Abstract:
A method and system for enhanced demolding of injection molded optical devices are disclosed. In one embodiment the system includes a metal moldplate without a coat of release layer and a curing device that generates high intensity pulses of UV light. The method includes: providing a moldplate made of a predetermined moldplate material; directly injecting optical material into cavities of a moldplate without a release layer; rapidly curing the injected optical material with high intensity pulses of UV light such that a predetermined optical device is formed; and separating the thus formed optical device from the cavities of the moldplate due to a differential thermal expansion between the optical device material and the moldplate material.
Abstract:
The present invention is a process for extracting pre-polymer from a polymer lens. The process comprises the step of contacting the lens with a super-cooled solvent for a period of time sufficient to extract pre-polymer from the polymer lens.
Abstract:
An apparatus for manufacturing a lens with a predetermined prescription from a number of lens molds, a gasket, and a source of a fluid material. The apparatus includes a device for selecting a first lens mold and a second lens mold based upon the prescription, a device for positioning the lens molds within the gasket, a device for inserting an amount of the fluid material within the gasket and between the molds, a device for curing the fluid material so as to form the lens, and a device for advancing the lens molds along a predetermined path through the selecting device, the positioning device, the fill device, and the cure device.
Abstract:
A compression process for fabricating a substantially finished coated/layered lens for eyeglasses with a thermoplastic lens preform, with the lens having surfaces for correcting vision. The process comprised suitably placing on at least one of a pair of molds with molding surfaces conforming to the surfaces of the finished lens a thermoplastic film-layer/coating or multiple layers or coatings, each having a given thickness and predetermined characteristics and/or properties desired in the finished lens. The lens preform is then placed on the thermoplastic film-layer/coating; and heating and molding in situ of the film-layer/coating with the lens preform is then conducted while the lens preform is under compressive forces of the compression process until a generally predetermined lens thickness is achieved. Then the molds are first cooled and opened so as to remove the substantially finished lens with the film-layer/coating simultaneously molded/coated thereon, whereby a finished molded prescription eyeglass lens is formed with the molded thermoplastic film-layer/coating molded thereto on one or both sides thereof during the compression process.
Abstract:
An apparatus and method for forming a lens using a structure having a front mold, a rear mold, and a gasket having opposed ends and defining an axially extending bore in which the front and rear molds are disposed within the bore and spaced apart from each other therein, comprising a piston for axially moving within the bore of the gasket a selected one of the front mold or the rear mold relative to the other mold to a desired one of a plurality of axial separation distances between the molds. A needle also preferably also communicates with the bore of the gasket between the molds to provide fluid communication between the outer surface of the gasket and the bore to facilitate axial movement of the molds relative to each other. Another needle is used for injecting a desired amount of a lens-forming fluid into the bore of the gasket intermediate the front and rear molds, in which the fluid is cured to form the lens.