Intraocular Lens Mandrel Structure for Wax-Free Haptic Milling
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Solution Overview
Problem
Current methods for manufacturing intraocular lenses face challenges such as the need for precise mandrel alignment, manual removal of wax residues, and reduced tool life due to wax usage, which complicates the milling process and affects the quality of the finished lens.
Innovation Solution
A mandrel design with a central cavity and peripheral projection to securely hold the intraocular lens blank, allowing for precise machining and milling, and a method involving mechanical deblocking without solvents to eliminate wax residues, enhancing the efficiency and quality of the intraocular lens production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wax is used to hold the intraocular lens blank during machining and milling, then the blank is securely held in place, but wax residues remain on the haptic surface and reduce tool life
Solution Approach 1:
The patent extracts the harmful wax material from the holding process by replacing it with a wax-free mandrel system. The mandrel directly holds the intraocular lens blank through mechanical engagement features (such as recesses and protrusions) without requiring wax adhesive, thereby eliminating wax residues from the haptic surface and preventing tool life reduction.
Solution Approach 2:
The mandrel acts as an intermediary between the machining tool and the intraocular lens blank. Instead of using wax as a mediator that leaves residues, the mandrel provides direct mechanical support and positioning through its structural features, serving as a clean intermediary that does not contaminate the haptic surface.
2Strength
If water soluble wax is used to hold the blank, then the blank is secured during machining, but the lens hydrates in the presence of dissolved wax impurities
Solution Approach 1:
The patent removes water soluble wax from the process entirely, replacing it with a mandrel-based holding system. This extraction eliminates the source of dissolved wax impurities that would otherwise cause lens hydration, while maintaining secure holding through mechanical engagement features.
3Manufacturing precision
If manual deblocking is used to remove wax residues, then complete removal is achieved, but productivity is reduced
Solution Approach 1:
The patent extracts the deblocking step from the manufacturing process by eliminating wax usage entirely. The mandrel system allows for direct mechanical release of the intraocular lens blank without requiring manual or chemical deblocking operations, thereby maintaining cleanliness while dramatically improving productivity.
Solution Approach 2:
The mandrel holding system enables continuous manufacturing flow by eliminating the interruptive deblocking step. The intraocular lens blank can be directly transferred from the mandrel to the next processing stage without stopping for manual wax removal, maintaining continuous productive action.
4Manufacturing precision
If the mill penetrates through the back surface of the haptic disk, then the haptic is formed, but tool life is reduced due to wax contact
Solution Approach 1:
The patent extracts wax from the machining environment, eliminating the harmful interaction between wax and the milling tool. The mandrel holding system allows the mill to penetrate and form the haptic without contacting wax residues, thereby preserving tool life while maintaining haptic formation precision.
Data Source
Figure 1(a)~1(d)
Figure 2(a)~2(d)
Figure 3(a)~3(d)
AI summary
A mandrel (300) for holding an intraocular lens blank (200) during manufacturing includes an intraocular lens holding section configured to hold an intraocular lens, the intraocular lens holding section including: a central cavity (310) configured to hold a mounting material (315) such that the mounting material contacts an optic of the intraocular lens blank when the intraocular lens blank is mounted on the mandrel, and a projection (325) extending around a periphery of the central cavity, the projection having an outer wall (330) and an inner wall (335), and the projection being configured such that an outer peripheral edge of the intraocular lens blank extends up to or beyond the projection when the intraocular lens blank is mounted on the mandrel. A second mounting material (320) is deposited in the first trench (340) and then the haptic is milled using e.g. an end mill (365).