Rotary Workpiece Turret for Unblocked Spectacle Lens Processing

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Solution Overview

Problem

Current methods for processing spectacle lens blanks are time-consuming, economically inefficient, and result in significant waste and optical quality degradation due to the use of heavy metals and UV-curing bonding agents, as well as the need for blocking procedures that alter the lens geometry and require extensive downstream processing.

Innovation Solution

The equipment features a rotatable workpiece turret with multiple receptacles of different surface curvatures, allowing for direct processing of lens blanks without blocking, minimizing material waste, and enabling high-precision finishing of spectacle lenses with reduced thickness and improved optical quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If blocking procedure is used to affix lens blanks to block elements, then lens blanks can be clamped and processed, but processing time increases and economic efficiency decreases

Engineering Contradiction:

Improveclamping capabilityVSAvoidprocessing time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The invention extracts and eliminates the blocking procedure from the processing workflow. Instead of affixing lens blanks to block elements, the patent uses specialized clamping devices that directly secure the lens blanks, removing the time-consuming blocking step while maintaining clamping capability for edge zone processing

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The clamping devices are designed with pre-configured clamping mechanisms that can directly secure lens blanks without requiring prior blocking. The devices incorporate adjustable clamping elements that can adapt to different lens blank sizes and shapes, enabling immediate clamping and processing

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If blocking procedure is used with heavy metal or UV-curing bonding agents, then lens blanks can be secured for processing, but material waste increases significantly

Engineering Contradiction:

Improveclamping capabilityVSAvoidmaterial waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The invention removes the blocking procedure entirely from the manufacturing process. The clamping devices use mechanical clamping mechanisms that do not require consumable bonding materials, thereby eliminating the significant material waste associated with heavy metals and UV-curing agents

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using expensive and environmentally harmful disposable bonding materials, the patent employs reusable clamping devices that can be used multiple times without degradation, eliminating both cost and waste issues associated with single-use bonding agents

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If blocking procedure is used with heat application, then lens blanks can be secured for processing, but optically effective surfaces degrade

Engineering Contradiction:

Improveclamping capabilityVSAvoidoptical surface quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention eliminates the heat application step from the blocking procedure. The clamping devices use mechanical clamping at ambient temperatures, thereby preventing thermal degradation of the optically effective surfaces while still providing secure clamping for processing

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the thermal/chemical blocking system with a purely mechanical clamping system. The clamping devices incorporate adjustable mechanical elements that secure lens blanks through physical contact and friction, eliminating the need for heat application and associated surface degradation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If blocking procedure is used, then lens blanks can be processed, but downstream processing complexity and costs increase due to individual shaping

Engineering Contradiction:

Improveclamping capabilityVSAvoiddownstream processing complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The clamping devices are designed as universal fixtures that can accommodate various lens blank sizes, shapes, and orientations without requiring custom blocking for each individual blank. This multi-functionality simplifies downstream processing by eliminating the need for specialized handling equipment for individually shaped blanks

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9751171B2Method to process spectacle lens blanks

Publication Date: 2017.09.05 OPTOTECH OPTIKMASCHINEN GMBH

AI summary

Manufacturing spectacle lenses using lens blanks blocked onto holding elements is laborious and time-consuming. Furthermore the manufacture is rendered difficult by different surface curvatures on the receiving side of the lens blanks. The purpose of the invention is to remedy such drawbacks. Accordingly this invention relates to equipment for processing lens blanks comprising a workpiece turret supported rotatably about a main axis of rotation, said turret being fitted with at least two workpiece receptacles configured each outside the main axis of rotation and being rotatable about spindle axes, each workpiece receptacle comprising a workpiece receiving surface having a surface curvature rotationally symmetrical about the spindle axis, whereby said surface curvatures of the workpiece receiving surfaces being different from each other.