Semi-Finished Optical Lens Geometry for Lower Material Waste

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Solution Overview

Problem

Existing methods for manufacturing ophthalmic lenses result in significant waste of optical lens material due to the use of thick and large semi-finished lenses to accommodate a wide range of prescriptions, including rare and uncommon ones, while common prescriptions require less material.

Innovation Solution

A method to optimize the geometrical parameters of semi-finished optical lenses by determining a subset of ophthalmic parameters based on order proportion data, allowing the production of optimized lenses with reduced material usage and waste, while maintaining the ability to manufacture lenses for the desired proportion of prescriptions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If thick and large diameter semi-finished optical lenses are produced to accommodate all prescriptions including rare ones, then the ability to manufacture lenses for all ophthalmic prescriptions is improved, but significant waste of optical lens material occurs during grinding, polishing and edging

Engineering Contradiction:

Improveability to manufacture lenses for all prescriptionsVSAvoidwaste of optical lens material

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent segments the set of all ophthalmic prescriptions into multiple subsets, each associated with a different semi-finished optical lens having specific geometrical parameters. This segmentation allows each lens type to be optimized for its specific prescription subset, eliminating the need to produce oversized lenses for all prescriptions and thereby reducing material waste during manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the geometrical parameters (diameter, thickness, base curve) of semi-finished optical lenses based on the specific prescription subset they are intended to serve. By adjusting these parameters to match actual prescription requirements rather than using uniform oversized lenses, the invention minimizes material removal during grinding, polishing and edging operations.

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If semi-finished optical lenses are optimized for common prescriptions with reduced diameter and thickness, then material waste is reduced, but the ability to manufacture lenses for rare prescriptions is compromised

Engineering Contradiction:

Improvewaste of optical lens materialVSAvoidability to manufacture lenses for rare prescriptions

Core Design Contradiction:

Loss of substanceVSAdaptability or versatility

Solution Approach 1:

The patent creates a multi-functional system where multiple types of semi-finished optical lenses, each optimized for specific prescription subsets, work together to cover the entire range of ophthalmic prescriptions. This universal approach ensures that common prescriptions receive optimized lenses with minimal material waste, while rare prescriptions are accommodated by specialized lens types designed for those specific cases.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If a single geometry is used for all semi-finished optical lenses, then manufacturing simplicity is maintained, but material waste increases for common prescriptions

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwaste of optical lens material

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent applies local quality by assigning different geometrical characteristics to different semi-finished optical lenses based on the specific prescription subsets they serve. Each lens type has locally optimized parameters (diameter, thickness, base curve) matched to its intended application, rather than using a uniform geometry for all lenses, thereby reducing material waste while maintaining manufacturing efficiency.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12510768B2Method for optimizing a geometrical parameter of a semi-finished optical lens

Publication Date: 2025.12.30 ESSILOR INTERNATIONAL(COMPAGNIE GENERALE D OPTIQUE)

AI summary

Disclosed is a method for optimizing a geometrical parameter of at least one semi-finished optical lens in a set of such lenses having a designated lens material, the semi-finished optical lens to be optimized has a designated base curve and an initially determined geometry allowing manufacturing finished ophthalmic lenses for an initial set of ophthalmic parameters, the method including: providing order proportion data reflecting each ophthalmic prescription in the initial set; providing a desired proportion selection rate; determining a subset of ophthalmic parameters in the initial set corresponding to the desired proportion selection rate; determining the optimized value of a geometrical parameter of an optimized semi-finished optical lens having the designated base curve and lens material and allows manufacturing finished ophthalmic lenses for each ophthalmic prescriptions in the subset of ophthalmic parameters; outputting the determined optimized value as the optimized geometrical parameter of said semi-finished optical lens.