Ophthalmic Lens Light Guide Segmentation for Compact Display Volume
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Solution Overview
Problem
Existing methods for manufacturing ophthalmic lenses with integrated optical displays often result in complex light beam generator systems with larger volumes and less efficient distribution, particularly when using a single light guide contained within the lens.
Innovation Solution
A method involving a mold with two mold portions to create an ophthalmic lens with two separate optical beam generator pieces, where a transparent light guide is temporarily secured to a stud using adhesive before molding, allowing for a more compact and efficient light beam path with refractive index matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single light guide is contained within the lens, then the display function is integrated, but the light beam generator system has larger volume and less efficient distribution
Solution Approach 1:
The light beam generator system is divided into two separate optical pieces (first beam generator piece 2A and second beam generator piece 2B) positioned on opposite sides of the light guide, rather than using a single integrated generator. This segmentation allows for more compact individual components and better spatial distribution of the light path.
Solution Approach 2:
The patent transitions from a single-sided light generation approach to a dual-sided arrangement where light is introduced from both the rear face (via piece 2A) and front face (via piece 2B) of the light guide. This dimensional change in the light path configuration optimizes the use of available space and improves light distribution efficiency.
2Reliability
If two beam generator pieces are placed on opposite sides of the light guide, then light beam distribution is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The two separate beam generator pieces (2A and 2B) are manufactured as an integrated unit using a single mold assembly with two mold portions (6A and 6B). This merging of the manufacturing process for the two optical pieces simplifies production compared to creating and assembling two separate components, while still achieving the desired dual-sided light generation configuration.
Solution Approach 2:
The single mold assembly performs multiple functions: it simultaneously forms both mold cavities (one for each beam generator piece), positions both pieces on the light guide, and integrates them into the final lens structure. This multi-functionality in the manufacturing process reduces the number of separate operations needed despite the complexity of the dual-piece design.
3Manufacturing precision
If the light guide is temporarily secured to a stud before molding, then precise positioning is achieved, but additional manufacturing steps are required
Solution Approach 1:
The light guide is temporarily secured to the stud (6C) before the actual molding process begins. This preliminary positioning action ensures that the light guide is correctly located and held in place during subsequent manufacturing steps, achieving precise positioning without requiring complex fixtures or adjustments during the molding operation itself.
Solution Approach 2:
The stud (6C) acts as an intermediary element that facilitates the temporary securing of the light guide to the mold assembly. This intermediate component enables precise positioning and stable holding of the light guide during manufacturing, while being simple enough to integrate into the standard molding process without significantly extending cycle time.
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 ophthalmic lenses with a smaller volume and improved light beam distribution, facilitating better vision correction and multimedia viewing while maintaining mass production reliability.
Implementation Method 1
a transparent light guide is temporarily secured to a stud using adhesive before molding
Implementation Method 2
molding the lens between this first mold portion and this second mold portion
Implementation Method 3
light beams emitted by an optical element of a light beam generator system are introduced and directed towards the eye of the wearer
Implementation Method 4
light beams coming from a micro display and emitted by an optical element of a light beam generator system are introduced via an entry surface and directed towards the eye of the wearer
Data Source
Figure 1~4
AI summary
Method of manufacturing an ophthalmic lens (1) into which light beams are directed towards the eye of the wearer to enable information content to be viewed, constituted by two optical pieces, a first one (2A) placed on the rear face and a second one (4B) placed on the front face of the lens. The first entry surface (4A) is formed by means of a stud (6C) secured to the second mold portion (6B), and the light guide (4) is temporarily secured to said stud (6C) prior to molding; The second entry surface (4B) is formed by means of a peripheral cylindrical element being placed between the first and the second mold portions (6A, 6B).