Stabilized Thin Lens Perimeter Flange Design
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Solution Overview
Problem
Thin polymeric optical lenses, especially polarized ones, tend to warp or deform after being removed from the mold due to the stress of regaining their un-stretched form, leading to unacceptable shapes and requiring longer cooling times in the mold to stabilize them, which decreases production throughput.
Innovation Solution
Forming a flange around the perimeter of the thin polymeric lens to maintain its intended geometry and shape, which can be made from various polymeric materials and may include functional films or laminates, and can be symmetric or asymmetric in design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the molded lens is cooled for increased amounts of time to achieve increased lens stability, then the lens stability is improved, but the production throughput is decreased
Solution Approach 1:
The flange is formed during the molding process itself, before the lens is removed from the mold. This preliminary structural preparation provides immediate stabilization support, eliminating the need for extended cooling periods and maintaining high production throughput while ensuring lens stability.
Solution Approach 2:
The lens structure is segmented into two functional parts: the optical lens portion and the stabilizing flange portion. The flange acts as a separate stabilizing element that prevents warping without interfering with the optical properties of the lens, allowing simultaneous achievement of stability and production efficiency.
2Weight of moving object
If the lens is made thinner to reduce weight and improve aesthetics, then the weight and thickness are reduced, but the lens becomes more prone to warping and deformation
Solution Approach 1:
The solution moves from two-dimensional lens thickness optimization to three-dimensional structural design by adding the flange. This dimensional transition provides stability through spatial distribution of material rather than relying solely on increased thickness, maintaining weight reduction while preventing warping.
Solution Approach 2:
The flange acts as a thin stabilizing structure that provides rigidity and prevents warping without significantly increasing the overall weight. This thin-film approach maintains the lightweight characteristic while adding necessary structural support against deformation forces.
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 flange effectively stabilizes the lens, preventing deformation and maintaining the intended shape without compromising production efficiency, allowing for consistent and market-acceptable lens production.
Implementation Method 1
the formation of a flange around all or a portion of a perimeter of the thin lens
Data Source
AI summary
A thin ophthalmic lens stabilized through incorporation of flange around all or a portion of a perimeter of the thin lens.