Lens Blank Support Material Sizing for Low-Waste Surfacing
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Solution Overview
Problem
A significant amount of support material is wasted during the surfacing step in the manufacturing of ophthalmic lenses, leading to substantial loss and environmental impact.
Innovation Solution
A method and apparatus are developed to determine the optimal diameter of the support material shape based on input data and predetermined thickness, overhang, and tolerance margins to minimize support material usage while ensuring effective lens blank fastening and surfacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large diameter support material is used to ensure secure fastening of the lens blank, then the reliability of fastening is improved, but the amount of support material waste during surfacing increases
Solution Approach 1:
The invention changes the parameter of support material diameter from a fixed standard size to an optimized variable size. By calculating the minimum required diameter based on lens blank dimensions, curvature radius, and overhang requirements, the support material diameter is precisely adjusted to match the actual needs, eliminating excess material that would otherwise be wasted during surfacing operations.
Solution Approach 2:
The invention performs preliminary calculation and optimization of the support material diameter before the actual fastening operation. By determining the optimal diameter in advance based on lens parameters and surfacing requirements, the system prepares the exact amount of material needed, preventing both insufficient fastening and excessive material usage.
2Loss of substance
If a small diameter support material is used to reduce material waste, then the loss of substance is reduced, but the reliability of fastening and stability during surfacing deteriorates
Solution Approach 1:
The invention transforms the support material diameter from a conservative fixed value to an optimized variable value. By establishing calculation formulas that consider lens blank diameter, curvature radius, and required overhang, the system determines the minimum sufficient diameter that maintains fastening reliability while minimizing material waste.
Solution Approach 2:
The invention creates a mathematical model that copies the essential geometric parameters of the lens blank (diameter, curvature radius) and uses them to calculate the optimal support material dimensions. This model-based approach ensures that the support material is precisely sized according to the specific lens requirements rather than using generic oversized materials.
3Ease of manufacture
If a standard fixed diameter support material is used, then the ease of manufacture is improved, but the productivity is reduced due to material waste and reprocessing
Solution Approach 1:
The invention changes the support material diameter parameter from a standard fixed value to a calculated optimized value. By implementing automatic calculation based on lens parameters, the system maintains manufacturing simplicity while eliminating the need for excessive material removal during surfacing, thereby improving overall productivity.
Solution Approach 2:
The invention replaces the traditional mechanical approach of using standard-sized support materials with a calculation-based determination method. By using mathematical formulas to calculate the optimal diameter, the system substitutes empirical material selection with precise computational determination, reducing material waste and improving efficiency.
4Loss of substance
If the support material diameter is optimized based on calculation, then the loss of substance is reduced, but the device complexity increases due to additional calculation steps
Solution Approach 1:
The invention creates a mathematical model that copies the essential parameters of the lens blank (diameter, curvature radius) and uses these copied values to calculate the optimal support material diameter. This model-based approach systematically determines the minimum required diameter while accounting for necessary overhang, reducing material waste through precise calculation rather than trial and error.
Solution Approach 2:
The invention transforms the support material diameter from a fixed standard parameter to a calculated parameter based on lens-specific dimensions. By establishing clear calculation formulas that relate lens parameters to optimal support material size, the system reduces material waste through precise parameter determination.
Data Source
AI summary
In a method of preparing a lens blank for a surfacing operation, the lens blank is fastened to a support with a base and a support material via which the lens blank is fastened. The support material has a circular periphery. The surfacing transforms the lens blank into a surfaced lens. The method includes: determining the surfaced lens shape based on input data; based on the surfaced lens shape, determining a maximum diameter of the support material shape based on a predetermined maximum thickness defining the maximum thickness of the support material allowed to be cut into during the surfacing of the lens blank; choosing a diameter for the support material shape ≤the maximum diameter for further fastening the lens blank to the support by forming the support material so the support material shape has a diameter corresponding to the chosen diameter.