Ophthalmic Lens Manufacturing Module with Dynamic Mold Exchange
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Solution Overview
Problem
Current manufacturing processes for contact lenses are inefficient in producing smaller lots with varying base curve radii and optical powers, leading to significant downtime and reduced flexibility, as they require line clearance and reconfiguration for each change in lens specifications.
Innovation Solution
A manufacturing module with a closed-loop production line that includes a mold changing station, toric axis setting station, and inkjet printing for unique lens identification, allowing for 'lot change on the fly' without interrupting production, enabling the rapid exchange of molds and adjustment of rotational positions to produce different lens geometries and powers continuously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing processes are used with line clearance and reconfiguration for each change in lens specifications, then manufacturing precision is maintained, but productivity decreases due to significant downtime
Solution Approach 1:
Molds are pre-loaded into mold carriers at mounting sites before production begins. The mold carrier system allows multiple molds to be prepared in advance, enabling rapid exchange during production without line clearance. This preliminary preparation eliminates the need for time-consuming reconfiguration when changing lens specifications.
Solution Approach 2:
The system employs dynamic mold exchange capability where molds can be quickly swapped between different lens mold carriers during production. The mold carrier design with multiple mounting sites allows flexible reconfiguration without stopping the production line, enabling continuous manufacturing with varying specifications.
2Adaptability or versatility
If traditional manufacturing processes are used with fixed lens mold carriers, then device complexity is reduced, but adaptability decreases when producing smaller lots with varying specifications
Solution Approach 1:
The mold carrier system is segmented into multiple independent mounting sites, each capable of holding a different mold. This segmentation allows individual molds to be exchanged independently while maintaining the overall carrier structure, providing flexibility for producing different lens specifications without requiring complete system reconfiguration.
Solution Approach 2:
The lens mold carrier is designed as a universal platform with multiple mounting sites that can accommodate different types of molds for various lens specifications. This multi-functional carrier can produce different lens geometries, base curve radii, and optical powers by simply changing which molds are mounted at which sites, eliminating the need for dedicated carriers for each lens type.
3Adaptability or versatility
If molds are exchanged during production, then adaptability increases for producing different lens specifications, but device complexity increases due to mold changing station requirements
Solution Approach 1:
Molds are pre-mounted onto mold carriers at designated mounting sites before production begins. This preliminary arrangement allows the mold changing station to perform simple exchange operations rather than complex installation procedures, reducing the complexity of the changing station while maintaining high adaptability.
Solution Approach 2:
The mold carrier acts as an intermediary between the mold storage system and the production line. It simplifies the mold exchange process by providing a standardized interface that the mold changing station can manipulate, reducing the complexity of direct mold handling while enabling flexible production of different lens specifications.
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
This approach enhances production efficiency by allowing the simultaneous manufacture of multiple lens lots with varying specifications without downtime, increasing flexibility and reducing production delays, especially for smaller batches.
Implementation Method 1
The manufacturing module further comprises an ink jet printing unit configured to print the unique lens identification code onto one of the molds
Implementation Method 2
the mold changing station is configured to be capable of removing a mold from its mounting site on the frame of a lens mold carrier and mounting a different mold to the frame at the mounting site
Data Source
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AI summary
A manufacturing module (MM) for ophthalmic lenses comprises a plurality of manufacturing stations (300, 301, 302, 310, 320, 321, 322, 330, 331, 340, 341, 342, 350, 351, 352) arranged in a closed loop and a plurality of lens mold carriers (1, 2) which are transported through the manufacturing stations. Each lens mold carrier (1, 2) comprises a frame (10, 20) having a predetermined number of mounting sites (100, 200) arranged along the frame. Each lens mold carrier (1, 2) further comprises a predetermined number of molds (112, 212) removably mounted to the frame (10, 20) at the mounting sites (100, 200), the molds being reusable male or female molds (212, 112). Two lens mold carriers (1, 2) are assigned to each other to form a pair, so that upon mating the pair of lens mold carriers (1, 2) the male and female molds (212, 112) are mated to form mold cavities defining the shape of the lenses. The manufacturing stations comprise a mold changing station (300, 301, 302) configured to be capable of removing a mold from its mounting site (100, 200) and mounting a different mold at the said mounting site (100, 200), or configured to change the rotational position of a mold (112, 212) mounted to the frame (10, 20), or both.