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307 views4 pagesLens Manufacturing Process
The lens manufacturing process includes generating the lens surfaces from a block of glass or optics through processes such as generating, honing, and polishing. Lenses can be manufactured individually or in series using automated processes. Common materials include mineral glass and organic plastics such as CR-39 and polycarbonate.
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0% found this document useful (0 votes)
307 views4 pagesLens Manufacturing Process
The lens manufacturing process includes generating the lens surfaces from a block of glass or optics through processes such as generating, honing, and polishing. Lenses can be manufactured individually or in series using automated processes. Common materials include mineral glass and organic plastics such as CR-39 and polycarbonate.
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LENS MANUFACTURING PROCESS.
The surfaces that delimit the ophthalmic lenses are characterized by their
geometry and roughness.
The manufacturer, starting from a block of glass, must obtain a certain
surface on each of its faces to obtain the finished lens.
Custom lens manufacturing steps.
Starting from a block.
1. Choosing the block and necessary tools: The most suitable block
and molds are chosen for refining and polishing each surface.
2. Generation of the previous surface: It consists of four stages:
clamping, generated, refined and polished.
3. Control: The sagitta of the first surface and the thickness of the
center are controlled.
4. Back surface generation: It consists of four stages: clamping,
generating, refining and polishing.
5. Control: Control the quality of the surfaces and the mass.
6. Packaging and storage.
Starting from a semi-finished product.
1. Choosing the semi-finished product and necessary tools: The most
suitable semi-finished product and the molds for refining and
polishing the posterior surface are chosen.
2. Back surface generation: It consists of four stages: clamping,
generating, refining and polishing.
3. Control: Control of the quality of the surfaces and the mass.
4. Packaging and storage.
□ Locked.
Its objective is to adapt a supplement to the glass block that allows it to be
held in the machines of each of the stages to follow to obtain an optical
surface.
To proceed with blocking, the surface opposite the one to be worked on is
covered with a lacquer, which improves its adhesion while protecting it
from possible attacks that could deteriorate it. In the central part, this
cylinder has a through hole through which the center thickness of the lens
can be measured. In the upper part of the supplement there are the
necessary anchors for adapting the set to the different machines.
Unlocking is achieved by submerging the assembly in a thermostated
container, with water at a temperature greater than 80°C, the supplement
separates from the glass and settles at the bottom of the container,
allowing it to be used again.
□ Generated.
Its objective is to ensure that the surface has a radius of curvature equal to
the desired one, as well as to make the surface uniform.
The procedure is the removal of material by mechanical means, carried out
using generators. The process time depends on the difference in curves
between the surface of the glass block and the desired surface, as well as
the hardness of the material to be worked on and the effectiveness of the
cutting tool incorporated into the generator.
In the current market, the most modern generators are machines equipped
with numerical control (CNC), which allow the generation of all types of
revolution and non-revolution surfaces, thus allowing any type of surface
used in ophthalmic lenses to be obtained. .
□ Tuned up.
Its objective is to ensure that the radius of curvature of the surface is
exactly what is desired, in addition to reducing surface roughness.
It consists of removing material by mechanical means, which is achieved
by friction between the surface to be refined and a mold. The process time
ranges between 10 and 30 seconds, depending on several factors, such as
the difference between the radius of the glass surface and that of the mold,
the average surface roughness before finishing, the working pressure and
the type of abrasive as the most significant factors.
□ Polished.
Its objective is to reduce the average surface roughness and maintain the
radius of curvature obtained in the refinement.
There are different mechanisms such as the mechanical effect of material
drag that uniformizes the surface, as well as the local rise in temperature,
which reduces the viscosity of the glass, which favors this material drag.
This process is carried out in machines identical to those used in refining,
using other types of molds and abrasives.
OBTAINING A MINERAL LENS.
Currently, the manufacture of semi-finished lenses is becoming
established, in which the convex surface has been generated, refined and
polished, and the concave surface has been left raw, as well as a certain
thickness of center and diameter, which are subjected to a control of
parameters and surface quality before being stored. Semi-finished lenses
and some completely finished lenses are manufactured in batches in
which the number of identical lenses is high, and the set of processes and
operations necessary to obtain them is called serial manufacturing.
Manufacturers have chosen to stock a large number of semi-finished
lenses, in which only the first surface has been finished. When you receive
an order, if you don't own the lens
finished in the warehouse, choose the optimal semi-finished product from
those stored and work the second surface until you obtain the desired
fully finished lens. In extreme cases, the lens will be made from a block of
glass. This type of manufacturing is called custom manufacturing, it must
be able to generate, refine and polish any geometry, therefore versatility
will be one of the essential requirements, with process time coming in
second place.
Serial lens manufacturing steps.
Finished:
1. Choosing lens design: A computer system sets the lens parameters.
2. Choosing the block and necessary tools: The appropriate block and
molds are chosen for refining and polishing each surface.
3. Machinery preparation: Stepped, fast and
automated.
4. Generation of the previous surface: It consists of four stages:
clamping, generated, refined and polished.
5. Control: Sampled.
6. Back surface generation: It consists of four stages: clamping,
generating, refining and polishing.
7. Control: Control the quality of the surfaces and the mass.
8. Packaging and storage.
Semi-finished:
1. Definition of the geometry of the semi-finished product: Determine
the radius of the previous surface and thickness.
2. Choosing the block and necessary tools: The appropriate block and
molds are chosen for refining and polishing.
3. Machinery preparation: Stepped, fast and
automated.
4. Generation of the previous surface: It consists of four stages:
clamping, generated, refined and polished.
5. Control: Unitary.
6. Packaging and storage.
ORGANIC MATERIALS.
The materials we call organic or plastic are the product of the
polymerization of chains that basically contain carbon, hydrogen and
oxygen.
The most important are:
diallylglycol carbonate (CR-39) of n=1,498
polycarbonate (PC) of n=1,585
Currently, a wide variety of organic materials with higher indexes are being
developed that allows them to compete with mineral products.
Properties:
Advantages.
They have a lower refractive index than minerals.
The high index ones are as dispersive as the flint material.
Although the refractive index varies, the variation in density is almost
negligible.
They are better conductors of heat.
Great shock resistance (low fragility).
Resistant to chemical agents and due to their internal structure they are
very easy to color and bleach.
Disadvantages.
The little hardness, which makes them scratch very easily.
MANUFACTURING PROCESS OF ORGANIC LENSES IN SERIES.
1. Calculation of lens parameters: Using computer support, the
parameters of the lens to be manufactured are calculated.
2. Choosing and preparing the appropriate mold: From the design, the
parameters of the mold necessary to manufacture the lens are
defined.
3. Preparation of the mixture to be polymerized: Basically made up of
two products, the monomer and the catalyst and must
stored at low temperature.
4. Mold filling: HE takes place in a white room. He
Prepolymer is introduced into the mold at low pressure and at room
temperature, through the hole in the plastic ring through which the
air from inside the mold is evacuated and is subsequently shaken to
eliminate air bubbles.
5. Polymerization: It is carried out in a water bath at about 40 ° C for 12
hours, after this time the temperature is raised to 97 ° C for 1 hour.
6. Demolding: It consists of removing the lens from inside the mold,
avoiding scratching the surface or chipping the edges of the glass
blocks.
7. Annealing: Eliminates stress on the lens.
8. Final control: Both its surfaces and the mass are inspected to detect
any possible defects and then the parameters are controlled.
