Abstract: The disclosed embodiments include a system and method for manufacturing a lens. In one embodiment, the system includes a lens mold. According to the embodiment, the lens mold contains a part cavity and a material flow path fluidly coupled to the part cavity and a lens material inlet. The system also includes a heat transfer insert. According to the embodiment, the heat transfer insert includes an insert surface positioned adjacent to a part surface of the cavity, a sealed fluid inlet, a sealed fluid outlet, and a conformal fluid conduit that extends from the sealed fluid inlet to the sealed fluid outlet.

Abstract: This invention relates to the development of a multi-layer PC polar laminate and its cut and form process. The laminate displays increased adhesion between a PC film layer and an adjacent film layer. As a result of the increased adhesion, less adhesive may be applied between laminate layers, which positively affects PC cracking and mold cavity contamination.

Abstract: Ophthalmic lens comprising an ophthalmic thermoplastic substrate and a light polarizing structure onto said substrate. The ophthalmic lens reduced warpage, in particular when submitted to mechanical, thermal and/or chemical treatment.

Abstract: The disclosed embodiments include a system and method for manufacturing a lens. In one embodiment, the system includes a lens mold. According to the embodiment, the lens mold contains a part cavity and a material flow path fluidly coupled to the part cavity and a lens material inlet. The system also includes a heat transfer insert. According to the embodiment, the heat transfer insert includes an insert surface positioned adjacent to a part surface of the cavity, a sealed fluid inlet, a sealed fluid outlet, and a conformal fluid conduit that extends from the sealed fluid inlet to the sealed fluid outlet.

Abstract: This invention relates to the development of a multi-layer PC polar laminate and its cut and form process. The laminate displays increased adhesion between a PC film layer and an adjacent film layer. As a result of the increased adhesion, less adhesive may be applied between laminate layers, which positively affects PC cracking and mold cavity contamination.

Abstract: Ophthalmic lens comprising an ophthalmic thermoplastic substrate and a light polarizing structure onto said substrate. The ophthalmic lens reduced warpage, in particular when submitted to mechanical, thermal and/or chemical treatment.

Abstract: An apparatus and method for producing defect-critical articles from a molding resin comprising at least 98% clear polymer and additives including a heat stabilizer and a UV blocker in an injection molding machine. According to the apparatus, there is provided an injection molding machine in combination with a molding resin. The injection molding machine's resin delivery assembly is made from a powder metallurgy formed into solid non-coated parts having a Chromium-Vanadium (Cr/V) blend. As the molding resin interacts with the resin delivery assembly, the resin only contacts the solid non-coated parts whereby the resin experiences less degradation and provides improved quality for the defect-critical articles. The method includes the steps of plasticizing, injecting, and cooling. During the plasticizing and injecting steps, the molding resin only contacts solid non-coated parts made from a powder metallurgy material containing a Chromium-Vanadium (Cr/V) blend thereby producing reduced defect articles.

Abstract: A method and system for monitoring lens material residence within a conduit to improve the quality of molded products by reducing defects arising from entrapped lens material. According to the method a finite element mesh representative of a conduit is stored in a digital storage device. A simulation is run on a digital computer in which one type of lens material sequentially flows through the conduit in discrete batches temporal history of the batches within the conduit is tracked. The simulation is useful for analyzing material delivery conduits in injection molding and casting systems, for example, for lens manufacturing. According to the system, a digital storage device stores a finite element mesh representative of a conduit. A digital computer is coupled to the digital storage device for executing a set of instructions to run a simulation and track the temporal history of the batches within the conduit.

Abstract: An apparatus and method for producing defect-critical articles from a molding resin comprising at least 98% clear polymer and additives including a heat stabilizer and a UV blocker in an injection molding machine. According to the apparatus, there is provided an injection molding machine in combination with a molding resin. The injection molding machine's resin delivery assembly is made from a powder metallurgy formed into solid non-coated parts having a Chromium-Vanadium (Cr/V) blend. As the molding resin interacts with the resin delivery assembly, the resin only contacts the solid non-coated parts whereby the resin experiences less degradation and provides improved quality for the defect-critical articles. The method includes the steps of plasticizing, injecting, and cooling. During the plasticizing and injecting steps, the molding resin only contacts solid non-coated parts made from a powder metallurgy material containing a Chromium-Vanadium (Cr/V) blend thereby producing reduced defect articles.

Abstract: A method and system for monitoring lens material residence within a conduit to improve the quality of molded products by reducing defects arising from entrapped lens material. According to the method a finite element mesh representative of a conduit is stored in a digital storage device. A simulation is run on a digital computer in which one type of lens material sequentially flows through the conduit in discrete batches temporal history of the batches within the conduit is tracked. The simulation is useful for analyzing material delivery conduits in injection molding and casting systems, for example, for lens manufacturing. According to the system, a digital storage device stores a finite element mesh representative of a conduit. A digital computer is coupled to the digital storage device for executing a set of instructions to run a simulation and track the temporal history of the batches within the conduit.

Abstract: Optical qualities of a production lot of base material used in the fabrication of semi-finished lenses may be accurately determined by employing chipper plate samples produced from the base material in accordance with aspects of the present invention. In various implementations of the present invention, the chipper plates samples may be fabricated by subjecting base material to an extended cycle time and temperature profile using a mold having cavities of different thicknesses. The resulting chipper plates provide an improved indication of the color of semi-finished lenses molded from the production lot as well as an improved indication of resin stabilizer defects that may be utilized during a pelletizing process to control and enhance the quality of a production lot. Furthermore, the chipper plates may be provided by suppliers as samples of a production lot to enable customers to base purchasing decisions on a reliable and accurate measure of optical properties.

Abstract: Optical qualities of a production lot of base material used in the fabrication of semi-finished lenses may be accurately determined by employing chipper plate samples produced from the base material in accordance with aspects of the present invention. In various implementations of the present invention, the chipper plates samples may be fabricated by subjecting base material to an extended cycle time and temperature profile using a mold having cavities of different thicknesses. The resulting chipper plates provide an improved indication of the color of semi-finished lenses molded from the production lot as well as an improved indication of resin stabilizer defects that may be utilized during a pelletizing process to control and enhance the quality of a production lot. Furthermore, the chipper plates may be provided by suppliers as samples of a production lot to enable customers to base purchasing decisions on a reliable and accurate measure of optical properties.

Abstract: A method and apparatus for improving the performance of rimless spectacle lenses. An abrasive wire is provided for polishing bore holes which are drilled in lenses. The abrasive wire includes a wire substrate with abrasive particles embedded along its length. The wire and particles are dimensioned for threading through the bore hole and allowing space to perform a soft-filing operation. By polishing the micro cracks formed during drilling, propagation leading to lens failure which arises from spectacle use can be reduced.