Universal Contact Lens Mold for Mixed-Parameter Production
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Solution Overview
Problem
The existing methods for mass-producing contact lenses with different parameters on a closed loop production line require a large number of molds, leading to logistical challenges and time-consuming refitting of the production line to accommodate varying lens types, resulting in production line stops and inefficiencies.
Innovation Solution
A method where reusable molds with lens identification codes are transported sequentially through treatment stations, allowing any mold type to be placed on any position, enabling the simultaneous manufacture of lenses with different parameters without the need for a fixed number of molds, and the codes are either physically embedded on the lenses or managed virtually to ensure accurate identification and sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of different molds are provided to manufacture contact lenses with different parameters, then the production line can produce a variety of lens types, but the number of molds increases significantly, leading to logistical challenges and increased maintenance effort
Solution Approach 1:
A single universal mold design is used that can manufacture multiple types of contact lenses with different parameters by changing the lens forming material and UV masking patterns, eliminating the need for multiple specialized molds
Solution Approach 2:
The mold is designed with adjustable parameters including variable UV masking patterns and different lens forming material compositions that can be changed to produce lenses with different refraction powers, base curves, and other parameters
2Adaptability or versatility
If the production line is refitted to accommodate different lens types, then the correct lens parameters can be produced, but the refitting process is time-consuming and labor-intensive, requiring production line stops
Solution Approach 1:
The mold is pre-designed with multiple UV masking patterns and lens forming material configurations that can be quickly swapped without physical refitting, allowing changeovers to be performed while the production line remains operational
Solution Approach 2:
The production line is designed with dynamic adjustability where UV masking patterns and lens forming materials can be changed during operation without stopping the production line, enabling continuous manufacturing of different lens types
3Reliability
If multiple molds are held in stock to ensure continuous production, then production can continue without interruption, but the logistics of handling and maintaining optimal condition of numerous molds requires considerable effort
Solution Approach 1:
A single universal mold replaces multiple specialized molds, dramatically reducing the number of items that need to be stored, handled, and maintained while ensuring continuous production capability
4Productivity
If a fixed number of molds are required for each parameter corresponding to the number of worktrays, then continuous cyclic manufacture is ensured, but the number of molds becomes very large when considering up to 50 different parameters and up to 38 worktrays
Solution Approach 1:
One universal mold can be used across all worktrays for producing different lens types, eliminating the need for separate molds for each parameter and worktray combination
Solution Approach 2:
The production system is segmented into worktrays that can independently use the same universal mold, allowing continuous cyclic manufacture without requiring duplicate molds for each worktray
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 approach reduces the number of molds required, allows continuous production without refitting, and prevents mix-ups of lens types, enabling the production line to efficiently meet market demands for various lens types without labor-intensive adjustments.
Implementation Method 1
the starting material is polymerized and/or cross-linked with ultraviolet (UV) light
Data Source
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AI summary
There is described a method for the simultaneous manufacture of contact lenses having different lens parameters on the same production line, where a number of molds, each comprising male and female mold halves, are transported in sequential rows of and in each row in side by side configuration through a series of treatment stations, which are arranged sequentially along a production line, in which lenses of specific parameters are manufactured from a lens forming material. During manufacture each lens is associated with a lens identification code. There is also described a closed cycle production line for carrying out the method.