Compliant Stage for Lens Assembly Alignment
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Solution Overview
Problem
Existing methods for manufacturing contact lenses with integrated fluid or rigid components face challenges in achieving consistent alignment and optical quality due to difficulties in bonding, leading to high rejection rates and unacceptable optical properties.
Innovation Solution
The use of a compliant stage during assembly, which is more pliable than traditional mold parts, facilitates improved alignment and bonding between lens members, allowing for lower force coupling and reduced distortion, thereby enhancing the optical quality and reliability of the lens assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid mold parts are used for assembly, then structural stability is maintained, but alignment accuracy and bonding quality deteriorate due to inability to accommodate minor imperfections
Solution Approach 1:
The patent changes the physical parameter of the support stage from rigid to compliant, allowing it to deform elastically under compression. This compliance enables the stage to accommodate minor imperfections in lens member surfaces, significantly improving alignment accuracy and bonding quality without complicating the assembly process
Solution Approach 2:
The compliant stage acts as a cushioning element that absorbs and compensates for surface imperfections before the bonding process occurs. By preemptively accommodating these imperfections through elastic deformation, the system ensures optimal alignment and bonding contact without requiring complex adjustment mechanisms
2Strength
If high force is applied during bonding to ensure complete contact, then bonding strength improves, but optical quality deteriorates due to wrinkles and distortions
Solution Approach 1:
The patent changes the compliance parameter of the support system, allowing the stage to deform under bonding force. This enables complete contact and strong bonding between lens members while the compliant material absorbs excess force, preventing wrinkles and optical distortions that would occur with rigid supports
Solution Approach 2:
The compliant stage serves as an intermediary element between the bonding force and the lens members. It mediates the force transmission, distributing it evenly across the contact surface to achieve complete bonding without creating localized stress concentrations that would cause optical distortions
3Adaptability or versatility
If rigid components are incorporated into contact lenses, then functional capabilities improve, but flexibility and comfort deteriorate
Solution Approach 1:
The patent applies local quality by incorporating rigid functional components (such as electronic elements or fluid reservoirs) only in specific localized areas of the contact lens, while the surrounding lens material remains flexible and compliant. This allows the lens to maintain overall flexibility and comfort while providing enhanced functionality in targeted regions
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 significantly increases the yield of lenses meeting optical quality specifications from approximately 10% to over 80%, reducing wrinkles and distortions, and ensuring complete bonding with minimal optical or physical distortion.
Implementation Method 1
The compliant stage may be formed from a cured rubber material having a Shore A hardness from 3 to 50, preferably from 10 to 30. The compliant stage is more pliable (i.e. softer and/or less stiff) than a first mold part and/or second mold part used to form the first or second lens member that are coupled together.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
Methods and apparatus for making lens assemblies that can be placed on an eye of a person and that include at least one component are described. Generally, a first lens member (100) and a second lens member (200) are formed. The second lens member (200) is transferred to a compliant stage (210). At least one component is placed in contact with one of the lens members (100, 200). The second lens member (200) is placed in contact with the first lens member (100) such that the compliant stage (210) can provide compression to the first and second lens members (100, 200). The second lens member (200) and the first lens member (100) are coupled together to form a lens assembly (10) with the at least one component located between the two lens members (100, 200).