Abstract: A process and method for fabricating a master lens array for use in the manufacture of duplicate lens arrays is provided. The fabrication methods provided herein are capable of maximizing the quality of the master lens array in an efficient and cost effective manner, thereby reducing the propagation of errors in the lenses formed using the master lens array.

Abstract: A mold for fabricating an optical fiber connector is provided. The mold includes a mold body, a core pin and a positioning block. The mold body defines a molding chamber, and the molding chamber has a lens forming portion for forming a lens. The core pin is configured for insertion into the molding chamber and forming an optical fiber insertion hole. The core pin includes a first portion and a second portion thinner than the first portion. The positioning block is configured for being arranged in the molding chamber. The positioning block includes an engaging hole for engagingly receiving the second portion.

Abstract: The invention concerns a process of manufacturing optical components. A replication tool, a sub-master or a replica is manufactured using a structured element (for example a master) and a substrate. A structure of the structured element is replicated into liquid or plastically deformable material disposed at a first place on said substrate, then hardened to make it dimensionally stable, whereon the structured element is removed. These replicating, hardening and removing steps are repeated for a second, third, etc. place on said substrate the same structured element.

Abstract: An apparatus for releasing a molded lens from a deformable mold includes a shear ring for temporarily retaining an annular portion of the deformable mold outside a periphery of the lens and a plunger for deforming an annular section of the deformable mold within the periphery of the lens. The apparatus can be employed to release a non-hydrated hydrogel lens from a deformable mold section.

Abstract: A first lens having a first bottom surface and a first top surface at opposite sides thereof; and a first supporter having a first supporting surface and a second supporting surface at opposite sides thereof, the first supporting surface being flat, the second supporting surface being in contact with the first bottom surface, the first supporter being made of transparent material, and a refraction index of the first supporter being different from a refraction index of the first lens. A lens assembly array and method of making the lens assembly array are also provided.

Abstract: Contact lens delensing methods are described, and the present delensing methods include using a gas to facilitate separation of a polymerized contact lens product from a contact lens mold member. The contact lens mold member is compressed to deform a portion of the mold member, and gas, such as air, is directed toward the polymerized contact lens product in contact with the portion. The contact lens mold member can be compressed as the mold member and lens product rotate. A vacuum device can be used to separate the polymerized contact lens product from the contact lens mold member after compressing the portion of the mold member and directing the gas towards the mold member. Delensing systems used to practice the present methods are also described.

Abstract: The method for producing at least one rotationally symmetrical lens consisting of an opto-ceramic includes the step of moulding a ceramic green body for the lens, wherein the mould has a shaping surface, which is described by the following equation B: y ? ? 1 = cz 2 1 + 1 - ( k + 1 ) ? c 2 ? z 2 + a 1 ? z 2 + a 2 ? z 4 + a 3 ? z 6 + a 4 ? z 8 + … ? , ( B ) y1 gives a position on an optical axis; x designates a perpendicular distance from the optical axis to the surface; k, c, and a1, a2, a3, a4, . . . are constants describing a surface of the lens to be moulded and z=|x|+b, wherein b is a constant with a value greater than 0 and less than 0.3 mm, which is a measure of a deviation of the shaping surface from the surface of the lens.

Abstract: Disclosed are a microlens array, and a method of positioning and aligning the microlens array on another device. Generally, the microlens array comprises an array of injection molded microlens elements, and a supporting flange. Each of the microlens elements has a generally spheroid or spherical shape, and the supporting flange connects together the array of microlens elements to facilitate positioning that array of lenses on a printed circuit board, semiconductor package or wafer. This array is well suited for use with vertical cavity surface emitting lasers (VCSELs); and, in particular, the preferred embodiment of the invention addresses the problem of VCSEL laser array alignment by using arrays of microlenses elements fabricated by injection molding.

Abstract: An apparatus for wetting and coating ophthalmic lenses having a tank with a cleaning or coating solution and a handling system for sequentially moving a lens and the solution in relation to each other, to wet the lens. A master control module is coupled to the handling system and configured execution a wetting profile. The wetting profile moves the lens to obtain a generally consistent lens surface wetting speed so that the lens coating has a more uniform thickness. According to a method, lenses are wetted in a liquid bath. The lens is placed in a handling system which moves the lens with respect to the bath according to a wetting profile. The wetting profile is based on the incremental vertical lens surface slope with respect to the surface of the solution.

Abstract: Methods and systems are provided for making an ophthalmic lens. The present methods and systems are effecting in coupling two mold sections together at two or more discrete regions. Embodiments of the methods and systems form a bore that extends completely through one of the mold sections and only partially through the other mold section. During formation of the bore, the mold material in proximity to the bore being foamed becomes molten and diffuses from the bore. A portion of the molten mold material is provided at a contact point between the two mold sections and when the molten material cools, the material foams a spot weld between the mold sections. By foaming multiple hollow spot welds in a mold assembly, the two mold sections can be securely coupled to each other during the manufacture of an ophthalmic lens, such as a silicone hydrogel contact lens.

Abstract: An apparatus and method for releasing a lens moulded in a cavity between posterior (21) and anterior mould (22) sections and adhered thereto. A post (30) is configured to support a flange (20) of the posterior section whilst the anterior section remains spaced from the post. Posterior section is compressed between a pin (40) applied to, an outer concave surface (29a) of the posterior section and the post, thereby initially releasing peripheral regions of the posterior section and subsequently the remaining portions thereof. Upon separation, the anterior section together with the lens (10) drops onto the post so that its outer convex surface (29a) rests on the post. A collar unit (50) with gas channels (53) presses against a flange (200) of the anterior section whilst blowing jets of gas towards an interface between a “monomer” ring (11) formed around the lens. In this manner, initially the “monomer” ring and then peripheral regions of the lens are separated from the anterior section.

Abstract: An apparatus for forming an optical element. The apparatus includes a pair of forming molds each of which has a facing surface facing each other. At least one of the pair of the forming molds is made so as to allow a hardening energy to pass through itself. A frame-like mold member is provided so as to be interposed between the facing surfaces of the pair of the forming molds to cover an outer peripheral portion which each of the forming molds has on its facing surface, thereby defining a cavity. In the thus arranged apparatus, an energy hardening resin is filled into the cavity and then hardened by being subjected to the hardening energy passing through the at least one of the pair of the forming molds.

Abstract: A casting mold is provided for forming a biomedical device including an ophthalmic device such as a contact lens. The casting mold includes an anterior mold section and a posterior mold section, wherein one of the mold sections includes a plurality of radially extending ribs and the remaining mold section includes an annular shoulder for engaging an outer end of the ribs to define a mold cavity.

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

Abstract: Apparatus and methods for injection molding intraocular lenses includes an embodiment having first and second runners extending into first and second optic cavities of a mold configured to make a dual optic lens device.

Abstract: A lens is manufactured by hardening soft material filled inside a molding tool by cooling. The lens includes a convex lens portion having an optical axis, and a marking portion located outside of an effective diameter of the lens portion. The shape or the position of the marking portion is set to prevent deformation of the marking portion by contact with the molding tool due to shrinkage of the material during cooling.

Abstract: An apparatus for releasing a molded lens from a deformable mold includes a shear ring for temporarily retaining an annular portion of the deformable mold outside a periphery of the lens and a plunger for deforming an annular section of the deformable mold within the periphery of the lens. The apparatus can be employed to release a non-hydrated hydrogel lens from a deformable mold section.

Abstract: The moulding tool is a near-net-shape negative mould for shaping a ceramic green body for the lens. The mould has a shaping surface, which is described by the following equation B: y ? ? 1 = cz 2 1 + 1 - ( k + 1 ) ? c 2 ? z 2 + a 1 ? z 2 + a 2 ? z 4 + a 3 ? z 6 + a 4 ? z 8 + … ? , ( B ) y1 gives a position on an optical axis; x designates a perpendicular distance from the optical axis to the surface; k, c, and a1, a2, a3, a4, . . . are constants describing a surface of the lens to be moulded and z=|x|+b, wherein b is a constant with a value greater than 0 and less than 0.3 mm, which is a measure of a deviation of the shaping surface from the surface of the lens.

Abstract: An apparatus for manufacturing optical elements at wafer level includes a lower mold core, an upper mold core, an aligning plate and an image pick-up device. The lower mold core has a lower alignment mark. The upper mold core has an upper alignment mark. The aligning plate has a first middle alignment mark corresponding to the lower alignment mark and a second middle alignment mark corresponding to the upper alignment mark. The image pick-up device is configured for capturing and analyzing images of the alignment marks to align the lower mold core, the aligning plate and the upper mold core.

Abstract: A method of manufacturing a lens presenting a graded tint, the lens comprising first and second layers each of which is made of a thermoplastic material, with only one of the layers being colored in the tint concerned, the method including the steps of: injecting the thermoplastic material of the first layer into a first mold cavity in order to form the first layer; and placing the first layer in a second mold cavity and injecting therein the thermoplastic material of the second layer so as to form the second layer on the first layer.

Abstract: This invention is related to the process of polishing the optically critical surface of the front piece as well as the back piece, or non-optical surface, used to make molds used in double-sided molding process to make contact lens for reducing warpage of the mold, radius changes in different cavities and amount of cylindrical distortion. The polishing of both of the front piece and back piece causes the mold material to see a very similar coefficient of friction on both top and bottom surface and provides uniform flow front.

Abstract: Contact lens molds and methods of producing soft cast-molded contact lens products are provided. The methods include placing a soft hydrophilic contact lens-forming composition in a cavity formed between a first mold member and a second mold member, subjecting the composition in the cavity to conditions effective to form a contact lens product from the composition, and repeating the placing and subjecting steps a plurality of times, thereby producing a plurality of soft contact lens products. At least the first mold members, and advantageously all of the first and second mold members, are injection-molded with a nucleated thermoplastic polyolefin resin having a melt flow rate in a range of 10 g/10 min to about 40 g/10 min.

Abstract: In a method for manufacturing a lens mold, a raw mold is provided. The raw mold defines a cavity therein. The cavity defines a raw molding surface. The raw molding surface includes a molding surface portion. The molding surface portion includes a center. Photoresist material is filled in the cavity, covering the molding surface portion. A photo mask is provided. The photo mask defines a through hole. The size through hole is the same as the molding surface portion of the lens mold. The photo mask is placed above the photoresist material with the through hole aligned with the center. The photoresist material is exposed and developed to form a photoresist portion. A rigid molding material is filled in the cavity. The resist portion is removed to expose the molding surface.

Abstract: An exemplary method for making a mold used for molding lenses includes the following. First, a base is provided. The base has parallel lines marked on a surface thereof. Second, a dispenser is provided. The dispenser dispenses lumps of molding material on selected positions on the surface of the base guided by the lines. Third, a roller is provided. The roller has a peripheral side surface. The peripheral side surface has spaced molding surfaces defined thereat, each molding surface corresponding to a surface of a lens to be formed. The roller is applied above the base, with the molding surfaces press-molding the lumps of molding material, thereby forming molding portions on the base. Thus, a mold including the base and the molding portions formed on the base is obtained.

Abstract: A microlens transcription molding roller used for transcription-molding a plurality of microlenses on a sheet includes a plurality of microlens molding surfaces arrayed on an outer circumference of the roller along one spiral around an axis of the roller at a constant interval.

Abstract: A lens mold comprises a first pressing portion, a second pressing portion, and a shaping portion disposed between the two, which comprises an upper slide and a lower slide. The upper slide and the lower slide are connected to the second pressing portion, and can slide along each other. A mold cavity in fluidic communication with a flow path and the inlet such that the lens material flows from the inlet to the mold cavity along the flow path to form a shaped lens. After the lens is formed, the upper slide and the lower slide away from each other separately, where a part of the shaped lens is remains in a recess defined in the second pressing portion, to help release the shaped lens from the mold.

Abstract: There is provided a process of making a mold for optical films. The process of making a mold for optical films comprises: etching a stereostructure in a surface of the mold having a flat surface or an engraved convex and concave surface, by using a laser beam. The process of making a mold for optical films may be useful to easily mark spots, to control the height of protrusions and the position where the protrusions are formed, and also to form the protrusions having constant depths even in a curved surface such as a convex and concave surface.

Abstract: A molding apparatus includes a first mold half, a first mold core, a second mold half, a second mold core and a plurality of spacers. The first mold core is received in the first mold half and has a first molding surface. The second mold half includes a receiving cavity defined therein and a plurality of parallel grooves angularly equidistantly spaced from each other. The second mold core is received in the receiving cavity and has a second molding surface facing the first molding surface. The first and second molding surfaces are configured for cooperatively defining a molding cavity therebetween. The spacers are configured for being selectively disposed in the corresponding grooves. Each spacer is configured for being sandwiched between the second mold half and the second mold core. The spacers are configured for aligning the second molding surface with the first molding surface.

Abstract: A mold for molding a lens includes a first mold part and a second mold part. The first mold part includes a substantially frustoconical guiding chamber defined therein, and a first molding surface in the substantially frustoconical guiding chamber. The second mold part includes a main body having a substantially frustoconical protrusion with a substantially cylindrical recess defined therein. The substantially frustoconical protrusion has a second molding surface in the substantially cylindrical recess. The substantially frustoconical protrusion is configured for inserting into and matingly engaged in the substantially frustoconical guiding chamber of the first mold part, thus aligning the first molding surface with the second molding surface.

Abstract: Methods of producing silicone hydrogel ophthalmic lenses include contacting one or more delensed silicone hydrogel ophthalmic lens with a liquid composition that contains alcohol, water, and a surfactant. The methods can be steps of an extraction/hydration procedure used in the production of silicone hydrogel contact lenses. In some examples, contacting silicone hydrogel ophthalmic lens products with a liquid composition that contains alcohol, water, and a surfactant can significantly reduce or prevent surface distortion of the ophthalmic lens resulting from the extraction procedure. Some methods include subsequently contacting the silicone hydrogel ophthalmic lens with a liquid composition consisting essentially of water and a surfactant.

Abstract: A mold releasing method for releasing a core member from a mold includes steps of: a) providing a supporting member and arranging the supporting member on the mold, the supporting member comprising a base and a number of sidewalls extending from the base to the mold, a through hole being defined in the substrate and co-axially aligned with the core member; b) providing a bolt, the bolt comprising a threaded rod extending through the through hole of the substrate and threadedly engaged with the core member; and c) rotating the bolt to move the core member to disengage from the mold.

Abstract: Retroreflective articles having cube corner elements are disclosed, with the dihedral angle errors of the cube corner elements selected to limit the visibility range of the retroreflective article. Also disclosed are methods for making the cube corner elements and the retroreflective articles.

Abstract: The object of the invention is a process for molding an optical element such as a lens (2). According to the invention, the element is obtained by a reaction injection molding process comprising the steps of mixing at least two polymerizing reactants and forcing the obtained reacting mixture by an injection duct (5) for filling under pressure a scaled mold cavity (4) having an entry side (43) provided with a casting opening (42) and an evacuation side (44) and providing a laminated flow of mixture in a spout (6) having a progressive enlarging transversal section between the outlet opening (52) of the injection duct (5) and the casting opening (42) of the mold cavity (4), for avoiding any turbulent area in said laminated flow, said evacuation side (44) being provided with means (45) for evacuating air contained in the mixture during mold filling. The invention also covers the molding installation adapted for using such a process.

Abstract: A centering device (13) is arranged to surround a loading table (11) on which a lens blank (1) is to be set, to set the geometric center of the lens blank (1) to coincide with the center of the loading table (11). The centering device (13) includes three clamp pins (31) which press the peripheral surface of the lens blank (1). When centering is ended, the loading table (11) on which the lens blank (1) is set is pushed up by a moving device (12) from a centering position (H1) to a block position (H2), and a peripheral portion of the lens blank (1) on a concave surface side is urged against the lower surfaces of locking portions (31A) of clamp pins (31). After a predetermined amount of wax (4) is dripped onto the lens blank (1), a lens holding unit (2) is moved downward by a predetermined amount and urged against the wax on the lens blank (1) to spread the wax thin and let the wax to solidify. Thus, the lens blank (1) and lens holding unit (2) are bonded to each other.

Abstract: A mold includes a plurality of inserts, a molding board, a base board, a plurality of fastening members, and a plurality of washers. The inserts each has a molding surface. The molding board includes a plurality of cavities for accommodating of the respective inserts. The base board for mounting the molding board thereto has a plurality of receiving holes. The fastening members are respectively received in the corresponding receiving holes for securing the corresponding inserts in the corresponding cavities of the molding board. The washers are sandwiched between the respective fastening members and an opposite ends of the inserts to the molding surfaces.

Abstract: An apparatus and method is provided for injection molding an ophthalmic lens mold section having an optical surface and a non-optical surface opposite the optical surface. The apparatus includes a non-optical tool assembly for forming the non-optical surface of the ophthalmic lens mold section. An optical tool assembly is in opposed relation to the non-optical tool assembly and together therewith forms a mold cavity for forming the ophthalmic lens mold section. In the preferred embodiment, the optical tool assembly includes a rotatably mounted core member and an optical insert removably secured the core member. The optical insert has an optical molding surface for forming an optical surface of the ophthalmic lens mold section opposite the non-optical surface thereof. A locking mechanism having, in a preferred embodiment, a locking pin selectively movable between a first position wherein the pin allows rotation of the core member and a second position wherein the pin prevents the core member from rotation.

Abstract: A method includes the following steps: a first shell (12) is immobilized in a first shell carrier (6); a second shell (29) is immobilized in a second shell carrier (27); the first shell carrier (6) is oriented in such a way that a useful moulding surface of the first shell (12) faces upwards and forms the base of a vessel; a pre-determined quantity of polymerizable material is placed in the vessel; the first shell carrier (6) and the second shell carrier (27) are moved into a pre-determined relative position wherein the first shell (12) and the second shell (29) are in a pre-determined moulding position, by at least partially arranging the second shell (29) in the vessel, at a distance from the edges thereof. The inventive device includes a structure for positioning the shell carriers.

Abstract: A method of forming an optical element forming metal mold to form an optical element, having steps of: laminating a heat insulation layer 13 on a surface of the base member 11 where the optical element is formed; laminating an intermediate metal layer 14 on a surface of the heat insulation layer 13 by thermal spraying; laminating a surface forming layer 15, on which a surface shape to be transferred to the optical element is formed, on the intermediate metal layer 14; wherein the intermediate metal layer 14 is laminated in a way that parts of the heat insulation layer 13 are exposed substantially evenly from the intermediate layer 14.

Abstract: A method of manufacturing a plastic lens by mixing plural polymerizable components, and immediately after mixing, casting a mixture into a casting mold and conducting polymerization to obtain a molded article. A method of manufacturing a plastic lens by casting a plastic lens starting material liquid flowing out of a casting jig opening into a casting mold and curing the above starting material liquid to form a molded article. A gasket for molding plastic lens comprised of a cylindrical member comprising openings for fitting by insertion of two molds. A casting mold for molding plastic lens, wherein the above molds are detachably held in the above openings of the above gasket so that molding surfaces of the two molds are positioned opposite at a prescribed interval to form a cavity corresponding to a lens shape within the above cylindrical member. A casting jig for plastic lens starting material liquid equipped with a nozzle for casting a plastic lens starting material liquid into the casting mold.

Abstract: A purpose is to provide an optical component molding apparatus for producing a small-size and high-precision optical component and achieving good transferability and stability of a molded product. A multi-cavity molding machine 100 has a gate 51, a runner 52, and a sprue 53 each having the shape determined to meet conditions (1) to (5): (1) “Miminum gate thickness”/“Maximum runner thickness” is in a range of more than 0.2 to less than 1.0; (2) “Gate length”/“Maximum runner thickness” is in a range of more than 0.4 to less than 4.0; (3) “Outlet diameter of sprue” is in a range of more than 1.0 mm to less than 5.5 mm; (4) “Sprue length” is in a range of more than 10 mm to less than 40 mm; and (5) “Outlet diameter of sprue”/“Inlet diameter of sprue” is in a range of more than 1 to less than 8.

Abstract: A molding apparatus includes a first mold half, a first mold core received in the first mold half, a second mold half opposite to the first mold half, a second mold core and a plurality of spacers. The second mold core includes a sleeve and a core insert. The sleeve is received in the second mold core. The sleeve includes a receiving hole defined therein, and a plurality of parallel grooves defined in an inner surface in the receiving hole. The grooves are angularly equidistantly spaced from each other. The core insert is received in the receiving hole of the sleeve. The plurality of spacers is configured for being selectively disposed in the corresponding grooves. Each of the spacers is configured for being sandwiched between the sleeve and the core insert.

Abstract: A mold for molding a product in a cavity formed by closing the mold is provided. The mold includes a first half; a second half; and a plurality of aligning members which contact respective outer circumferential surfaces of a first die of the first half and a second die of the second half, at least in three directions, when the mold is closed. At least one of the aligning members is moved toward the outer circumferential surfaces of the first die and the second die, and then each of the aligning members sandwiches the first die and the second die, which enables a center axis alignment between the first die and the second die.

Abstract: The present invention includes molds for forming ophtalmic lenses, such as contact lens. In particular, the present invention relates to apparatus, molds and methods for fashioning an ophthalmic lens with a mold assembly that includes two or more mold parts with at least one of the mold parts including a flange surface and a static charge differential between each mold part, including the flange surface.

Abstract: An adjustable mold includes a distortable boundary, a flexible membrane, and a pressurizer, and method of use thereof. Pressure is applied to the flexible membrane, which causes the membrane to distort over the boundary. The shape of the boundary and the distortion of the flexible membrane control the optical characteristics of a lens resulting from the application and curing of a molding composition placed on the flexible membrane or to cast other items having variable shapes determined in part by the flexible membrane. In addition, a mold edge is used to allow casting in predetermined shapes, reducing need for grinding or edging. Visual and emission device calibration features used in conjunction with calibration reference images allow uniform selective distortion of the flexible membrane.

Abstract: A method is provided of forming a biomedical device in a casting mold which has an anterior mold section and a posterior mold section, wherein one of the mold sections includes a plurality of radially extending ribs and the remaining mold section includes an annular shoulder for engaging an outer end of the ribs to define a mold cavity. The method includes engaging the mold sections along a peripheral seal of the mold cavity and a plurality of circumferentially spaced contact points on a shoulder of one of the mold sections. Cured excess material bonds to the ribs of the one mold section and provides repeatable retention and location of the excess material after formation of the biomedical device.

Abstract: A method for in-mold coating of an injection molded thermoplastic lens that resides in an injection molding machine oriented to a horizontal parting line. An optical lens is initially formed by injecting molten thermoplastic resin into an edge-gated lens-forming cavity held closed under a primary clamp force. The mold is opened at a time when the lens is rigid enough to retain its shape. An unpressurized full metered charge of coating is applied onto the center of the lens. The coating is co-molded by ramping up the clamp force from zero to a secondary clamp force less than the primary clamp force to compress the coating into a uniformly thick, fringe-free layer.

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

Abstract: A plastic molding die provided with a cavity where a plastic material is put in, wherein a part of an inner surface of the cavity is configured with an elastic body. A molding portion corresponding to a molding surface of a molded product is disposed on the inner surface of the cavity, and the elastic body is arranged on a portion other than the molding portion of the inner surface of the cavity. The plastic molding die may be a molding die for compression molding. The elastic body is made of rubber, and has an upper temperature limit higher than a glass-transition temperature of the plastic material. The degree of rubber hardness of the elastic body is from 50 to 100.

Abstract: A microlens transcription molding roller used for transcription-molding a plurality of microlenses on a sheet includes a plurality of microlens molding surfaces arrayed on an outer circumference of the roller along one spiral around an axis of the roller at a constant interval.

Abstract: In a mold, at least a first half includes an insert member forming a cavity surface on one end side; a body member having an insertion part into which the insert member is inserted; and an insert member fixer interposed between the insert member and the insertion part, for holding the insert member. The insert member fixer is made of a shape memory alloy, and presses and holds the insert member when the insert member fixer restores its memorized shape, to make a center axis alignment of the insert member with respect to the body member.