Adjustable Contact Lens Mandrel for Multi-Mold Delensing
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Solution Overview
Problem
The existing delensing systems for molded lenses require frequent mandrel replacements and tight tolerances, leading to increased downtime and manufacturing costs due to the need for multiple mandrels and expensive mold tooling, especially when dealing with differently structured or sized mold sections.
Innovation Solution
An adjustable mandrel with pivotable clutches and a central core allows for easy adjustment to accommodate variously sized and structured mold sections, eliminating the need for multiple mandrels and reducing downtime by maintaining compatibility without decoupling from the delensing apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple mandrels are used to accommodate differently structured mold sections, then the delensing process can handle various mold sections, but the downtime for mandrel replacement increases and manufacturing costs increase
Solution Approach 1:
The mandrel is designed with a universal engagement surface that can accommodate multiple differently structured mold sections through a single interface geometry. This allows one mandrel to perform multiple functions by retaining various mold section configurations without requiring replacement, directly resolving the contradiction between versatility and downtime.
Solution Approach 2:
The mandrel engagement surface is designed to dynamically adapt to different mold section structures through a standardized interface that can accommodate varying dimensions and configurations. This dynamic adaptability allows the same mandrel to effectively retain differently structured mold sections without replacement, eliminating mandrel replacement downtime while maintaining versatility.
2Adaptability or versatility
If multiple mandrels are maintained for different mold sections, then the delensing process can be performed on various mold sections, but the number of mandrels required increases and manufacturing costs increase
Solution Approach 1:
The mandrel is designed with a universal engagement surface that can accommodate multiple differently structured mold sections through a single interface geometry. This allows one mandrel to perform multiple functions by retaining various mold section configurations without replacement, directly resolving the contradiction between versatility and downtime.
Solution Approach 2:
The patent merges the functionality of multiple specialized mandrels into a single universal mandrel by designing an engagement surface that can accommodate various mold section structures. This consolidation reduces the total number of mandrels required from multiple to one, eliminating the need to maintain a inventory of different mandrels while preserving the ability to process various mold sections.
3Reliability
If tight tolerances are applied to mandrel engagement surfaces, then correct engagement is ensured, but expensive mold tooling is required and mold sections must be scrapped if out of specification
Solution Approach 1:
The patent changes the engagement parameter from tight dimensional tolerances to a standardized interface geometry that accommodates variations. By shifting from precision-dependent engagement to geometry-based compatibility, the system maintains reliable engagement without requiring expensive tight-tolerance tooling or risking scrap of out-of-spec mold sections.
Solution Approach 2:
The engagement interface is segmented into standardized geometric features that can accommodate variations in mold section dimensions. This segmentation allows the mandrel to engage different mold sections through standardized geometric interfaces rather than requiring each interface to be within tight tolerances, reducing tooling costs and scrap risk while maintaining engagement reliability.
Data Source
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AI summary
Method and device for manufacturing a contact lens using an adjustable mandrel (10) to fixedly retain a single mold section (12) carrying a polymerized contact lens product (82) and delensing the contact lens product from the single mold section.