Method and installation for measuring a casting assembly provided for production of a lens, method and installation for checking the casting assembly, and method and installation for producing at least one lens
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- RODENSTOCK GMBH
- Filing Date
- 2024-10-23
- Publication Date
- 2026-06-03
AI Technical Summary
The quality of lenses produced using casting packages is compromised due to manufacturing tolerances and assembly deviations, leading to incorrect gap heights between the casting package parts, which are only detected after lens production, resulting in wasted material and time.
A procedure and system for measuring and checking the gap parameter value between the first and second casting package parts before filling the cavity with casting resin, allowing for the recognition and modification of defective casting packages to ensure accurate gap heights.
This approach improves the quality of lenses produced by identifying and correcting deviations in the casting package gap heights before resin filling, thereby reducing post-processing issues, material waste, and production time.
Smart Images
Figure EP2024079875_01052025_PF_FP_ABST
Abstract
Description
[0001] Description
[0002] Method and system for measuring a casting package intended for the production of a lens, method and system for testing the casting package and method and system for producing at least one lens
[0003] The present invention relates to a method and a system for measuring a casting package intended for the production of a lens, a method and a system for testing the casting package and a method and a system for producing at least one lens.
[0004] If, to produce a lens, a cavity of a casting package formed between a first and second casting package part is filled with a casting resin, the quality of the lens depends on the accuracy with which the cavity has a desired gap.
[0005] The actual gap may vary, particularly due to manufacturing tolerances of the casting package parts and assembly tolerances during assembly of the casting package.
[0006] However, deviations between the actual and desired gap are usually only detected by measuring the lens thickness or strength on the manufactured and possibly processed lens, which can result in a manufactured and possibly processed lens having to be laboriously reworked or disposed of, thus wasting expensive material and production time.
[0007] An object of an embodiment of the present invention is to improve the manufacture of lenses and / or to improve measuring or testing of mold packages intended for the manufacture of lenses.
[0008] This object is achieved by a method having the features of claims 1, 8 and 9, respectively. Claim 16 protects a system which is configured, preferably used, for carrying out a method described here. The subclaims relate to advantageous developments. According to one embodiment of the present invention, a method for measuring a casting package intended for the production of a lens, according to one embodiment of the present invention, a method for testing this casting package intended for the production of a lens, according to one embodiment of the present invention, a method for producing one or more lenses, comprises the step:
[0009] Providing (each) a casting package (for the production of the respective lens), which (each)
[0010] - a first casting package part, and
[0011] - has a second casting package part, wherein the second casting package part of the provided casting package is held relative to the first casting package part of the casting package in such a way, in one embodiment on the first casting package part and / or by a holder, in a further development by the seal explained below or a different or separate holding device, that a cavity is formed between the first and second casting package part.
[0012] The lens is preferably an ophthalmic lens, particularly preferably a spectacle lens or a lens therefor. The present invention is particularly suitable for such lenses or casting packages, particularly due to the corresponding requirements for precision and economical production, but is not limited thereto.
[0013] In one embodiment, in a further development, the first and second casting package parts are arranged relative to one another taking into account a predetermined one- or multi-dimensional target parameter (value) (for the arrangement of the two casting package parts relative to one another), in one embodiment using a casting package assembly device and / or at least partially automated and / or at least partially manually. Thus, the provision of a casting package can in particular comprise the arrangement of the two casting package parts relative to one another, preferably taking into account a predetermined target parameter (value), and / or the feeding of the casting package with the two casting package parts and the cavity formed between them. According to one embodiment of the present invention, the method for measuring or testing or for manufacturing comprises the step:
[0014] - Determining (each) a one-dimensional or multi-dimensional gap parameter value (for the (respective) casting package), wherein this determination of the gap parameter value comprises determining a first, preferably shortest, distance between the (respective) first and second casting package part (of the provided casting package), in particular surfaces of the casting package parts facing each other or the cavity, at a first location in the cavity, and the gap parameter value depends on this first distance, in a further development increasing or decreasing with increasing first distance.
[0015] One embodiment of the present invention is based on the idea of determining the gap height of the cavity, on which the quality of the manufactured lens depends, preferably before the cavity is filled with casting resin. In this way, a defective casting package can advantageously be identified and, if necessary, sorted out or discarded, or a current casting package and / or a subsequently produced or provided casting package can be modified if necessary, preferably before the cavity is filled with casting resin. This reduces the likelihood of complex rework or scrap, thus saving expensive material and production time.
[0016] In one embodiment, the provided casting package (already) has a seal for the cavity formed between the first and second casting package parts when determining the first distance, and in a further development (also) when determining the further distance or one or more of the further distances, wherein this cavity preferably has not yet been filled with casting resin during this determination. In other words, in one embodiment, the casting package provided with the seal or having this seal is measured, preferably before the cavity is filled with casting resin.
[0017] In one embodiment, this allows for the detection of an incorrect gap height resulting from or (also) due to the sealing, and for the corresponding casting package already having the seal to be responded to accordingly, in particular by modifying or rejecting the corresponding casting package already having the seal and / or by modifying subsequently (manufactured or provided) casting packages. Thus, the provision of a casting package can in particular include the application of the seal.
[0018] In one embodiment, the casting package has the seal for the cavity formed between the first and second casting package parts. However, this seal is only formed after the first distance has been determined, or in a further development (also) after the further distance or one or more of the further distances has been determined, and this cavity preferably has not yet been filled with casting resin during this determination. In other words, in one embodiment, the casting package is provided and measured before it is provided with the seal or has this seal, preferably before the cavity is filled with casting resin.
[0019] In one embodiment, this allows an incorrect gap height to be detected particularly early and reacted to accordingly, in particular by modifying or sorting out the corresponding casting package before or by adding the seal to the provided casting package.
[0020] Both designs can also be combined in such a way that first the first distance, in a further development (also) the further distance or one or more of the further distances, is / are determined, then the casting package is modified if necessary, (only) then the seal is arranged or attached, and then again a first distance, in a further development (also) one or more further distances, is / are determined, and then the casting package is modified (again) if necessary.
[0021] In one embodiment, the seal comprises a single- or multi-layer sealing tape which is or will be connected to the first and second casting package parts, preferably in a material-to-material manner, preferably by means of an adhesive, at least temporarily for production purposes.
[0022] According to one embodiment of the present invention, the testing method comprises the step:
[0023] - Testing the casting package based on the (determined) gap parameter value. According to one embodiment of the present invention, the manufacturing method comprises the following steps:
[0024] - modifying the casting package if the gap parameter value meets a specified modification criterion; and
[0025] - Filling the cavity of the casting package, preferably comprising the seal, with a casting resin, preferably after determining the gap parameter value, testing the casting package, and optionally modifying the casting package; wherein the manufactured lens comprises the cured casting resin. Accordingly, in one embodiment, the cavity of the casting package is filled with the casting resin without this modification if the gap parameter value meets a predetermined acceptance criterion, in particular if it does not meet the modification criterion. In one embodiment, the modification of the casting package takes place before and / or after the arrangement of the seal.In other words, in one embodiment, the casting package is optionally modified before the seal is arranged, and / or the casting package, which may have been modified once or multiple times before the seal is arranged, already has the seal when a gap parameter value is determined, possibly again, and is optionally modified (again). In this case, by modifying it before the seal is arranged, the casting package can advantageously be modified earlier and / or more easily, while by modifying it after the seal is arranged, in particular, an incorrect gap height caused by or with the seal can be corrected or compensated for.
[0026] In one embodiment, this can improve the quality of the manufactured lens(es) and / or reduce the reworking and / or scrap rate, thus saving material and / or production time. Testing can include, in particular, comparing the determined gap parameter value with predefined target values and / or tolerance ranges and / or evaluating and / or classifying the casting package based on the determined gap parameter value, in particular comparing the determined gap parameter value with predefined target values and / or tolerance ranges.
[0027] In one embodiment, the casting resin with which the cavity has been filled hardens; in a further development, it is cured, in particular by tempering and / or exposure to light. Thus, in one embodiment, a method according to the invention can comprise curing the casting resin with which the cavity has been filled. Particularly advantageously, the casting resin with which the cavity is filled is a highly viscous fluid and / or comprises at least one polymer, in particular a photochromic and / or UV-curing polymer, and can in particular be such a polymer.
[0028] In a particularly advantageous embodiment, the cured casting resin forms a coating, particularly preferably a self-tinting or photochromic color coating, or a dirt-repellent coating, an anti-reflective coating, an anti-scratch coating, or the like, in a preferred embodiment. For this purpose, the cured casting resin is preferably separated from the second casting package part, preferably before, during, or after removal of the seal, and the manufactured lens comprises the first casting package part connected to the cured casting resin, in particular by a material bond or by casting. The present invention is particularly advantageous for such casting coatings, in particular due to the generally very thin coatings.Accordingly, the first casting package part can in particular be a base body, preferably a base glass body, particularly preferably a base plastic glass body, and / or the second casting package part can have, in particular be, a mold shell, and the cured casting resin can form a coating of the lens or this base body.
[0029] In a likewise advantageous embodiment, the cured casting resin is separated from the first and second casting package parts, preferably before, during, or after removal of the seal. It can, in particular, form an aforementioned base plastic glass body or a so-called semi-finished product or blank for the production of a spectacle lens or the like. Accordingly, the first and second casting package parts can each have a mold shell, in particular, a mold shell.
[0030] In a likewise advantageous embodiment, the seal is optionally removed, and the manufactured lens comprises the first casting package part connected to the cured casting resin, in particular by a material fit or by casting, and the second casting package part connected to the cured casting resin, in particular by a material fit or by casting. Accordingly, the cured casting resin can form an intermediate layer of the lens. The lens manufactured in this way, in particular a coated lens, a blank or base glass, or a lens with an intermediate layer, is further processed in one embodiment, for example based on a prescription and / or (further) coating and / or material removal and / or separation. Thus, in one embodiment, a method according to the invention can comprise processing the manufactured lens which has the cured casting resin.
[0031] In one embodiment, determining the gap parameter value comprises determining a further, preferably shortest, distance or several further, preferably shortest, distances between the first and second casting package parts (of the respective casting package), in particular surfaces of the casting package parts facing each other or the cavity, at (each) a further location in the cavity, wherein the gap parameter also depends on this further distance or these further distances, and in a further development increases or decreases with increasing further distance or further distances. This can improve the significance and / or reliability of the test. Distances are particularly advantageously determined at three or more locations in the cavity, which particularly advantageously do not lie on a straight line, since this enables 3D mapping and (also) detection of a prismatic tilt or distance variation that is particularly relevant for the lens.
[0032] In one embodiment, the gap parameter value meets the specified modification criterion if the first distance (or the deviation of the first distance from a specified target value) is not within a specified (permissible) range, or if the modification criterion is specified in such a way. This allows for a particularly fast test.
[0033] In one embodiment, the gap parameter value satisfies the predefined modification criterion if the first distance (or the deviation of the first distance from a predefined target value) is not within a predefined (permissible) range or the further distance (or the deviation of the further distance from a predefined target value) is not within a predefined (permissible) range, or the modification criterion is predefined in this way. This allows a more reliable and / or more significant test to be carried out. In one embodiment, the gap parameter value satisfies the predefined modification criterion if the first distance (or the deviation of the first distance from a predefined target value) or at least one of the further distances (or the deviation of at least one of the further distances from a predefined target value) is not within a predefined (permissible) range, or the modification criterion is predefined in this way.This allows for a more reliable and / or significant test to be carried out.
[0034] Different target values and / or permissible deviations or ranges can be specified for the first distance and one or more of the additional distances, which allows different, more complex geometries to be particularly well accommodated. Accordingly, the gap parameter (value) can be a multidimensional parameter or value, and the modification criterion a multidimensional criterion; in particular, the gap parameter (value) can specify the distances measured at the various locations.
[0035] Likewise, the gap parameter (value) can also specify, for example, an average or maximum value of the measured distances, or an average or maximum value of the deviations of the measured distances from the target values. This allows the test to be performed particularly quickly and, at the same time, to be particularly informative.
[0036] A permissible range can in particular also be specified by specifying a correspondingly complementary impermissible range. Purely by way of example, the modification criterion can be specified in such a way that the gap parameter value fulfills the modification criterion if the deviation of the first distance from a predetermined target value is not within a predetermined permissible range [a, b], or in such a way that the gap parameter value fulfills the modification criterion if this deviation is within a predetermined impermissible range [u, a[ ]b, v].
[0037] In one embodiment, at least one distance between the first and second casting package parts, in particular the first distance or the further distance or at least one of the further distances, is determined at a location in a central region of the cavity. Such a distance can be particularly significant. Additionally or alternatively, at least one distance between the first and second casting package parts, in particular the first distance or the further distance or one or more of the further distances (in each case), is determined at a location in an edge region of the cavity; in an advantageous development, two or more of these distances are determined at different locations in the edge region of the cavity. Preferably, two or more of these adjacent locations in the edge region are offset from one another (in each case) by at least 45° and / or at most 135°. Such distances can be determined particularly well and / or can be sensitive with regard to assembly and / or manufacturing tolerances.
[0038] A location of the cavity in the sense of the present invention can, in one embodiment, comprise a radial and / or shortest distance to a longitudinal and / or optical (main) axis through a center of the lens and / or an angle between a normal to a longitudinal and / or optical (main) axis through a center of the lens and a reference normal to this axis or Cartesian coordinates in a plane, in particular be perpendicular to a longitudinal and / or optical (main) axis through a center of the lens and / or in the cavity.
[0039] In a central region of the cavity referred to here, all locations or points have a radial and / or shortest distance to the longitudinal and / or optical (main) axis through a center of the lens, which is at most equal to one third of a maximum (radial) distance of a circumference of the cavity from this axis.
[0040] In a peripheral region of the cavity, as defined here, all locations or points have a radial and / or shortest distance to the longitudinal and / or optical (main) axis through a center of the lens that is at least two-thirds of a maximum (radial) distance of a circumference of the cavity from this axis. In other words, for a circular ring-shaped cavity with an outer radius R, its peripheral region is a concentric circular ring-shaped cavity with an outer radius R and an inner radius of 2R / 3, and its central region is a concentric circular region with an outer radius R / 3.
[0041] In one embodiment, determining at least two of the distances comprises measuring using the same measuring device, preferably by moving and / or rotating the measuring device and casting package relative to one another and / or by scanning, in particular rasterizing, the corresponding locations using the measuring device. In one embodiment, this allows more reliable measurements to be carried out. In one embodiment, to determine at least two of the distances, in particular only or also, the measuring device is adjusted, in particular pivoted and / or moved. In one embodiment, this allows the measuring device to be positioned particularly advantageously. Additionally or alternatively, in one embodiment, to determine at least two of the distances, in particular only or also, the casting package is adjusted, in particular pivoted and / or moved. In one embodiment, this allows the measuring device and casting package to be positioned particularly advantageously relative to one another.
[0042] Additionally or alternatively, determining at least two of the distances comprises measuring at least one of the distances using a (first) measuring device and measuring, in particular simultaneously or subsequently, at least one other of the distances using a (further) measuring device, which is preferably spaced apart from the one or first measuring device. In one embodiment, measurements can thus be performed more quickly and / or more precisely.
[0043] In one embodiment, the first distance and / or the further distance, or one or more of the further distances, are (each) measured using one, preferably the same or multiple, confocal sensors. Accordingly, (at least) one measuring device mentioned here can preferably (each) comprise, in particular be, a confocal sensor. As a result, measurements can be performed more quickly and / or more precisely in one embodiment.
[0044] In one embodiment, determining a distance, in particular the first distance and / or the further distance or one or more of the further distances, comprises a preferably sensory measurement, wherein in one development the measurement is an optical and / or contactless measurement and / or a measurement of a distance between a measuring device and a surface, preferably facing the cavity, of the first casting package part and a distance between another measuring device or particularly preferably this one or the same measuring device in the same pose and a surface, preferably facing the cavity, of the second casting package part. As a result, in one embodiment the distance can be measured particularly quickly, reliably and / or precisely. In one embodiment the first casting package part is arranged between the cavity and the measuring device for measuring the distance between the measuring device and the surface of the first casting package part.This can be particularly advantageous if the first casting package part is a base body on which the cured casting resin forms a coating, since such a base body can be easily seen through or irradiated with an optical measuring device, and / or particularly advantageous if the second casting package part is not or only partially transparent and is, for example, a metallic mold shell.
[0045] In one embodiment, the second casting package part is arranged between the measuring device for measuring the distance between the measuring device and the surface of the first casting package part and the cavity. This can be particularly advantageous if the second casting package part is a, preferably transparent, mold shell, since such a shell is very thin and can therefore be easily viewed or illuminated with a measuring device.
[0046] In one embodiment, modifying the casting package comprises changing the arrangement, in particular a distance in the direction of an optical (main) axis of the lens, of the first and second casting package parts relative to one another. In a preferred further development, modifying a one-dimensional or multi-dimensional target parameter predetermined for the arrangement of the first and second casting package parts relative to one another and / or based on a predetermined assignment (of the change) to the determined gap parameter value, in one embodiment in tabular form, as a calculation rule, with the aid of a database or the like. For this purpose, in one embodiment, the casting package is at least partially disassembled and prepared anew. In a further development, if necessary, the seal is removed, if already present, and after changing the arrangement of the first and second casting package parts relative to one another, a new seal is attached or the seal is replaced orThe seal is only formed or applied after the (successful) modification, if necessary after retesting the modified casting package, which, in one embodiment, does not yet have the seal upon at least one determination of the first distance or of one or more of the further distances. Additionally or alternatively, modifying the casting package in one embodiment comprises replacing the first casting package part and / or the second casting package part, in particular also replacing the entire casting package. This allows a particularly simple and / or effective response to the test or the determined gap parameter value in one embodiment.
[0047] In a further development, the gap parameter value is determined for the modified casting package, preferably in the same way as previously for the casting package before modification, the modified casting package is tested based on this (newly) determined gap parameter value, and the modified casting package is modified again if this (newly) determined gap parameter value (again) satisfies the specified modification criterion, before, if applicable, the seal is applied and / or the cavity of the (possibly multiply) modified casting package is filled with the casting resin. In other words, the modification and (re-)testing can be repeated one or more times until the gap parameter value of the (possibly multiply) modified casting package satisfies the modification criterion.As also explained elsewhere, it may also be expedient to first determine the gap parameter value of the casting package provided without a seal, to modify it one or more times if necessary, in particular based on a newly determined gap parameter value in each case, then apply the seal and then determine the gap parameter value of the casting package now provided with a seal and to modify it (again) one or more times if necessary, in particular based on a newly determined gap parameter value in each case. Additionally or alternatively, an error message can be issued in one embodiment if a gap parameter value determined for a modified casting package (also) meets the specified modification criterion.In one embodiment, this can improve the quality of the manufactured lens(es) and / or reduce the reworking and / or scrap rate, thus saving material and / or production time.
[0048] In one embodiment, the (respectively) determined gap parameter value and / or the fulfillment of the modification criterion and / or the subsequent modification criterion described below is signaled, in a further development visually, preferably by means of a screen, a control lamp, or the like, and / or to an operator, who then, if necessary, initiates and / or carries out the modification or sorting of the casting package. In one embodiment, the method for producing multiple lenses comprises the steps:
[0049] - producing at least one first lens according to a method described herein; and
[0050] - Producing at least one further lens, preferably also according to a method described here, wherein this production of a further lens (in each case) comprises:
[0051] - Providing a further casting package comprising a first casting package part and a second casting package part, which is held relative to this first casting package part such that a cavity is formed between these first and second casting package parts; and
[0052] - Filling this cavity of the further casting package, which for this purpose preferably has a seal for the cavity formed between the first and second casting package parts, with a casting resin; wherein a predetermined one- or multi-dimensional target parameter value for the arrangement of these first and second casting package parts of the at least one further casting package is changed, in one embodiment based on a predetermined assignment to the gap parameter value determined for the at least one first lens, if this gap parameter value determined for the at least one first lens fulfills a predetermined successor modification criterion. Preferably, the first(s) and further lens(es) belong to the same production lot or production batch and / or are of identical construction.
[0053] The underlying idea is to react accordingly (in a compensating manner) when a deviation in the gap parameter value is detected during the testing of at least one first casting package during the provision of the at least one further casting package. Accordingly, in one embodiment, the provision of the further casting package(s) (in each case) comprises arranging the two casting package parts relative to one another, taking into account the changed target parameter value (for this arrangement), in one embodiment using a casting package assembly device(s) and / or at least partially automated and / or at least partially manual.Thus, the provision of the (respective) further casting package can in particular comprise this arrangement of the two casting package parts relative to one another taking into account the changed target parameter value and / or the application of the seal, wherein the application of the seal, as already described elsewhere, can also take place after the determination of the first distance or of one or more of the further distances.
[0054] The assignment between the gap parameter value determined for the first lens(es) and the modified target parameter value for the further lens can be specified in particular in tabular form, as a calculation rule, with the aid of a database or the like and / or in such a way that the gap parameter value of the further casting package is unlikely to meet the modification criterion (already from the outset) or to pass the test.
[0055] The modification criterion and the successor modification criterion can be identical, so that upon fulfillment of the (successor) modification criterion, both the current casting package is modified and the target parameter value for the at least one further casting package is changed. In another embodiment, the two criteria are different, preferably specified such that a set of gap parameter values that (already) fulfill the successor modification criterion do not (yet) fulfill the modification criterion or do not also fulfill the modification criterion, so that a change in the target parameter value for the further casting package is initiated or carried out, but not a modification of the first casting package.In particular, the successor modification criterion can be specified in such a way that a gap parameter value fulfills this if one or more distances or their deviations from predetermined target values each lie in a predetermined first range, and the modification criterion can be specified in such a way that a gap parameter value fulfills this if one or more distances or their deviations from predetermined target values each lie in a predetermined larger second range, which preferably comprises the first range.
[0056] In one embodiment, target values for distances and / or (permissible) ranges of the modification criterion and / or the successor modification criterion specified for these distances or deviations between target values and distances are specified differently for different optical values and / or dimensions, in particular thicknesses, diameters, and / or curvatures, of the lens, the base body, and / or the cured casting resin. This allows for particularly advantageous consideration of complex geometries and / or manufacturing and / or optical constraints.
[0057] The successor modification criterion can, in particular, also include the fact that the gap parameter values determined for two or more first lenses each satisfy one, preferably the same, successor modification sub-criterion. In other words, a change in the target parameter value for the further casting package(s) is (only) initiated or implemented if the successor modification sub-criterion is met not only during the production of a first lens, but also during the production of a predetermined minimum number of first lenses. This allows a change in the target parameter values to be implemented more reliably.
[0058] In one embodiment, the determination of the first distance and / or the further distance, or one or more of the further distances, for the one or more of the casting packages and the subsequent testing are carried out before filling with casting resin. This can, in particular, save expensive casting resin.
[0059] The determination of the first distance and / or the further distance or one or more of the further distances for the one or more of the casting packages and the testing based thereon takes place in one embodiment after the provision of the casting package, in particular the arrangement of the (respective) two casting package parts relative to one another, and in one embodiment after the arrangement or formation of the (respective) seal and / or, if appropriate additionally, before the arrangement or formation of the (respective) seal. By determining after the arrangement or formation of the (respective) seal, displacements and / or rotations of the casting package parts caused by the arrangement or formation of the (respective) seal can be taken into account, and by determining before the arrangement or formation of the (respective) seal, appropriate measures can advantageously be taken at an early stage, in particular by modifying or sorting out the corresponding casting package.
[0060] Additionally or alternatively, the determination of the first distance and / or the further distance or one or more of the further distances for the one or more of the casting packages and the testing based thereon can be carried out in one embodiment when the casting package is provided, in particular (also and / or already) when arranging the (respective) two casting package parts relative to one another and / or (also and / or already) before and / or when arranging or forming the (respective) seal. This allows, in particular, modifications to be carried out (even) earlier and thus more easily.
[0061] A gap parameter value that is or has been determined in the manner described here can advantageously be used to determine shrinkage of the casting resin with which the cavity is or has been filled, after or as a result of the curing of the casting resin. This shrinkage can then advantageously be taken into account when dimensioning additional casting packages, in particular their spacing from one another or the cavity formed between them. This is particularly advantageous for polymerizable casting resins for forming an additional layer on a base body for determining shrinkage during polymerization.In this way, shrinkage can be taken into account, allowing lenses to be manufactured in an improved manner, particularly with reduced material usage and therefore advantageously more cost-effectively. Without knowledge of the actual shrinkage, particularly due to polymerization, a larger casting gap than actually required is often chosen as a precautionary measure to ensure that a sufficiently thick layer is formed after curing or polymerization. With knowledge of the shrinkage, the tolerance limits for the casting gap can be selected more tightly, thus reducing the risk of shrinkage.
[0062] Accordingly, in one embodiment, a method for measuring a casting package intended for the production of a lens comprises, after determining the gap parameter value, which in this embodiment indicates at least one, preferably shortest, distance between the first and second casting package parts, in particular surfaces of the casting package parts facing each other or the cavity, at one location in the cavity, in a further development several, preferably shortest, distances between the first and second casting package parts, in particular surfaces of the casting package parts facing each other or the cavity, at different locations in the cavity, the further steps:
[0063] - comparing a determined, preferably measured, wall thickness of the cured casting resin at the location(s) of the casting resin corresponding to the location(s) at which the distance(s) between the first and second casting package part(s) was / are determined; and
[0064] - determining a shrinkage of the casting resin, which in one embodiment is maximum and / or averaged, from the difference(s) between the (respective) distance and the (respective) wall thickness or thickness; wherein in one embodiment the shrinkage determined in this way is taken into account when dimensioning further casting packages, in particular their distance from one another or the cavity formed between them, if appropriate taking corresponding tolerances into account; in a further development the shrinkage determined in this way is added to a target wall thickness or target thickness of the cured casting resin and, based on this, a target gap for the cavity between the first and second casting package part of the (respective) further casting package is determined. Determining or measuring the wall thickness or thickness can in particular also include measuring an overall wall thickness or-thickness of a composite of cured casting resin and casting package parts and subtracting a determined, preferably measured, wall thickness or thickness of the casting package part(s) and / or form a step of the method.
[0065] According to one embodiment of the present invention, a system for measuring a casting package (for producing a lens), in a further development a system for testing the casting package, in one embodiment a system for producing one or more lenses, in particular in terms of hardware and / or software or programming, is set up to carry out a method described here and has a device for determining the first distance between the first and second casting package parts of the (respective) casting package, and optionally also the further distance(s), which in one embodiment comprises the measuring device(s). In one embodiment, the system has means, in particular handling means, for feeding or providing the (respective) casting package and / or for transporting or removing the measured or tested casting package or the produced lens.In one embodiment, the production plant comprises a device for filling the (respective) cavity with the casting resin and, in a further development, the casting package assembly device.
[0066] In one embodiment, one or more, in a further development all, steps of the method, in particular the feeding or provision of the casting package and / or the determination of the gap parameter value and / or the testing of the casting package and / or the filling of the cavity with casting resin and / or the modification of the casting package and / or the changing of the target parameter value and / or the further transport or removal of the casting package or the lens are carried out completely or partially automatically, in particular by the system.
[0067] Further advantages and features emerge from the subclaims and the exemplary embodiments. The following shows, partly schematically:
[0068] Fig. 1: a system for manufacturing lenses according to an embodiment of the present invention, which includes a system for measuring and testing mold packages according to an embodiment of the present invention; and
[0069] Fig. 2: a method for manufacturing lenses according to an embodiment of the present invention, including a method for measuring and testing mold packages according to an embodiment of the present invention.
[0070] Fig. 1 shows a lens manufacturing plant according to an embodiment of the present invention, which includes a plant for measuring and testing mold packages according to an embodiment of the present invention.
[0071] The system comprises a feeding and casting package assembly device 1, a device for determining distances between a first casting package part 11 and a second casting package part 12 of a casting package to be measured or tested, comprising a measuring device in the form of a confocal sensor 21, a holder 22 for the casting package and a processing and display device 23, a device 3 for filling a cavity 14 formed between the first and second casting package parts 11, 12 with a casting resin and a device 4 for removing the casting package.
[0072] In the mold package assembly device 1, mold packages are provided one after the other, each of which has a first mold package part 11, a second mold package part 12 and a seal 13 of the cavity 14 formed between the first and second mold package parts 11, 12 (Fig. 2: step S10).
[0073] During and / or after the provision of the respective casting package, in particular during and / or after the arrangement of its first and second casting package parts relative to one another and / or before, during and / or after the application or formation of the seal 13, a distance between the confocal sensor 21 and a cavity-facing surface 11a of the first casting package part and, at the same time, a distance between this confocal sensor 21 and a cavity-facing surface 12a of the second casting package part is measured (in each case) with the aid of the confocal sensor 21 at four locations in the edge region and one location in the central region of the casting package. From this, a distance between the first and second casting package parts at the corresponding location is determined with the aid of the processing and display device 23 (Fig. 2: step S20) and it is checked (Fig. 2: step S30) whether the respective distance lies within a permissible first range.
[0074] If this is the case for all five distances of the casting package (S30: “Y”), a specified successor modification criterion and a specified modification criterion are both not met or a casting gap between the two casting package parts is OK and the cavity is filled with a casting resin (Fig. 2: step S45).
[0075] If at least one of the distances is no longer within the permissible first range (S30: "N"), but all distances are still within a (still) permissible second, larger range (S35: "Y"), the modification criterion is not met or the casting gap between the two casting package parts is still acceptable, but the subsequent modification criterion is met. The cavity is therefore also filled with casting resin (Fig. 2: step S45) and, in addition, a predetermined target parameter value for further casting packages is changed accordingly to compensate (Fig. 2: step S40). In a modification, this only occurs when, for a certain minimum number greater than one, at least one of the distances is no longer within the permissible first range but is still within the permissible second range.
[0076] If at least one of the distances is no longer within the permissible second range (S35: "N"), the specified modification criterion is met or the casting gap between the two casting package parts is no longer acceptable and the currently tested casting package is first modified (Fig. 2: step S55) and then tested again in the manner described above before its cavity is filled with the casting resin if necessary (Fig. 2: step S45). In addition, the specified target parameter value for additional casting packages can also be changed accordingly to compensate (Fig. 2: step S50). In a variation not shown, an error message is issued if an already modified casting package also meets the modification criterion.
[0077] The fulfillment of the modification criterion and / or the successor modification criterion is signaled by means of the processing and display device 23.
[0078] In the exemplary embodiment, the modification criterion and the successor modification criterion are specified such that they are met if at least one of the distances no longer lies within a correspondingly permissible specified range. Various modifications are possible here; for example, deviations of the measured distances from specified target values can be used instead of the distances; a maximum or average value of the distances or deviations can be used, or similar values.
[0079] Likewise, measurements can be taken at more or fewer locations, or in particular, measurements can be taken at only one location and this distance can be used as the gap parameter value.
[0080] Additionally or alternatively, in a modification, the confocal sensor 21 can be integrated into the casting package assembly device 1.
[0081] After filling with casting resin, in step S45 the casting resin can be cured and / or the cured casting resin can be separated from the first and / or second casting package part.
[0082] In the present disclosure, "has an X" generally does not imply an exhaustive list, but is a shortened form of "has at least one X" and also includes "has two or more Xs" and "has Y in addition to X." Although exemplary embodiments have been explained in the foregoing description, it should be noted that numerous modifications are possible.
[0083] In particular, one or more further sensors, preferably confocal sensors or other sensors, can be used and / or the confocal sensor 21 can also be arranged on the lower side of the casting package or second casting package part 12 in Fig. 1, so that the second casting package part 12 would be arranged between the cavity and the confocal sensor 21 for measuring the distance between the confocal sensor 21 and the surface 11a of the first casting package part 11.
[0084] Furthermore, it should be noted that the exemplary embodiments are merely examples and are not intended to limit the scope of protection, applications, or structure in any way. Rather, the preceding description provides the skilled person with a guide for implementing at least one exemplary embodiment. Various modifications, particularly with regard to the function and arrangement of the described components, may be made without departing from the scope of protection as defined by the claims and equivalent combinations of features.
[0085] List of reference symbols
[0086] 1 feeding and casting package assembly device
[0087] 11 first casting package part
[0088] 11a Surface 12 second casting package part
[0089] 12a Surface
[0090] 13 Sealing
[0091] 14 Cavity
[0092] 21 Confocal sensor 22 Mount
[0093] 23 Processing and display device
[0094] 3 Device for filling with casting resin
[0095] 4 Device for removal
Claims
Patent claims 1 . A method for measuring a casting package intended for the production of a lens, comprising the steps: - Providing (S10) the casting package, which - a first casting package part (11) and - a second casting package part (12) which is held relative to the first casting package part such that a cavity (14) is formed between the first and second casting package parts; and - Determining (S20) a gap parameter value, wherein determining the gap parameter value comprises determining a first distance between the first and second casting package parts at a first location of the cavity of the provided casting package and the gap parameter value depends on this first distance.
2. Method according to claim 1, characterized in that the provided casting package has a seal (13) of the cavity (14) formed between the first and second casting package parts when determining the first distance.
3. Method according to claim 1, characterized in that the casting package has a seal (13) of the cavity (14) formed between the first and second casting package parts, which is formed after the first distance has been determined.
4. Method according to one of the preceding claims, characterized in that - that determining the gap parameter value comprises determining at least one further distance between the first and second casting package parts at a further location in the cavity and the gap parameter also depends on this further distance; and / or - that determining a distance comprises measuring, wherein the measuring is an optical and / or contactless measuring and / or a measuring of a distance between a measuring device (21) and a surface (11a) of the first casting package part and a distance between this or another measuring device and a surface (12a) of the second casting package part.
5. The method according to claim 4, characterized in that the first casting package part is arranged between the cavity and the measuring device for measuring the distance between the measuring device and the surface of the first casting package part.
6. The method according to claim 4, characterized in that the second casting package part is arranged between the cavity and the measuring device for measuring the distance between the measuring device and the surface of the first casting package part.
7. Method according to one of the preceding claims, characterized in that at least one distance between the first and second casting package part is determined at a location in a central region of the cavity and / or at least one distance between the first and second casting package part is determined at a location in an edge region of the cavity and / or the determination of at least two of the distances comprises measuring using the same measuring device.
8. A method for testing a mold package intended for the production of a lens, comprising the steps of: - measuring the casting package according to a method according to any one of the preceding claims; and - Checking (S30, S35) the casting package based on the determined gap parameter value.
9. A method for producing at least one lens, comprising the steps: - testing a casting package according to a method according to the preceding claim; - modifying (S55) the casting package if the gap parameter value meets a predetermined modification criterion; and - filling (S45) the cavity with a casting resin; wherein the manufactured lens comprises the cured casting resin.
10. The method according to claim 9, characterized in that the cured casting resin is separated from the second casting package part and the manufactured lens has the first casting package part connected to the cured casting resin.
11. Method according to claim 9, characterized in that the cured casting resin is separated from the first and second casting package parts.
12. The method according to claim 9, characterized in that the manufactured lens has the first and second casting package parts connected to the cured casting resin.
13. Method according to one of the preceding claims 9 - 12, characterized in that - that the modification of the casting package comprises a change in the arrangement of the first and second casting package parts relative to one another, in particular a predetermined target parameter therefor and / or on the basis of a predetermined assignment to the determined gap parameter value, and / or a replacement of the seal and / or the first casting package part and / or the second casting package part; and / or - that the gap parameter value is determined for the modified casting package, the modified casting package is checked on the basis of this determined gap parameter value and the modified casting package is modified again and / or an error message is issued if this determined gap parameter value meets the specified modification criterion.
14. Method according to one of the preceding claims 9-13, comprising the steps: - producing at least one first lens according to a method according to any one of the preceding claims 9-13; and - Producing at least one further lens, comprising: - Providing a further casting package comprising a first casting package part and a second casting package part, which is held relative to this first casting package part such that a cavity is formed between these first and second casting package parts; and - filling this cavity with a casting resin; wherein a predetermined target parameter value for the arrangement of this first and second casting package part of the at least one further casting package is changed, in particular on the basis of a predetermined assignment to the gap parameter value determined for the at least one first lens, if this is required for the at least a first lens determined slit parameter value meets a predetermined successor modification criterion.
15. Method according to one of the preceding claims, characterized in that the determined gap parameter value and / or the fulfillment of the modification criterion and / or the successor modification criterion is signaled.
16. System for measuring a casting package for producing a lens, in particular for testing the casting package, in particular for producing at least one lens, wherein the system is set up to carry out a method according to one of the preceding claims and has a device (21, 23) for determining the first distance between the first and second casting package parts (11, 12).