Abstract: A process is described for forming a lighting louver that includes a plurality of louver members. The process includes the steps of providing a sheet of thermoformable material and heating the sheet to a pliable state. A further step includes providing a forming mandrel having a series of mandrel partitions arranged with spaces between the partitions. The heated sheet is positioned over the forming mandrel, and is forced against the forming mandrel to form the heated sheet over the mandrel partitions and thereby produce a formed louver blank including formed louver segments that conform to the mandrel partitions and webbing segments that span the spaces between the partitions on the forming mandrel. In one preferred form the webbing segments are removed. In another preferred form, transparent webbing segments are formed that do not require removal and will transmit light. The webbing segments in the first form are removed from the louver blank to form light transmissive openings through the louver blank.

Abstract: A method for producing diffractive optic molding tools with improved durability is accomplished by depositing a layer of chromium carbide on a substrate material. This layer of chromium carbide becomes the receptor for a final machinable coating such as electroless nickel. The pattern for the desired diffractive surface is predetermined and a single-point-diamond turning machine is used to cut the negative of this predetermined pattern into the machinable layer to produce the pattern of concentric zones to the required depths. The pattern is then uniformly etched in the machinable layer down into the intermediate layer of chromium carbide resulting in the complete removal of all of the electroless nickel. In that the etching rates of electroless nickel and chromium carbide differ from one another, it is necessary to dimensionally adjust the negative pattern turned into the electroless nickel surface to allow for the different etch rates.

Abstract: An improved method for forming plastic molds for casting articles having an optical surface such as contact lenses employs a plastic tool having an optically smooth surface.

Abstract: In an injection step, actual injection speed V is closed-controlled so that the actual injection speed V becomes equal to first or second preset speed V.sub.1 or V.sub.2 while comparing the actual injection speed V with the first or second preset speed V.sub.1 or V.sub.2 in the section between S.sub.0 and S.sub.1 from the time when injection of molten resin is started up to the time when the molten resin reaches this side of a gate portion 46 or the section between S.sub.1 and S.sub.2 from the time when the molten resin reaches this side of the gate portion 46 up to the time when the molten resin reaches the inside of a cavity 3. The injection speed V is open- controlled to third preset speed V.sub.3 in the section between S.sub.2 and S.sub.3 from the time when the molten resin reaches the inside of the cavity 3 up to the time when injection of the molten resin is completed.

Abstract: An injection molding process for molding an assembly of a frontcurve molds in a plurality of unitary solid piece of polymer in which plurality of frontcurve molds are arranged symmetrically around a single center polymer injection gate. In this arrangement the molten polymer flows radially outwardly therefrom uniformly in all directions to the four frontcurves to form one common molded piece of polymer. In a compression injection molding process, the pressure on the molten polymer is maintained relatively constant, and the mold is mechanically collapsed during the molding operation. The present invention molds an assembly of frontcurve molds in a manner in which there is a significant reduction of residual stress locked into the resultant assembly of frontcurve molds. This results in a significant reduction in warpage and shrinkage of each frontcurve mold, which is not optically stressed, and results in a subsequent casting of an ophthalmic lens which is not optically stressed.

Abstract: In press molding, a shaft (metal mold 13) is moved by positional or torque control to cause upper and lower molds to reach a set position slightly before a position where the upper and lower molds are set in a final mold closed state. As soon as the upper and lower molds reaches the set position, the control is switched to torque control using a small force which does not deform a glass material to perform feedback control. For this reason, when the cooling process is started, the mobile shaft is moved by the same amount as a contraction amount of the shaft, the actual position of the shaft is moved. However, a tight contact state between the molds and the glass material is kept without changing the thickness of the glass material, and positional control and torque control can be apparently performed at once. Thereafter, when temperature reaches an almost glass transition point, final pressing is performed.

Abstract: Methods and apparatus which are utilized for the production of ophthalmic lenses, and more particularly, a method for the removal or demolding of molded ophthalmic contact lenses from the individual molds in which they are produced. The apparatus implements the demolding of such ophthalmic lenses, the latter of which may consist of suitable hydrogel contact lenses or other types of high-precision ophthalmic lenses; for example, such as intraocular contact lenses. Mechanical prying apart of such mating mold half portions, and to facilitate this procedure at a reduced application of force, while concurrently potentially preventing or at least appreciably ameliorating the extent of any possible sticking together of the mold half portions is effected in that mechanical leverage applied to the upper mold half portion, in addition to the application of the heating action thereto.

Abstract: A method of making a long, thin, flexible lens. The method comprises the steps of providing a mold having a top surface shape corresponding to a desired lens shape. A curable optical material is dispenses onto the top surface. A thin, flexible structural layer is placed onto the top surface, over the curable optical material to form a mold assembly. The mold assembly is cured. The flexible lens is removed from the mold top surface. The flexible lens is capable of flexing in at least a 180.degree. arc while maintaining its diffraction limited optical characteristics.

Abstract: A one-piece intraocular lens made entirely of three-dimensionally crosslinked polymethyl methacrylate is prepared by selectively press-stretching a lens blank at a temperature of 125 to 140.degree. C. in those areas around the periphery of the central effective optic area and from which the haptic portions are formed rendering areas more robust and less prone to fracture while the central effective optic area is not press-stretched. The lenses are durable to YAG laser irradiation.

Abstract: The present invention provides a method of manufacturing plastic lenses of urethane type resin having no or very little optical strain by the casting polymerization method. In the casting polymerization process, polymerization is effected while a suitable motion, for example, a particular rotative motion, or a motion based on rotation with the rotatable shaft disposedhorizontal is imparted to the shell to change the direction of the gravity acting on any minute portion of a monomer injected into the shell.

Abstract: A method of making an ophthalmic lens including the steps of: preparing a polymerizable composition comprising excessive oxygen content; contacting the polymerizable composition with a gas that is inert or substantially inert to the polymerizable composition, and deoxygenating or partially deoxygenating the polymerizable composition; conveying all or part of the polymerizable composition to an ophthalmic lens mold; polymerizing all or part of the polymerizable composition and obtaining a polymeric ophthalmic lens, and the lens produced by such process.

Abstract: A rotational indexing base curve deposition array for assembling contact lens base curves and front curves with a prescribed and programmable angular orientation to produce a contact lens having a selected axis placement therein, such as a toric axis for a toric contact lens. An array of front curve molds are arranged in a support pallet with a dosed amount of monomer mixture deposited into each of the front curve molds. An array of deposition tubes, positioned in a support plate and coupled to a vacuum source, is used to pick up and support an array of base curve molds. Each of the deposition tubes is then angularly rotated in to the support plate to a selected angularly indexed position therein. A common angular rotational drive is coupled to each of the deposition tubes in the array to angular index each of the deposition tubes to a precise angular position in the support plate.

Abstract: An apparatus and method for 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 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 partially polymerizing the polymerizable monomer or monomer mixture contained in each contact lens mold.

Abstract: Method and apparatus for producing vitreous optical elements by injection molding, which essentially includes the stages of: melting down a glass material into a molten state in a viscosity at or lower than a working point of the glass material; injecting molten glass under pressure into a mold cavity defined between transfer surfaces of relatively movable mold members of a mold assembly unit in communication with a sprue connecting the mold cavity with an injection port on the outer side of the mold assembly unit; and applying a predetermined pressure on the glass material in the mold cavity while cooling the mold assembly unit down to a temperature in the vicinity of yielding point of the glass material.

Abstract: A retroreflective sheeting includes a first array of cube corner element opposing pairs and a second array of cube corner element opposing pairs. The symmetry axes of the cube corner elements in the first and second arrays are tilted in a backward direction at an angle of about 12.degree. to about 30.degree. from an axis normal to a base surface. The second array of cube corner elements is oriented approximately perpendicular to the first array to yield a retroreflective article providing generally uniform total light return about a 360.degree. range of orientation angles and/or a minimum total light return of about 5% across such 360.degree. range. Also disclosed is a mold assembly suitable for use in forming the present retroreflective sheeting and a method of making a retroreflective article using the mold.

Abstract: The polymethyl methacrylate (PMMA) or copolymer thereof used to produce one-piece intraocular lenses is modified by a compression molding process to produce a much tougher material with improved mechanical properties. The process takes material in rod form and compresses into lens blanks. The molded lens blanks receive little or no compression strain in the center 4 mm optic zone. The compression is limited to the periphery region outside the center 4 mm zone. The intraocular lens fabricated from the molded lens blank exhibits greatly increased haptic mechanical properties and resistance to breakage.

Abstract: In a process for the manufacture of contact lenses, a polymerizable contact lens material is dispensed into a mould half (1) and the mould is subsequently closed by means of the second mould half (2). The material located between the two mould halves in the moulding cavity (12) is then polymerized, thus forming an as yet unhydrated contact lens (CL). The moulding surface of one of the two mould halves (1, 2) is pre-treated, before use, in a region (20) outside the optically active zone of the contact lens (CL) in such a manner that, when the mould is opened, the contact lens (CL) adheres to the pre-treated mould half.

Abstract: A multi-colored lens assembly is produced in a multi-station injection molding apparatus having non-indexing ejector halves and indexing cover halves. Material is shot on an unexposed illumination side of the lens assembly from valve gated nozzle drops contained in the non-indexing ejector halves thereby producing a viewing side of the lens assembly free of surface blemishes and surface stress defects. Lens assemblies are retained in the indexing cover halves by retention mechanisms provided to overlap peripherally extreme features of the lens assemblies. Lens assemblies are affirmatively released from the non-indexing ejector halves by ejection pins or blades simultaneously with parting of the mold halves.

Abstract: Collimated white light is transmitted through a transparent lens mold having a molded lens resting on a curved surface thereof. A telecentric lens and a camera having a digital output are used to view the illuminated lens to obtain pixel image data of the lens. The pixel image data is analyzed by a computer to detect deformities in the molded lens.

Abstract: A method of manufacturing complex optical surfaces in soft contact lenses includes a first step of defining the complex optical surfaces with a computer assisted drafting program using a mix of patient determined parameters and selected manufacturing process determined parameters to define a mathematical "meta lens". A machine code data set is then generated to machine a plurality of contact lens mold inserts to define a complex optical surface on each of the inserts. The machining step is conducted with a single point diamond lathe having submicron precision and repeatability. A first and second plurality of intermediate contact lens mold halves are then molded with said contact lens mold inserts to define said complex optical surfaces on said mold halves having micron range transitions between optical surfaces. The complex geometric forms and optical surfaces include bifocal lenses, aspheric lenses, and toric lenses wherein the lenses may include parabolic or elliptical geometry.

Abstract: Molds for press molding an optical element of glass are disclosed. Proposed are: (1) A mold contains oxygen at the interface between a mold base of the mold and a carbon film formed at least on the molding surface of the mold base with an oxygen amount of 0-10 atom % and with the interface of a width of 0-500 .ANG., (2) a mold subjected to carbon ion injection at least on the molding surface of the mold base, and (3) a mold subjected to ion injection during or after formation of a carbon film at least on the molding surface of the mold base material.

Abstract: An upper die 1 of a movable die corresponding with a lower die 2 of a stationary die is composed of a die body 3 and a die fitting member 4, in which a back insert 29, a hydraulic cylinder 23 and a pressure receiving portion 30 as a holding member of an insert 20 forming a cavity 22 is abutted to the die fitting member 4 by being urged upward by a spring 32. After resin, fed into the cavity 22, is compressed with the insert 20 by lifting the die fitting member 4 down, when the die fitting member 4 is lifted up at the degree of slightly opening S, by lifting the insert 20 down to be relatively to the die fitting member 4 with an eject pin 34, a space A between a molding 44 and the insert 20 is to be smaller, and the molding 44 is pushed out by causing the eject pin 34 to lift the insert 20 down when the upper die 1 and the lower die 2 are separated.

Abstract: A plastic molding apparatus and method employs a pair of dies having at least one cavity with a mirror surface and wherein a plastic base material which is pre-molded is inserted into the cavity and clamped by the pair of dies. The plastic base material is then heated and melted at glass transition temperature or higher so that a resin internal pressure is generated, and then the plastic base material is annealed so that the mirror surface is transferred to the plastic base material. One of the dies has a separation die in which the cavity is formed. A cavity forming portion thereof has a cavity forming surface and a cavity side board portion which is adjacent to the cavity forming portion and surrounds the cavity forming surface. A separating die clamping structure clamps the separation die from both sides so as to compress an elastic member mounted between the cavity forming portion and the cavity side board.

Abstract: The present invention is directed to a composition of polystyrene or polypropylene with at least 0.5% (w/w)of an additive or wetting agent, the article of manufacture comprised thereof, such as a mold for making contact lenses and the mold assembly containing said mold, and the use of such mold so to minimize defects, such as holes, puddles, chips and tears in the lens.

Abstract: An apparatus for separating individual contact lens mold assemblies, the assemblies each being a front curve mold half and a back curve mold half, each mold half having annular circumferential flanges, is included. The apparatus includes a device for applying steam to the back curve mold half to form a temperature gradient from the front mold half to the back mold half. The apparatus also includes a second device to pry the mold halves apart.

Abstract: An improved method for cast molding RGP contact lenses employs mold sections injection molded from a specific class of thermoplastic, polyolefin resins.

Abstract: A progressive power lens has an effective surface including a progressive surface which progressively varies the power, and a peripheral rim surface portion which surrounds the progressive surface yet does not function as an effective surface. The rim surface is curved. The invention is also directed to a mold to produce a progressive power lens. The mold includes a portion which forms progressive surface which progressively varies the power of the lens and a curved rim surface forming portion which forms a rim surface of the lens which does not function as a progressive surface.

Abstract: Demolding apparatus for reliably and repeatedly mechanically separating contact lens mold assemblies without damaging the contact lens formed therebetween. The mold assembly includes a frontcurve mold having a central mold section with a surrounding flange, and a corresponding backcurve mold also having a central mold section with a surrounding flange, with a contact lens being molded therebetween. The demolding apparatus includes a conductive heating probe which contacts the backcurve mold of the lens mold assembly to conductively heat the backcurve mold. Heat is conducted by the backcurve mold to cause a temperature gradient between the backcurve mold and the lens being demolded. The temperature gradient causes a differential expansion and shifting of the surface of the backcurve mold relative to the surface of the lens to lessen the adhesion therebetween to assist in separation of the molds, while leaving the lens in the frontcurve mold.

Abstract: An apparatus and method for removing a molded ophthalmic lens from between the mold portions in which it is produced. A source of intense electromagnetic radiation is applied to at least one of the mold portions in a predetermined scanning pattern through the intermediary of galvanometer-driven mirrors. Differential expansion of the heated mold polymer relative to the cooler polymer shifts one surface with respect to the other, and the shear force breaks the polymerized lens/polymer mold adhesion and assists in the separation of mold portions. The greater the temperature gradient between the surfaces of the mold portions, the greater the shearing force and the easier the mold portions separate. The heated back mold portion is promptly removed so that very little energy is transferred to the polymer lens, avoiding the possibility of thermal decomposition of the lens.

Abstract: An automated method and apparatus is provided to mold and cure soft contact lenses. At a first station, front curve mold halves are partially filled with a polymerizable monomer. At a second station, a surfactant coating may be applied to a flange on the front curve mold half to provide subsequent preferential adhesion of any excess hydrogel to a back curve mold half at the time the mold halves are separated. At a third station, the mold halves are assembled under vacuum, and clamped to displace any excess hydrogel from the mold cavity. This clamping step firmly seats the back curve mold half, severs any excess monomer from the monomer in the cavity, defines the lens edge, and seals the cavity in a vacuum. Following assembly of the mold halves, the assembly is transported to a precure station and reclamped, and the monomer is precured with actinic radiation, such as UV, to partially cure the monomer to a gel like consistency.

Abstract: Method and apparatus for lens thickness adjustment in injection molding of thermoplastic vision-corrective spectacle lenses without manual addition or removal of shims, of inserts or of any other mold part. Thickness adjustment can be made quickly between molding cycles with a simple manual setting and locking step while the lens mold is kept at very hot operating temperatures, yet with minimal risk of burning the operator. A rotatable adjustment head is mounted externally onto the mold's operator side, and manually-driven rotation turns a threaded screw which engages a mechanical assembly which produces an axially perpendicular motion which in turn drives forward or back the settable position of an optically polished insert within the lens mold's cavity. Preferably, this manually-driven rotation turns a worm gear mechanism which rotates a threaded male shaft within a mated threaded female bore axially perpendicular to the parting line.

Abstract: A method and apparatus for forming an optical device of a desired shape presses a heat-softened optical material using a set of molds. The optical material is aligned with respect to the molds by two or more aligning members which move around the center of the mold relative to each other. The optical material may also be aligned by inserting a pin into an aligning hole which is fixed to the mold body and has been aligned with respect to the molds.

Abstract: In a process for the manufacture of mouldings, especially optical lenses, specifically contact lenses (CL), a starting material that is crosslinkable by the impingement of suitable energy is introduced into a mould (1) having a cavity (15), which mould is at least partially permeable to the energy concerned. The starting material is introduced into the cavity in a still at least partially uncrosslinked state, the mould cavity determining the shape of the moulding (CL) to be produced. By means of impingement of the energy concerned, the starting material is crosslinked to an extent sufficient for it to be possible for the moulding (CL) to be released from the mould. The filling of the mould cavity is carried out in the starting material that is still at least partially in the uncrosslinked state.

Abstract: In a process for the production of optical lenses, in particular contact lenses, a lens material is introduced between two mould halves. The mould halves each have a moulding surface and enclose a cavity in the closed state of the mould. After the lens material has been introduced the two moulding surfaces are moved towards each other and the lens material is enclosed in the cavity. If necessary, the lens material enclosed in the cavity is then polymerised. The first moulding surface is provided on the one mould half and the other mould half includes a mould part that is movable inside it with a close fit in the manner of a piston and on which the second moulding surface is provided, so that by moving that mould part towards the first moulding surface the cavity is closed. For this purpose, the two mould halves are first assembled, then the movable mould part which has the second moulding surface is moved in the direction towards the first moulding surface.

Abstract: Roll-forming apparatus and method for more precisely shaping an extruded-plastic Fresnel lens. A drive/support roller is rotatably mounted to the support frame and the surface of which engages and rotates to support the smooth outer surface of an extruded arcuate, elongated linear Fresnel lens. A tooth-forming roller is rotatably mounted to the support frame and has an external profile with tooth-forming projections formed thereon for engagement with the grooves on the inner surface of the extruded sheet, said tooth-forming roller being positioned on the inner surface of the Fresnel lens opposite the drive/support roller and being loosely mounted on the support frame to track the grooves formed in the Fresnel lens to improve the profile of the lens section by sharpening the root radius and flattening the optical face of each lens section.

Abstract: An automated demolding apparatus for reliably and repeatedly mechanically separating contact lens mold portions of a mold assembly without damaging the contact lens formed there between. Before demolding, the second mold portion is irradiated by a laser beam, which is absorbed thereby to cause a substantial temperature gradient between the second mold portion and the contact lens being demolded.

Abstract: New intraocular lenses and methods for producing such lenses. In one embodiment, the intraocular lens includes an optic; and at least one fixation member, e.g., haptic, secured to and extending from the optic, the fixation member being made from a rotated item including a polymer, the rotated item being derived by placing an item having a thickness and the same chemical make-up as the rotated item between two surfaces so that the surfaces each contact the item and are separated by the thickness, and rotating at least a portion of one of the surfaces around an axis substantially parallel to the thickness, provided that the intraocular lens has increased tensile strength relative to a substantially identical intraocular lens made from the original item. Methods of making intraocular lenses are also included.

Abstract: The invention relates to a method of making an intraocular implant having a flexible lens. The method includes in using a mold having two parts (12) and (16) which are disposed on either side of a plate (20), e.g. made of PMMA, which plate includes a central orifice. The material (32) that is to constitute the lens portion is disposed in the central cavity of the mold. This material may be an acrylic, for example. After unmolding, the plate (20) is machined to make the haptic, and optionally the part (32) is machined to make the lens.

Abstract: A method and apparatus for releasably securing mold pieces used to mold an artificial eye lens, for example a hydrophilic contact lens. The apparatus includes an ultrasonic welding system to provide directed energy, modified so that the output horn is convex to extend within the outer concave portion of one of the mold pieces and has a shoulder to rest upon the flange of said piece thereby centering it. The method applies directed energy, such as ultrasonic vibrations, through the energy emitter horn to soften or melt then fuse the mating peripheral edge portion of the lens mold pieces.

Abstract: The method and apparatus can manufacture a plastic sheet of uniform thickness and reduced distortion, by use of metallic molds and in accordance with cast molding polymerization (casting) technique. The plastic sheet manufacturing apparatus for manufacturing a plastic sheet by injecting a raw material into a polymerization cell (101) and by polymerizing the injected raw material by heat, includes a pair of first and second molds (104A, 104B) for forming the polymerization cell (101); and first and second heat conductors (102, 103) attached to both outside surfaces of the first and second molds, respectively, so as to be opposed to each other and to sandwich the first and second molds therebetween. Here, in particular, each of the first and second heat conductors is formed with a fluid passage (210) therein to circulate a heated fluid whose temperature is controlled.

Abstract: A synthetic resin layered lens for a vehicle lighting device in which an upper lens layer is disposed on a lower lens layer thereby forming a layered lens of integral construction. The lower lens layer is molded in a state that the surface of the lower lens layer where it contacts the upper lens layer, faces the injection gate. The gate scar of the lower layer is thus hidden by the upper layer.

Abstract: An injection molding process for the manufacture of composite, molded, thermoplastic articles comprising an insert member contiguous with a second body of molded thermoplastic material, is carried out in a mold assembly comprising a core member and a cavity member engageable therewith. The core and cavity members cooperate to define a first molding station having a first cavity for molding an insert member, and a second molding station which is configured to receive and support an insert member therein, and to provide a second molding cavity contiguous with the insert member for molding a thermoplastic body contiguous with the insert. At the start of the process, an insert is supported in the second station, and thermoplastic materials are injected into the molding cavities in the first and second stations so as to mold an insert and a completed, composite member.

Abstract: Plastic injection-compression multi-cavity molding of flash-free improved-cleanliness thermoplastic spectacle lenses (16) are suitable to be robotically dip hardcoated. Special spring-loaded (25, 26) molds having variable-volume mold cavities are used in an injection-compression molding process to form, without parting line flash, pairs of a wide range of differing optical power of polycarbonate Rx spectacle lenses (16). These pairs have special molded-on design features which are specially suited for full automation, starting with a novel way for ejection out of the mold into a takeout robot which is integrated via full automation with subsequent dip hardcoating. A molded-on tab with each pair of lenses is specially suited for manipulation by SCARA type robot.

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 and apparatus for forming on-site tinted and coated optical elements from 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 a hard coat layer having unreacted chemical groups. The hard coat may be tinted with dyes that are standard in the art. 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 hard coat layer, optionally tinted, is added. When using the mold with a lens resin having unreacted chemical groups, the coupling agent layer, hard coat layer, optionally tinted, 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: A selectively, rotatably adjustable riser pin for aligning a predetermined characteristic on an asymmetrical mold surface with the gate of an injection molding machine for enhanced flow dynamics of the mold material across the mold surface. The riser pin is divided into two co-linear portions which are biased towards one another such that application of a predetermined torque will allow the front riser pin portion, which carries the mold tool, to be rotated independently of the back riser pin portion.

Abstract: Optical material, which was already roughly molded, is deposited into a space defined by a top mold, a bottom mold and a drum mold, and is then heated, pressed and molded, thus providing an optical element. By controlling the rate of plastic deformation of the optical material so as to prevent the material from entering clearance sections between the outside diameter of the top mold or of the bottom mold and the inside diameter of the drum mold, an optical element of high precision with no burr nor strain is provided at low cost.

Abstract: Plastic injection-compression multi-cavity molding of flash-free improved-cleanliness thermoplastic spectacle lenses are suitable to be robotically dip hardcoated. Special spring-loaded molds having variable-volume mold cavities are used in an injection-compression molding process to form, without parting line flash, pairs of a wide range of differing optical power of polycarbonate Rx spectacle lenses. These pairs have special molded-on design features which are specially suited for full automation, starting with a novel way for ejection out of the mold into a takeout robot which is integrated via full automation with subsequent dip hardcoating. A molded-on tab with each pair of lenses is specially suited for manipulation by SCARA type robot.

Abstract: A method and apparatus for the manufacture of lens molds used in the formation of optical contact lenses, the apparatus including a center gate aligned on the central axis of the lens mold cavity for delivery of the melt polymer in an axisymmetrical manner. The methodology produces lens molds of extremely precise dimensions as measured against lens molds produced with side gated technology.

Abstract: Male and female members for contact lenses where either member is able to hold the contact lens as it moves from station to station during the hydration process. The female member fits together with the male member forming a chamber. Each of the members contains a line centrally located so that both surfaces of the contact lens are flushed during the hydration process, and drainage takes place radially on the outside of the mated male and female chamber members. These members may be produced on a frame with a plurality of members, usually eight to a frame, to allow ease of processing. Full automation is possible, and complete and positive lens control during and step of the process through the packaging step is achieved.