Lens Block Mold With Multi-Size Openings and Integrated Cooling
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Solution Overview
Problem
Existing lens blocking technologies face challenges in efficiently and cost-effectively changing block sizes, leading to complex retooling and reduced throughput due to the use of positioning drives and time-consuming support ring changes.
Innovation Solution
A block mold with multiple block openings and a switching drive allows for quick and easy changes between different block sizes, featuring a plate-shaped design with integrated coolant channels for efficient cooling and a compact, high-throughput apparatus design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single block mold with multiple block openings is used, then the ease of changing block sizes is improved, but the device complexity increases due to the need for a switching mechanism
Solution Approach 1:
The block mold is segmented into multiple block openings within a single mold body, allowing different block sizes to be formed by selecting different openings. This segmentation enables size variation without requiring multiple complete molds, reducing overall system complexity while maintaining operational ease.
Solution Approach 2:
The block mold is made movable and selectable rather than fixed, allowing dynamic switching between different block openings based on the required block size. This dynamic capability is achieved through a simple switching mechanism that can position different openings in the working location, balancing operational flexibility with mechanical simplicity.
2Manufacturing precision
If positioning drives are used to tilt the block mold, then the manufacturing precision is improved, but the device complexity and cost increase
Solution Approach 1:
The complex positioning drive mechanism is extracted and replaced with a simpler approach. Instead of using motorized positioning drives to tilt the block mold, the invention uses gravity-assisted tilting where the block mold can be manually or simply mechanically positioned at the required angle, maintaining precision while eliminating complex actuators.
Solution Approach 2:
The block mold design incorporates self-aligning features and gravity-based positioning that allow the mold to achieve and maintain the correct tilting angle without active positioning drives. The geometry of the mold and its mounting structure work together to provide stable, precise positioning passively.
3Adaptability or versatility
If support rings are changed manually from a magazine, then the adaptability to different lens sizes is improved, but the productivity decreases due to time-consuming changes
Solution Approach 1:
The support function and the mold cavity function are merged into a single integrated block mold structure. The block mold itself provides both the cavity for forming the block material and the support surface for the lens, eliminating the separate support ring component. This integration allows instant size changes by selecting different openings in the same mold rather than physically exchanging entire support components.
Solution Approach 2:
The single block mold serves multiple functions: it provides support for the lens, forms the block material cavity, and can be configured for different block sizes through selective opening usage. This multi-functionality replaces the need for multiple specialized components (different support rings for different sizes), enabling rapid adaptation while maintaining high throughput.
4Productivity
If a plate-shaped block mold with multiple openings is used, then the productivity is improved through faster size changes, but the manufacturing cost increases
Solution Approach 1:
The block mold is designed as a plate structure with multiple openings segmented into different size zones. This segmentation allows the mold to be manufactured as a single integrated component using standard casting or machining processes, distributing the complexity across the plate area rather than requiring multiple separate molds. The plate shape facilitates efficient material removal and cooling channel integration, reducing manufacturing cost.
Solution Approach 2:
Instead of discarding and replacing entire block molds when size changes are needed, the invention allows selective usage of different openings within the same mold plate. The unused openings remain as part of the permanent mold structure, ready for future use. This approach recovers the investment in mold manufacturing by making it reusable for multiple size configurations throughout the mold's service life.
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
Enables simple and fast adaptation to varying lens sizes, enhancing throughput and reducing operational complexity while maintaining high efficiency and cost-effectiveness.
Implementation Method 1
The block mold can have integrated coolant channels for efficient cooling
Implementation Method 2
The block mold can have integrated coolant channels for efficient cooling
Data Source
AI summary
An apparatus and a block mold for blocking a lens are proposed, wherein the lens is blocked on a block piece by means of a block material. The space between the lens and the block piece is laterally delimited by a block mold. The block mold is preferably plate-shaped and has a plurality of block openings for forming different block sizes and has an integrated coolant channel. This enables easy and fast changing between different block sizes and very good cooling.