Optical Element Blocking Device with Adjustable Pins
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Solution Overview
Problem
The existing manufacturing processes using alloy-free glue materials for optical lenses suffer from low throughput due to the solidifying time of thermoplastic materials and inadaptability for prism prescriptions, leading to reduced efficiency compared to low-temperature metal alloys.
Innovation Solution
A blocking device with adjustable pins and a locking mechanism to precisely position optical elements, combined with a cooling device to accelerate the solidification of glue materials, allowing for parallel processing and efficient transfer between stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If alloy-free glue materials (thermoplastic materials) are used to block optical lenses, then environmental safety and non-toxicity are improved, but manufacturing throughput deteriorates due to long solidification time
Solution Approach 1:
The patent applies parameter changes by controlling temperature variations during the blocking process. The thermoplastic material is heated above its melting point to become fluid for positioning, then cooled to solidify and block the lens. This temperature parameter control enables the material to transition between states, achieving both environmental safety and improved manufacturing throughput by reducing solidification time through active cooling.
Solution Approach 2:
The patent utilizes phase transitions of the thermoplastic blocking material between solid and liquid states. The material is melted to a fluid state for lens positioning, then solidified to create the blocking effect. This phase transition mechanism allows the material to be repositionable during manufacturing while providing stable blocking when solidified, resolving the contradiction between ease of positioning and manufacturing speed.
2Adaptability or versatility
If thermoplastic blocking material is used, then adaptability to different prescriptions (including prism) is improved, but processing time increases due to solidification requirements
Solution Approach 1:
The patent applies preliminary action by pre-heating the thermoplastic blocking material to its melting point before lens positioning. This ensures the material is in the optimal fluid state for adaptation to different prescriptions including prism configurations. The preliminary heating action eliminates delays during the positioning process, allowing quick adaptation to various lens requirements before controlled solidification begins.
Solution Approach 2:
The patent implements periodic action through controlled heating and cooling cycles of the thermoplastic material. The material is periodically heated to melting point for positioning adjustments, then cooled for solidification. This periodic temperature control enables multiple positioning adjustments if needed while minimizing total processing time, thus improving both adaptability and reducing time loss.
3Productivity
If low temperature metal alloys are used for blocking, then manufacturing throughput is maintained, but environmental hazards and health risks worsen due to toxic metals
Solution Approach 1:
The patent applies mechanics substitution by replacing the traditional low-temperature metal alloy blocking system with a thermoplastic polymer-based system. The metal alloys are substituted with organic thermoplastic materials that provide similar blocking functionality without the toxic effects. This substitution maintains manufacturing throughput through controlled phase transitions while eliminating health and environmental hazards associated with cadmium, lead, and other toxic metals.
Solution Approach 2:
The patent utilizes composite materials by formulating thermoplastic blocking compositions that combine multiple polymer components and additives to achieve the desired properties. These composite thermoplastic materials replicate the functional characteristics of metal alloys (blocking capability, temperature response) while being environmentally safe. The composite nature allows optimization of both processing characteristics and final blocking performance without toxic constituents.
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
Significantly increases the throughput of optical lens manufacturing by reducing solidification time and enabling simultaneous processing of multiple lenses, making alloy-free glue materials more competitive.
Implementation Method 1
heating the surface of the lens blocking composition to its melting or softening point
Implementation Method 2
a cooling device to accelerate the solidification of glue materials
Data Source
AI summary
A blocking device for positioning and blocking an optical element to an insert at a given position, including an insert having a surface intended to be blocked against a face of the optical element with a glue material, the insert being positioned in respect with a blocking station; at least three pins to support the optical element at the given position, wherein the height of the extremity of each pin is adjustable independently of each other, the extremities being configured to position the optical element at the given position; and a locking device to hold the position of the optical element at the given position while the glue material is solidifying, the locking device including a lock associated with each pin.