Additive Ophthalmic Lens Marking with Dual Refractive Indices
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Solution Overview
Problem
Current methods for manufacturing ophthalmic lenses with permanent technical marks are multi-step processes that can introduce deviations and errors due to reliance on different intermediate frames of reference, making them complex and prone to inaccuracies.
Innovation Solution
A single-step additive manufacturing process that deposits materials with different complex indices of refraction to create both the optical surfaces and permanent technical marks simultaneously, ensuring precise positioning of marks relative to the optical reference frame defined by the lens's optical surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-step manufacturing processes are used to create permanent technical marks on ophthalmic lenses, then the marks can be produced using conventional laser marking machines, but the process introduces deviations and errors due to reliance on different intermediate reference frames
Solution Approach 1:
The patent combines the manufacturing of the ophthalmic lens and the creation of permanent technical marks into a single additive manufacturing step. The lens body and technical marks are deposited simultaneously using different materials with different complex indices of refraction, eliminating the need for separate marking operations and intermediate reference frames, thereby achieving precise positioning without multi-step complexity
Solution Approach 2:
The patent uses composite materials with different complex indices of refraction to differentiate between lens material and technical mark material. This allows the additive manufacturing process to distinguish and deposit lens portions versus mark portions in a single operation, enabling precise positional accuracy while maintaining process simplicity
2Ease of manufacture
If permanent technical marks are made after lens machining, then the lens optical surfaces can be completed first, but the marks require additional positioning steps and reference frames
Solution Approach 1:
The patent performs the creation of permanent technical marks during the preliminary additive manufacturing stage, before the lens requires subsequent machining or mounting operations. By depositing the marks and lens body simultaneously in the additive manufacturing process, the positional reference is established upfront, eliminating the need for later positioning operations and ensuring high registration accuracy
3Reliability
If conventional laser marking is used to ablate or degrade lens material, then permanent technical marks can be created, but material is removed and lens properties may be altered
Solution Approach 1:
The patent replaces the mechanical/thermal ablation process of conventional laser marking with an additive manufacturing process. Instead of removing material through laser-induced degradation, the technical marks are created by selectively depositing different materials during additive manufacturing, eliminating material removal and associated deformations while maintaining mark permanence
Solution Approach 2:
The patent changes the fundamental parameter of material interaction from removal (ablation) to addition (deposition). By using additive manufacturing to deposit materials with different complex indices of refraction, the process creates permanent technical marks without the harmful effects of material degradation, maintaining lens integrity while ensuring mark permanence
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the precise and economical creation of ophthalmic lenses with permanent technical marks in a single step, eliminating the need for multiple reference frames and reducing errors, while maintaining the optical properties and registration accuracy required for correct lens positioning.
Implementation Method 1
additively manufacturing said body and said first and second faces, by depositing a plurality of first predetermined volume elements of a first material having a first complex refractive index
Implementation Method 2
a first material having a first complex refractive index, in order to obtain said first and second optical surfaces; additively manufacturing said technical permanent marks by depositing, during said deposition of a plurality of said first volume elements of said first material, at least one second predetermined volume element of a second material having a second complex refractive index different from said first complex refractive index of said first material
Data Source
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AI summary
The invention relates to a method for manufacturing an ophthalmic lens (12), comprising a marking step for producing permanent technical marks (24) on said lens, which comprises a body (29), a first surface (20) and a second surface (28) opposite said first surface (20); the step of additive manufacturing (110-112) of said body and said first and second surfaces, by depositing a plurality of first predetermined volume elements of a first material having a first complex index of refraction (35), in order to obtain first and second optical surfaces, respectively, of the first and second surfaces; and the step of additive manufacturing (113) of said marks by depositing, during said deposition of a plurality of said first volume elements of said first material, at least one second predetermined volume element of a second material having a second complex index of refraction (30) other than said first complex index of refraction of said first material.