Print Pad with Segmented Curvature for Concave Lens Mold Printing
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Solution Overview
Problem
Existing print pads with spherical tips fail to apply print evenly across the concave surface of contact lens molds, causing distortion and uneven printing, especially at the outer edges.
Innovation Solution
A print pad with a unique configuration featuring a nearly spherical tip section, diverging midsections, and a frustoconical base, allowing for uniform axial deflection and even printing on concave surfaces without side divergence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a spherical tip configuration is used, then the print pad can successfully apply print to the center of the concave mold, but it cannot apply printing to the outer edges without causing distortion
Solution Approach 1:
The print pad is segmented into multiple functional zones along its longitudinal axis: a spherical tip section for center contact, a first midsection with intermediate curvature for transition, and a second midsection with smaller curvature for outer edge coverage. Each segment is optimized for specific regions of the concave mold surface, enabling comprehensive coverage without distortion.
Solution Approach 2:
Different sections of the print pad have different geometric properties tailored to their specific functions. The tip section has a larger radius of curvature for gentle center contact, while the second midsection has a smaller radius of curvature to reach the outer edges of the concave mold, ensuring each region prints with appropriate pressure and contact.
2Adaptability or versatility
If the print pad diverges radially outwardly when force is applied, then it can contact the outer edges of the mold, but it does not print evenly around the outer circumference
Solution Approach 1:
The print pad features an asymmetric longitudinal profile with differently curved sections. The first midsection has a larger radius of curvature that transitions smoothly from the spherical tip, while the second midsection has a smaller radius of curvature that enables radial divergence to contact outer edges. This asymmetric design allows controlled divergence without compromising printing uniformity.
3Device complexity
If a spherical forward end is used, then the structure is simple, but it cannot maintain linear axial compression when force is applied to the concave mold
Solution Approach 1:
The print pad incorporates a dynamic longitudinal profile with multiple curved sections that adapt during compression. As axial force is applied, the different curvature sections engage sequentially, allowing the pad to maintain linear compression behavior while adapting to the concave mold geometry. The transition between sections ensures smooth deformation without buckling or lateral divergence.
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
The print pad ensures even and distortion-free printing across the entire concave surface of contact lens molds, maintaining print quality and preventing smearing.
Implementation Method 1
A print pad that is capable of printing such a design onto the convex surface of a mold for manufacturing a contact lens must be capable of deforming so as to contact the entire inner surface of the concave mold
Data Source
AI summary
A print pad has a nearly spherical tip section having a first radius. A partially spherical first midsection is behind the tip section, the first midsection having a radius less that the radius of the tip section. A frustoconical second midsection is behind the first midsection. A bell shaped third midsection is behind the second midsection, and a frustoconical base is behind the third midsection.