Design build test cycle reduction

• US 7,123,985 B2
• Filed: 04/10/2003
• Issued: 10/17/2006
• Est. Priority Date: 04/12/2002
• Status: Expired due to Fees

• Current Assignee: Johnson & Johnson Vision Care Incorporated (Johnson & Johnson)
• Original Assignee: Johnson & Johnson Vision Care Incorporated (Johnson & Johnson)
• Inventors: Daniel, Jason, Pinella, David F., Damodharan, Krish, Perez, Jose L., Wildsmith, Christopher, Roy, Jeffrey M., Lust, Victor
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): Rapp, Chad
• Application Number:
  US10/410,802
• Publication Number:
  US 20040075809A1
• Time in Patent Office: 1,286 Days
• Field of Search: 700/197, 700/200, 700/204, 700/182, 264/1.32, 264/25
• US Class Current: 700/197
• CPC Class Codes: G05B 19/4097 characterised by using design data to control NC machines, e.g. CAD/CAM G05B19/4093 takes precedence
• CPC Class Codes: G05B 2219/35028 Adapt design as function of manufacturing merits, features, for manufacturing, DFM
• CPC Class Codes: G05B 2219/45157 Grind optical lens
• CPC Class Codes: G05B 2219/49008 Making 3-D object with model in computer memory
• CPC Class Codes: G16H 20/00 ICT specially adapted for therapies or health-improving plans, e.g. for handling prescriptions, for steering therapy or for monitoring patient compliance
• CPC Class Codes: G16H 40/63 for local operation
• CPC Class Codes: G16H 50/50 for simulation or modelling of medical disorders
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An ophthalmic lens design and modeling system comprises a user interface providing functionality for generating a template associated with a desired lens design to be manufactured, the template comprising design information sufficient for generating three-dimensional (3D) models of lens, and 3D models of associated components required for lens manufacture in an ophthalmic lens manufacturing system. The system further includes functionality for generating and/or specifying linking information, via the user interface, that governs the physical behavior of lens design features included in said template in accordance with one or more process parameters affecting lens manufacture and manufacture of associated components in an ophthalmic lens manufacturing system. The use of the template and design and linking information therein thus facilitates rapid lens modeling and lens manufacturing operations with greater accuracy, thereby reducing lens design build and test (DBT) cycle time.

Claims

1. An ophthalmic lens design and modeling system comprising:

a) means for generating a user interface display device providing functionality for generating a template associated with a desired lens design to be manufactured, said template comprising design information sufficient for generating three-dimensional (3D) models of the lens, and 3D models of associated components comprising at least one of;

a lens mold, an insert and a core;

b) means for generating a 3D model of the lens and the associated components;

c) means for receiving data descriptive of a change of a manufacturing process parameter based upon data descriptive of operating conditions of a manufacturing line, said process parameter comprising at least one of;

shrinkage of plastic from an insert and hydration of contact lens monomer;

d) means for generating linking information for governing the lens design information included in said template in accordance with one or more of;

process parameters affecting lens manufacture and parameters affecting manufacture of the associated components;

e) means for modifying design information via the linking information and based upon the data descriptive of a change in a manufacturing process parameter;

f) means for generating a revised 3D model of the lens and the associated components, based upon the modified design information; and

g) means for utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system.

2. The system as claimed in claim 1, further comprising:

a) memory storage means for storing templates that have been generated, said user interface mean is providing functionality for accessing a stored templates;

b) editing means enabling a user to modify one of;

lens, lens mold, mold insert, template design information and linking information provided with a the stored template; and

c) means for automatically generating a new 3D model of a lens, lens mold, and mold insert, each 3D model automatically based upon the modified lens, lens mold, mold insert, template design information or linking information, wherein said memory storage means a catalogue of developed templates that may be accessed and re-used for producing new lens designs.

3. The system as claimed in claim 2, wherein said means generating a user interface display provides functionality for specifying expansion and shrinkage factors associated with manufacture of said lens design as performed by said ophthalmic lens manufacturing system, whereby specified changes to said factors are automatically reflected in resultant 3D models generated.

4. The system as claimed in claim 3, wherein a template further comprises manufacturing data associated with a lens design including machining data and engineering drawings, said manufacturing data available as direct input to an ophthalmic lens manufacturing system for driving the lens manufacturing process necessary to achieve a particular lens design.

5. The system as claimed in claim 4, wherein associated manufacturing components for said lens include one or more lens mold and mold inserts used in lens mold manufacture, said template further comprising manufacturing data for enabling manufacture of one or more lens mold according to lens mold designs associated with a particular lens design, and, manufacture of mold inserts according to mold insert designs, each said lens mold and lens mold design accounting for process parameter variations by specified linking information.

6. The system as claimed in claim 4, wherein said lens design information comprises one or more of:

a text file or electronic data representing an output of a three-dimensional computer aided design (CAD) system.

7. The system as claimed in claim 5, wherein said functionality for generating a template associated with a desired lens via said user interface includes means for importing lens design information into said template, and generating a 3D lens models for visual presentation via said user interface.

8. The system as claimed in claim 5, wherein a 3D CAD/CAM modeling software is Non-Uniform Rational B-Spline (NURB)-based, obviating the need for programmers to write lines of computer code for the lens, lens mold and insert designs, and assemblies.

9. The system as claimed in claim 5, further comprising means for automatically generating manufacturing data from said template, said generated data being directly input to an ophthalmic lens manufacturing system for driving the lens manufacturing and component build process necessary to achieve the associated lens design.

10. An ophthalmic lens design and modeling system comprising:

a) means generating a user interface display device providing functionality for generating a template associated with a desired lens design to be manufactured, said template comprising design information sufficient for generating three-dimensional (3D) models of lens, and 3D models of associated components required for lens manufacture in an ophthalmic lens manufacturing system and wherein said means generating a user interface display device provides functionality for specifying expansion and shrinkage factors associated with manufacture of said lens design as performed by said ophthalmic lens manufacturing system, whereby specified changes to said factors are automatically reflected in resultant 3D models generated, wherein a template comprises manufacturing data associated with a lens design including machining data and engineering drawings, said manufacturing data available as direct input to an ophthalmic lens manufacturing system for driving the lens manufacturing process necessary to achieve a particular lens design and wherein associated manufacturing components for said lens include one or more lens mold and mold inserts used in lens mold manufacture, said template further comprising manufacturing data for enabling manufacture of one or more lens mold according to lens mold designs associated with a particular lens design, and, manufacture of mold inserts according to mold insert designs, each said lens mold and lens mold design accounting for process parameter variations by specified linking information;

b) means generating linking information for governing physical behavior of lens design features included in said template in accordance with one or more process parameters affecting lens manufacture and manufacture of associated components in an ophthalmic lens manufacturing system;

c) means for utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system, wherein use of said template and design and linking information therein facilitates rapid lens modeling and lens manufacturing operations with greater accuracy, thereby reducing lens design build and test (DBT) cycle time, wherein said lens design data comprises one or more of;

text file or an electronic file representing an output of a three-dimensional computer aided design (CAD) system;

d) memory storage means for storing templates that have been generated, said use interface means providing functionality for accessing stored templates; and

e) editing means enabling a user to modify lens, lens mold, mold insert, template design information and linking information provided with a template to create a new lens, lens mold, mold insert, template design, said memory storage means defining a catalogue of developed templates that may be accessed and re-used for producing new lens designs wherein said lens design information comprises one or more equations utilizing process parameters that govern lens manufacturing operating conditions, said equations provided for linking the lens design with the manufacture of a back curve (BC) lens mold;

linking the lens design with the manufacture of a front curve (FC) lens mold; and

, linking the manufacture of a BC and FC lens mold with a resultant physical lens mold assembly, and then the insert pair designs of BC and rear core insert, and FC and front core design;

wherein said lens design information comprises one or more equations utilizing process parameter is that govern lens manufacturing operating conditions, said equations provided for;

linking the lens design with the manufacture of a back curve (BC) lens mold;

linking the lens design with the manufacture of a front curve (FC) lens mold; and

, linking the manufacture of a BC and FC lens mold with a resultant physical lens mold assembly, and then the insert pair designs of BC and rear core insert, and FC and front core design.

11. A method for designing and modeling ophthalmic contact lenses comprising the steps of:

a) generating a user interface display device providing functionality for generating a template associated with a desired lens design to be manufactured, said template comprising design information sufficient for generating three-dimensional (3D) models of lens, and 3D models of associated components comprising at least one of;

a lens mold an insert and a core

b) generating a 3D model of the lens and the associated components;

c) receiving data descriptive of a change of a manufacturing process parameter based upon data descriptive of operating conditions of a manufacturing line, said process parameter comprising at least one of;

shrinkage of plastic from an insert and hydration of contact lens monomer;

d) generating linking information for governing physical behavior of lens design information included in said template in accordance with one or more process parameters affecting lens manufacture and manufacture of associated components in an ophthalmic lens manufacturing system;

e) modifying design information via the linking information and based upon the data descriptive of a change in a manufacturing process parameter;

f) generating a revised 3D model of the lens and the associated components, based upon the modified design information; and

g) utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system.

12. The method as claimed in claim 11, further comprising the steps of:

storing each template that has been generated, said user interface display providing functionality for accessing stored templates;

modifying one of;

lens, lens mold, insert and template design information and linking information provided with a stored template; and

automatically generating a new 3D model of a lens;

lens mold, and mold insert, each 3D model automatically based upon the modified lens, lens mold, mold insert, template design information or linking information, wherein said memory storage means a catalogue of developed templates that may be accessed and re-used for producing new lens designs.

13. The method as claimed in claim 12, wherein said generated user interface display device provides functionality for specifying expansion and shrinkage factors associated with manufacture of said lens design as performed by said ophthalmic lens manufacturing system, whereby specified changes to said factors are automatically reflected in resultant 3D models generated.

14. The method as claimed in claim 13, wherein a template further comprises manufacturing data associated with a lens design, said method including the step of directly inputting manufacturing data available from said template to an ophthalmic lens manufacturing system for driving the lens manufacturing process necessary to achieve a particular lens design.

15. The method as claimed in claim 14, wherein associated manufacturing components for said lens include one or more lens mold and mold inserts used in lens mold manufacture, said method further including:

utilizing manufacturing data in said template for enabling manufacture of one or more lens mold according to lens mold designs associated with a particular lens design, and, manufacture of mold insert according to mold insert designs, each said lens mold and lens mold design accounting for process parameter variations by specified linking information.

16. The method as claimed in claim 14, wherein said lens design information comprises one or more of:

text file or an electronic file representing an output of a three-dimensional computer aided design (CAD) system.

17. The method as claimed in claim 15, wherein said step of generating a template comprises associated with a desired lens via said user interface includes the step of:

importing lens design information into said template, and generating a 3D lens models for visual presentation via said user interface.

18. The method as claimed in claim 15, wherein said user interface display comprises 3D modeling software that is Non-Uniform Rational B-Spline (NURB)-based, obviating the need for programmers to write lines of computer code for the lens, lens mold and insert designs.

19. The method as claimed in claim 15, further including the step of:

automatically generating manufacturing data from said template, said generated data being directly input to an ophthalmic lens manufacturing system for driving the lens manufacturing and associated component build processes necessary to achieve the associated lens design.

20. The method as claimed in claim 19, wherein said manufacturing data available as direct input to an ophthalmic lens manufacturing system includes computer numeric control (CNC) data.

21. The method as claimed in claim 19, wherein said manufacturing data available as direct input to an ophthalmic lens manufacturing system includes M&

G data.

22. A method for designing and modeling ophthalmic contact lenses comprising the steps of:

a) generating a user interface display device providing functionality for generating a template associated with a desired lens design to be manufactured, said template comprising design information sufficient for generating three-dimensional (3D) models of lens, and 3D models of associated components required for lens manufacture in an ophthalmic lens manufacturing system, wherein associated manufacturing components for said lens include one or more lens mold and mold inserts used in lens mold manufacture, said method further including;

utilizing manufacturer data in said template for enabling manufacture of one or more lens mold according to lens mold designs associated with a particular lens design, and, manufacture of mold insert according to mold insert design, each said lens mold and lens mold design accounting for process parameter variations by specified linking information and wherein said generated user interface display device provides functionality for specifying expansion and shrinkage factors associated with manufacture of said design as performed by said ophthalmic lens manufacturing system, whereby specified changes to said factors are automatically reflected in resultant 3D models generated and wherein a template comprises manufacturing data associated with a lens design, said method including the step of directly inputting manufacturing data available from said template to an ophthalmic lens manufacturing system for driving the lens manufacturing process necessary to achieve a particular lens design;

b) generating linking information for governing physical behavior of lens design features included in said template in accordance with one or more process parameters affecting lens manufacture and manufacture of associated components in an ophthalmic lens manufacturing system;

c) utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system, wherein use of said template and design and linking information therein facilitates rapid lens modeling and lens manufacturing operations with greater accuracy, thereby reducing lens design build and test (DBT) cycle time; and

d) storing each template that has been generated, said user interface display providing functionality for accessing stored templates; and

, modifying or editing lens, lens mold, insert and template design information and linking information provided with a template to operate a new lens design, said memory storage means defining a catalogue of developed templates that may be accessed and re-used for producing new lens designs;

wherein said lens design information comprises one or more equations utilizing process parameters that govern lens manufacturing operating conditions, said equations provided for;

linking the lens design with the manufacture of a back curve (BC) lens mold;

linking the lens design with the manufacture of a front curve (FC) lens mold; and

, linking the manufacture of a BC and FC lens mold with a resultant physical lens mold assembly, and then the insert pair designs of BC and rear core insert, and FC and front core design.

23. A program storage device readable by a machine, tangibly embodying a program of instructions executable by the machine to perform method steps for designing and modeling ophthalmic contact lenses, said method comprising the steps of,

a) generating a user interface display device providing functionality for generating a template associated with a desired lens design to be manufactured, said template comprising design information sufficient for generating three-dimensional (3D) models of lens, and 3D models of associated components comprising at least one of:

a lens mold, an insert and core;

b) generating a 3D model of the lens and the associated components;

c) receiving data descriptive of a change of a manufacturing process parameter based upon data descriptive of operating conditions of a manufacturing line, said process parameter comprising at least one of;

shrinkage of plastic from an insert and hydration of contact lens monomer;

generating linking information for governing lens design information included in said template in accordance with one or more process parameters affecting lens manufacture and parameter affecting manufacture of the associated components in an ophthalmic lens manufacturing system;

e) utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system, wherein use of said template and design and linking information therein facilitates rapid lens modeling and lens manufacturing operations with greater accuracy, thereby reducing lens design build and test (DBT) cycle time

e) modifying design information via the linking information and based upon the data descriptive of a change in a manufacturing process parameter;

f) generating a revised 3D model of the lens and the associated components, based upon the modified design information; and

g) utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system.

24. The program storage device readable by a machine as claimed in claim 23, wherein said method further comprises the steps of:

storing each template that has been generated, said user interface display providing functionality for accessing stored template; and

, modifying or editing lens, lens mold, mold insert and template design information and linking information provided with a template to create a new lens, lens mold, mold insert and template design, said memory storage means defining a catalogue of developed templates that may be accessed and re-used for producing new lens designs.

25. The program storage device readable by a machine as claimed in claim 23, wherein said generated user interface display device provides functionality for specifying expansion and shrinkage factors associated with manufacture of said lens design as performed by said ophthalmic lens manufacturing system, whereby specified changes to said factors are automatically reflected in resultant 3D models generated.

26. The program storage device readable by a machine as claimed in claim 25, wherein said method further comprises the step of:

automatically generating manufacturing data from said template, said generated data functioning as direct input to an ophthalmic lens manufacturing system for driving the lens manufacturing and associated component build processes necessary to achieve the associated lens design.

27. The program storage device readable by a machine as claimed in claim 26, wherein said associated manufacturing components for said lens one or more lens mold and mold inserts used in lens mold manufacture, said method further including:

utilizing said generated manufacturing data to enable manufacture of one or more lens molds according to lens mold designs associated with a particular lens design, and, manufacture of mold inserts according to mold insert designs, each said lens mold and lens mold design accounting for process parameter variations by specified linking information.

28. An ophthalmic lens design system comprising

a) means generating a user interface display device providing functionality for designing an ophthalmic contact lens and associated components required for manufacture of that lens by an ophthalmic lens manufacturing system and generating design information that is stored in a database accessible by a user via said interface;

b) means for automatically generating a three-dimensional (3D) model of said ophthalmic contact lens and models of each of associated components required for manufacture of that lens, and displaying said 3D model via said user interface;

c) means for manipulating said 3D models via said user interface for modifying lens design features and features of associated components required for manufacture of that lens design as required for optimizing said lens design;

d) means for automatically updating design information of the lens and the all of associated components based upon the manipulation of a 3-D model of one or more of the lens and the components;

d) means for generating lens design data and data governing design of associated components thereof for storage in said database, and automatically updating data as said 3D models of said lens design and associated components are manipulated by said user; and

,

e) means capable of automatically generating manufacturing data from said stored data, said generated data functioning as direct input to said ophthalmic lens manufacturing system for driving the lens manufacturing and associated component build processes necessary to achieve the associated lens design, wherein modeling and lens manufacturing operations are performed with greater accuracy in less time.

29. The system as claimed in claim 28, further comprising:

means for generating linking information governing physical behavior of lens design features in accordance with one or more process parameters affecting lens manufacture and manufacture of said associated components in said ophthalmic lens manufacturing system.

30. The system as claimed in claim 29, wherein said associated components include:

lens mold and mold insert associated with manufacture of a particular lens design.

31. The system as claimed in claim 30, further comprising means for generating a template structure for receiving said lens design and linking information required to create a lens and associated lens mold and mold inserts and, storing said templates in said database means, wherein a plurality of developed templates are stored for user access and may be re-used for generating new lens designs.

32. The system as claimed in claim 31, wherein said means generating a user interface display device provides functionality for specifying expansion and shrinkage factors associated with manufacture of said lens design as performed by said ophthalmic lens manufacturing system, whereby specified changes to said factors are automatically reflected in resultant 3D models generated.

33. The system as claimed in claim 32, further comprising means for automatically generating manufacturing data from said template, said generated data functioning as direct input to an ophthalmic lens manufacturing system for driving the lens manufacturing and associated component build processes necessary to achieve the associated lens design.

34. The system as claimed in claim 33, wherein said associated manufacturing components far said lens include one or more lens mold and mold inserts used in lens mold manufacture, said method further including:

utilizing said generated manufacturing data to enable manufacture of one or more lens molds according to lens mold designs associated with a particular lens design, and, manufacture of mold inserts according to mold insert designs, each said lens mold and lens mold design accounting for process parameter variations by specified linking information.