Ophthalmic Lens Contour Control via DMD Convergence Process
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Solution Overview
Problem
Existing methods for manufacturing ophthalmic lenses, such as those using contour forming apparatus, often fail to consistently meet acceptance criteria for lens design, leading to suboptimal lens performance and vision correction.
Innovation Solution
Implementing a Convergence Process that includes masking techniques, modality adjustments, and thickness correction methods using a digital micromirror device (DMD) to iteratively refine the lens design until it meets the specified acceptance criteria, involving techniques like radial masking, sector masking, apex-locking, and thickness correction methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional contour forming apparatus is used to manufacture ophthalmic lenses, then production efficiency is maintained, but the lenses fail to consistently meet acceptance criteria for lens design
Solution Approach 1:
The patent implements a feedback mechanism where the manufactured lens is measured and compared against the desired design, and the contour forming instruction is modified based on the measured deviations. This closed-loop feedback process enables iterative refinement of the lens geometry to meet acceptance criteria while maintaining production efficiency.
Solution Approach 2:
The patent applies preliminary action by pre-calculating the modified contour forming instruction before the actual manufacturing process. The instruction modification is prepared in advance based on predicted deviations, allowing the manufacturing process to proceed with corrected parameters from the outset, thereby improving consistency without sacrificing productivity.
2Manufacturing precision
If iterative convergence process is implemented to refine lens design, then lens precision is improved, but manufacturing time increases
Solution Approach 1:
The patent applies partial action by implementing masking techniques that selectively apply the convergence process only to specific regions of the lens where deviations from the desired design are most significant. This approach refines precision in critical areas while minimizing the time required for non-critical regions, thereby reducing overall manufacturing cycle time.
Solution Approach 2:
The patent segments the lens manufacturing process into multiple zones (e.g., optical zone, peripheral zone) and applies different convergence strategies to each segment. This segmentation allows the iterative refinement process to focus computational and manufacturing resources on the most critical areas, reducing the total time required while maintaining high precision where it matters most.
3Manufacturing precision
If masking techniques and convergence modalities are applied, then lens thickness uniformity is improved, but process complexity increases
Solution Approach 1:
The patent applies local quality by using masking techniques that apply different processing parameters to different regions of the lens. Specifically, radial masking, sector masking, and segment masking create zone-specific instructions that address local thickness variations while maintaining overall lens uniformity. This localized approach improves thickness uniformity without requiring complete process redesign.
Solution Approach 2:
The patent employs parameter changes by modifying the contour forming instruction parameters (e.g., thickness, curvature, asphericity) based on the measured lens geometry and desired design. The convergence process dynamically adjusts these parameters through iterative calculations, enabling precise control over lens thickness uniformity while managing process complexity through systematic parameter optimization.
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
Ensures the production of ophthalmic lenses that precisely conform to the desired lens design, enhancing vision correction and performance by iteratively adjusting and refining the lens parameters until they meet the acceptance criteria.
Implementation Method 1
an ophthalmic lens is formed on a substrate with an arcuate optical quality surface via a source of actinic radiation controllable to cure a definable portion of a volume of reactive mixture
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2d
AI summary
This invention describes methods and apparatus for implementing a Convergence Process to Converge a Lens Design wherein a previous DMD Show may be modified for a subsequent Iteration. In preferred embodiments, an Iterative Loop may be initiated during a Convergence Process wherein one or more of various: techniques, modalities, and thickness correction methods may be implemented.