suitable for use as an immersion liquid. Those skilled in the art will understand that the immersion liquid must enable the formation of a desired morphology and / or the geometry of the volume of curable liquid immersed therein. In some embodiments, the immersion liquid of the present invention is characterized by sufficient density to enable the immersion of a volume of curable liquid into the immersion liquid. In some embodiments, the density of the immersion liquid is set to provide a predetermined buoyancy (e.g., buoyancy sufficient to predefine the curvature of at least one surface of the curable liquid). In some embodiments, the density of the immersion liquid of the present invention is set to provide neutral buoyancy conditions. In some embodiments, the density of the immersion liquid is set to provide conditions within 30%, 25%, 20%, 15%, 10%, 5%, and 3% of neutral buoyancy, including any range therebetween. In some embodiments, the immersion liquid of the present invention is immiscible with the curable liquid. In some embodiments, the immersion liquid comprises a hydrophilic liquid, and the curable liquid is hydrophobic. In some embodiments, the immersion liquid of the present invention comprises a lipophilic liquid, and the curable liquid is hydrophilic. In some embodiments, the immersion liquid comprises a polar solvent (e.g., an aqueous ionic solution). In some embodiments, the immersion liquid of the present invention comprises water.

[0043] In some embodiments, the density of the immersion liquid of the present invention differs from the density of the curable liquid of the present invention. In some embodiments, the density of the immersion liquid is greater than the density of the curable liquid. In some embodiments, the density of the immersion liquid of the present invention is less than the density of the curable liquid of the present invention. In some embodiments, the density of the immersion liquid of the present invention is configured to provide buoyancy sufficient to predefine the curvature of at least one surface (e.g., the upper surface) of the curable liquid. In some embodiments, the density of the immersion liquid of the present invention is configured to provide buoyancy sufficient to predefine the curvature of both surfaces (upper and lower surfaces) of the curable liquid of the present invention. In some embodiments, the density of the immersion liquid is configured to provide buoyancy sufficient to predefine the curvature of both surfaces (upper and lower surfaces) of the curable liquid of the present invention.

[0044] In some embodiments, the immersion liquid of the present invention comprises an aqueous solution. In some embodiments, the immersion liquid of the present invention comprises an aqueous solution of ethylene glycol. In some embodiments, the immersion liquid of the present invention comprises an aqueous solution of a polyol. In some embodiments, the immersion liquid of the present invention comprises glycerol or a mixture of glycerol and water. In some embodiments, the immersion liquid comprises water as a solvent and additives such as organic and / or inorganic salts (e.g., acetates, carbonates, halides, hydroxides, sulfates, thiosulfates, or bicarbonates), and organic water-miscible compounds (e.g., glycerol, methanol, ethanol, acetone). In some embodiments, the immersion liquid is chemically stable under curing conditions. In some embodiments, the immersion liquid has a boiling point compatible with the manufacturing conditions. In some embodiments, the immersion liquid is chemically inert relative to the curable liquid. In some embodiments, the immersion liquid comprises fluorocarbon oil. Such fluorocarbon oils are immiscible with most other liquids and can therefore be used as immersion liquids for a variety of curable liquids. The density of the fluorocarbon oil can be controlled by mixing several types of fluorocarbon oils or by mixing with a specific organic compound (e.g., hexane) that is miscible with it. These types of fluorocarbon oils mainly include perfluoroperhydrophenanthrene, tetradecylfluorohexane, methoxyperfluorobutane, 1H,1H,2H,2H-perfluoro-1-octanol, Kritox, Fluorinert, Cytop, etc.

[0045] The article manufacturing system 100 may also include an immersion liquid hydraulic system 130, which includes at least one control valve 132 and at least one bidirectional immersion liquid pump 134. System 130 in... Figure 1B The block diagram further illustrates this. In some embodiments, the submerged fluid hydraulic system 130 is configured to: allow pressure equalization between at least one first portion 12 and at least one second portion 14; and regulate the volume or pressure of the submerged fluid in at least one first portion 12. In some embodiments, at least one control valve 132 may be a one-way valve or a two-way valve. In some embodiments, the pump 134 may be selected from piston pumps (e.g., syringe pumps), positive displacement pumps, gear pumps, Roots pumps, peristaltic pumps, etc.

[0046] exist Figure 1A In the illustrated non-limiting example, the submerged liquid hydraulic system 130 may include a pressure control valve 132 fluidly connected between at least one first portion 112 and at least one second portion, and configured to allow pressure equalization between at least one first portion 112 and at least one second portion 114. In some embodiments, the pressure control valve 132 may be a two-way valve. In some embodiments, the submerged liquid hydraulic system 130 may also include at least one two-way pump 132 fluidly connected to the first portion 112 and configured to control the volume or pressure of the submerged liquid in at least one first portion 112.

[0047] In some embodiments, the immersion liquid hydraulic system 130 may include two bidirectional pumps (not illustrated) fluidly connected to the first portion 112, wherein the first bidirectional pump is configured to provide a solvent (e.g., water) solution, and the second bidirectional pump is configured to provide at least one solute solution (e.g., an ionic solution comprising a salt). In some embodiments, the properties of the immersion liquid (e.g., density) are determined based on the ratio between the solvent solution and the solute solution.

[0048] In some embodiments, the density of the solvent solution is less than the density of the curable liquid, and the density of the solute solution is greater than the density of the curable liquid.

[0049] In such embodiments, the immersion liquid hydraulic system 130 may further include a first mixer for mixing the solvent solution and solute solution before providing the immersion liquid to the first portion. In some embodiments, a second mixer may be placed inside the first portion 112 and / or the second portion 114 to ensure uniform mixing of the solvent and solute.

[0050] In another non-limiting example (not illustrated), the submerged liquid hydraulic system 130 may include a two-way pressure control valve 132 and at least one two-way pump 134. The two-way pressure control valve 132 is fluidly connected to a first portion 112, a second portion 114, and at least one two-way pump 132. The two-way pressure control valve 132 may be configured to allow flow between the first portion 112 and the second portion 114 while shutting off flow to the pump 134, and to allow flow from the two-way pump 132 to the first portion 112 while shutting off flow between the first portion 112 and the second portion 114.

[0051] In some embodiments, the submerged liquid hydraulic system 130 may include a pressure sensor 136 fluidly connected to at least one first portion 112 and configured to measure pressure in the first portion 112. In some embodiments, the submerged liquid hydraulic system 130 may include an additional valve 138 configured to control the pressure of the submerged liquid in the first portion 112.

[0052] The article manufacturing system 100 may also include a solidifiable liquid supply unit 140, such as Figure 1C and Figure 2A As illustrated, it is configured to supply a curable liquid to the article frame 122. In some embodiments, the curable liquid supply unit 140 may include a port 142 configured to supply curable liquid from a curable liquid reservoir 146 to the article frame 122. In some embodiments, the curable liquid supply unit 140 may also include at least one curable liquid pump 144 fluidly connected to the port 142 and the curable liquid reservoir 146.

[0053] In some embodiments, port 142 is configured to inject a curable liquid. Port 142 may be configured to inject a curable liquid to contact or be adjacent to frame 122 to obtain a predetermined volume of curable liquid. For example, port 144 may be configured to transfer curable liquid on top of, adjacent to, or in contact with frame 122.

[0054] In some embodiments, pump 144 can be controlled to provide a predetermined amount of curable liquid to port 142. In some embodiments, this amount is based on the article (e.g., Figure 2A , Figure 2C and Figure 5 The dimensions of the illustrated article 200 are determined by its geometry (e.g., required size, curvature, desired shape, etc.). In some embodiments, the pump 144 may be selected from plunger pumps (e.g., syringe pumps), positive displacement pumps, gear pumps, roots pumps, peristaltic pumps, etc.

[0055] In some embodiments, the term "curable liquid" refers to one or more fluids capable of undergoing hardening or solidification. In some embodiments, the terms "curable liquid" and "hardening liquid" are used interchangeably herein. In some embodiments, a curable liquid is capable of solidification to produce a solid or semi-solid state. In some embodiments, a curable liquid is in a solid state after hardening or solidification. In some embodiments, a curable liquid is capable of solidification to significantly reduce its fluidity. In some embodiments, a curable liquid is or comprises a liquid. In some embodiments, a curable liquid comprises a liquid capable of curing. In some embodiments, a curable liquid is in a liquid state. In some embodiments, a curable liquid comprises a liquid polymer. In some embodiments, the liquid polymer is curable. In some embodiments, a curable liquid comprises a curable polymer.

[0056] In some embodiments, the curable liquid and the immersion liquid are immiscible. In some embodiments, the immersion liquid comprises a hydrophilic liquid, and the curable liquid is hydrophobic. In some embodiments, the immersion liquid of the present invention comprises a lipophilic liquid, and the curable liquid is hydrophilic. In some embodiments, the density of the immersion liquid... ρ im Density of curable liquid ρ The difference is less than 15%.

[0057] In a non-limiting example, the curable liquid of the present invention may refer to a composition comprising at least one of the following: monomers, oligomers, polymers, or mixtures thereof, wherein the composition is at least partially polymerizable (e.g., via free radical polymerization) upon exposure to light in the UV and / or visible light range. In some embodiments, the curable liquid is a liquid polymer comprising any methacrylate or acrylate resin that polymerizes upon exposure to UV light. In some embodiments, polymerization occurs in the presence of a free radical photoinitiator. In some embodiments, the liquid polymer comprises one or more low molecular weight materials, such as methacrylates, dimethacrylates, triacrylates, and diacrylates, or any combination thereof.

[0058] In some embodiments, the curable liquid may include a photoinitiator, such as an α-cleavage (unimolecular decomposition process) photoinitiator or a hydrogen-abstracting photosensitizer-tertiary amine synergist, operable to absorb UV light, preferably between 200 nm and 400 nm or between 300 nm and 385 nm, to generate one or more free radicals.

[0059] In some embodiments, the liquid polymer includes a photopolymer. Some non-limiting examples of photopolymerizable molecules include: styrene, N-vinylpyrrolidone, allyl acrylate, diacrylates (e.g., epoxides, urethanes, ethers, or esters functionalized with acrylates), tetrahydrofurfuryl methacrylate, triethylene glycol dimethacrylate, 2-phenoxyethyl methacrylate, lauryl methacrylate, ethoxylated trimethylolpropane triacrylate, tricyclodecanediethanol diacrylate, 2-phenoxyethyl acrylate, triethylene glycol diacrylate, monofunctional aliphatic polyurethane acrylate, polypropylene glycol monomethyl methacrylate, etc. Acrylic esters, polyethylene glycol monomethacrylate, cyclohexanediol diacrylate, tridecyl methacrylate, tri(meth)acrylates (e.g., 1,1-trimethylolpropane triacrylate or trimethacrylate, ethoxylated or propoxylated 1,1,1-trimethylolpropane triacrylate or trimethacrylate, ethoxylated or propoxylated glycerol triacrylate, pentaerythritol monohydroxy triacrylate or trimethacrylate, hydroxyethyl methacrylate (HEMA), tri(2-hydroxyethyl)isocyanurate triacrylate) or any combination thereof.

[0060] The article manufacturing system 100 may also include a controller 150 configured to control components of the system 100, such as an immersion liquid hydraulic system 130 and a curable liquid supply unit 140.

[0061] Controller 150 may include processor 152, which may be, for example, a central processing unit (CPU) processor, chip, or any suitable computing or computational device. Processor 152 (or one or more processors, possibly spanning multiple units or devices) may be configured to perform the methods described herein and / or perform or act as various modules, units, etc. According to embodiments of the invention, system 100 may include more than one computing controller 152.

[0062] Controller 150 may include memory 154, which may or may include, for example, random access memory (RAM), read-only memory (ROM), dynamic RAM (DRAM), synchronous DRAM (SD-RAM), double data rate (DDR) memory chip, flash memory, volatile memory, non-volatile memory, cache memory, buffer, short-term memory cell, long-term memory cell, or other suitable memory cell or storage unit. Memory 154 may be or may include multiple possibly different memory cells. Memory 154 may be a non-transitory readable medium for a computer or processor, or a non-transitory storage medium for a computer, such as RAM. In one embodiment, a non-transitory storage medium, such as memory 154, a hard disk drive, another storage device, etc., may store instructions or code that, when executed by a processor, cause the processor to perform the methods described herein.

[0063] According to some embodiments of the present invention, memory 154 may store at least one of an operating system, executable code, and a database thereon.

[0064] Controller 150 may also include a communication unit 156, which may include one or more input and output devices. For example, input devices may be or may include any suitable input device, component, or system, such as a detachable keyboard or keypad, mouse, etc. In another example, output devices may include one or more (possibly detachable) displays or monitors, speakers, and / or any other suitable output devices. Any applicable input / output (I / O) device may be connected to controller 150. For example, a wired or wireless network interface card (NIC), a universal serial bus (USB) device, or an external hard drive may be included in the input and / or output devices.

[0065] In some embodiments, the controller 150 may be configured to control the immersion liquid hydraulic system 130 to equalize the pressure between the first portion 112 and the second portion 114; control the immersion liquid hydraulic system 130 to block the flow between the first portion 112 and the second portion 114; control the curable liquid supply unit 140 to supply curable liquid to the article frame 122; and control the immersion liquid hydraulic system 130 to increase or decrease the amount or pressure of the immersion liquid in the first portion 112.

[0066] In some embodiments, the controller 150 may be configured to receive pressure measurements from the pressure sensor 136 and to control at least the pump 134 and / or the valve 138 based on the received measurements.

[0067] Regarding Figure 2B The flowchart discusses in detail the method according to an embodiment of the present invention to be performed by controller 150.

[0068] In some embodiments, system 100 may further include at least one light source 160 configured to illuminate an article. In some embodiments, at least one light source 160 is located at at least one of the following locations: the end of the first portion 112 or the second portion 114 opposite to the article frame 122 (as illustrated), the side of the article frame 122, on the wall of the first portion 112 or the second portion 114, and outside the chamber 110. In such cases, the chamber 110 includes at least one transparent window (e.g., window 164) located between the light source and the article. In some embodiments, the light source 160 may be configured to emit light in the ultraviolet (UV), visible, or infrared (IR) spectrum. In some embodiments, controller 150 may be configured to control the supply of light from the light source 160.

[0069] Some non-limiting examples of the light source 160 may include an array of light-emitting diodes (LEDs), a discharge lamp, a halogen lamp, and an incandescent bulb, etc.

[0070] In some embodiments, system 100 may further include a diffuser 162 configured to diffuse light onto an article. In some embodiments, system 100 may further include a transparent window 164 that allows light to enter chamber 110.

[0071] Figure 1BThe illustrated article manufacturing system 101 may include substantially the same components as article manufacturing system 100. In some embodiments, article manufacturing system 101 may further include at least one imaging device 170 configured to capture light transmitted through or reflected from a curable liquid. Light may be emitted from an imager light source 175. In such cases, at least one light source 160 (e.g., an LED array) may include a gap / aperture 172 that allows light to travel from the imager light source 175 to at least one imaging device 170. In some embodiments, at least one imaging device 170 may be selected from a camera and a wavefront sensor. In some embodiments, controller 150 may be configured to: receive an image from at least one imaging device; and control at least one of a curable liquid supply unit, an immersion liquid hydraulic system, and at least one light source based on the image.

[0072] Additional aspects of the invention may include a kit for article manufacturing. The kit may include an article manufacturing system 100 according to any of the embodiments disclosed herein; an immersion liquid; and a curing liquid.

[0073] Now for reference Figure 2A , Figure 2B and Figure 2C These are illustrations and flowcharts of steps in a method of manufacturing an article according to some embodiments of the present invention. The method can be executed by system 100 under the supervision of controller 150 or any other controller.

[0074] In step 210, immersion fluid may be supplied to at least one first portion and at least one second portion of the chamber separated by the partition. In some embodiments, controller 150 may control immersion fluid hydraulic system 130 to supply immersion fluid from immersion fluid reservoir (not illustrated) to chamber 110. For example, immersion fluid pump 134 may pump immersion fluid from the reservoir to supply the first portion 112. Since the opening in the partition 120 remains open at this stage, the second portion 114 may also be filled with immersion fluid.

[0075] In step 220, the valve may open between at least one first portion and at least one second portion. In some embodiments, as long as valve 132 is open, controller 150 may control valve 132 to allow pressure equalization between the first portion 112 and the second portion 114. Steps 210 and 220 are... Figure 2A Example in the first example of.

[0076] In step 230, a curable liquid can be supplied to the article frame included in the separator. In some embodiments, the controller 150 can control the curable liquid supply unit 140 to supply the curable liquid to the article frame 122 of the separator 120. For example, a pump 144 can pump a predetermined amount of curable liquid from a curable liquid reservoir and inject / insert the curable liquid into the article frame 122 via port 142. When supplied to the frame 122, the curable liquid fills the entire frame due to capillary action, thereby closing the openings in the separator 120 and the frame 122. At this stage, the first portion 112 is separated from the second portion 114, which are held together only by valve 132. As long as valve 132 remains open, the pressure of the immersion liquid in both the first portion 112 and the second portion 114 is equalized. Step 230 in Figure 2A Example in the second example of .

[0077] In step 240, the valve may, for example, be closed by controller 150, thereby completely separating the first portion 112 from the second portion 114. Due to the seal (e.g., by gasket 128), the immersion liquid cannot leak from the first portion 112 to the second portion 114, and vice versa.

[0078] In step 250, a pump can be used to adjust the volume or pressure of the immersion liquid in at least one first section to control the curvature of the article. For example, controller 150 can control pump 134 of the immersion liquid hydraulic system 130 to increase the pressure / volume of the immersion liquid in the first section 112 by adding immersion liquid to the first section 112, such as... Figure 2A Steps 240 and 250 are illustrated. In this case, a concave curvature can be formed in the curable liquid. Alternatively, the controller 150 can control the pump 134 of the immersion liquid hydraulic system 130 to reduce the pressure / volume of the immersion liquid in the first portion 112 by extracting the immersion liquid from the first portion 112. In this case, a convex curvature can be formed in the curable liquid.

[0079] In step 260, only Figure 2AAs illustrated, a curable liquid can be cured to form an article. For example, controller 150 can control light source 160 to irradiate the curable liquid with one of UV light, IR light, or visible light, thereby hardening the curable liquid to form article 200. In some embodiments, the simulation of curing the curable liquid can adjust the volume or pressure of the immersion liquid in at least one first portion during curing. This can be done to eliminate any undesirable pressure that may be applied to the curable liquid during curing, which could deform the article during curing. In some embodiments, if the pressure in the first portion 12 exceeds a predetermined threshold, adjustment can be passively made by releasing the immersion liquid, and / or actively made by operating pump 134 to adjust the volume or pressure of the immersion liquid in at least one first portion.

[0080] In step 270, only Figure 2A As illustrated, the article can be removed from the immersion fluid, and optionally also from frame 122, such as... Figure 2C exemplified.

[0081] exist Figure 2C In a non-limiting example, article 200 is an optical article, more specifically a lens for eyeglasses. In a non-limiting example, article 200 is made of an optical-grade polymer and has a curvature suitable for a prescription from an optometrist. In some embodiments, the precise curvature may be determined based on at least one of a structure of frame 122 (discussed below), adjustment of the pressure / volume of the immersion liquid in portion 112, the amount of curable liquid, and the ratio between the densities of the immersion liquid and the curable liquid.

[0082] Some additional aspects of the invention relate to a frame for manufacturing articles, such as frame 122. Frame 122 may include a housing 121 ( Figure 3 (As illustrated in the example), it has a wall with a variable height along the outline of the shell.

[0083] Now for reference Figure 3 It includes models of frames according to some embodiments of the invention and examples of frames for manufacturing articles. In some embodiments, the variability of the height is determined based on the intersection of the profile 121 of the housing with the surface 123 having the desired shape of the article.

[0084] In some embodiments, the frame 122 can be designed to have an arbitrary footprint based on the theoretically curable liquid, as discussed above with respect to equations 1 to 1.6. In some embodiments, the theoretically circular article can be considered, for example, an optical lens with a desired formulation, larger than the desired frame 121. The article can consist of two surfaces. h top= h top ( x , y )and h bot = h bot ( x , y The two surfaces are described by the shape of the frame and the distance between them. Therefore, the two surfaces can be analytically described as a function of the frame's shape and theoretical volume. V lens , V add A function of (the volume of the solidifiable fluid and the volume injected into the bottom of the tank).

[0085] In some embodiments, the planar space occupied by the frame 121 is determined by a coordinate set ( x F , y F Description (e.g.) Figure 3 As illustrated, the two edges of the required frame are formed by... z top = h top ( x F , y F ), z bot = h bot ( x F , y F The following is given, as illustrated in the figure. Then, the walls of frame 121 are formed by surface 123 and edges. z top and z bot The definition of intersection is shown in the figure.

[0086] For example, the desired morphology can satisfy Equation 1 or Equation 1.6 of the fluid forming process discussed above. In another example, the desired morphology can be defined as the surface resulting from injecting a curable liquid into the frame 122.

[0087] In some embodiments, the outline 121 of the housing is determined based on the receiving device of the receiving article 200, and Figure 2CThe following is an example. In a non-limiting example, article 200 is a lens or mirror, and the receiving device is selected from eyeglass frame 210 (as illustrated), microscope, telescope, binoculars, and laser cavity. In some embodiments, frame 122 is an integral part of receiving device 210. In a non-limiting example, the entire receiving device (e.g., eyeglass frame) can be inserted into article manufacturing system 100 and can be held by separator 120, so article 200 can be manufactured directly in the frame integrally included in receiving device 210. In a non-limiting example, eyeglass frame can be inserted into article manufacturing system 100, and each lens in the lens can be manufactured directly by system 100 into frame 122 of eyeglass frame 210.

[0088] Now for reference Figure 4 This illustrates a simulation of a frame and an article (e.g., a lens) according to some embodiments of the invention. Specific frames 122A or 122B are customized to give the article the correct shape. A non-circular frame with incorrect height values ​​can cause undesirable variations in the spherical and cylindrical power of the desired shape. Figure 4 Two lenses that can be manufactured under the same conditions are shown, wherein the frames have the same ( x F , y F Coordinates and equal injection volumes. The right frame 122B has a uniform height "naive" design, while the left frame 122A has a variable height based on a method according to an embodiment of the invention. Manufacturing an article using a frame 122B made of a uniform height frame may cause the article 200B to exhibit significant inhomogeneity in terms of spherical power and high cylindrical power. According to an embodiment of the invention, using a frame 122A with a variable height, an article 200A with uniform spherical power and cylindrical power can be produced.

[0089] Now for reference Figure 5The illustration shows two additional frames and corresponding lenses made using these frames, according to some embodiments of the invention. In some embodiments, at least a portion of the surfaces of frames 122 and 122A may be configured to form connectors for connecting at least one of the frames and the article to a receiving device. In some embodiments, the inner surfaces of the frames including 122 and 122A may include at least one element 125 and / or 127. In some embodiments, at least one element 125 and / or 127 is configured to form a connector for connecting to a space in the receiving device at the article. For example, at least one element may be a recess 125 and / or a protrusion 127 located on the inner surface of the wall of frame 122 (as illustrated). Thus, if frame 122 is removed from article 200, the article may be inserted into a space in receiving device 210 (e.g., an eyeglass frame), as illustrated. Alternatively, frame 122 may remain attached to article 200, and thus at least one connecting element 125 and / or 127 may be located on the outer surface of frame 122. In such cases, the frame 122 holding the item 200 can be inserted into the space in the receiving device 210.

[0090] Now for reference Figure 6 It is a flowchart of a method for creating a frame used to manufacture items. Figure 6 The method can be executed by any computer-aided manufacturing platform, such as additive manufacturing platforms (e.g., 3D printing), CNC milling machines, etc. Figure 6 The method can be performed on-site or at the point of sale, such as in an optometry shop.

[0091] In step 610, the outline of the receiving device can be received. For example, the controller of any computer-aided manufacturing platform can receive the outline of an item from a user via a user device / user interface. The outline can be selected from a list of known outlines (e.g., a list of eyeglass frames), or it can be received from image analysis of an image of the frame.

[0092] In step 620, the outer shell profile of the frame can be determined to fit the profile of the space within the receiving device. For example, the mathematical function determining the edges of frame 122 can be derived from... z top = h top ( x F , y F )and z bot = h bot ( x F , y F) is given, such as regarding Figure 3 As illustrated and discussed. In some embodiments, the controller may determine the mathematical function, for example, by using a lookup table associated with a list of known contours from image analysis, etc.

[0093] In step 630, the desired shape of the article can be received. For example, the desired shape can be received from a user using a user device or user interface. In some embodiments, the desired shape may satisfy Equation 1 or Equation 1.6. In a non-limiting manner, the desired shape may be determined based on an optical prescription.

[0094] In step 640, the height of the wall along the profile of the housing can be determined based on the intersection of the housing profile and the surface having the desired morphology, for example, as per [reference to...]. Figure 3 Examples and discussions.

[0095] In step 650, the outer shell walls can be manufactured to form a frame. For example, one or more manufacturing units of a computer-aided manufacturing platform may use at least one of additive manufacturing (e.g., 3D printing), machining, milling, grinding, etc., to manufacture the frame 122.

[0096] In some embodiments, the method may include adding at least one external connecting element to the outer surface of the frame, wherein the at least one external connecting element is configured to form a connector for connecting at least one of the frame and the article to the contour of a space in a receiving device, as per the description of... Figure 5 The discussion.

[0097] Example An analytical model was developed. According to some embodiments of the invention, the analytical model correlates the desired optical formulation with the geometric parameters required to manufacture the lens. Figure 7A , Figure 7B , Figure 7C and Figure 7D An example of an elliptical lens is given, along with the analysis results of the optical power of a fluid lens as a function of the frame geometry and injection volume.

[0098] Figure 7A A schematic diagram shows a fluid lens formed within a frame at height t, the fluid lens being composed of a radius... R 0 circular bottom outline and half diameter a , b It consists of an elliptical top profile. The volume of liquid-hardened material contained within the frame is... V lens And the volume enclosed between its bottom surface and the xy plane is V encIn a steady state, the system achieves its minimum energy configuration, which can be achieved through the top surface. h top ( x , y ) and bottom surface h bot ( x , y It is described by minimizing the energy functional of ).

[0099] In this non-limiting example, the bottom surface is guaranteed to have a radius of curvature. R bot A spherical cap, and its top surface has two radii of curvature. R xtop and R ytop The complex surface. The spherical power of such lenses is given by the lens maker's equation (Equation 8). in It is the average radius of curvature of the top surface. d It is the center thickness of the lens, and n It is the reflectivity of the hardened liquid.

[0100] Similarly, the cylindrical power is given by Equation 9. Using the minimum energy model, the radius of curvature can be related to the geometry of the frame and the injection volume of the hardening fluid. The spherical and cylindrical powers can be expressed by equations 10(a) and 10(b) through the thin lens approximation. in ,and It is the gap distance between the center of the xy plane and the center of the bottom surface, such as Figure 7A exemplified.

[0101] Combining equations 10(a) and 10(b), we can derive equation 11. Its indication is achieved by adjusting the eccentricity of the frame. It can achieve any combination of spherical and cylindrical power.

[0102] For those with R 0 = 25 mm n = 1.525 and h A lens with a diameter of 0 = 3 mm. Figure 7B The cylindrical power shown is a function of spherical power and eccentricity. Figure 7BThis demonstrates the degrees of freedom in the design, where for a given radius... R 0 and the desired gap h For a lens with a power of 0, the desired spherical power can be selected, and the required eccentricity can be obtained to satisfy the desired cylindrical power. Using equations 10(a) and 10(b), the volume of the hardened liquid needs to be determined. V lens To produce a lens. Figure 7E The flowchart in the diagram can be used to determine the physical parameters (frame geometry and liquid volume) required to achieve any combination of spherical and cylindrical lenses.

[0103] For the simplified case where the cylinder power is zero, Figure 7C The volume of the hardened liquid is given in the figure. V lens As a function of lens size. The values ​​shown include typical sizes for children's and adult frames, but can naturally be extended beyond the range presented. Typical injection volumes are in the milliliters. The curves in the figure illustrate the sensitivity of diopter to inaccuracies in the injection. For example, for a frame diameter of 50 mm, a deviation of 1 / 8 diopter (which is well within the range that the human eye can normally not perceive) is due to 50 μm. l This is caused by volume inaccuracies. Maintaining this level of volume accuracy (on the order of 1% of total volume) can be easily achieved using low-cost injection systems.

[0104] The curvature difference between the top and bottom surfaces is determined and therefore affected by... V enc Unlike spherical lenses, which have a very small impact, cylindrical lenses are controlled solely by the elliptical (apex) surface and therefore have little effect on... V lens and V enc Both are much more sensitive.

[0105] Figure 7D The figure shows the cylindrical power of the lens as a function of eccentricity and total volume Δ for a base diameter of 50 mm and a refractive index of 1.525. V lens + V enc The blue curve depicts the sensitivity of cylindrical power to the combined injection volume, with a magnitude one order of magnitude lower than that of spherical power. This curve represents the sensitivity of cylindrical power to changes in eccentricity for two injection volumes (3 ml (typical) and 6 ml (limit)). The sensitivity to changes in eccentricity is most pronounced for lenses without a cylindrical power. Even in this extreme case, the diameter (a or b) can change by up to 300 μm and still remain within a 1 / 8 diopter range. This sensitivity decreases significantly with increasing nominal cylindrical power.

[0106] Now for reference Figure 7E This is a flowchart of a method for calculating the frame geometry and liquid volume required to manufacture a desired lens according to some embodiments of the present invention. In step 710, the method may include receiving desired input parameters, including spherical power (…). P ), cylinder power ( C ), the desired size of the lens ( R 0), the gap between the eyes ( h 0), the refractive index of the polymer liquid ( n ), and for negative lenses, the permissible lens thickness ( d In some embodiments, for a positive lens, the parameters may further include the frame thickness ( t ).

[0107] In step 720, the method may include using items. To calculate the eccentricity of the frame. This calculation can produce the half-diameter of the elliptical boundary ( a , b Step 720 may also include calculating the volume enclosed below the bottom surface of the lens using Equation 12. V enc . In step 730, the method may include using equation (13) to calculate Δ V lens . In step 740, the method may include using the volume of the immersion liquid ( V enc ) and Δ V lens The value is used to calculate the total volume of the immersion liquid that should be injected. In step 750, for a negative spherical lens, the method may include using equation (14) to calculate the height of the bounding box; and for a positive spherical lens, this value is one of the inputs. In step 760, the method may include using frame geometry, Δ V lens and enclosed submerged liquid volume V enc To calculate the volume of polymer liquid to be injected V lens .

[0108] In step 770, the method may include receiving the frame geometry a, b, t and the desired volume. V lens , V imm .

[0109] Now for reference Figure 8A , Figure 8B , Figure 8C and Figure 8D These are experimental results and characterizations of eyeglass lenses manufactured using fluid forming methods according to some embodiments of the present invention. Figure 8A Normalized refractive power is shown P̃ = P ·(π R 4 ) / (4( n -1), as a function of the injected polymer volume, for 92 lenses manufactured using a ring frame, spanning both negative and positive refractive powers, for two frame diameters and for two different polymers—one UV-curable and the other thermosetting. The horizontal error bars indicate... V lens The uncertainty stems from uncertainties in the injection volume and frame dimensions. The degree value represents the average degree over the entire area of ​​the lens, measured by a Mohr deflectometer (Mapper from Rotlex, Israel). The results are in excellent agreement with calculations using equations 1.9a and 1.9b (solid straight line), where... a = b = R 0. And demonstrate the ability to design and manufacture lenses covering a wide range of optical diopters (here, between P = -6 and P = 5 diopters).

[0110] For a given manufactured lens, the quality is determined by the uniformity of its optical power over its area. Figure 8B and Figure 8C The study presents the deviations between the measured spherical and cylindrical power distributions of two high-quality lenses manufactured using fluid forming and their expected theoretical values. Figure 8B The image in the image corresponds to a lens produced in a circular frame. e = 0, R 0 = 25 mm That is, the intention is to perform pure spherical correction.

[0111] In this case, the spherical power deviates from the intended value by 0.11 diopters (D), and the spatial standard deviation is 0.04D. The lens shows a residual cylindrical power of 0.17D, with a standard deviation of 0.1D. Based on the sensitivity of the human eye, the cylindrical deviation is within generally acceptable limits, and the spherical deviation meets the more stringent requirement of <1 / 8 D.

[0112] Figure 8D The image in the image corresponds to the lens produced in the elliptical frame. e = 0.552, a = 30 mm, b = R 0 = 25 mm), where the injected liquid volume is designed to achieve the same... Figure 8D It has the same spherical power but a significant 1.7D cylindrical power. This illustrates the ability to independently define two nominal powers. Again, the standard deviations of both powers are within generally acceptable ranges. An additional important criterion for evaluating optical components is their surface roughness—lenses with poor surface quality are unusable functionally. Figure 4 Figure d presents AFM measurements, showing an average surface roughness of 1.4 nm over a 3 µm x 3 µm measurement area. Measurements were performed at nine different locations on four different lenses. As expected, the results are independent of the lens position or shape, since surface roughness is determined by surface tension and the molecular structure of the polymer. Across the nine measurement sites, the root mean square (RMS) values ​​ranged from 0.43 nm to 3.3 nm, with an average of 1.4 nm. These values ​​are one to two orders of magnitude better than industry standards, which are in the tens of nanometers range.

[0113] Unless explicitly stated otherwise, the method embodiments described herein are not bound by a particular order or sequence. Furthermore, all formulas described herein are intended as examples only, and other or different formulas may be used. Additionally, some of the described method embodiments or elements thereof may occur or be performed at the same point in time.

[0114] While certain features of the invention have been illustrated and described herein, many modifications, substitutions, alterations, and equivalents can be made by those skilled in the art. Therefore, it should be understood that the appended claims are intended to cover all such modifications and variations falling within the true spirit of the invention.

[0115] Various embodiments have been presented. Each of these embodiments may, of course, include features from the other presented embodiments, and embodiments not specifically described may include the various features described herein.

Claims

1. An article manufacturing system, comprising: A chamber configured to contain an immersion liquid; A partition, including a through-hole opening, divides the chamber into at least one first portion and at least one second portion, the partition including an article frame and a liner located between the partition and the frame; An immersion liquid hydraulic system comprising at least one control valve and at least one bidirectional immersion liquid pump, wherein the immersion liquid hydraulic system is configured to: Allowing for pressure equalization between the at least one first part and the at least one second part; as well as Adjust the volume or pressure of the immersion liquid in at least one of the first portions; A curable liquid supply unit, comprising a curable liquid reservoir, is configured to supply curable liquid to the article frame; as well as The controller is configured as follows: Control the immersion liquid hydraulic system to balance the pressure between the first portion and the second portion; Control the immersion liquid hydraulic system to block the flow between the first part and the second part; Control the curable liquid supply unit to supply the curable liquid to the article frame; as well as Control the immersion liquid hydraulic system to increase or decrease the amount or pressure of the immersion liquid in the first part.

2. The article manufacturing system according to claim 1, wherein the immersion liquid hydraulic system further comprises: The at least one control valve is a pressure control valve, fluidly connected between the at least one first portion and the at least one second portion, and configured to allow equalization of the pressure between the at least one first portion and the at least one second portion. And wherein the at least one bidirectional pump is fluidly connected to the first portion and is configured to control the volume or pressure of the immersion liquid in the at least one first portion.

3. The article manufacturing system of claim 2, wherein the immersion liquid hydraulic system comprises two bidirectional pumps fluidly connected to the first portion, wherein a first bidirectional pump of the two bidirectional pumps is configured to provide a solvent solution, and a second bidirectional pump of the two bidirectional pumps is configured to provide at least one solute solution, and wherein the controller is configured to control the first bidirectional pump and the second bidirectional pump to provide the solvent and the solute in a predetermined ratio to form the immersion liquid.

4. The article manufacturing system of claim 3, further comprising a first mixer for mixing the solvent solution and the solute solution before providing the immersion liquid to the first portion.

5. The article manufacturing system of claim 3, further comprising a second mixer for mixing the solvent solution and the solute solution in the chamber.

6. The article manufacturing system according to any one of claims 3 to 5, wherein the density of the solvent solution is less than the density of the curable liquid, and wherein the density of the solute solution is higher than the density of the curable liquid.

7. The article manufacturing system according to any one of claims 1 to 6, The bidirectional pressure control valve is fluidly connected to the first part, the second part, and the at least one bidirectional pump.

8. The article manufacturing system according to any one of claims 1 to 7, wherein the curable liquid supply unit further comprises: A port configured to supply a curable liquid from the curable liquid reservoir to the article frame; as well as At least one bidirectional pump for curable liquid is fluidly connected to the port and the reservoir for curable liquid.

9. The article manufacturing system according to any one of claims 1 to 8, wherein the separator further comprises A partition plate having the aforementioned through-hole opening; and A frame retainer that secures the gasket and the frame to the spacer ring in a sealing manner.

10. The article manufacturing system according to any one of claims 1 to 9, further comprising at least one imaging device configured to capture light transmitted through or reflected from the curable liquid.

11. The article manufacturing system of claim 10, wherein the at least one imaging device is at least one of a camera and a wavefront sensor.

12. The article manufacturing system according to claim 10 or claim 11, wherein the controller is configured to: Receive images from the at least one imaging device; and The image is used to control at least one of the curable liquid supply unit, the immersion liquid hydraulic system, and the at least one light source.

13. The article manufacturing system according to any one of claims 1 to 12, further comprising: At least one light source is configured to illuminate the article.

14. The article manufacturing system of claim 13, wherein the at least one light source is located at at least one of the following locations: the end of the first portion opposite to the article frame, or the end of the second portion opposite to the article frame, on the wall of the first portion or the wall of the second portion, and outside the enclosed chamber, wherein the enclosed chamber includes at least one transparent window located between the light source and the article.

15. The article manufacturing system of claim 13 or claim 14, wherein the controller is further configured to control the at least one light source to provide light to the curable liquid.

16. The article manufacturing system according to any one of claims 13 to 15, wherein the light source comprises at least one of a light-emitting diode (LED) array, a gas discharge lamp, and an incandescent bulb.

17. The optical article manufacturing system according to any one of claims 13 to 16, further comprising a diffuser configured to diffuse the light onto the article.

18. The article manufacturing system according to any one of claims 1 to 17, further comprising a pressure sensor fluidly connected to the at least one first portion, wherein the controller is configured to also control the immersion liquid hydraulic system based on pressure measurements received from the pressure sensor.

19. The article manufacturing system according to any one of claims 1 to 18, wherein the curable liquid and the immersion liquid are immiscible.

20. The article manufacturing system according to any one of claims 1 to 19, wherein the density of the immersion liquid is... ρ im With respect to the density of the curable liquid ρ The difference is less than 15%.

21. The article manufacturing system according to any one of claims 1 to 20, wherein the article is a curved article.

22. The article manufacturing system according to any one of claims 1 to 21, wherein the article is an optical article and the curable liquid is at least partially transparent.

23. The article manufacturing system according to any one of claims 1 to 22, wherein the article is a mold for optical manufacturing.

24. A kit for article manufacturing, comprising: Article manufacturing system according to any one of claims 1 to 23; The immersion liquid; as well as The solidified liquid.

25. A method of manufacturing an article, comprising: Immersion liquid is supplied to at least one first portion and at least one second portion of a chamber separated by a partition; Open the valve between the at least one first part and the at least one second part; A curable liquid is supplied to the article frame included in the separator; Close the valve; The volume or pressure of the immersion liquid in at least one of the first parts is adjusted using a pump to control the curvature of the article; as well as The curable liquid is cured to form the article.

26. The method of claim 25, further comprising receiving a measurement of the pressure of the immersion liquid in the at least one first portion, and The adjustment of the volume or pressure of the immersion liquid in the first part is based on the pressure measurement and the desired characteristics of the article.

27. The method of claim 25 or claim 26, wherein curing the curable liquid includes adjusting the volume or pressure of the immersion liquid in the at least one first portion during curing.

28. The method of claim 27, wherein regulation comprises: passively releasing the introduced immersion liquid if the pressure in the first portion exceeds a predetermined threshold, and actively operating the pump to regulate the volume or pressure of the immersion liquid in the at least one first portion.

29. The method according to any one of claims 25 to 28, wherein the article is a curved article.

30. The method according to any one of claims 25 to 29, wherein the article is an optical article and the curable liquid is at least partially transparent.

31. The method according to any one of claims 25 to 30, wherein the article is a mold for optical manufacturing.

32. A frame for manufacturing articles, the frame comprising: An outer shell having walls having a variable height along the contour of the outer shell.

33. The frame of claim 32, wherein the outline of the housing is determined based on the receiving device receiving the article.

34. The frame of claim 33, wherein the article is a lens or face mirror, and the receiving device is selected from eyeglass frames, microscopes, telescopes, binoculars, and laser cavities.

35. The frame according to any one of claims 32 to 34, wherein the frame is a component of the receiving device.

36. The frame according to any one of claims 32 to 35, wherein the variability of the height is determined based on the intersection of the profile of the shell with the surface having the desired shape of the article.

37. The frame of claim 36, wherein the desired morphology of the surface satisfies the following fluid shaping equation: Where r is the normalized radius variable, h is the normalized surface height variable, the subscript indicates the spatial derivative of h with respect to the radial or azimuth direction, and A and B are free parameters.

38. The frame according to any one of claims 31 to 36, wherein at least a portion of the surface of the frame forms a connector for connecting at least one of the frame and the article to the receiving device.

39. The frame of claim 37, wherein the inner surface of the frame includes one or more connector forming elements to form at least one connector on the contour of the article for connecting the article to the receiving device.

40. The frame of claim 38, wherein the at least one connector forming element is selected from recesses and protrusions and any combination thereof.

41. The frame of claim 37, wherein the outer surface of the frame includes the connector for connecting the frame to the receiving device.

42. A method for making a frame for manufacturing an article, comprising: The outline of the receiver within the receiving device; The outer shell profile of the frame is determined to fit the profile in the receiving device; Receive the desired shape of the item; The height of the shell wall along the contour is determined based on the intersection of the shell's contour with a surface having the desired morphology. as well as Manufacture the outer shell wall.

43. The method of claim 41, further comprising adding at least one external connecting element to the outer surface of the frame, wherein the at least one external connecting element is configured to form a connector for connecting at least one of the frame and the article to the contour of the space in the receiving device.

44. The method of claim 41 or claim 42, wherein the desired morphology of the surface satisfies the following fluid shaping equation. Where r is the normalized radius variable, h is the normalized surface height variable, the subscript indicates the spatial derivative of h with respect to the radial or azimuth direction, and A and B are free parameters.

Images