Core Locking Assembly for Asymmetric Ophthalmic Lens Orientation
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Solution Overview
Problem
In injection molding of ophthalmic lenses, particularly those with asymmetric surfaces, the existing optical tool assemblies face challenges in maintaining consistent rotational positioning of optical and non-optical inserts relative to the injection molding gate, leading to variations in mold sections and subsequently in the lenses produced, due to the difficulty in selectively and rotatably positioning these inserts after installation.
Innovation Solution
A rotatably mounted core member with a locking mechanism that includes a selectively movable locking pin, allowing the core member and optical insert to be rotated to a specific position, and a non-optical tool assembly with a water jacket, together forming a mold cavity for injection molding ophthalmic lenses with asymmetric surfaces, enabling precise control over the rotational positioning of the inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the optical insert and non-optical insert are installed in the injection molding tools, then the mold sections can be formed, but the rotational positioning of the inserts becomes difficult to control and maintain consistency
Solution Approach 1:
The patent applies preliminary action by providing pre-configured rotational positioning features (such as alignment pins, indexed holes, or keyed interfaces) on the inserts and tooling before the molding process begins. These features are designed in advance to automatically establish and maintain the correct rotational orientation, eliminating the need for complex manual positioning operations during production.
Solution Approach 2:
The patent introduces intermediary elements such as positioning pins, alignment keys, or rotational indexing mechanisms that mediate between the insert and the tooling. These intermediary components facilitate precise rotational positioning by providing physical constraints and guidance, making it easier to achieve and maintain consistent orientation without requiring direct manual control.
2Ease of operation
If the inserts are made rotatably mounted to allow positioning adjustment, then the ease of operation improves, but the stability and consistency of rotational positioning deteriorates
Solution Approach 1:
The patent applies dynamics by designing a positioning system that transitions from a static fixed connection to a dynamic adjustable connection. The inserts are mounted to allow controlled rotation during setup, enabling ease of positioning, while incorporating locking mechanisms (such as locking pins, indexed positions, or friction locks) that engage during the molding process to maintain stable and consistent rotational positioning throughout production.
Solution Approach 2:
The patent uses preliminary action by providing pre-configured rotational positioning features (such as alignment pins, indexed holes, or keyed interfaces) on the inserts and tooling before the molding process begins. These features are designed in advance to automatically establish and maintain the correct rotational orientation, eliminating the need for complex manual positioning operations during production.
3Ease of manufacture
If the mold sections are used only once and then discarded, then the manufacturing simplicity is maintained, but the productivity and resource efficiency deteriorates
Solution Approach 1:
The patent applies preliminary action by providing pre-configured rotational positioning features (such as alignment pins, indexed holes, or keyed interfaces) on the inserts and tooling before the molding process begins. These features are designed in advance to automatically establish and maintain the correct rotational orientation, eliminating the need for complex manual positioning operations during production.
Solution Approach 2:
The patent applies parameter changes by modifying the mold section design to include features that enable reuse, such as improved structural integrity, protective coatings, or modular components that can be easily replaced or repaired. By changing parameters such as material selection, thickness, or structural reinforcement, the mold sections can withstand repeated use while maintaining manufacturing simplicity.
Data Source
AI summary
An apparatus and method is provided for injection molding an ophthalmic lens mold section having an optical surface and a non-optical surface opposite the optical surface. The apparatus includes a non-optical tool assembly for forming the non-optical surface of the ophthalmic lens mold section. An optical tool assembly is in opposed relation to the non-optical tool assembly and together therewith forms a mold cavity for forming the ophthalmic lens mold section. In the preferred embodiment, the optical tool assembly includes a rotatably mounted core member and an optical insert removably secured the core member. The optical insert has an optical molding surface for forming an optical surface of the ophthalmic lens mold section opposite the non-optical surface thereof. A locking mechanism having, in a preferred embodiment, a locking pin selectively movable between a first position wherein the pin allows rotation of the core member and a second position wherein the pin prevents the core member from rotation.