Abstract: The present invention relates to a method for producing a shell for a Luneberg lens in which an amount of a dielectric material composition containing particles of an expandable plastic material coated with an amount of a titanium-oxygen compound, is introduced into a mould and heated to an appropriate temperature for moulding. As a plastic material use is made of an expandable plastic material which is non-expanded or partly pre-expanded. The moulding temperature is selected such that expansion of the particles takes place. As an expandable plastic material preferably use is made of polystyrene. The dielectric moulding composition preferably comprises 5-65 wt. % of the titanium-oxygen compound with respect to the total weight of the composition.

Abstract: Method and apparatus for making and coating a plastic lens. Oxygen barrier containing photoinitiator is used to cure incompletely cured lens portions. Radiation pulses are used to control lens curing rate. Lens is postcured while in a mold cavity using a conductive heat source.

Abstract: Mold assembly for forming a lens blank for an ophthalmic lens, wherein upper and lower tapered inner surfaces of intermediate sleeve are adapted to be held in press-fitting engagement with respective outer surfaces of upper and lower molds, to effect fluid-tight connection of the upper and lower molds with the intermediate sleeve, with the upper mold being held in abutting contact with a shoulder of the intermediate sleeve, and with stopper surfaces of the intermediate and lower molds being held in abutting contact with each other to determine a relative axial position therebetween, such that a mold cavity to be filled with a liquid monomer composition is defined by the upper and lower molds and the intermediate sleeve, while a liquid reservoir for storing an excess amount of the monomer composition which has been discharged from the mold cavity is defined by the upper mold and the intermediate mold.

Abstract: Stress-relieved molded acrylic opthalmic lenses, and injection-coining mold processes for molding stress-relieved plus and minus to high-minus diopter ophthalmic lenses of optically superior acrylic resin, able to pass standardized impact drop tests for use in eyeglass lenses, are described. The injection-coining processes use two-plate and three-plate mold assemblies. The cavity of a two plate runnerless mold is partially filled under partial tonnage, and the movable half of the mold controlled to coin and densify the acrylic resin under secondary or full tonnage, when a velocity-pressure changeover point is reached. In a process which employs a three-plate mold assembly, the lens mold cavities are partially filled under less than total clamp tonnage, with a cavity plate held by hydraulic pressure against movable half of the mold.

Abstract: A mold assembly for forming an ophthalmic lens, or a lens blank from which one ophthalmic lens is produced by effecting a cutting operation on at least one of a front surface and a back surface of the lens blank, the mold assembly consisting of a first mold having a molding surface and a second mold having a molding surface, which first and second molds are assembled together so as to define therebetween a mold cavity having a profile corresponding to that of the ophthalmic lens or the lens blank, the mold cavity being filled with a polymeric material which is polymerized to form the ophthalmic lens or the lens blank, wherein at least one of the first and second molds is a layered mold which is constituted by a composite sheet comprising a metal sheet layer and at least one resin layer which are laminated on each other, the at least one resin layer of the composite sheet providing the molding surface of the layered mold which partially defines the mold cavity.

Abstract: Lens mold assembly including a first and a second mold cooperating with each other to define a mold cavity for molding an ophthalmic lens with the first and second molds being held in line contact with each other at a radial position, wherein at least one of the two molds consists of a central molding portion located radially inwardly of the radial position, and an outer rim portion located radially outwardly of the radial position, the central molding portion cooperating with the other mold to define the mold cavity, the above-indicated at least one mold having a mold surface which is opposed to a mold surface of the other mold when the two molds are assembled together, the mold surface of the at least one mold consisting of a central lens-forming region in the central molding portion, and an outer peripheral non lens-forming region in the outer rim portion, at least a part of the lens-forming region adjacent to the radial position providing a concave portion, while at least a part of the outer peripheral no

Abstract: A device comprises a lower die 6 composed of a lower die base portion and a lower die columnar portion of which tip surface is formed with a lower die molding surface corresponding to one surface of an ocular lens material; an upper die 8 composed of an upper die base portion that is fitted into an upper portion of a hollow hole of the cylindrical main body for parting the hollow hole into two, forming an intermediate chamber 18 between itself and the lower die base portion into which the monomer composition is filled, and forming an exterior accumulating chamber 20 on a side of an upper aperture of the hollow hole into which the monomer composition is accumulated, and an upper die columnar portion of which tip surface is formed with an upper die molding surface corresponding to another surface of the ocular lens material, wherein a molding cavity 22 having a communicating portion 24 is formed between the upper die molding surface and the lower die molding surface; and not less than three piercing holes 16 pr

Abstract: A method of making a lens, such as a contact lens, with a colored portion involves introducing a lens-forming monomer mixture and an ionic colored material to a lens mold, applying an electrical field to the monomer mixture and the colored material, whereby the colored material migrates in response to the electrical field to form a desired pattern, and curing the lens-forming monomer mixture with the colored material forming a desired colored pattern in the lens.

Abstract: System for making a plastic lens is provided. More particularly, a system for applying alternating periods of ultraviolet light to a lens forming composition is described. The lens forming composition is cured while controlling the rate of heat generation and/or dissipation via manipulation of the duration of the ultraviolet light or the cooling in the curing chamber. The ultraviolet light is preferably directed toward the lens forming composition which is disposed in a mold cavity formed by two mold members. The ultraviolet light may be directed in pulses or continuously.

Abstract: A method of manufacturing a composite optical element, in which method a lens material of plastic is formed on a lens. The lens has a first optical surface and a second optical surface, and a lateral edge tilted at an angle relative to the perpendicular center line of the lens. The lens material is formed into a lens medium which covers only the first optical surface and a portion of the lateral edge of the lens. A tight binding is then established between the lens and the lens medium, which is formed of the lens material.

Abstract: The bottom surfaces of an entering surface-forming portion 1a for forming a light-entering surface 11a of a reflector type prism 11 and of an emitting surface-forming portion 1b for forming a light-emitting surface 11b of the reflector type prism 11 are formed as concave surfaces in a die 1. Even if shrinkage of the reflector type prism 11 occurs during its formation, the light-entering surface 11a and the light-emitting surface 11b are, at least, not formed as concave surfaces, so that a light beam entering the reflector type prism 11 and a light beam emitted from the reflector type prism 11 are prevented from becoming scattered.

Abstract: An apparatus and method for partially curing a polymerizable monomer or monomer mixture to form a soft contact lens includes a transport device for transporting a plurality of contact lens molds to a precure station in a low oxygen environment, each contact lens mold including a first and second mold half with a polymerizable monomer or monomer mixture therebetween. A clamping member having a plurality of mold engagement members clamps a first contact lens mold half against a second contact lens mold half for a predetermined pressure and time. While the mold halves of the contact lens mold are clamped, the polymerizable monomer or monomer mixture is exposed to a radiant energy source for polymerizing the polymerizable monomer or monomer mixture contained in each contact lens mold.

Abstract: System for making a plastic lens. Mold members are spaced apart to define a mold cavity. Ultraviolet light is directed against at least one of the mold members to cure a composition and form a substantially clear eyeglass lens in less than one hour.

Abstract: Apparatus for making a plastic lens is described. More particularly, an apparatus for applying alternating periods of ultraviolet light to a lens forming composition is described. The lens forming composition is cured while the rate of heat generation and/or dissipation is controlled via manipulation of the duration of the ultraviolet light or the cooling in the curing chamber. The ultraviolet light is preferably directed toward the lens forming composition which is disposed in a mold cavity formed by two mold members. The ultraviolet light may be directed in pulses or continuously.

Abstract: A method and apparatus for practicing the method of making toric contact lenses having a toric axis and ballast axis located on the anterior and posterior surfaces of a lens. Detectable features are formed on the anterior and posterior mold sections corresponding to the location of the toric axis and ballast axis, respectively. An axis alignment tool having detecting means thereon is used to set the mold sections to a known angular position. The desired axial offset is input into a computer which establishes the axial offset between the mold sections.

Abstract: A cast-molding material for a plastic lens which is almost free from causing defective dyeing when dyed, and a process for producing plastic lenses almost free from causing defective dyeing, the cast-molding material containing, as essential components, a combination of (A) diethylene glycol bisallylcarbonate or a mixture of diethylene glycol bisallylcarbonate and a monomer copolymerizable therewith, with (B) a polyether-modified silicone compound, and the process comprising cast-molding the above cast-molding material in a mold.

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.

Abstract: A multiple axes electroform is created by first locating a plurality of reflex or optical pins and a mold matrix that extends generally parallel to a first axis. A second mold matrix is created by loading into a fixture yet another set of pins that are generally parallel to a second axis. Electroforms are then made from each mold matrix. The resulting electroforms are then placed into yet another fixture whereby a third electroform is made. The third electroform is then placed into a final fixture where a master electroform is made which will be used in the tooling that is used to injection mold the final automotive lens assembly.

Abstract: A method of manufacturing a lens having a lens body integral with a functional sheet on one side thereof, includes an insert molding process including the steps of: placing the functional sheet as an insert in position in a mold defining a suction hole therein; and while attracting the functional sheet against a molding surface of the mold by a peripheral portion thereof by suction through the suction hole, supplying to the mold a molten plastic material for forming the lens body, to form the lens.

Abstract: A lens molding system which uses glass molds to mold polycarbonate blanks. The blanks are preheated, then additionally surface heated, molded, and cooled under pressure.

Abstract: Disclosed are a molding apparatus for glass optical elements a plurality of molds each constituted of an upper mold and a lower mold, a matrix supporting the molds, and heating means wound around the matrix for heating the molds, wherein the matrix extends in a longitudinal form and has a constant width, wherein the plurality of the molds are arranged in the matrix in a line so that the center of each mold is located on a center line of the matrix, and wherein a distance between the heating means and the matrix is constant at least at an edge of the matrix in a transverse direction, and a molding method for optical elements comprising the steps of: softening a plurality of glass material pieces by heat; and making a simultaneous press molding of the glass material pieces with a plurality of molds, constituted of upper and lower molds, arranged in a longitudinal form matrix, in a line extending in a longitudinal direction, wherein each mold is heated by thermal conductance from the matrix heated by heating mea

Abstract: In a method of producing a lightguide plate for surface light source according to the present invention, a plate-shaped metal mold for defining the shape of a part of a cavity of a molding die and particularly, the shape of a light emitting surface of the lightguide plate for surface light source (a concavo-convex shape, a lenticular lens shape, etc.) is provided so as to be replaceable, to form a cavity having a desired shape by the replacement of the plate-shaped metal mold. Resin liquid is injected into the cavity, its resin liquid is solidified, and the resin is then released from the cavity. Consequently, a lightguide plate for surface light source having a desired shape and particularly, having its light emitting surface in a desired shape is produced.

Abstract: A progressive lens mold, a method of making a progressive lens mold, and progressive lenses made using such mold or method. Back faces of progressive molds are preferentially tapered at their edges to reduce prism effects in lenses made using such molds. The tapering is accomplished by removing more of the back face adjacent the near portion vision zone of the mold versus the back face adjacent to the far vision zone of the molds.

Abstract: A method for curing a lens-forming fluid, including exposing the lens-forming fluid to an ultra-violet light, wherein the exposure time is between twenty seconds and thirty minutes, which can completely cure the fluid. The exposure can occur by placing the lens-forming fluid intermediate a plurality of ultraviolet light sources, in which the intensity of the ultra-violet light is at least 1.2.times.10.sup.-2 watts per square centimeter at a wavelength of 350 nanometers. The lens-forming fluid preferably is a monomer. The prior art, in contrast, requires significantly longer exposure times to cure monomer or other lens-forming fluids.

Abstract: Disclosed herein is a method and apparatus for forming on-site tinted and coated optical elements from a mold. The apparatus is a mold having a polymer release layer; an optical coating, such as an anti-reflective coating; a coupling agent layer to bind to the optical coating and having unreacted chemical groups; and, optionally, a tinted hard coat layer having unreacted chemical groups. The mold can be shipped to a lab that prepares optical elements, such as ophthalmic lenses, after the coupling agent layer is added or after the tinted hard coat layer is added. When using the mold with a lens resin having unreacted chemical groups, the coupling agent layer, tinted hard coat layer and optical element all crosslink as the optical element is cured to form, on-site, a durable and stable lens with chemically bound optical coatings.

Abstract: An apparatus and method for casting lens without using a gasket that can be used to form all powers and geometric shapes of lenses. An elastomeric strip is used to wrap around the edges of two molds to form a sleeve-like structure, which in turn cooperates with the molds to form a molding cavity. Moreover, this sleeve-like structure does not crumple or shrink during the lens polymerization process. Instead, it allows the molds to slide axially within it to compensate for any shrinkage that occurs during the lens polymerization 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.

Abstract: A method of forming an optical component wherein imperfections in molding the optical component, such as a lens, are removed by: heating an optical material to its plastic state; forming the optical material into the desired shape by employing a mold apparatus and applying a molding pressure; releasing all pressure from the shaped optical material by separating sections of the mold in order to relieve internal stress in the optical material while the optical material is at its plastic state temperature; slowly and controllably reducing the temperature of the optical material.

Abstract: Method and apparatus for making and coating a plastic lens. Oxygen barrier containing photoinitiator is used to cure incompletely cured lens portions. Radiation pulses are used to control lens curing rate. Lens is postcured while in a mold cavity using a conductive heat source. Air may be directed toward the mold cavity to help remove heat from the lens. An in-mold scratch resistant coating may be formed from two separate material which both contain a photoinitiator.

Abstract: An apparatus and method for assembling a lens-forming structure, the structure having a front mold, a rear mold, and a gasket defining an axially extending bore, including a collet for supporting the gasket so that at least one of the front mold or the rear mold are insertable into the bore thereof, a robotic arm for inserting the front mold into the bore of the gasket, and a piston for inserting the rear mold into the bore of the gasket. The piston axially moves 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. Alternatively, the robotic arm can move the selected mold relative to the other mold.

Abstract: A mold assembly for forming a lens blank which gives a contact lens includes an upper and a lower mold half which cooperate with each other to define a substantially fluid-tight mold cavity when the two halves are assembled together. The mold cavity is filled with a monomer liquid which is polymerized to provide the lens blank that is to be subjected to a cutting operation for forming a base and a front curved surface of the contact lens. The upper mold half includes a flexible thin-walled portion which has a downwardly convex shape and which partially defines the mold cavity. The thin-walled portion is deformable to absorb expansion or shrinkage of the monomer liquid during polymerization thereof in the mold cavity. The lower mold half includes a base portion at which the lower mold half is clamped by a chuck of a lathe during the cutting operation. A mold portion of the lower mold half has a molding surface which is provided with a recess or protrusion for holding the lens blank on the lower mold half.

Abstract: A contact lens production line pallet system transports contact lens mold materials throughout a facility for producing ophthalmic lenses. Specifically, the contact lens production line pallet system includes a pallet for carrying one or more contact lens mold assemblies throughout a contact lens production line, the pallet having one or more first recesses formed in a surface thereof for receiving either a first mold half or a complementary second mold half, the first and second mold halves when placed together constitute an individual contact lens mold assembly. A conveyor device for transporting the pallet from station to station throughout the production line facility is provided, as is a locating device formed in the pallet surface for enabling precise positioning of the pallet at one or more manufacturing stations in the production line facility.

Abstract: A gasket defining an axially extending bore therethrough, a front mold having a an edge circumscribing the front mold, wherein the edge is of a size to be complementarily received within at least a portion of the bore of the gasket so that the edge and the bore form a seal therebetween, and a rear mold having a rim circumscribing the rear mold, wherein the rim is sized to be complementarily received within at least a portion of the bore so that the rim and the bore form a seal therebetween. When the front mold and the rear mold are both disposed within the bore of the gasket, a volume is formed between the back surface of the front mold and the front surface of the rear mold and the interior surface of the gasket. A selected one of the front mold or the rear mold is axially and slidably movable within the bore relative to the other mold disposed within the bore to a desired one of a plurality of axial separation distances between the molds, whereby the volume is different for each separation distance.

Abstract: The present invention relates to making optical articles such as opthalmic lenses by molding and, in particular, to using a continuous extrusion-compression molding method to make plastic lenses whereby a polymer melt is fed from an extruder or melting apparatus to a first die of a plurality of rotating or conveyed sequentially processed compression die sets comprising a first die and a second die. The die sets are positioned on die supports on a rotating turntable or conveying system, the lenses formed by compressing the die sets with pressing means associated with each die support, the lenses separated from the dies and the dies recycled to die loading and the melt feed step of the process and the process repeated until the desired number of lenses or other optical articles such as compact disk substrates are produced.

Abstract: An automated method and apparatus is provided to mold and cure soft contact lenses. A molding station injection molds first and second mold parts for the production of the lenses and these mold parts are transferred to an inert gas or low oxygen environment wherein a series of automated stations receive the mold parts, deposit a polymerizable hydrogel within the first mold part, assemble and clamp the first and second mold parts together, apply radiant energy for polymerizing the hydrogel and subsequently separate the mold parts.

Abstract: A method for separating one mold section from another mold section and a contact lens molded in the two mold sections provides improved reliability that the lens is not damaged during this operation and that the lens is retained selectively on the desired. Various embodiments of apparatus for carrying out the method are disclosed.

Abstract: An extrusion-compression molding process is provided for making optical articles wherein a melt shot of optical polymer extrudate is fed to sequentially moving lower dies of a die set including a lower die and an upper die and then the upper die positioned on top of the melt shot containing lower die and the die set compressed forming the optical article. After the optical article is formed, the lower die and upper die are separated and recycled for forming additional optical articles. The optical polymeric material may be in the form of pellets and melted in an extruder. A reaction extruder may also be employed where the optical polymeric material is produced in the reaction extruder from optical polymer monomers. A shuttle carriage is preferably used to transport the lower die, melt shot containing lower die and melt shot containing die set through the steps of the molding process. A control system is used to obtain input data and generate output signals to monitor and control the process steps.

Abstract: This invention relates to a method of making a microprism master mold which is suitable for use in the production of cube-corner retroreflectors, especially in the form of thin retroreflective sheeting, and permits the formation of hexagonal prism type microprisms having both high reflectivity and excellent angularity. This method is characterized in that, in making a cube-corner microprism master mold by stacking a plurality of flat sheets having two mutually parallel major surfaces, cutting V-shaped grooves on one lateral surface of the resulting flat sheet stack in a direction perpendicular to the major surfaces and at a fixed pitch to form a series of successive roof-shaped projections having a vertical angle of about 90.degree., and then shifting the flat sheets so that the vertices of the roof-shaped projections formed on each flat sheet meet the bottoms of the V-shaped grooves formed on an adjacent flat sheet. The flat sheets having a thickness of 50 to 500 .mu.

Abstract: A die for press-molding glass optical elements comprising (a) a base material having heat resistance and sufficient strength to withstand press-molding of optical glass elements; (b) a film on said base material comprising an alloy film containing B and one metal selected from the group consisting of Ni, Co, and Fe, and one metal selected from the group consisting of Si, Ti, Cu, Zr, Nb, Mo, Ru, Rh, Pd, Hf, Ta, W, Re, Os, and Ir, to form a cutting layer; and (c) a surface protective layer on top of said cutting layer made of an alloy film comprising at least one metal selected from the group consisting of Pt, Pd, Ir, Rh, Os, Ru, Re, W, and Ta.

Abstract: An aspheric soft intraocular lens, having an optical power surface, which may have multiple radii portions or aspherical portions, as well as spherical portions, intended to replace the crystalline lens of a patient's eye, in particular after a cataract extraction. Such an aspheric soft lens is molded in a coined mold. A pair of core pins, positioned within the mold cavity during the lens forming process, will produce a pair of haptic-mounting holes within the lens. As the lenses are subsequently tumbled to remove flash, indentations will form adjacent to the haptic-mounting holes. These indentations allow for tangential attachment of the haptic to the lens which, in turn, enables maximum flexibility without exceeding the width of the optic.

Abstract: A method for manufacturing preforms used in molding optical elements includes: (1) forming an array made from a material for optical elements, in which a plurality of preform portions used in molding optical elements are connected; (2) applying vibration to the outer peripheral part of the preform portion in the thickness direction of the array by a pair of punches; and then (3) punching the preform portions.

Abstract: A lens device which can be used as an objective lens in an optical pickup apparatus includes an objective lens provided along a light path facing a disc and having a predetermined effective diameter, and light controlling means provided along the light path for controlling the light in an intermediate region between near and far axes of an incident light beam, thus providing a simplified and inexpensive device for using discs of differing thickness in a single disc drive, by reducing the spherical aberration effect.

Abstract: Designs for basecurves are disclosed which are designed to promote adhesion of an excess polymer HEMA ring to the basecurve during a demolding operation such that the excess polymer HEMA ring is removed along with the basecurve during the demolding operation. The basecurve mold designs promote and maintain adhesion of an excess polymer HEMA ring to the basecurve in a process for molding cast contact lenses in mold assemblies, each comprising a frontcurve and a spaced basecurve, and wherein a molded lens is formed therebetween. In an embodiment of the invention, the annular area of the basecurve mold can be formed with an annular step which includes projecting teeth positioned therearound which project into the excess polymer HEMA ring.

Abstract: A molded optical component which is comprised of a lens portion, an annular outer rim integrally formed around the circumference of the lens portion, an annular reference surface formed on the circumference of the outer rim in a predetermined width along one end thereof, and an obliquely cut surface formed across the circumference of the outer rim by stripping a gate stub therefrom. The obliquely cut surface is extended from the other end of the outer rim up to a position falling short of near boundaries of the reference surface.

Abstract: A contact lens button and a block are integrally formed together when the contact lens button is cast in a cup having an aperture formed in the center of the bottom wall of the cup. The block has a first elongated end forming a spindle and a second end which is of circular, generally planar configuration. The spindle end is inserted through the aperture in the bottom wall of the cup providing an interference fit with the circular end portion located inside the cup spaced parallel to and slightly upwardly from the bottom wall, and the first spindle end extends exteriorly of the cup. A quantity of liquid lens material is dispensed into the cup, completely surrounding the circular end portion of the block. The material cures around the block second end, with the formed button and block removable from the cup as a single unit. The block first end is secured to a lathe chuck for rotating the button to cut the concave base surface of the lens.

Abstract: In an injection compression molding method of a lens, in which a mold is closed to preserve a predetermined compressing margin in a cavity 3 for a lens, molten resin is injected and fed into the cavity 3 for the lens, and compressed for the aforementioned predetermined compressing margin before or after the injection and the feed of the molten resin is completed, the predetermined compressing margin (the degree of slightly opening S.sub.(-)) for producing a minus lens is molded is defined to be larger than the predetermined compressing margin (the degree of slightly opening S.sub.(+)) for producing a plus lens is molded. As a result, even when the minus lens is molded, the larger area of the cavity can be ensure and a flow property of the molten resin in the cavity is improved, so that the molten resin reached the inside of the cavity 3 flow through the central portion of the cavity 3 into the peripheral portion, with the result that the appearance of a weld mark in the central portion is avoided.

Abstract: A method and apparatus for curing lenses involves supporting mold assemblies containing lens-forming mixture on plates, where the plates are stacked vertically with sufficient clearance to separate adjacent plates of mold assemblies.

Abstract: A method of injection molding contact lens molds for cast molding contact lenses having a rotationally asymmetric lens surface, and apparatus for carrying out the method, are disclosed.

Abstract: A contact lens production line pallet system transports contact lens mold materials throughout a facility for producing ophthalmic lenses. Specifically, the contact lens production line pallet system includes a pallet for carrying one or more contact lens mold assemblies throughout a contact lens production line, the pallet having one or more first recesses formed in a surface thereof for receiving either a first mold half or a complementary second mold half, the first and second mold halves when placed together constitute an individual contact lens mold assembly. A conveyor device for transporting the pallet from station to station throughout the production line facility is provided, as is a locating device formed in the pallet surface for enabling precise positioning of the pallet at one or more manufacturing stations in the production line facility.

Abstract: A method for making optical preforms of optical elements without residual stress or distortion is provided. In this method, an optical material is supplied between upper and lower molds. The upper mold has a plurality of recesses arranged in a predetermined pitch, and each recess corresponds to a first surface shape of the optical element. The lower mold has a plurality of recesses facing the recesses of the upper mold and each recess of the lower mold corresponds to a second surface shape of the optical element. The supplied optical material is pressed between the upper and lower molds to be a set of optical preforms. The set of optical preforms is processed by die punching or tool cutting to separate each optical preform from the set of optical preforms. Each optical preform is used for producing an optical element by further pressing. Alternatively, optical element can be formed directly by the press molding process.