Optical Lens Molding with Independent Shell Supports
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Solution Overview
Problem
Existing methods for fabricating optical lenses, such as ophthalmic lenses, face challenges in achieving high-quality and high-throughput production while maintaining flexibility, often requiring complex shell supports and seals that impose thickness constraints and accuracy issues.
Innovation Solution
A method and device using a set of removable shells with separate supports for each shell, positioned flat and facing each other, eliminating the need for a common support or seal, allowing for precise immobilization and accommodation of material shrinkage during polymerization without elastic means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a common support or seal is used to position the two shells, then the shells can be maintained at a predetermined distance, but this imposes thickness constraints at the edge and center of the lens and increases device complexity
Solution Approach 1:
The invention divides the positioning system into two independent parts: a first support for the first shell and a second support for the second shell. Each support independently positions its respective shell, eliminating the need for a complex common support structure or seals. This segmentation resolves the contradiction by simplifying the overall device while maintaining precise positioning of both shells relative to each other.
2Reliability
If joining parts or seals are used between shells, then the shells can be held together, but this increases the minimum thickness constraints at the edge and center of the lens
Solution Approach 1:
The invention extracts and eliminates the joining parts and seals from the shell assembly by using separate independent supports. Each shell is held by its own support structure, removing the need for intermediate connecting elements that would otherwise increase the required thickness of the lens material at the edges and center.
3Adaptability or versatility
If elastic seals are used to accommodate shrinkage during polymerization, then the mold can adapt to material shrinkage, but this increases device complexity and may affect positioning accuracy
Solution Approach 1:
The invention implements a dynamic positioning system where the second shell support can move relative to the first shell support during polymerization. This allows the mold cavity to adapt to material shrinkage through controlled movement rather than elastic deformation, maintaining positioning accuracy while accommodating volume changes.
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 high-quality, flexible, and accurate molding of optical lenses with reduced thickness constraints, achieving precise positioning and efficient polymerization while avoiding the need for joining parts or seals, thus improving production efficiency.
Implementation Method 1
fabrication of such lenses... from a polymerizable material... after polymerization of the material in the mold
Data Source
AI summary
A method includes the following steps: a first shell (12) is immobilized in a first shell carrier (6); a second shell (29) is immobilized in a second shell carrier (27); the first shell carrier (6) is oriented in such a way that a useful moulding surface of the first shell (12) faces upwards and forms the base of a vessel; a pre-determined quantity of polymerizable material is placed in the vessel; the first shell carrier (6) and the second shell carrier (27) are moved into a pre-determined relative position wherein the first shell (12) and the second shell (29) are in a pre-determined moulding position, by at least partially arranging the second shell (29) in the vessel, at a distance from the edges thereof. The inventive device includes a structure for positioning the shell carriers.