Compliant Stage Lens Assembly Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing contact lenses with embedded 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, improves the accuracy and reliability of bonding between lens members and components by allowing for complete contact and reduced force requirements, thereby enhancing the optical quality and consistency 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 stage from rigid to compliant (flexible), allowing it to deform and accommodate minor misalignments between lens members and components. This compliant stage absorbs positioning tolerances and ensures complete contact during bonding, directly improving alignment accuracy without requiring more complex assembly procedures
Solution Approach 2:
The compliant stage acts as an intermediary element between the rigid mold parts and the lens components. It mediates the interaction by providing a flexible interface that compensates for dimensional variations and ensures uniform contact pressure during bonding, thereby improving assembly quality without increasing overall process complexity
2Strength
If forceful bonding is applied to ensure complete contact, then bonding strength is improved, but optical quality deteriorates due to wrinkles and distortions
Solution Approach 1:
The patent changes the compliance parameter of the supporting stage, allowing it to deform under bonding forces. This distributes the applied force uniformly across the bonding interface, achieving complete contact and strong bonding without creating localized stress concentrations that would cause wrinkles or optical distortions in the lens material
Solution Approach 2:
The compliant stage serves as a cushioning element that absorbs excess bonding force. By being positioned beforehand in the assembly path, it prevents forceful bonding from transmitting directly to the lens components, thereby protecting optical quality while still ensuring adequate bonding strength through controlled deformation
3Productivity
If assembly process is simplified for commercial scale manufacture, then productivity is improved, but bonding quality deteriorates due to inability to accommodate imperfections
Solution Approach 1:
The patent introduces a compliant stage that passively compensates for assembly imperfections through its flexibility. This eliminates the need for complex active alignment systems or multiple inspection steps, maintaining simplified commercial-scale manufacturing processes while significantly improving bonding quality and reducing reject rates
Solution Approach 2:
The compliant stage performs self-alignment and self-adjustment during the bonding process. It automatically accommodates minor imperfections in lens member positioning and dimensions without requiring external intervention or complex control systems, thereby maintaining high productivity while improving bonding quality
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 proper alignment and bonding with minimal optical or physical distortion.
Implementation Method 1
the compliant stage provides compression to the first pliable membrane and the second pliable membrane
Data Source
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).