Lens Blocking Device for Optical Surface Machining
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Solution Overview
Problem
Current methods for machining optical lenses face challenges in precisely aligning and orienting semi-finished lenses during the manufacturing of desired prisms, often requiring complex blocking processes and materials like resins or lead-based alloys, which are time-consuming and inefficient.
Innovation Solution
A method involving a lens blocking device with a blocker and blocking ring, where the lens blank is clamped and tilted relative to the machining device's rotation axis, allowing for easier orientation and machining of prisms without complex blocking, using a vacuum or cast material for secure positioning, and optimizing tilt angles to minimize angular differences for precise surface machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lens blocking methods using resins or glues are used to hold the semi-finished lens, then the lens can be securely positioned, but the manufacturing time increases due to long setting and cooling periods
Solution Approach 1:
The invention extracts and eliminates the adhesive material (resin or glue) from the blocking process. Instead of using chemical adhesives that require setting time, the patent uses a mechanical blocking device with a blocker and blocking ring that physically holds the lens blank without any bonding agents, thereby removing the time-consuming setting and cooling periods while maintaining secure positioning.
Solution Approach 2:
The invention replaces the chemical bonding mechanism (adhesives) with a mechanical holding system. The blocking device uses physical contact and mechanical constraints through the blocker applied to the front surface and the blocking ring positioned on the periphery, substituting the chemical-adhesive-based positioning system with a purely mechanical one that provides immediate and secure holding without waiting for material setting.
2Manufacturing precision
If prismatic blockers are used to orient the semi-finished lens at a given inclination, then the desired prism can be achieved, but the process requires complex blocking procedures and additional materials
Solution Approach 1:
The blocking device serves multiple functions: it holds the lens blank securely (positioning function) and simultaneously orients it at the required inclination angle for prism machining (orientation function). The blocker and blocking ring work together to provide both clamping and angular positioning capabilities in a single integrated system, eliminating the need for separate prismatic blockers and their associated complex procedures.
Solution Approach 2:
The invention changes the approach from using specialized prismatic blockers with fixed intricate geometries to a more flexible system where the orientation is achieved by adjusting parameters such as the tilt angle of the blocking device relative to the rotation axis. This allows the same basic blocking mechanism to accommodate different prism orientations by simply changing angular parameters rather than requiring different complex blocking fixtures.
3Strength
If the lens blank is securely clamped for machining, then the cutting forces can be counteracted, but the alignment and orientation adjustments become more difficult
Solution Approach 1:
The blocking device is configured and positioned before the lens blank is fully clamped and secured. The blocker is applied to the front surface at the precise angular and axial position required, and the blocking ring is positioned on the periphery, establishing the correct orientation and alignment in advance. Once this preliminary positioning is set, the clamping forces are applied to secure the lens, ensuring that the alignment is already established before the strong clamping occurs, thus avoiding the difficulty of adjusting alignment under heavy clamp forces.
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
This approach simplifies the blocking process, reduces the need for adhesives, and enhances the precision and quality of optical surface machining by allowing for more straightforward and efficient alignment and machining of prisms, improving the optical properties of the lens.
Implementation Method 1
using a vacuum or cast material for secure positioning
Data Source
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AI summary
Method for machining an optical surface of an optical lens, the method comprising: - a lens blank providing step, during which a lens blank blocked on a lens blocker is provided, - a clamping step, during which the lens blocker holding the lens blank is clamped in a lens machining device, - a tilting step, during which the lens blank and lens blocker are tilted relative to the rotation axis of the lens machining device, - a surface position determining step, during which the position of the surface to be machined is determined based on the tilt angle of the lens blank and lens blocker relative to the rotation axis of the lens machining device, - a machining tool configuration step, during which the operational parameters of the lens machining tool are configured in order to manufacture the surface to be manufactured according to the determined surface position so that the desired optical properties of the optical lens are respected.