Optical Lens Surfacing Data Compensation for Surface Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical lens manufacturing methods suffer from defects such as mean sphere and/or cylinder defects, and polishing ring defects, which affect the precision and accuracy of complex surfaces, particularly in progressive lenses.
Innovation Solution
A method using computer means to determine surfacing data based on lens data and transfer laws to compensate for manufacturing defects introduced by surfacing, polishing, and coating processes, ensuring precise production of lenses with targeted optical functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If digital surfacing or molding methods are used to manufacture optical lenses, then production efficiency is improved, but surface defects such as mean sphere defects, cylinder defects, and polishing ring defects are introduced
Solution Approach 1:
The patent applies preliminary action by determining transfer laws before the actual manufacturing process. The computer means calculates compensation values in advance based on the selected manufacturing method (molding or digital surfacing), and these compensation values are integrated into the surfacing data before production begins. This pre-compensation approach allows the manufacturing process to proceed efficiently while the precision issues are addressed through预先 calculated corrections.
Solution Approach 2:
The patent changes parameters by modifying the surfacing data with compensation values. The computer means adjusts the optical surface parameters (such as sagitta, curvature, or aspheric coefficients) based on the transfer law that models the manufacturing-induced defects. This parameter transformation allows the final optical surface to achieve the desired precision despite the inherent defects of the manufacturing method used.
2Manufacturing precision
If polishing is applied to correct surface defects, then surface precision is improved, but polishing ring defects and time consumption increase
Solution Approach 1:
The patent eliminates the need for corrective polishing by performing the compensation action preliminarily through computer calculation. The transfer law models the polishing process effects and calculates the exact compensation values needed before manufacturing. This pre-compensation replaces the traditional post-manufacturing polishing step, thereby eliminating polishing ring defects and reducing time consumption while maintaining high surface precision.
Solution Approach 2:
The patent substitutes the mechanical polishing process with a computational approach. Instead of using mechanical polishing to correct defects after manufacturing, the system uses computer means to calculate transfer laws and modify the surfacing data accordingly. This replacement of mechanical correction with computational prediction eliminates the harmful side effects of polishing (such as polishing rings) while achieving the same precision improvement.
3Adaptability or versatility
If complex surfaces with multiple optical elements are manufactured, then optical function is improved, but manufacturing complexity and defect susceptibility increase
Solution Approach 1:
The patent applies universality by creating a multi-functional computer means system that handles various manufacturing methods (molding, digital surfacing), different lens types (progressive lenses, ophthalmic lenses), and multiple optical elements within a single integrated platform. The transfer law methodology is universally applicable across all these different scenarios, providing a unified approach to compensate for manufacturing defects regardless of the specific manufacturing method or lens complexity.
Solution Approach 2:
The patent manages manufacturing complexity by systematically transforming parameters through the transfer law. The computer means takes the complex multi-element surface design parameters and automatically calculates the corresponding compensation values based on the selected manufacturing method. This automated parameter transformation process handles the complexity of multi-element surfaces without requiring manual intervention for each element, thereby maintaining adaptability while controlling manufacturing complexity.
Data Source
AI summary
Disclosed is a method implemented by a computer for determining surfacing data to obtain a surface of a lens element, the surface of the lens element including: a refraction area having a first curvature; and multiple optical elements placed on at least part of the finished optical surface, each optical element having at least a second curvature.