Universal Blocker Support for Optical Lamination
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Solution Overview
Problem
The repetitive blocking and deblocking operations in the manufacturing of optical articles are time-consuming and prone to defects and errors during the surfacing and lamination steps, particularly due to the need for separate blockers for surfacing and lamination processes.
Innovation Solution
A lamination machine with an article support that can receive and transmit laminating forces to a surfacing blocker, allowing the same blocker to be used for both surfacing and lamination steps, eliminating the need for additional blockers and reducing operator handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate blockers are used for surfacing and lamination steps, then each process can be optimized independently, but the number of blocking and deblocking operations increases, leading to more time-consuming manual handling and higher risk of defects
Solution Approach 1:
The blocker is designed with a universal interface that can be used for both surfacing and lamination operations. The blocker support structure includes a bearing surface that can receive and securely hold the blocker during different manufacturing steps, eliminating the need for separate blockers for each process while maintaining process optimization
Solution Approach 2:
The patent merges the function of multiple blockers into a single universal blocker that can serve both surfacing and lamination purposes. By combining these functions into one component, the number of blocking operations is reduced, manual handling is minimized, and the risk of defects from repeated blocking/deblocking is lowered
2Productivity
If the same blocker is used for both surfacing and lamination, then the number of handlings is reduced and manufacturing time is shortened, but the blocker must be designed to withstand and transmit lamination forces
Solution Approach 1:
The blocker is pre-designed and pre-configured with the necessary structural strength and bearing surfaces to handle both surfacing and lamination forces. The blocker support structure is prepared in advance with appropriate bearing surfaces that can transmit lamination forces effectively, eliminating the need for additional strengthening modifications later
Solution Approach 2:
The blocker design incorporates parameter changes to accommodate different force requirements. The bearing surface geometry and material properties are optimized to transmit both surfacing forces and lamination forces effectively. The blocker support structure parameters are adjusted to provide appropriate support during different operational phases
Data Source
AI summary
Disclosed is a lamination machine including: a film support for receiving a functional film to be laminated; an article support configured to receive and position the optical article in a predetermined orientation; and an actuating member configured to move the film support and the article support toward each other for laminating at a predetermined pressure the functional film received in the film support onto the optical article received within the article support. The article support is a blocker support configured to receive a surfacing blocker onto which the optical article is to be disposed for lamination, the article support being further configured to transmit laminating forces induced by the predetermined pressure to the lamination machine during a lamination operation.