Contact Lens Mold Linearization for Assembly Cycle Rate
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Solution Overview
Problem
The existing injection molding processes for contact lens production face challenges in achieving high cycle rates for the removal and assembly of contact lens part molds, while ensuring traceability and efficient use of installation space, particularly in arranging and aligning circular cavity arrangements for optimal plastic distribution and molding results.
Innovation Solution
A method and device that utilize a linearization process to transfer and align contact lens part molds from circular arrangements to linear rows, allowing for simultaneous removal and assembly, with a linearization device facilitating the transformation of molds into semi-circular and then linear arrangements, enabling efficient storage and assembly, and a transfer device for perpendicular placement to optimize space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If contact lens part molds are removed and assembled manually or using conventional sequential processes, then traceability of molded parts to their cavities is maintained, but the cycle rate of removal and assembly is too low for high-volume production
Solution Approach 1:
The invention divides the circular cavity arrangement into multiple linear rows, allowing independent handling and assembly of parts from different cavities. The linearization device separates the simultaneous removal operation into discrete linear sequences, enabling parallel processing and faster assembly cycles while maintaining cavity traceability through the structured linear arrangement.
Solution Approach 2:
The linearization device acts as an intermediary between the circular cavity arrangement and the assembly station. It receives molded parts from the circular mold, repositions them into linear rows, and facilitates rapid assembly while preserving the relationship between parts and their source cavities, thus solving both speed and traceability requirements.
2Manufacturing precision
If circular cavity arrangements are used for injection molding, then even distribution of molten plastic and good injection molding results are achieved, but the removal and assembly process becomes time-consuming and reduces cycle rate
Solution Approach 1:
The invention maintains the circular cavity arrangement for injection molding to ensure quality, then segments the removed parts into linear rows for assembly. This segmentation allows the mold to retain its optimal circular geometry for manufacturing precision while the linearized output enables faster handling and assembly operations.
Solution Approach 2:
The linearization device dynamically reconfigures the spatial arrangement of molded parts from circular to linear format. This dynamic transformation occurs after molding, allowing the system to optimize for both molding quality (circular) and assembly speed (linear) at different stages of the process.
3Productivity
If all injection molded parts are transferred to the linearization device simultaneously, then the removal device is occupied for extended periods, but transferring in multiple steps with relative movement increases cycle efficiency
Solution Approach 1:
The transfer process is segmented into multiple steps, with the linearization device receiving parts in discrete batches rather than all at once. This segmentation allows the removal device to be reused between transfers, increasing overall system productivity despite the added complexity of coordinated multi-step transfers.
Solution Approach 2:
The system employs periodic action by repeatedly cycling the removal device between the mold and the linearization device. The removal device performs multiple transfer cycles, each handling a portion of the parts, which optimizes utilization of the removal device while the linearization device progressively builds up the linear arrangement.
Data Source
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AI summary
The invention relates to a combined demoulding method and assembly method of injection moulded articles, in particular for demoulding the mould halves of contact lenses and assembly of the contact lens moulds consisting of respectively two half moulds, said method comprising several steps. The invention further relates to a device for carrying out said method.