Universal Lens Blank with Zeroed Reference Light-Filtering Layer
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Solution Overview
Problem
Optical labs face challenges in efficiently filling progressive power spectacle lens prescriptions due to the need for a variety of semi-finished lens blanks, leading to inventory management issues and delayed patient care.
Innovation Solution
A universal lens blank system with a first and second light-transmitting layer and one or more light-filtering layers, where the position of the light-filtering layers is determined and positioned at a zeroed reference on a coordinate axis, allowing for shaping instructions to prevent intersection with these layers, enabling the use of a reduced inventory and facilitating the production of semi-finished or finished lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If optical labs maintain a variety of semi-finished lens blanks with different base curves and add powers, then the ability to fill diverse progressive power prescriptions is improved, but inventory complexity and storage requirements increase
Solution Approach 1:
The patent applies universality by creating a single universal lens blank that can serve multiple functions for different progressive power prescriptions. The blank includes a light-filtering layer positioned at a specific depth that can accommodate various base curves and add powers through digital surfacing, eliminating the need for multiple specialized blanks. This multi-functional design allows one blank type to replace many traditional blank variants.
Solution Approach 2:
The patent utilizes parameter changes by varying the positioning and optical properties of the light-filtering layer within the universal blank to achieve different prescription outcomes. By adjusting the depth position of the light-filtering layer and applying different digital surfacing parameters, the same physical blank can produce lenses with different base curves, add powers, and optical characteristics, thereby reducing inventory while maintaining versatility.
2Adaptability or versatility
If optical labs maintain a variety of semi-finished lens blanks, then the range of applicable base curves and add powers is improved, but the time to select and prepare the correct blank increases
Solution Approach 1:
The universal lens blank eliminates the need for time-consuming selection processes by being applicable to all progressive power prescriptions. The single blank design with programmable light-filtering layer positioning allows any prescription to be accommodated, reducing the selection time from searching through multiple blank types to simply loading the universal blank and configuring the digital surfacing parameters.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the light-filtering layer at an optimal depth within the universal blank during manufacturing. This preliminary configuration, combined with digital surfacing capabilities, allows the blank to be rapidly adapted to specific prescriptions without requiring time-consuming manual measurement and adjustment, thereby reducing preparation time while maintaining versatility.
3Manufacturing precision
If the light-filtering layer is positioned at a zeroed reference position on the coordinate axis, then the precision of shaping instructions is improved, but the complexity of positioning and alignment increases
Solution Approach 1:
The patent introduces a coordinate system with a zeroed reference position as an intermediary framework for positioning the light-filtering layer. This standardized reference frame acts as a mediator between the digital surfacing instructions and the physical blank, enabling precise positioning through software control without requiring complex mechanical alignment mechanisms. The zeroed position serves as a common reference point that simplifies the control system.
Solution Approach 2:
The patent replaces complex mechanical positioning and alignment systems with digital control methods. By using a coordinate-based reference system and software-driven surfacing instructions, the patent eliminates the need for manual measurement tools, physical alignment fixtures, and mechanical adjustment mechanisms, thereby achieving high precision through computational methods rather than mechanical complexity.
Data Source
Figure 1
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Figure 2C~2C(vi)
AI summary
Systems and processes for generating a finished or semi-finished lens, such as a spectacle lens, from a lens blank that comprises an intermediate functional layer. Some embodiments, of the process involve locating the functional layer and positioning the lens blank according to the location of the functional layer. The location of the functional layer can be ascertained by measuring the thickness of one or more layers of the lens blank. The lens blank can be surfaced on one or both sides to form a finished or semi-finished lens. Other embodiments are also described.