Optical Lens Casting Gasket With Rigid Support Substrate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing process for forming cast ophthalmic lenses with optically functional characteristics, such as polarization, is inefficient due to the mechanical weakness of polyvinyl alcohol (PVA) wafers, requiring delicate and time-consuming manual manipulation, which limits production yield and introduces imperfections.
Innovation Solution
A casting system with a cylindrical gasket featuring a groove and vent port, along with optically functional wafers having non-circular shapes and increased mechanical rigidity, allowing for easier loading and faster curing of the monomer composition, reducing manual handling and increasing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PVA polarizing wafer is used in a lens casting gasket, then optically functional characteristics (polarization) are achieved, but the wafer is mechanically weak and easily distorted
Solution Approach 1:
The patent uses a composite structure consisting of a PVA polarizing film bonded to a rigid support substrate. The PVA layer provides the optical polarization function while the rigid substrate provides mechanical strength and dimensional stability, preventing distortion during handling and curing processes
Solution Approach 2:
The rigid support substrate is positioned specifically at the periphery and edges of the wafer where mechanical strength is most needed, while the central PVA region maintains its optical properties. The support structure is designed to provide localized reinforcement without interfering with the optical function
2Ease of operation
If manual manipulation is used to insert the PVA wafer into the gasket groove, then the wafer can be positioned, but the process is time-consuming and skilled labor is required
Solution Approach 1:
The PVA polarizing film is pre-bonded to a rigid support substrate before insertion into the gasket. This preliminary bonding action creates a self-supporting wafer that can be automatically handled and inserted without delicate manual manipulation, enabling automation of the insertion process
Solution Approach 2:
The rigid support substrate acts as an intermediary carrier that facilitates automatic handling and insertion of the PVA wafer. The support structure provides a robust interface for automated pick-and-place equipment, eliminating the need for skilled manual manipulation
3Reliability
If the curable casting composition is introduced through ports away from the wafer, then the wafer can be protected from direct pressure, but the monomer must flow around the wafer periphery which slows the process
Solution Approach 1:
The PVA wafer is pre-bonded to the rigid support substrate before monomer introduction, creating a stable assembly that can withstand higher filling speeds. This preliminary bonding allows the monomer to be introduced more rapidly without risking wafer distortion or displacement
Solution Approach 2:
The rigid support substrate changes the mechanical parameters of the wafer assembly, increasing stiffness and reducing compliance. This allows the monomer introduction process to proceed at higher speeds with greater pressure without causing wafer distortion, reducing the overall curing time
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
The system enhances lens production efficiency by minimizing wafer distortion and imperfections, enabling faster and more automated processing of optically functional lenses with improved mechanical properties.
Implementation Method 1
Once the gasket is filled with the curable casting composition or monomer, the curable casting composition or monomer is cured to form the cast lens, for example through ultraviolet or thermal curing.
Implementation Method 2
Once the gasket is filled with the curable casting composition or monomer, the curable casting composition or monomer is cured to form the cast lens, for example through ultraviolet or thermal curing.
Data Source
AI summary
An optical lens casting gasket, wafer, and system and method that provides for more efficient formation of optical lenses employing optically functional wafers.