Abstract: A mold for press molding an optical element of glass has carbon atoms injected in amounts from 10.sup.15 to 10.sup.18 ion/cm.sup.2 into a molding surface of a mold base of the mold and subjected to further treatment to form on the molding surface a diamond film, a hydrogenated amorphous carbon film, a hard carbon film or a mixture of at least two such films. The film on the molding surface can be formed by heat treatment and, additionally, by irradiation with hydrogen plasma, after carbon ion injection.

Abstract: Production of precision reflective mirror surfaces on low cost, lightweight molded plastic substrates (10). The process involves making a master pattern (12) having a precision machined contoured surface (13) corresponding to the precision mirror surface desired on the plastic substrate. A release layer (14) and a reflective layer (17) are applied to the master pattern and then transferred to the molded plastic substrate (10), with a curable replication layer (18) therebetween preferably comprising a filler-reinforced polymer composition which is compatible with the polymeric substrate and has a low coefficient of thermal expansion (CTE) which closely matches the CTE of the substrate. The replication layer (20) is cured to replicate the precision of the surface (13) of the master pattern (12), which can be reused to produce a multiplicity of high precision molded plastic mirrors (21).

Abstract: An apparatus for molding polystyrene mold halves which are used, for subsequent molding of a soft contact lens. The apparatus is designed with superior heat conduction capacity so as to minimize the molding cycle time, while simultaneously producing uniformly precise and accurate optical quality surfaces. Molten polystyrene is provided via a hot runner system to a plurality of mold cavities. In a specific variation, the convex surface provides the optical quality surface to the concave surface of the mold half produced thereby. The structural element which defines the convex surface includes a hollow cylindrical bushing and a removable power insert mounted therein, which may be changed so that the prescription strength of the contact lens to be formed by the mold may be varied. In a first embodiment, the power insert includes only a convex surface at its operational end.

Abstract: A die for press-molding glass optical elements which can press-mold glass optical elements having high melting points and various shapes repeatedly, which includes a base material having high strength on which a cutting layer having heat resistance and free cutting machinability is formed. After cutting the cutting layer into the desired shape with high accuracy, the die is coated with a surface protective film.

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. A support pallet is provided for supporting the mold assembly. A wedge separating fixture provides at least one separating wedge positioned between the spaced flanges of the mold assembly, and the wedge separating fixture and support pallet are translated relative to each other to progressively separate the frontcurve mold from the backcurve mold.

Abstract: An automated method for high speed production rates in the hydration of soft contact lenses. The method includes the use of robotic transfer equipment to transfer contact lens molds containing contact lenses to and from a hydration station and a flushing station.

Abstract: An apparatus for separating individual contact lens mold assemblies that each contain a contact lens mold between a front curve mold half and a back curve mold half, each of the mold halves having annular circumferential flanges, is disclosed. The apparatus comprises a first device for applying steam at a first temperature to the back curve mold half to form a temperature gradient ranging from about 2.5.degree. C. to 6.0.degree. C. between the back curve mold half relative to the front curve mold half, and, a second device including a set of pry tools that are inserted between the circumferential flanges of the front mold and back mold halves of the contact lens mold assembly, the pry tools including a first set of pry fingers for retaining the front curve mold half and a second set of pry fingers for biasing the back curve mold half upwardly at a predetermined force with respect to the front curve mold half to effectively remove the back mold half therefrom.

Abstract: The present invention is directed to a composition comprising polystyrene with at least 0.1% (w/w) of an additive, the article of manufacture thereof, such as a mold for making contact lenses and the mold assembly containing said mold, and the use of such mold so to facilitate demolding from a two mold assembly in the process of making contact lenses.

Abstract: An apparatus for coating a multifocal lens, lens blank, or lens mold is disclosed. The lens, lens blank, or mold is spun about an axis offset from the geometric center thereof. The lens, lens blank, or mold for the lens has at least two focal regions defined by at least one ledge line, and the axis of spinning passes perpendicularly through the ledge line or an extension thereof. Structure is provided to apply a coating, and spinning is continued until the coating is sufficiently dry that it has adhered with little risk of deformation to the coating on the lens, lens blank, or lens mold upon removal or movement.

Abstract: An apparatus for causing the polymerized excess monomer to separate from a molded lens by increasing the surface energy of the flange area of one mold piece, causing the polymerized excess monomer to stick thereto. Specifically when manufactured under inert atmosphere conditions, a particular manifold is needed to supply an oxygen bearing gas, air, to the area to be treated while preventing the oxygen from contaminating the lens manufacturing area of the molds or diluting the nitrogen atmosphere of other lens process areas. It has been found that generation of the ionized oxygen by means of a corona treatment electrode sufficiently increases the adherence of the polymer to the mold piece so treated.

Abstract: There is disclosed a mold for pressing molding of an optical element of glass. On at least the molding surface of the mold base of the mold, there is formed a mixing layer which consists of carbon and at least one of the elements constituting the mold base. The atomic percentage of carbon increases toward the molding surface and decreases toward the mold base, while the atomic percentage of the other element decreases toward the surface and increases toward the mold base. The mold may contain an intermediate layer at least on the molding surface of the mold base.

Abstract: An implantable ophthalmic lens manufactured at least partly out of soft, elastic and pliable material substantially in the shape of a saucer is described. It includes an outer optical face forming one side of the lens, and an inner optical face forming the other side of the lens. A center portion of the inner optical face of the lens as well as the lens rim each have the shape of meniscus derived from the corresponding meniscus of a liquid precursor prior to solidification, the center portion meniscus and the rim meniscus being connected by an annular ring, all surfaces of the lens except the center portion of the inner optical face and the lens rim being replicas of a solid mold from which it is formed. The inner optical face center portion and the lens rim have the shape of a liquid precursor solidified in contact with an inert fluid.

Abstract: A mold for making an optical lens and formed of two molding shells disposed on edge and an annular closure member around their periphery and defining with them a molding cavity. To fill the mold a molding material is introduced into the molding cavity through a casting opening formed for this purpose in the closure member. The casting opening is in the lower part of the molding cavity.

Abstract: An apparatus, for making a lens from thermoplastic material in the form of a monolithic preform mass, having a press; and a pair of lens molds positioned in said press. The monolithic preform mass has at least one or more radii and is disposed between the lens molds such that said one or more radii make point or line contact with said lens molds. Means are provided for closing the pair of lens molds, and pressing the molds toward each other and against said preform mass to a predetermined pressure; and for heating up the molds until the preform mass begins to soften with the predetermined pressure varying slightly therefrom.

Abstract: A retroreflective structure has a window side and a facet side. The facet side has a plurality of steps with treads and risers intersecting at an angle. The risers include an array of retroreflective elements. Preferably, the elements are cube-corner prisms. The method includes forming the structure by polymerizing a polymerizable material in a mold having a facet side including a tiered structure having a plurality of steps with treads and risers intersecting at an angle and wherein the risers include an array of retroreflective elements.

Abstract: An apparatus for forming contact lenses, wherein front curve mold halves are filled with a hardenable transparent material, such as a polymerizable hydrogel, and back curve mold halves are coupled to the front curve, therein forming a lens. More particularly, the apparatus includes a conveyor for transporting pallets of mold halves to the apparatus, an array of piston structures for raising and aligning the back curves with respect to the filled front curve halves, a mechanism for reciprocating the piston array to couple pairs of front and back curves, and a vacuum chamber for maintaining a vacuum around the curves during coupling. In addition, there is provided individual spring biasing to each reciprocating element whereby sensitivity to thickness variations and pallet misfeeds may be minimized. Further, there is provided a vacuum sleeve, through which the pistons reciprocate within the vacuum chamber, which sleeve preserves the vacuum within the chamber.

Abstract: An apparatus for filling and assembling mold parts for a contact lens includes a first automated station for receiving a plurality of front curve contact lens mold parts and depositing in each front curve mold a predetermined amount of a polymerizable monomer or monomer mixture, and, a second automated station for receiving the plurality of front curve mold parts and assembling each front curve mold part with a back curve mold part under vacuum to prevent entrapment of gas between the mold parts. The front curve mold parts are transported to the first and to the second automated stations by a pallet having registration guides that cooperate with the second station to register the pallet prior to assembly of the mold parts.

Abstract: A machine and process for making an ultraviolet cured block for an ophthalmic lens are provided in which a lens is placed at an input port to the machine by an operator. Data related to the lens is fed to or stored in the machine from either a keyboard or a data base. The lens is then collected from the input port for processing and transported, preferably by means of pneumatics, to a block molding point within the confines of the machine. A special adhesive is administered to the surface of a mold unit and the mold unit is then positioned to receive the lens. Pressure is applied to squeeze the lens against the adhesive and the mold. After molding the adhesive onto the lens, the lens and mold are transported via servo slide to a UV station where curing takes place from above the lens. After preliminary curing, the lens and mold unit are taken to a removal station and the lens, together with the adhesive cured to its front surface, is removed from the mold unit, again preferably by means of pneumatics.

Abstract: A method and apparatus releasably secure 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: A lens mold cavity is formed and then evacuated via a vacuum channel contained within a mold member. A fluid valve is opened to expose the lens mold cavity to liquid lens material, whereby a vacuum of the lens mold cavity draws the liquid lens material to fill the lens mold cavity. The fluid valve is then closed and the liquid lens material within the lens mold cavity is cured to obtain an opthalmic lens such as a contact lens.

Abstract: In forming a plano-convex lens from a column-like lens blank by heating the blank to a temperature higher than the transition temperature thereof and by pressurizing an upper die with a closed space formed between the blank and the upper die, there are alternately repeated operations of pressurizing the upper die and stopping the application of pressure thereto. Through the control of the amount of displacement of the upper die, the maximum pressure of gas in the closed space at each pressurizing step is so controlled: as to be low according to the surface viscosity of the blank to the extent that no local concave deformation in the surface of the blank is produced; and as to be high to the extent that gas caught in the closed space is discharged at each step of stopping the application of pressure.

Abstract: A method for forming a preform mass of thermoplastic material into a lens by compression molding between a pair of molds without the formation of air bubbles or the entrapment of air pockets in the finished lens by preheating the preform mass and molds, and further continuing to apply increased pressure while increasing the temperature or maintaining a predetermined temperature and pressure until the mass has been compressed between the two molds into the shape of a substantially finished lens.

Abstract: A method of producing an optical device, includes the steps of forming a space between an optical member and a first mold and a second mold by arranging the optical member between the first mold and the second mold, at least either the first or second mold is arranged to touch one surface of the optical member. A resin member is injected through an injection port provided with the first or second mold in the formed space.

Abstract: Ophthalmic lens manufacturing equipment includes lens die assemblies constructed to accommodate fragile, high quality glass lens dies. The lens die supports of the assemblies provide a series of grooves of critically small widths on their interface surfaces to apply vacuum pressure from an external source to the backs of the lens dies and thereby hold them in place. The vacuum securement also enables rapid lens die changeover using robotic arms.

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: The invention provides a disposable plastic mold assembly for an intraocular lens or the optic body thereof, which is inexpensive, less labor intensive than prior art intraocular lens molding techniques, and produces an intraocular lens having smooth, polished edges which require little or no post-mold finishing work. Numerous innovative features of the invention include an edge design which assures a seal between the male and female molds to thereby minimize flash during the cast molding operation, and the provision of a way to pre-align the male and female molds during assembly, consisting of an interference fitting relationship between the male and female molds.

Abstract: The specification describes a fiber lightguide connector for interconnecting large arrays of lightwave fibers. Linear arrays of lightwave fibers, for example those in so-called ribbon cables, are effectively interconnected using known v-groove connector assemblies. According to the invention two or more such v-groove connector assemblies are stacked to increase the fiber capacity of a connector assembly. Attempts to stack known v-groove connector plates have encountered problems with aligning the v-groove arrays on opposite sides of the internal or intermediate plate of the stack. An alignment technique is described for assuring precise alignment between linear arrays of v-grooves on opposite sides of the interior plates of stacked linear array connectors.

Abstract: A machining chamber encloses a glass molding apparatus including a molding die assembly composed of upper and lower molding dies cooperating to define a mold therebetween. The glass molding apparatus, contained within the sealed machining chamber, further includes a clamping/heating/compressing station, a cooling station and a preform-loading/molding-ejecting station. A shutter is provided in the casing for selectively opening the casing to the ambient atmosphere. An annular nozzle surrounds a molding surface provided on one of the upper and lower molding dies and is used to supply a first inactive-gas to the region between the two dies. A second, independent inactive-gas supply provides inactive-gas directly into the sealed casing, whereby the region between the dies is maintained at a lower oxygen level than that within the remainder of the sealed casing.

Abstract: In this method of making a mold for molding an optical lens an annular closure sleeve is fitted around two molding shells and cooperates with them to define the required molding cavity. The closure sleeve is made from a heat shrinkable synthetic material and is heated to shrink it onto the molding shells. Applications of the method include molds for molding ophthalmic lenses.

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: A method of cast molding toric contact lenses having a toric posterior surface permits aligning the mold sections at multiple rotational positions.

Abstract: A liquid filling method and in particular a lens material liquid filling method suitable for manufacturing a plastic lens. A thermal sensing portion (2a) of a temperature sensor (2) is set and kept to a temperature different from that of a liquid (3). The liquid (3) is poured into a vessel (8), a change of an output from the temperature sensor (2) is detected when the surface of the liquid (3) comes into contact with the thermal sensing portion (2a) by temperature detecting means (5), and control means (6) determines that the liquid surface has reached a desired level and sends a pouring stop command to a pouring mechanism (7) to complete the filling of the liquid.

Abstract: In an aging device used to manufacture a plastic molded product, injecting and aging processes are separated from each other. Namely, a plastic base material is approximately processed in advance in a final shape by injection molding. Thereafter, the plastic base material is inserted into an aging die having plural cavities and attached to a press machine such that the aging die is clamped and opened. Next, the plastic base material is heated and melted until a temperature equal to or higher than a glass transition point so as to generate an internal resin pressure. Next, the plastic base material is gradually cooled to transfer a mirror face thereto. The aging device has a die cooling device having plural heat pipes for cooling the die and has a die heating device having plural heaters for heating the die. The heat pipes and the heaters are arranged in a die plate of the press machine.

Abstract: A method of molding a series of contact lenses having a range of optical powers using a matrix of posterior and anterior molds having varying surface characteristics such that the optical powers vary while maintaining constant fitting characteristics, and using a number of mold types which is less than the total number of contact lenses produced in the series.

Abstract: A lens/mirror tower (LMT) of a multiple-disk array, optical storage system includes a plurality of lens and mirror elements integrally formed on a monolithic, optically-clear substrate. There is a specific lens/mirror set for each recording disk surface of the optical storage device; however, the mirror elements are preferably configured as one reflective surface of the substrate. The lenses are molded onto the opposite surface in a single operation that fixes their relative positions. The LMT is generally fabricated using a lens replication process. Initially, a glass substrate is formed with a trapezoidal configuration. A lens array mold is also formed with a plurality of cavities arranged in overlapping pairs. The cavities are filled with optical-quality resin and the mold is applied to the surface of the substrate opposing the reflective angular, e.g., 45.degree., surface. Once cured, the resin serves as an array of lenses that are aligned with the optical paths to the objective lenses of the disk array.

Abstract: A method and apparatus releasably secure 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 the one 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: A mould for cast moulding a contact lens includes a first cup member having a male mould surface and a second cup member with a female mould surface. The two cup members form a piston and cylinder and are used in a pressure vessel so as to apply loading pressure to deflect the mould surfaces to maintain the surfaces in contact with a lens being cast. The mould is opened with the mould surface facing upwardly. Hydrating fluid is added to the first cup member and a cover sealed to the top of the first cup member.

Abstract: Spacers or wedges are disclosed for use in combination with mold elements such as lens and/or reflex reflector pins in a pin block or matrix assembly. Such assemblies are used in the manufacture of molds for producing, for example, front and/or rear light units for motor vehicles. The wedges or spacers are selectively located between rows or banks of reflex or optic pins to provide required orientation to selected groups of the pins so that the necessary reflectivity of the finished product is provided in the curved portion thereof.

Abstract: It is an object of this invention to provide an optical element molding method capable of correcting local processing errors in an optical element without increasing the size of an apparatus or raising the manufacturing cost.

Abstract: In a method of manufacturing an optical lens from a polymerizable synthetic material a lens molding assembly is provided including two molding shells and an annular closure member disposed around the molding shells and defining therewith a required molding cavity. The mold is filled with molding material and polymerization of the molding material is at least started. The operations of assembling the mold, filling it and at least starting polymerization of the molding material are conducted in the lens molding assembly.

Abstract: An arrangement for molding a front or back polystyrene mold half which is used, with a second complementary back or front mold half, for subsequent molding of a soft contact lens such as a hydrogel soft contact lens. Each mold half defines a convex curved surface and a concave curved surface spaced therefrom, with one of the surfaces defining an optical quality curved surface for the soft contact lens. A heated molding machine introduces molten polystyrene through a hot runner system to a plurality of mold cavities, each of which defines an optical quality curved surface and also a second noncritical surface. The optical quality surface of the mold cavity is positioned further away from the heated hot runner side of the mold than the second surface, which allows faster cooling of the optical quality surface of the mold cavity. Each mold cavity has a first insert on the optical quality side of the mold cavity and a second insert on the second side.

Abstract: A method of and apparatus for employing a surfactant which is provided in order to assist in the release from each other of mold components of a multi-part mold employed in the molding of polymeric articles; for instance, such as a hydrophilic contact lens, upon completion of the molding process for the polymeric articles. The surfactant is applied in the form of a film or coating on surface portions of one of the mold components in order to facilitate the disengagement between the mold components during demolding, and the removal of excess polymeric molding material adhesively deposited on surfaces thereon.

Abstract: In a contact lens (1) provided with a front curve (2) formed with a plurality of distance portion curved surfaces (F.sub.1, F.sub.2, . . . ) for seeing a distant place . . . )and a plurality of near portion curved surfaces (N.sub.1, N.sub.2, for seeing a near place arranged alternately and repeatedly in concentric zone shape, the distance portion curved surfaces formed at least a central zone of the front curve have respective curvature centers (O.sub.F1, O.sub.F2, . . .

Abstract: Disclosed are mold halves useful in molding a contact lens by polymerization of a polymerizable composition disposed between the mold halves. The mold halves are of rigid thermoplastic, preferably polystyrene, transparent to ultraviolet light.

Abstract: A die for press-molding a glass optical element which includes a base material having a surface to press-mold glass and a tantalum(Ta)-containing alloy thin layer on the surface, the base material being heat-resistant and strong enough to withstand press-molding.

Abstract: An improved, automated method and apparatus for molding contact lenses generally comprises the steps of: (1) forming anterior and posterior mold cavities in longitudinally spaced relation in first and second webs of material, respectively; (2) dispensing a liquid, curable, lens material (e.g., monomer) in each anterior cavity of the first web; (3) aligning and bringing the posterior and anterior cavities into sequential, mating, centered engagement with each other; (4) curing the lens material captured between respective posterior and anterior molds; and (5) separating the webs to release the lenses cast therebetween. In an advantageous embodiment of the invention, the mold cavities are vacuum-formed in the respective webs, and packaging receptacles are formed in one or both of the webs used to mold the lenses.

Abstract: Hard substrates such as ophthalmic lenses or molds are coated with a UV curable monomer which is polymerized to construct a scratch resistant coating on a surface of the lens. The present invention is directed to an apparatus for and method of applying the UV curable monomer to the surface of the ophthalmic lens or mold. Polymerization of the monomer occurs by radiation of UV light while the lens is encased in a curing chamber. The spin coater of the present invention has the following advantages: Excess monomer is collected in a dish away from UV exposure and is readily disposed of. The substrate is revolved at a high rate of speed during the application of the coating to achieve a uniform coating of monomer. Only the holder and substrate are moved to the curing chamber minimizing the items exposed to UV light. The UV light is electrodeless, it has a standby mode and operates cyclically during use so as to prolong its life and to allow a greater degree of control over extent of polymerization.

Abstract: A method of making a multifocal refractive lens to focus light on the retina of the eye. The lens includes a plurality of segments, having different optical powers, at least one for distance vision and another for near. The lens does not require orientation to produce adequate far and near vision and normal stereoscopic effect. One or both of the segments having the optical powers may have aspherical lens surface. The central zone of the lens consists of only one lens segment, providing a clear central axis. Segments of the other optical power border the first segment along a path defined by a semi-circle or hyperbola that extends from one point along the periphery of the adjoining segments to another point along the periphery of the adjoining segments.

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 while the lens mold is kept at very hot operating temperatures, yet 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 moves one wedge block of a slideably mated pair of opposing wedge blocks in a plane parallel to the parting line, thus moving the opposing wedge block axially forward or back perpendicular to the parting line, but always retaining proper alignment and loadbearing support of optical inserts, even in multicavity injection-compression molding. After many re-polishings of inserts, lens thickness specifications are still maintained without needing shims.

Abstract: A method of making multifocal refractive contact lens to focus light on the retina of the eye uses a plurality of at least two of each alternating segments having different optical powers for distance vision and for near. The lens of the invention does not require orientation to produce adequate far and near vision and normal steroscoptic effect. One or both of the segments having the optical powers may have aspherical lens surface. Preferably, the lens has at least one aspherical lens surface and the segments are divided by an arcuate path going from the center of the lens to edge. Such a lens is manufactured by taking lens molds and cutting the molds from the edge through the center to the opposite edge along a predetermined path. The molds are cut so that the segments produced are interchangable and can be fitted together to make a mold that can produce the multifocal refractive contact lens by molding.