Edged Lens Holding Peg Layout for Precise Adhesive Registration
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Solution Overview
Problem
Existing methods for manufacturing edged optical elements, such as electrochromic cells and liquid crystal lenses, face challenges in accurately positioning and orienting these elements due to variations in size and shape, leading to position uncertainty and internal defects during adhesive application.
Innovation Solution
A holding device with three pegs and a base that restricts movement of edged optical elements within a narrow position and orientation range, ensuring precise placement and orientation by optimizing the spread of pegs to minimize position and orientation variability, allowing for accurate application of adhesive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a central dot is used as a reference point for positioning edged lenses, then the method is simple and easy to implement, but position uncertainty increases due to variations in lens dimensions
Solution Approach 1:
The patent introduces a mechanical intermediary system consisting of a base with multiple positioning pins that physically contact and constrain the edged lens. This intermediary mechanism translates the simple act of placing a lens on a base into precise positional control, eliminating the need for complex visual reference systems while maintaining manufacturing simplicity.
Solution Approach 2:
The invention changes the positioning parameters from a single-point reference (central dot) to a multi-point constraint system. By using three or more positioning pins distributed across the base, the system controls multiple degrees of freedom simultaneously, transforming the positioning approach from one that is sensitive to dimensional variations to one that is robust against such variations.
2Device complexity
If edged lenses are held without specific positioning constraints, then the device structure is simple, but positioning consistency varies between operators
Solution Approach 1:
The positioning base is designed to be self-aligning and operator-independent. When an edged lens is placed on the base, the positioning pins automatically constrain the lens to a specific position and orientation without requiring the operator to perform alignment actions. The lens itself serves to define the position through its physical contact with the pins.
Solution Approach 2:
The positioning function is segmented into multiple independent constraints provided by individual positioning pins. Each pin controls a specific degree of freedom, and their collective arrangement creates a stable positioning system. This segmentation allows the device to maintain simplicity while achieving reliable, consistent positioning.
3Productivity
If the closed path for adhesive application is registered based on assumed lens position, then the registration process is quick, but positioning accuracy decreases when lens dimensions vary
Solution Approach 1:
The positioning pins are pre-positioned on the base according to the desired adhesive path geometry. Before the lens is placed, the reference framework is already established through the fixed pin locations. This preliminary setup ensures that when the lens is positioned on the pins, the adhesive path can be accurately registered relative to the actual lens position, accommodating dimensional variations.
Data Source
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AI summary
The disclosure relates to holding devices adapted for holding edged optical elements, manufacturing systems comprising such holding devices and to a corresponding method for manufacturing a compound optical element. The holding devices comprise a base for supporting a main surface of an edged optical element and either exactly three pegs or a plurality of clamps. The pegs are arranged so that two pegs are in contact with a first area of the side surface of an edged optical element positioned on the base while the remaining peg is in contact with a second area of the side surface only if a specific portion of the first or of the second area is within a specific position and orientation range about three perpendicular axes The clamps are arranged to collectively hold an edged optical element positioned on the base by restricting its mobility with respect to three degrees of freedom.