Coated Spectacle Lens Structuring with a Digital Twin
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Solution Overview
Problem
Existing methods for structuring spectacle lenses require masking layers or local melting of materials, which can be inefficient and limited in their ability to create specific optical elements with precise dimensions and powers.
Innovation Solution
A digital twin of a coated spectacle lens is created using a computer, providing a mathematical description of the lens surfaces and structures, allowing for precise manufacturing of optical elements without the need for masking layers or local melting, using laser process parameters to achieve predefined structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If masking layers or local melting methods are used to structure spectacle lenses, then optical elements can be formed on the lens surface, but the manufacturing process becomes inefficient and limited in creating precise optical elements
Solution Approach 1:
The patent replaces mechanical masking and melting processes with a digital modeling and direct manufacturing approach. A digital twin of the coated spectacle lens is created using computer-based mathematical descriptions of lens surfaces and structures, which then guides the manufacturing process to directly produce the desired optical elements without physical masking layers or localized melting, thereby improving both precision and efficiency
Solution Approach 2:
The patent performs preliminary digital modeling and simulation by creating a complete digital twin of the coated spectacle lens before actual manufacturing. This includes pre-defining all lens surfaces, coating layers, and optical element structures in a virtual environment, allowing for optimization and verification before production, which eliminates the need for iterative masking and melting adjustments during manufacturing
2Adaptability or versatility
If masking layers are used to create specific optical elements, then structured lens surfaces can be achieved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The patent creates a digital copy or digital twin of the coated spectacle lens that contains all the information about lens surfaces, coating layers, and optical element structures. This digital model serves as a virtual blueprint that can be modified and optimized without affecting the physical lens, allowing for high adaptability in designing specific optical elements while keeping the actual manufacturing process simple and direct
Solution Approach 2:
The digital twin methodology serves multiple functions simultaneously: it acts as a design tool, a simulation environment, a manufacturing guide, and a verification system. This single digital model replaces multiple separate manufacturing steps and tools that would otherwise be needed to create and verify optical elements, reducing overall process complexity while maintaining versatility
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 method enables the efficient and precise manufacturing of spectacle lenses with various optical elements, such as lenslets, discrete optical elements, and light modulating cells, by directly translating the digital twin into physical reality, ensuring accurate dimensions and powers.
Implementation Method 1
selectively curing a coating composition by means of laser radiation
Implementation Method 2
applying the determined laser process parameters to said uncured coating composition(s)
Data Source
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AI summary
The invention is directed to a method configured designing a digital twin of a coated spectacle lens by means of a computer for the purpose of a use of the digital twin for manufacturing the coated spectacle lens, and to a method for manufacturing a coated spectacle lens.