Removable Overlay for Optical Element Blocking Alignment
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Solution Overview
Problem
Existing methods for blocking semi-finished optical elements, such as ophthalmic lenses, face challenges in providing consistent and efficient attachment for surfacing operations, particularly when the finished face has a different shape than the blocking device, leading to suboptimal alignment and stiffness support.
Innovation Solution
A system comprising a semi-finished optical element, a blocking device with an axisymmetric contact face, and a removable overlay of rigid material that can change configurations to align with both the blocking device and the optical element, allowing for adjustable stiffness support and efficient attachment, even when the optical element's shape differs from the blocking device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a blocking device is directly attached to the finished face of the semi-finished optical element, then the attachment process is simplified, but alignment accuracy and stiffness support deteriorate when the shapes differ
Solution Approach 1:
The patent introduces a removable overlay as an intermediary component between the blocking device and the semi-finished optical element. The overlay has a first face that conforms to the finished face of the optical element and a second face that interfaces with the blocking device. This mediator enables accurate alignment and stiff support even when the shapes of the optical element and blocking device differ, while keeping the attachment process relatively simple.
2Manufacturing precision
If a removable overlay is introduced to improve alignment and stiffness support, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The removable overlay serves as a mediator that can be pre-formed and then attached to the optical element. It provides the necessary alignment and stiffness support without requiring complex integration into the blocking device itself. The overlay can be removed after use, allowing the blocking device to be reused with different optical elements.
Solution Approach 2:
The overlay can be pre-formed to match the specific geometry of the optical element's finished face before attachment. This preliminary preparation ensures that when the blocking device is attached via the overlay, optimal alignment and stiffness are achieved without adding complexity to the blocking device design.
3Manufacturing precision
If the blocking device is designed to match the finished face shape, then alignment accuracy improves, but adaptability deteriorates when dealing with different optical element shapes
Solution Approach 1:
The removable overlay acts as an adaptable intermediary that can be customized for different optical element shapes. Instead of redesigning the blocking device for each shape, the overlay can be pre-formed to match various finished face geometries, enabling the same blocking device to work with different optical elements while maintaining high alignment accuracy.
Solution Approach 2:
The blocking device is designed with a universal interface (the second face of the overlay) that can accommodate multiple optical element shapes through different overlay configurations. This makes the blocking device multi-functional and adaptable to various applications without sacrificing alignment precision.
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 solution enhances the alignment and stiffness support for surfacing operations, reducing deformation and material waste by allowing the removable overlay to adjust its thickness and shape to match the optical element, thereby improving the accuracy and efficiency of the surfacing process.
Implementation Method 1
The removable overlay is made of a material having a moldable state above ambient temperature and a rigid state at ambient temperature, and said method includes the step of warming said material to reach said moldable state and casting said removable overlay in said moldable state and leaving said removable overlay to cool so as to become rigid
Implementation Method 2
said retaining effect is vacuum-based and the blocking device includes a rigid part and a flexible non-skid wafer covering said rigid part on one side and forming said contact face on the side opposite to said one side
Implementation Method 3
an adhesive film is interposed between the semi-finished optical element and the removable overlay, said adhesive film having an adhesive face attached to the first face of the semi-finished optical element
Data Source
AI summary
A set includes a molding device having a molding face having the same shape as a contact face of the blocking device. A removable overlay of rigid material has a first face attached to a first face of the semi-finished optical element and a second face opposite to the first face having the same shape as the contact face of the blocking device, the set being configured for having a first subset configuration in which the second face of the removable overlay is in molding contact with the molding face of the molding device, then a second subset configuration in which the second face of the removable overlay is free and then a third subset configuration in which the second face of the removable overlay is retained in contact with the contact face of the blocking device.