Reusable Machining Support for Ophthalmic Lens Positioning

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Solution Overview

Problem

Existing methods for manufacturing ophthalmic lenses, such as those using disposable plastic blocking pieces, are inefficient and lose positioning reference between surfacing and edging steps, leading to reduced quality and increased costs due to the need for precise alignment and the disposal of the blocking piece.

Innovation Solution

A reusable machining support unit with separable surfacing and edging members, where the surfacing member is withdrawn after surfacing, allowing the substrate to be retained on the edging member for precise edging without losing positioning, enabling improved quality and cost-effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a disposable plastic blocking piece is used for both surfacing and edging, then the substrate can be blocked and positioned for machining, but the positioning reference is lost between surfacing and edging steps requiring realignment

Engineering Contradiction:

Improvepositioning reference retentionVSAvoidblocking piece structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The blocking piece is divided into two separable members: a surfacing member with a cavity and an edging member that fits within the cavity. This segmentation allows the edging member to remain attached to the substrate while the surfacing member is removed, maintaining positioning reference without requiring the entire blocking piece to remain in place.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The surfacing member is extracted or removed from the assembly after the surfacing operation is complete. This extraction allows the edging member to be freely accessible for the edging operation while the substrate remains positioned on the edging member, preserving the positioning reference established during surfacing.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If a single blocking piece is used for surfacing and edging, then the process can be simplified, but a substantial portion of the blocking piece must be removed during edging resulting in material waste

Engineering Contradiction:

Improveprocess simplicityVSAvoidblocking piece material

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

By segmenting the blocking piece into separable surfacing and edging members, the edging member can be used repeatedly across multiple substrates without being consumed. Only the disposable substrate is removed during edging, not the blocking members, thereby eliminating the material waste of the blocking piece itself.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The edging member is recovered and reused for subsequent edging operations on different substrates. The surfacing member may be discarded after use, but the critical edging member is preserved and reused, reducing overall material consumption compared to removing portions of a single-use blocking piece.

Inventive Principle:

Principle #34Discarding and recovering

3Ease of operation

If the substrate is unblocked between surfacing and edging, then the blocking piece can be accessed, but the positioning reference is lost requiring realignment

Engineering Contradiction:

Improveaccess to blocking pieceVSAvoidalignment between surfacing and edging

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The blocking piece is segmented into a surfacing member and an edging member. The surfacing member is designed to be removable or separable, allowing access to the edging member and substrate interface without disrupting the positioning reference. The substrate remains blocked on the edging member throughout, maintaining alignment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The blocking system transitions from a static single-piece structure to a dynamic separable structure. The surfacing member can be dynamically removed or separated to allow access for edging operations, while the edging member remains in place to maintain the positioning reference, combining ease of operation with manufacturing precision.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10850362B2Method of manufacturing ophthalmic lenses and system for the manufacturing of such ophthalmic lenses

Publication Date: 2020.12.01 ESSILOR INTERNATIONAL(COMPAGNIE GENERALE D OPTIQUE)

AI summary

The invention concerns a method of manufacturing an ophthalmic lens, comprising the steps of providing, mounting and blocking a substrate (10) on a machining support unit (65), surfacing an upper face (12) of said substrate, edging a peripheral edge (13) of said substrate, wherein said machining support unit comprises a surfacing member (40) and an edging member (30) which are separable, said surfacing member having a cavity (51) in which said edging member is located during said step of surfacing, said surfacing and edging members being configured so that said substrate is mounted and blocked on said machining support unit in a first predetermined position for the surfacing and the edging and, between said steps of surfacing and edging, the method comprises the step of withdrawing said surfacing member from said machining support unit by retaining said substrate on said edging member.