Optical Lens Blocking via Three-Pin Positioning and Substrate Docking
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Solution Overview
Problem
Current methods for blocking semi-finished ophthalmic lenses lack precision, leading to inaccuracies in machining and optical lens quality due to secondary emphasis on the moving step during the blocking process, despite the use of ultra-precision computer-controlled apparatus.
Innovation Solution
A method and system that positions an unfinished optical lens on at least three pins, allowing the second face to be docked onto a preformed optical substrate block without a moving step, using a thermoplastic material with a controlled softening point and hardness for improved accuracy and reduced component usage, and incorporating camera-assisted positioning and measuring steps to correct orientation errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a moving step is used to transfer the lens from orienting station to blocking station, then the lens can be positioned and blocked separately, but the machining accuracy deteriorates due to positioning errors during movement
Solution Approach 1:
The patent merges the positioning function and blocking function into a single integrated blocking device. The positioning pins are directly integrated with the blocking jaws, allowing the lens to be positioned and blocked simultaneously in one operation, eliminating the moving step that causes positioning errors.
Solution Approach 2:
The patent extracts the moving step from the blocking process by implementing a direct blocking mechanism where the lens is blocked in its original position on the positioning pins, removing the source of positioning errors.
2Reliability
If conventional blocking methods with multiple components are used, then the lens can be securely blocked, but the device complexity increases and accuracy decreases
Solution Approach 1:
The patent segments the blocking device into three simple positioning pins and three blocking jaws, each performing a single function. This modular segmentation simplifies the overall structure while maintaining reliable lens blocking capability.
Solution Approach 2:
The blocking jaws serve multiple functions: they provide mechanical blocking force, maintain lens position, and allow for precise adjustment. This multi-functionality reduces the need for separate components for each function.
3Extent of automation
If ultra-precision computer-controlled apparatus are used, then automated processing is achieved, but machining errors persist due to insufficient emphasis on the moving step
Solution Approach 1:
The patent replaces the complex computer-controlled moving mechanism with a simple mechanical blocking system that uses the inherent precision of the positioning pins and blocking jaws, eliminating the errors introduced by automated movement.
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
Enhances the accuracy of lens positioning and machining, reducing errors and improving the quality of finished optical lenses by eliminating the need for complex components and ensuring precise alignment during the blocking process.
Implementation Method 1
a preformed optical substrate block providing step S3 in which a preformed optical substrate block is provided
Implementation Method 2
using a thermoplastic material with a controlled softening point and hardness
Data Source
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AI summary
Method of blocking an unfinished optical lens (10) to be machined, the unfinished optical lens comprising an unfinished face and a second face, the method comprising: an unfinished optical lens providing step in which the unfinished optical lens is provided; a positioning step in which the unfinished optical lens is positioned in a first reference position by positioning the unfinished face of the unfinished optical lens on the top of at least three pins; a preformed optical substrate block providing step in which a preformed optical substrate block (32) is provided; a docking step in which the second face of the unfinished optical lens in the first reference position is docked to the docking surface of the preformed optical substrate block.