Abstract: A mold apparatus is arranged to produce molded optical elements. The apparatus includes a first mold unit for defining mold cavities and flow passageways, and a second mold unit having a patterned surface for sealing against the first unit. The patterned mold surface may be formed with a plurality of optical patterns, and mold pins may be used to complete the mold cavities. The patterned surface may be formed on a flat metal puck. The puck may be replaced by another puck insert so that the apparatus can be used to produce products having different optical characteristics. Other parts of the apparatus may be changed out to produce molded optical elements of various sizes and shapes. A variety of techniques are described for forming micro-refractive, diffractive and/or other patterns in the metal puck surface.

Abstract: A composition containing 3,3?-thiobis(propane-1,2-dithiol) and one or more enic compounds which composition is photocurable and can give a cured product having a high refractive index and adequate hardness.

Abstract: A method for manufacturing a plurality of kinds of sheets is provided. Each of sheets has a substrate and an ionizing radiation curing type resin layer on at least one of the substrate. There is carried out formation of the ionizing radiation curing type resin layer for each of the sheets, while changing forming conditions based on preset values for each of the sheets.

Abstract: The present invention is aimed to produce a cured product having excellent photochromism which can be easily polymerized in a short period of time. The cured product is obtained by photopolymerizing a polymerizable composition comprising (A) a radical polymerizable monomer, (B) an ultraviolet polymerization initiator having the main absorption at an ultraviolet range and a molar absorption coefficient for light having a wavelength of 400 nm of 150 liter/(mol·cm) or more, (C) a thermopolymerization initiator such as a thermopolymerization initiator having a temperature at which the half-life thereof is 10 hours of 60° C. or more and (D) a photochromic compound by irradiating activation energy rays having a wavelength of 400 nm or more as the main emission spectrum, preferably to ensure that the temperature of the cured product does not exceed 50° C., and further thermopolymerizing the composition by heating.

Abstract: A method of manufacturing a composite photochromic ophthalmic lens having an index of refraction of at least 1.49 is disclosed.

Abstract: The invention provides a method for producing tinted contact lenses in which diffusion of monomer into the colorant is aided by heating of the molds. The invention provides a method, and lenses produced by that method, that reduces the residual, unbound polymer on the lens surface and lens surface roughness.

Abstract: The invention relates to a process for the manufacture of a molding comprising the steps of a) preparing an aqueous solution comprising a water-soluble prepolymer having crosslinkable groups and a further polymer which is devoid of crosslinkable groups, b) introducing the solution obtained into a mold, c) triggering the crosslinking, and d) opening the mold such that the molding can be removed from the mold. According to the process of the invention moldings such as contact lenses may be manufactured with an improved quality and an improved overall yield.

Abstract: A method is disclosed for pre-conditioning inserts for improved replication during injection molding. The pre-conditioned inserts provide improved bonding with the injection-material and improved replication of complex molding surfaces. The pre-conditioning of the inserts comprises placing the insert in position against the molding surface, followed by heat-soaking the insert. Heat-soaking can be accomplished using infrared energy, preferably broadband infrared energy or energy that is preferentially absorbed by the insert.

Abstract: An apparatus for manufacturing a lens sheet comprises an application device, a substrate supply device, a pressing device and an irradiation device. The application device applies ionizing radiation curing type resin in the form of liquid on the upper surface of a forming die for a lens sheet to form an uncured resin body on the upper surface of the forming die. The substrate supply device places a substrate on the uncured resin body. The pressing device presses the substrate against the uncured resin body to flatten the uncured resin body, so as to form a uncured resin layer, while spreading the uncured resin body to an outside periphery of the forming die. The irradiation device irradiates ionizing radiation on the uncured resin layer through the substrate to cure the uncured resin layer.

Abstract: There is provided a radiation sensitive refractive index changing composition containing an inorganic oxide particle, a polymerizable compound, a radiation sensitive decomposer and an escapable compound. The radiation sensitive decomposer decomposes upon exposure to radiation to form an acid, base or radical, and this decomposed product increases the molecular weight of the polymerizable compound.

Abstract: A method and mold assembly to control the polymerization of a molded article. In one embodiment, an amorphous posterior mold comprising a non-critical surface having a controlled radius of curvature is used to produce molded articles. In an alternate embodiment, ophthalmic lenses are produced using a posterior mold in which the concave surface of the non-critical surface is filled with a liquid having a similar refractive index as the mold material. In still another embodiment, a positive lens is placed at a predetermined distance adjacent to the mold assembly to alter the irradiation path to the mold assembly. In still another embodiment, a positive lens is placed within the concave surface of the posterior lens.

Abstract: The invention is directed towards techniques for creating optical data storage disks. In one embodiment, the invention provides a simultaneous two-sided rolling bead process. For example, a method may include positioning a first bead of photopolymer for distribution between a bottom stamper and a substrate, and positioning a second bead of photopolymer for distribution between a top stamper and the substrate. The method may also include passing a roller over the top stamper to distribute the beads of photopolymer, curing the photopolymer, and removing the substrate from the stampers. The simultaneous two-sided rolling bead process can be repeated on the same medium to create a two-sided dual-layer data storage medium or a two-sided multi-layer data storage medium.

Abstract: The invention is concerned with the problem that with known plastic casting moulds, especially those of polypropylene, the lenses produced with these moulds have a slippery surface. The invention solves this problem through the use of polymers which are notable for their very low oxygen permeability.

Abstract: A measured amount of a material that is crosslinkable by impingement of a suitable form of energy, especially UV light, is introduced into a two-part mould of which the cavity determines the shape of a moulding to be produced. The two mould halves are held a small distance from one another so that a thin annular gap is formed between them, which gap is in communication with the mould cavity and through which gap excess material can escape. The crosslinking is triggered by impingement of the selected form of energy, the impingement being spatially restricted to the cavity by suitable masking so that material disposed outside the mould cavity is not crosslinked. In that manner mouldings are obtained that do not require subsequent mechanical processing, and the mould is reusable. The process is especially, but not, however, exclusively, suitable for the manufacture of contact lenses.

Abstract: An enhanced K-type polarizer includes a molecularly oriented sheet of polyvinylalcohol/polyvinylene block copolymer material having polyvinylene blocks formed by molecular dehydration of a sheet of polyvinylalcohol wherein the molecularly oriented sheet comprises light-polarizing molecules of polyvinylalcohol/polyvinylene block copolymer material varying in length, n, of conjugated repeating vinylene unit of the polyvinylene block, wherein an absorption concentration of each of the polyvinylene blocks in the range of n=19 to 25 is not less than approximately 65% of the absorption concentration of any of the polyvinylene blocks in the range of n=14 or 15, wherein the absorption concentration is determined by absorption of wavelengths from about 200 nm to about 700 nm by the polyvinylene blocks, and wherein the molecularly oriented sheet exhibits a photopic dichroic ratio, RD, of at least approximately 75.

Abstract: The wavefront aberrator of the present invention includes a pair of transparent windows, or plates, separated by a layer of monomers and polymerization initiator, including a broad class of epoxies. This monomer exhibits a variable index of refraction across the layer, resulting from controlling the extent of its curing. Curing of the epoxy may be made by exposure to light, such as ultraviolet light. The exposure to light may be varied across the surface of the epoxy to create a particular and unique refractive index profile.

Abstract: A process for manufacture of a photochromic polymeric article comprising: providing a fluid polymerisable composition; subjecting the fluid polymerisable composition to a first curing step to provide a solid article of intermediate hardness; contacting the solid article of intermediate hardness with a photochromic substance; and subjecting the solid article of intermediate hardness to a further curing step to increase the hardness and provide a polymeric article imbibed with the photochromic substance.

Abstract: A method for fabricating an integrated optical isolator includes depositing a wire grid material on a magneto-optical substrate and depositing a resist film on the wire grid material. The method further includes bringing a mold with a wire grid pattern on contact with the resist film and compressing the mold and resist film together so as to emboss the wire grid pattern in the resist film. The method further includes transferring the wire grid pattern in the resist film to the wire grid material on the magneto-optical substrate by etching.

Abstract: A process for preparing a polarizer is described whereby an article comprising an oriented, vinylalcohol polymer film layer, and an acid donor layer comprising a photoacid generator, is exposed to radiant energy at a temperature sufficient to effect a partial dehydration of the vinylalcohol polymer to a vinylalcohol/poly(acetylene) copolymer.

Abstract: A method and mold assembly to control the polymerization of a cast optical device. The mold assembly includes at least one mold portion having a non-critical surface with fresnel or diffractive geometry. Alternately, a fresnel lens or diffractive lens may be placed at a predetermined distance from the mold.

Abstract: A measured amount of a material that is crosslinkable by impingement of a suitable form of energy, especially UV light, is introduced into a two-part mould of which cavity determines the shape of a moulding to be produced. The two mould halves are held a small distance from one another so that a thin annular gap is formed between them, which gap is in communication with the mould cavity and through which gap excess material can escape. The crosslinking is triggered by impingement of the selected form of energy, the impingement being spatially restricted to the cavity by suitable masking so that material disposed outside the mould cavity is not crosslinked. In that manner mouldings are obtained that do not require subsequent mechanical processing, and the mould is reusable. The process is especially, but not, however, exclusively, suitable for the manufacture of contact lenses.

Abstract: A production process of an optical disk, wherein when a layer of an ultra violet rays curing resin which constitutes a portion of the optical disk is formed, a comi-transparent film of a metal is formed an a molded substrate on which a pattern was transcribed and this molded substrate is used as a semi-transparent stamper, and the production of an optical disk with two layers at one side is made easy thereby.

Abstract: A method for optically coupling a thermoplastic material to an outer surface layer of an organic, dielectric, optical film and the resulting optical filter. Initially, a dielectric film is selected that includes (i) repeating optical layers of at least two polymers having different refractive indexes from each other, (ii) an exterior film surface, (iii) a refractive boundary along the exterior film surface, and (iv) a delamination threshold based on total thermal energy delivered to the film. A thermoplastic material which is miscible with the exterior film surface is fused to the refractive boundary with thermal energy below the delamination threshold to form a polydisperse region having a higher optical transmission than the refractive boundary. Add-on filters in the form of hardcoat layers, anti-reflection layers, holograms, metal dielectric stacks and combinations of these may be combined with the thermoplastic-film construct.

Abstract: An apparatus for preparing a plastic eyeglass lens includes a coating unit and a lens curing unit. The apparatus is preferably configured to allow the operation of both the coating unit and the lens curing unit. The apparatus may also include a post-cure unit and a controller. The controller is configured to control the operation of the coating unit, the lens curing unit and the post-cure unit. The lens forming unit may include an LCD filter disposed between activating light sources and a mold assembly. The mold assembly preferably includes two mold members held together by a gasket. The gasket preferably includes four protrusions spaced at 90 degree intervals about the gasket. A lens forming composition may include a first photochromic compound, a second photochromic compound and a light effector. The light effector may alter the color of a lens when exposed to photochromic activating light, when compared to a lens formed from a lens forming composition which does not include a light effector.

Abstract: A method for photopolymerizing a monomer mixture to form a lens involves photopolymerizing a mixture of lens-forming monomers that includes an initiator of the formula: wherein: Ar represents an aromatic radical; Ra represents a secondary amino radical; Rb represents an ethylenically unsaturated radical or an aromatic radical; and Rc represents a secondary amino radical.

Abstract: This invention relates to solvents which may be used to extract polymers that are made of hydrophilic and hydrophobic monomers.

Abstract: The present invention provides a method for producing a medical device, preferably an ophthalmic device, more preferably a contact lens, made of a stabilized poly(oxyalkylene)-containing polymeric material. The method of the invention comprises the steps of: curing, in a mold, a composition comprising (a) a prepolymer having at least one poly(oxyalkylene) unit, (b) a biocompatible organic multi-acid or biocompatible salt thereof in an amount sufficient to improve the stability of the poly(oxyalkylene)-containing polymer made from the composition, (c) optionally a photoinitiator or a thermal initiator, and (d) optionally one or more vinylic monomers, to form the medical device being less susceptible to oxidative degradation; and removing the medical device from the mold.

Abstract: A process of fabricating a non-gap 3-D microstructure array mold core comprises a first step in which a buffer layer is coated on a substrate. A photomask layer is then coated of the buffer layer. A pattern is subsequently formed on the photomask by photo-lithography. The patterned photomask layer is subjected to a reflow by which a microstructure array is formed on the photomask layer. The microstructure array is coated with a metal conductive layer. The microgaps of the microstructure array are eliminated by an electrocasting layer which is coated on the microstructure array. The non-gap microstructure array mold core so fabricated is made into a metal molding tool by microinjection molding or microthermo-pressure molding.

Abstract: A method and apparatus for forming a lens using two molds that interconnect together so that their respective interior surfaces form the negative image of the lens to be cast therein. The molds are preferably made of plastic. A monomer fills the volume formed by the interior surfaces of the molds and is cured or polymerized to form a lens having desired dimensions and characteristics. It is noted that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to ascertain quickly the subject matter of the technical disclosure. The abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims pursuant to 37 C.F.R. § 1.72(b).

Abstract: An object of the invention is to provide a method of manufacturing a microlens array and a projection-type liquid crystal display apparatus which can increase the efficiency of use of light, facilitate a method of manufacturing a microlens array and reduce the cost of equipment. By an operation of only irradiating a first lens with parallel light which has an intensity distribution corresponding to the shape of a second lens and irradiating an ultraviolet curing resin layer with transmission light, the first and second lenses are placed with a high alignment accuracy in a mutual positional relation thereof. By irradiating the first lens with the parallel light, it becomes possible to uniformly expose a broad area, and it becomes possible to expose by the wafer.

Abstract: The present invention provides a production process of, duplication plate material for duplication of, and medium provided with an optically diffractive structure such as a hologram and diffraction grating having excellent optically diffractive effect, wherein the optically diffractive structure has a surface configuration having plural corrugation-like convexo-concave shapes, and the convexo-concave shapes of the final medium is formed by using a duplication plate material. The convexo-concave shapes of the duplication plate material have a cross-sectional surface which is crosswise to the peaks of the convexo-concave shapes, and a salient section defined by a salient line and a middle line has a smaller area than that of an adjacent reentrant section defined by a reentrant line and the middle line. Herein, the middle line is drawn by connecting midpoints of the height of the convexo-concave shapes.

Abstract: Process for producing an anticounterfeit label having a holographic image, and labels produced according to the process.

Abstract: A mold assembly holder is described that will facilitate the positioning and the conveyance of mold assemblies. The mold assembly holder includes at least one, preferably two, portions configured to hold a mold assembly. In one embodiment, the portions are indentations machined into a plastic or metal block that is configured to hold a standard mold assembly. The mold assembly may be placed in the indentation.

Abstract: A method of infusing a dye into the surface of an article formed of a plastic material comprises contacting the surface with a solution including one or more solvents each aggressive to the plastic material, one or more dyes and one or more substances each capable of plasticizing the plastic material. If the plastic material is polycarbonate, then the aggressive solvent may be one or more chlorinated hydrocarbons. The dye may be a photochromic dye, a cosmetic tinting dye, dyes for absorbing infrared, laser and ultraviolet radiation, or combinations thereof. A wide range of plasticizers has been investigated. The article is contacted by the solution for ten seconds to one minute; and nearly all the infused solvent is then evaporated from the article by heating. The use of one or more plasticizers reduces or eliminates bubbling or hazing of the contacted surface during solvent evaporation.

Abstract: A system for dispensing a heated polymerizable lens forming composition is described. The dispensing system includes a body configured to hold the lens forming composition, a heating system coupled to the body for heating the monomer solution, and a valve positioned proximate an outlet of the body for controlling the flow of the lens forming composition out of the body.

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: The present invention is to provide a production method for an optical disc, capable of obtaining a good S/N ratio without deterioration of the stamper quality due to reaction with an electron attractive group contained in a resist material. The processes of forming a resist film on a substrate, patterning the resist film on the substrate by an electron beam cutting, forming a nickel alloy thin film on the patterned resist film, forming a nickel layer on the nickel alloy thin film by the electrocasting, and injection molding of a resin, using the nickel layer peeled off from the nickel alloy thin film as a stamper, are provided. The nickel alloy thin film has a composition containing Ni element as the main component as well as Ru element by less than 25% by weight.

Abstract: A liquid-form adhesive, which is a raw material of the cover layer, is supplied to a plate surface of the disc substrate, which has been set on a turntable, after which a dummy substrate is set on the disc substrate. The dummy substrate is positioned to be concentric with the disc substrate. A setting surface of the dummy substrate is disposed to face the plate surface. In this state, the disc substrate is rotated together with the dummy substrate by rotation of the turntable, and the adhesive is spread to an outer peripheral side of the disc substrate by centrifugal force. Thus, the adhesive fills a space between the plate surface and the setting surface, and is spin-coated on the plate surface. Irregularities in thickness of the applied adhesive are suppressed by the setting surface of the dummy substrate.

Abstract: Elastomeric stamps facilitate direct patterning of electrical, biological, chemical, and mechanical materials. A thin film of material is deposited on a substrate. The deposited material, either originally present as a liquid or subsequently liquefied, is patterned by embossing at low pressure using an elastomeric stamp having a raised pattern. The patterned liquid is then cured to form a functional layer. The deposition, embossing, and curing steps may be repeated numerous times with the same or different liquids, and in two or three dimensions. The various deposited layers may, for example, have varying electrical characteristics, interacting so as to produce an integrated electronic component.

Abstract: A grayscale mask for imaging operations, including a substrate layer and a mask layer having a plurality of apertures forming a mask pattern to form a grayscale image. Each edge of each aperture includes a plurality segments forming a serrated edge, resulting in mixed edge diffraction. The apertures may be in an irregular and non-symmetric pattern and may be of variable size. A random diffusing layer may be in proximity to or integral with the substrate layer. The grayscale mask may be used for generating an optical element by printing the initial grayscale mask onto a photoresist layer and transferring the photoresist pattern onto a transparent layer and the mask may include areas or layers of variable transmission. Also described are methods for diffractive intensity averaging, diffractive error diffusion, diffractive spatial dithering, and diffractive intensity averaging.

Abstract: A method for optically coupling a thermoplastic material to an outer surface layer of an organic, dielectric, optical film and the resulting optical filter. Initially, a dielectric film is selected that includes (i) repeating optical layers of at least two polymers having different refractive indexes from each other, (ii) an exterior film surface, (iii) a refractive boundary along the exterior film surface, and (iv) a delamination threshold based on total thermal energy delivered to the film. A thermoplastic material which is miscible with the exterior film surface is fused to the refractive boundary with thermal energy below the delamination threshold to form a polydisperse region having a higher optical transmission than the refractive boundary. Add-on filters in the form of hardcoat layers, anti-reflection layers, holograms, metal dielectric stacks and combinations of these may be combined with the thermoplastic-film construct.

Abstract: The present invention relates to an improved method of manufacture of molded polymeric devices using variable frequency microwaves. Molded polymeric devices include, for example, contact lenses, corneal rings, intraocular lenses and drug delivery devices such as anterior or posterior chamber inserts. Contact lenses include soft and rigid gas permeable contact lenses as well as, lens blanks lathed into finished contact lenses. Molded polymeric devices further include medical devices such as prosthetics including hip joints. According to the present invention, a mold having a cavity the shape of the desired molded polymeric device, the cavity containing a composition comprising one or several monomers having double polymerizable bonds, is placed in a microwave chamber. The mold can be plastic, glass, ceramic or metal. Plastic is preferred. The mold is then swept with at least one range of microwave frequencies to polymerize the composition, thus forming the molded polymeric device.

Abstract: A method and a device for removing molded soft contact lenses, high-precision intraocular lenses and the like, from the individual molds in which they are produced. Provided is an infra-red radiation or heater device constituted of silicon carbide IR-emitters, and which employs an individual infra-red emitter for each individual mold, to impart a desired thermal gradient.

Abstract: A microlens of the present invention may include a liquid droplet whose position and/or surface curvature may be changed (tuned), e.g., by selectively biasing one or more electrodes configured to said droplet. The droplet may then be solidified to fix a desired configuration (e.g., focal length) of the microlens. In one embodiment, the droplet has an optically curable liquid adhesive that is polymerized under exposure to UV light. Microlenses of the present invention may be used, for example, in optical devices to obtain and then maintain optimal coupling between various optical components.

Abstract: The invention is concerned with the problem that with known plastic casting molds, especially those of polypropylene, the lenses produced with these molds have a slippery surface. The invention solves this problem through the use of polymers which are notable for their very low oxygen permeability.

Abstract: A method of preparing phakic intraocular lenses from hydrophobic materials is described. In this process, the lens is tested to determine whether it can float submerged in an aqueous medium. If it cannot (e.g., if it remains on top of the aqueous medium), the lens is surface treated (for example, by vacuum UV or corona discharge processes) to increase its wetting ability (e.g., to reduce its hydrophobicity). The lenses prepared by this process are also described.

Abstract: A super resolution optical disk mother mold, having a substrate, a super resolution structure and a patterned photoresist layer. The super resolution is disposed between the substrate and the patterned photoresist layer. The super resolution optical disk mother mold is fabricated on the substrate prior to formation of the photoresist layer. The above process does not cause the problem of pre-exposing the photoresist layer. In addition, the surface roughness caused by thin-film particle will not occur to the optical disk mother mold fabricated by the above process. Therefore, the optical disk stamper made by the optical disk mother mold will not suffer from the problem of the surface roughness.

Abstract: The present invention provides methods and compositions for producing lenses by casting. The processes utilize a two-stage, ultraviolet cure to provide a fast and reliable method for producing ophthalmic lenses.

Abstract: The invention tackles the problem of improving the production process for contact lenses further, so that the production costs for contact lenses can be reduced further and the production capacities can be increased. To this end, provision is made for the two mould halves, which together form the mould for producing a contact lens, to be fixed to each other and/or detachably connected to each other by means of individual half-mould guide. In conjunction with a cyclic production process, a high degree of automation can be achieved in this way.

Abstract: The present invention provides a method of forming micro lenses over a base structure of a solid state image pick-up device. The method comprises the steps of: forming a light-transmitting material layer on the base structure; and pushing a die having a die pattern against the light-transmitting material layer to transfer the die pattern of the die to the light-transmitting material layer, thereby forming micro lens patterns over the base structure.