Calendering Roller Modules for Spherical Microstructure Transfer
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Solution Overview
Problem
Existing methods struggle to transform microstructure arrays from a spherical surface, such as an ophthalmic lens, to a planar surface, like a calendering roller, leading to deformation and increased time and cost in designing microstructures for these surfaces.
Innovation Solution
A method involving a spherical microstructure mold module is designed for a calendering roller, calculating curvatures and radius to determine microstructure locations, allowing for efficient transformation of microstructures from a spherical to a planar surface, using interchangeable modules for different optical designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If microstructure arrays are transformed from a spherical surface to a planar surface using existing methods, then the microstructures can be applied to a film, but the microstructure arrays deform and require increased time and cost for design
Solution Approach 1:
The patent applies spheroidality by designing the calendering roller with a spherical surface that matches the curvature of the ophthalmic lens. The microstructure mold module is specifically configured with spherical geometry to correspond to the lens surface, allowing direct transfer of microstructures without deformation. This curvature matching eliminates the need for complex transformation calculations and prevents distortion during the embossing process.
Solution Approach 2:
The patent segments the calendering roller into interchangeable microstructure mold modules. Each module can be independently replaced or updated without affecting the entire roller system. This segmentation allows for rapid design changes and updates by simply swapping modules rather than redesigning the entire roller, significantly reducing design time and cost while maintaining manufacturing precision.
2Manufacturing precision
If microstructure arrays are transformed from a spherical surface to a planar surface using existing methods, then the microstructures can be applied to a film, but the design cost increases
Solution Approach 1:
The patent applies spheroidality by designing the calendering roller with a spherical surface that matches the curvature of the ophthalmic lens. The microstructure mold module is specifically configured with spherical geometry to correspond to the lens surface, allowing direct transfer of microstructures without deformation. This curvature matching eliminates the need for complex transformation calculations and prevents distortion during the embossing process.
Solution Approach 2:
The patent segments the calendering roller into interchangeable microstructure mold modules. Each module can be independently replaced or updated without affecting the entire roller system. This segmentation allows for rapid design changes and updates by simply swapping modules rather than redesigning the entire roller, significantly reducing design time and cost while maintaining manufacturing precision.
3Ease of manufacture
If traditional calendering rollers are used for embossing microstructures, then the process is simple, but updates and repairs require replacing the entire roller
Solution Approach 1:
The patent segments the calendering roller into interchangeable microstructure mold modules mounted on a cylindrical carrier. Each module can be independently replaced or updated without affecting the entire roller system. This segmentation allows for rapid design changes and updates by simply swapping modules rather than redesigning the entire roller, significantly reducing repair complexity and cost while maintaining process simplicity.
Solution Approach 2:
The patent implements dynamics by making the microstructure mold modules interchangeable and replaceable. The system transitions from a static, fixed roller design to a dynamic, adaptable configuration where modules can be swapped based on production requirements. This enables flexible updates and repairs without dismantling the entire calendering system.
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 reduces time and cost associated with producing ophthalmic lenses with varied microstructures by enabling efficient embossing of microstructures on films with spherical surfaces, facilitating faster updates and repairs by replacing only specific modules.
Implementation Method 1
The first roller and the second roller are controlled to reach a predetermined temperature and a predetermined pressure
Implementation Method 2
The first roller and the second roller are controlled to reach a predetermined temperature and a predetermined pressure
Data Source
AI summary
The present disclosure relates to a method of designing a spherical microstructure mold (604-614) module to be incorporated into a calendering roller (600) for generating a microstructure (108) on a planar surface (104), comprising calculating a first curvature (204) on a cross-sectional planar surface (202) for a first microstructure point of the spherical microstructure mold module, calculating a second curvature (210) of a spherical surface (102) of the spherical microstructure mold module, measuring a radius (214) of the spherical surface (102), the radius (214) being from the center of the spherical surface (102) to the first microstructure point, and determining a location of the microstructure (108) on the planar surface (104), the location being derived from the first curvature (204), the second curvature (210), and the radius (214).