Lens Mold Orientation Adjustment for Diverse Lens Orders
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Solution Overview
Problem
The existing methods for producing spectacle lenses require a large number of lens blanks with thick unfinished surfaces to accommodate various design conditions, leading to inefficiencies in handling and stocking, and necessitate the use of jigs for holding molds at specific inclination angles.
Innovation Solution
A method involving the rotation and/or inclination of molds in space coordinates to form lens molds, allowing for the assembly of molds with specific posture adjustments, which reduces the need for multiple lens blanks and simplifies the handling of various lens orders by maintaining the rotation and inclination angles during the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If lens blanks with thick unfinished surfaces are stocked to accommodate various design conditions, then the ability to handle diverse lens orders is improved, but the quantity of material stored and handling complexity increase
Solution Approach 1:
A single lens blank with a thick unfinished rear surface can be processed into multiple different lens designs by varying the molding parameters (inclination angles, rotation angles, positioning) during the injection molding process. This makes the lens blank universal, capable of producing different prescription lenses without requiring separate blanks for each design variation.
Solution Approach 2:
The molding process uses adjustable inclination angles and rotation angles of the mold cavities, allowing dynamic reconfiguration of the molding parameters. This enables the same lens blank to be transformed into different lens designs by changing the molding orientation and positioning, rather than requiring fixed dedicated blanks for each design.
2Ease of manufacture
If traditional tape molding method is used to form lens molds, then lens production is achieved, but jigs are required to hold molds at specific inclination angles increasing device complexity
Solution Approach 1:
The lens mold cavity itself is designed with integrated positioning features and adjustable mechanisms that allow it to self-adjust to the required inclination angles and rotation angles. The mold structure includes built-in adjustment mechanisms that eliminate the need for external jigs to hold the molds at specific orientations.
Solution Approach 2:
The invention introduces a movable support structure and positioning mechanism that acts as an intermediary between the mold cavity and the injection molding machine. This intermediary system provides the necessary angular adjustments and positioning without requiring complex external jigs, simplifying the overall device structure.
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 enables the production of spectacle lenses with improved surface smoothness and reduced material usage, allowing for the handling of diverse lens orders with fewer blanks and eliminating the need for complex jig systems, thereby enhancing efficiency and reducing production costs.
Implementation Method 1
a curing step of polymerizing and curing the filled lens material liquid so as to form the lens
Data Source
Figure 1~3
Figure 4(a)~4(d)
Figure 5~6
AI summary
A lens-mold producing method includes a position and posture determining step S101 of specifying positions and postures, in space coordinates, of a first mold having a molding surface R1 for forming one optical surface of a lens and a second mold having a molding surface R2 for forming the other optical surface, a mold holding step S102 of rotating and/or inclining, based on the positions and postures in the space coordinates, at least one of the first mold and the second mold, maintaining a rotation angle and/or an inclination angle of a reference plane of the first mold with respect to a reference plane of the second mold, and holding the first mold and the second mold, and an assembling step S103 of arranging the molding surface R1 of the first mold and the molding surface R2 of the second mold so as to face each other, fixing outer peripheries of the first mold and the second mold, and assembling a lens mold.