Assembled Lens Blank Segmentation for Optical Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for manufacturing ophthalmic lenses require large amounts of material for molding lens blanks, resulting in excessive material removal during machining, which is inefficient and costly.
Innovation Solution
A method involving the assembly of distinct parts with two end faces to form a lens blank, which is then machined to create optical faces, reducing the material needed and the volume to be removed during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If lens blanks are molded as single large pieces to ensure sufficient thickness for various lens shapes, then the lens blank can be used to manufacture lenses of various shapes, but a large amount of material is required and a large amount of material must be removed during machining
Solution Approach 1:
The lens blank is divided into multiple separate parts that are assembled together. Each part can be optimized for its specific function and position, reducing the overall material volume required while maintaining the ability to create various lens shapes. The segmentation allows for precise material placement only where needed.
Solution Approach 2:
Multiple parts are nested or assembled together to form the complete lens blank structure. This allows the lens blank to achieve the necessary thickness and shape complexity through layered assembly rather than requiring a single large solid piece, thereby reducing total material consumption.
2Loss of substance
If smaller lens blanks are used to reduce material consumption, then less material is required and less material needs to be removed during machining, but a large number of molding shells of distinct shapes would be required
Solution Approach 1:
The modular parts system enables a small set of standard molding shells to produce multiple different lens configurations through various assembly combinations. Each part can be used in different positions and orientations to create diverse lens shapes, reducing the need for numerous specialized molds.
Solution Approach 2:
By segmenting the lens blank into standardized modular parts, the system achieves versatility through combination rather than requiring unique molds for each lens type. The segmented approach allows reconfiguration of the same parts to create different lens shapes and sizes.
3Adaptability or versatility
If large lens blanks are molded to ensure sufficient material for machining various lens shapes, then lenses of various shapes can be manufactured, but the weight of the lens blank is 5 times greater than the weight of the finished lens
Solution Approach 1:
The lens blank is segmented into multiple parts that are assembled only where material is actually needed for the specific lens design. This eliminates the need for oversized blanks and reduces the overall weight while maintaining the capability to produce various lens shapes through different part combinations.
Solution Approach 2:
Material is distributed non-uniformly in the lens blank, with higher density or thickness only in regions where optical functionality is required. The segmented assembly allows for local optimization of material placement, ensuring sufficient material where needed while minimizing weight in non-critical areas.
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 minimizes the required manufacturing material and reduces material removal during machining, making the process more cost-effective and environmentally friendly.
Implementation Method 1
said at least two parts are bonded by means of a glue having a second refraction index
Implementation Method 2
said at least two parts are made of a material having a first refraction index and are bonded by means of a glue having a second refraction index
Data Source
Figure 1~3
Figure 4~7
AI summary
The invention relates to a method for manufacturing an optical article (30), comprising steps: S1) of providing at least two distinct parts (10), each one having two end faces (11, 12), S2) of assembling said at least two parts so that their end faces (11, 12) form main faces (21, 22) for the assembling (20) of parts, and S3) of machining at least one of said main faces to generate at least one optical face for the optical article.