Abstract: The present invention encompasses, in part, a method and apparatus for lens casting in which two molds, preferably formed of plastic, are interconnected or joined together via a ring to form a mold cavity having substantially the same dimensions of the lens to be formed therein. The invention is further directed to compositions and methods used in lens casting. In a first implementation the invention includes a mold having a ring having an interior periphery; a front mold formed of a plastic and having a lens-forming surface, an edge circumscribing the lens-forming surface that is sized to be complementarily received within a portion of the interior periphery of the ring, and a base having dimensions greater than the interior periphery; and a rear mold formed of a plastic and having a lens-forming surface.

Abstract: The present invention relates to a method of applying an anti-reflective coating to an optical surface of a mold. In one embodiment, the method includes the steps of: providing a lens mold having an optical surface; forming a layer of a super hydrophobic material with a thickness of about 30 to 40 nm over the optical surface, wherein the super hydrophobic material contains dipodal silane; forming an anti-reflective coating layered structure over the layer of the super hydrophobic material; and forming a layer of a cyclic azasilane coupling agent that is deposited with a monolayer thickness to the anti-reflective coating layered structure using vapor deposition or by dip coating using a solution of cyclic azasilane coupling agent in an aprotic solvent.

Abstract: The present invention relates to a method for manufacturing a polarized lens. In one embodiment, the method includes the steps of treating a polarized film with a composition to form a treated polarized film, providing a front lens mold having a concave surface with a curvature, spin-coating a hard coat composition onto the concave surface of the front lens mold to form a hard coat layer thereon, forming a first adhesive layer on the hard coat layer, placing the treated polarized film on the adhesive layer, curing the adhesive layer with UV or visible light to bond the treated polarized film to the hard coat layer, thereby forming a polarized front lens mold, and forming a polarized lens with the polarized front lens mold.