Optimizing Semi-Finished Ophthalmic Lens Geometry

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Solution Overview

Problem

The existing method of manufacturing semi-finished ophthalmic lenses results in significant material wastage due to the production of thick and large lenses to accommodate a wide range of prescriptions, with many prescriptions not requiring such extensive lenses, leading to inefficiency and environmental impact.

Innovation Solution

A method that optimizes the geometry of semi-finished ophthalmic lenses using evolutionary algorithms, such as genetic algorithms, to determine final geometries based on prescription data and manufacturing constraints, minimizing material usage and costs while ensuring all prescriptions can still be manufactured.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If semi-finished ophthalmic lenses are produced with thick and large geometry to accommodate a wide range of prescriptions, then all prescriptions can be manufactured from a single set of lenses, but significant lens material wastage occurs

Engineering Contradiction:

Improveability to manufacture all prescriptionsVSAvoidlens material wastage

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent divides the single set of semi-finished lenses into multiple sets, each optimized for specific prescription ranges. The optimization system segments the lens population based on prescription characteristics (sphere power, cylinder power, axis) and frame types, creating specialized subsets that reduce material waste for each segment while maintaining overall coverage of all prescriptions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the geometric parameters (thickness, diameter, base curve) of semi-finished lenses based on prescription requirements. The optimization system adjusts these parameters to match actual demand patterns, producing lenses with precise geometries rather than universal oversized geometries, thereby reducing material wastage while maintaining manufacturing capability for all prescriptions.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If semi-finished lenses are produced with large diameter and thickness to suit all prescriptions including rare outliers, then manufacturing coverage is maximized, but transportation costs and material usage increase

Engineering Contradiction:

Improvemanufacturing coverage for all prescriptionsVSAvoidtransportation cost

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The patent segments the lens inventory into multiple optimized sets rather than transporting single large lenses. By dividing the population into prescription-based segments, the system enables transportation of smaller, lighter lens sets that collectively cover all prescriptions, reducing overall transportation weight and cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies partial action by producing lens sets with geometries optimized for specific prescription ranges rather than excessive action of producing single large lenses for all cases. Each optimized set contains lenses with appropriate sizes for its target prescription segment, eliminating the need to transport oversized lenses for every prescription type.

Inventive Principle:

Principle #16Partial or excessive action

3Ease of manufacture

If a single set of semi-finished lenses with fixed geometry is used, then manufacturing process is simple, but material wastage is significant for common prescriptions

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidmaterial wastage for common prescriptions

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent introduces dynamics into the manufacturing system by making lens geometry parameters adaptive rather than fixed. The optimization system dynamically adjusts thickness, diameter, and base curve parameters based on prescription data and demand patterns, enabling the manufacturing process to respond to specific requirements while maintaining overall simplicity through automated optimization.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes geometric parameters of semi-finished lenses based on prescription characteristics. The optimization system modifies thickness, diameter, and base curve parameters to match actual prescription demands, reducing material wastage for common prescriptions while maintaining ease of manufacture through systematic parameter adjustment rather than complex procedural changes.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10437077B2Method of optimizing geometry of a semi-finished ophthalmic lens in a set of semi-finished ophthalmic lenses

Publication Date: 2019.10.08 CARL ZEISS VISION INTERNATIONAL GMBH

AI summary

The present invention provides a method, a system, and a computer program code for optimizing geometry of at least one semi-finished ophthalmic lens in a set of semi-finished ophthalmic lenses having a designated lens material, each of the semi-finished ophthalmic lenses in the set having an Initially determined geometry including one of a plurality of base curves determined to allow manufacture of finished ophthalmic lenses for ophthalmic lens prescriptions.