Ophthalmic Lens Laser Alignment for Automated Optical Feature Formation
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Solution Overview
Problem
Current methods for manufacturing ophthalmic lenses with patterns of optical elements are labor-intensive and lack automation, leading to inefficiencies in producing lenses for myopia control.
Innovation Solution
An automated system that aligns an ophthalmic lens relative to a laser system using optical alignment techniques, allowing for precise formation of optical elements on the lens surface or in its bulk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated laser system is introduced to form optical elements on ophthalmic lenses, then manufacturing precision and throughput are improved, but device complexity increases
Solution Approach 1:
A fiducial marker is introduced as an intermediary element between the lens and the laser system. The marker serves as a reference point that enables the automated system to locate and align with the optical center of the lens without requiring complex vision algorithms. This simple visual reference resolves the alignment problem while keeping the system relatively simple.
Solution Approach 2:
The patent replaces manual mechanical alignment methods with an automated optical alignment system using a camera and fiducial marker. Instead of relying on operators to physically position and align lenses manually, the system uses image capture and processing to automatically determine lens position and orientation, thereby improving precision while enabling automation.
2Productivity
If manual alignment methods are used to position optical elements on lenses, then device complexity remains low, but productivity and manufacturing efficiency deteriorate
Solution Approach 1:
The system enables self-alignment through the use of a fiducial marker that automatically provides reference information to the camera. The lens essentially aligns itself with the system by presenting the marker in a detectable position, eliminating the need for complex active control mechanisms or high-level automation while still achieving automated processing and improved throughput.
3Manufacturing precision
If complex automated alignment systems are implemented, then manufacturing precision improves, but ease of operation and ease of manufacture worsen
Solution Approach 1:
The fiducial marker is a simple, inexpensive, and easily replaceable component. Rather than investing in complex, expensive alignment systems that are difficult to implement and maintain, the patent uses a simple visual marker that can be easily manufactured and replaced if needed. This approach achieves high precision while maintaining ease of manufacture and implementation.
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
The automated system significantly improves the throughput of manufacturing myopia control lenses by accurately aligning the lens with the laser system, ensuring precise formation of optical elements and enhancing the efficiency of the manufacturing process.
Implementation Method 1
exposing locations of the ophthalmic lens to a laser beam from the laser system to form the pattern of optical features on the ophthalmic lens
Implementation Method 2
measuring light transmitted or reflected by the ophthalmic lens or a surface property of the ophthalmic lens using the first apparatus
Implementation Method 3
measuring light transmitted or reflected by the ophthalmic lens or a surface property of the ophthalmic lens
Data Source
AI summary
Ophthalmic lenses and method of manufacturing ophthalmic lenses that include automated steps are disclosed.