Cardanic Joint Bonding Head for Ophthalmic Lens Sealing
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Solution Overview
Problem
Existing apparatuses for thermally bonding cover films to ophthalmic lens packages, such as contact lens packages, face challenges in ensuring precise sealing and reproducibility due to rotational movement and material fatigue, leading to inconsistencies in sealing pressure and quality.
Innovation Solution
The apparatus employs a cardanic joint with two rotational axes and an articulated connector that allows for precise positioning and tilting of the bonding head, ensuring uniform pressure and preventing twisting, combined with attenuators for fatigue resistance and easy replacement, to achieve accurate and reproducible thermal bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rubber mount is used to allow tilting of the bonding head, then the bonding head can be positioned relative to the carrier, but rotational movement around the displacement axis causes twisting of the rubber mount leading to rotation of the bonding contour and deficiencies in sealing
Solution Approach 1:
The bonding head is divided into two separable parts: a rigid bonding contour support that maintains precise sealing geometry, and a tilting mechanism that allows positioning adjustment. The rigid support is connected to the carrier via a tilting mechanism with controlled degrees of freedom, enabling positioning without rotation. This segmentation allows the bonding head to be positioned relative to the carrier while preventing rotational movement that would compromise sealing accuracy.
2Adaptability or versatility
If the bonding head is allowed to tilt for positioning, then adjustment is possible, but material fatigue of the rubber mount occurs leading to negative influence on sealing quality
Solution Approach 1:
The flexible rubber mount is replaced with a rigid bonding contour support connected to the carrier through a controlled tilting mechanism. This mechanical substitution eliminates material fatigue issues inherent in rubber mounts while maintaining the necessary positioning and tilting capabilities. The rigid construction ensures consistent sealing quality over time without degradation from cyclic loading.
3Manufacturing precision
If the bonding head is fixed without tilting capability, then rotational stability is maintained, but the ability to position and adapt to different packaging orientations is limited
Solution Approach 1:
The bonding head is designed with controlled dynamic tilting capability through a mechanism providing specific degrees of freedom. The bonding contour support itself remains rigid to maintain bonding accuracy, while the connection to the carrier allows tilting motion for positioning adjustment. This dynamic design enables the bonding head to adapt to different packaging orientations and positions while maintaining precise sealing geometry during the actual bonding process.
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 solution ensures high-quality, reproducible thermal bonding with uniform pressure, maintaining strict sealing requirements and resisting material fatigue, while allowing for high-speed operation and easy maintenance.
Implementation Method 1
a heatable bonding contour arranged on a side of the bonding head facing the carrier... pressing the heated bonding contour of the bonding head against the cover film
Implementation Method 2
the articulated connector connecting the bonding head to the mounting portion is a cardanic joint having two rotational axes, a first and a second rotational axis
Data Source
Figure 1~2b
Figure 3~4
Figure 5~7
AI summary
An apparatus for thermally bonding together a cover film (11) of an ophthalmic lens package (1) and a base (12) part of the package, including a carrier (2) for supporting the base part with film arranged thereon; a bonding unit (3) above the carrier having a mounting plate (4) with a bonding stamp (5) extending therefrom, the bonding stamp having a mounting portion (51) fixedly attached to the mounting plate, a bonding head arranged beneath the mounting portion with a heatable bonding contour (53) on a side of the bonding head facing the carrier, and an articulated connector (6) arranged between and connecting the mounting portion and the bonding head; and an actuator (10) for performing movement of the carrier and the bonding stamp towards and away from each other for thermally bonding the film with the base part by pressing the heated bonding contour against the film and subsequent separation of the bonding head from the cover film bonded to the base part, the articulated connector being a cardanic joint with two rotational axes.