Abstract: A high volume lens curing system is described. The high volume lens curing system is configured to cure multiple eyeglass lenses in a continuous manner.

Abstract: A radiation-transparent die half for a forming die in which a beam outlet from a shaping beam outlet surface is spatially limited by a diaphragm is manufactured in a simpler and more economical manner. Further, a long life is additionally ensured through the possibility of reworking the forming beam outlet surface in combination with effective protection of the diaphragm. According to the invention, the diaphragm is constructed as a radiation-impermeable layer which is enclosed up to its end faces by radiation-transparent material.

Abstract: A molding apparatus for lenses includes first and second molding units. Each of the first and second molding units has a mold core holder, a plurality of mold cores disposed in the mold core holder, and a plurality of fixing elements. The mold core holder has an abutment surface and a plurality of cavities, each of which includes an open end and a positioning portion. Each fixing element engages removably the positioning portion of a respective cavity, and retains a respective mold core in the respective cavity. Individual removal of the mold cores for replacement is permitted by operating the fixing elements.

Abstract: A mold of ductile metal has a shape comprising consecutive sub-shapes corresponding to respective optical sub-elements having substantially identical shapes arranged in a pattern. The mold is shaped by means of a die having a die surface corresponding to the sub-shape, which sub-shape is imprinted in the ductile metal with a predetermined force one at a time in consecutive positions in accordance with the pattern, each position corresponding to a single optical sub-element.

Abstract: A high volume lens curing system is described. The high volume lens curing system is configured to cure multiple eyeglass lenses in a continuous manner.

Abstract: A device has a first mold plate mounted rotatably using a shaft, and a second mold plate, between which a cavity is formed. The device further has an apparatus for applying an erecting force to the first mold plate such that in the open state of the device the first mold plate is inclined to the second mold plate, and an angle of inclination decreases with increasing degree of clamping of the device. The device further contains an axial guide in which the shaft of the first mold plate is mounted rotatably and at the same time displaceably in the direction of the second mold plate.

Abstract: The present invention encompasses, in part, a method and apparatus for lens casting in which two molds, preferably formed of plastic, are interconnected or joined together via a ring to form a mold cavity having substantially the same dimensions of the lens to be formed therein. In one implementation the invention includes a the casting device comprising a plurality of front molds, each front mold formed of a plastic and having a lens-forming surface. The front molds are configured to form a plurality of lenses of different effective diameters. The casting device further includes a rear mold formed of a plastic and having a lens-forming surface; wherein the rear mold is configured to be paired with each of the plurality of front molds to form a plurality of lenses of different effective diameters.

Abstract: A method of adjusting a forming die unit held by a die holding member, comprising steps of discharging a pressure transmitting medium from at least one of the forming die unit and the die holding member to the other one so as to apply a power in a direction that the forming die unit is spaced away from the die holding member; and displacing the forming die unit relatively to the die holding member.

Abstract: A high volume lens curing system is described. The high volume lens curing system may be configured to cure multiple eyeglass lenses in a continuous manner. The system may include ones or more lens curing units, a mold assembly, mold assembly holders and/or a conveyor system. At least one lens curing unit may include a heating system.

Abstract: An optical component has working surfaces separated by neutral surfaces which constitute discontinuities between the working surfaces. The component is made by a method which comprises: forming, in a mould, surfaces complementary to the working and neutral surfaces of the component; and moulding the component on these surfaces of the mould. The step of forming the complementary surfaces in the mould is carried out by continuous cutting of a block of material using a cutting tool.

Abstract: A molding assembly, that includes: a plurality of support pillars fixedly attached to a support structure, wherein each support pillar includes a recessed seat; a mold support member, and; a flexible ring for holding a mold in contact with the mold support member, wherein the flexible ring, while holding the mold, rests upon the recessed seat of the support pillar.

Abstract: According to one aspect, the invention provides a blocking apparatus and a blocking method for precisely aligning a button holder against a block during blocking process of lens manufacturing. According to another aspect, the invention provides an adjustable offset that enables pivotal movement of a button holder for precision alignment. According to yet another aspect, the invention provides a button holder that may flexibly float on a seat stage of a blocking apparatus, where the button holder may include a mechanism to self-align on the seat stage after a block of the blocking apparatus interfaces with the button holder.

Abstract: A high volume lens curing system is described. The high volume lens curing system may be configured to cure multiple eyeglass lenses in a continuous manner. An embodiment of a system may include a mold assembly, a lens curing apparatus, a mold filling apparatus and a controller. In some embodiments, the system may include a conveyor system and/or a coating apparatus.

Abstract: A high volume lens curing system is described. The high volume lens curing system is configured to cure multiple eyeglass lenses in a continuous manner.

Abstract: Systems and methods for storing, locating, identifying and coating eyeglass lens mold members for use in the production of eyeglass lenses are disclosed. An embodiment includes storing eyeglass lens mold members in a storage array. A plurality of indicators may be coupled to the storage array and associated with storage locations. A controller may be configured to select mold members, and to identify the locations of the mold members. A user may input mold member identifying information. The controller may activate indicators associated with determined storage location. A mold reader may be used to input the mold member identifying information. The mold reader may detect a light pattern formed by illumination of the identifying information and determine the identity of the mold member based on the light pattern. Additional embodiments relate to separating a cast lens from a lens mold. Such embodiments may include a clamping mechanism for elastically deforming the lens mold.

Abstract: Novel methods and apparatus are disclosed for handling carriers for soft contact lenses in a lens manufacturing system. In accordance with a first aspect of the invention, article handling devices are located beneath a pre-cure station and a curing station of the system to move lens carriers within those stations. As a result of locating these devices beneath these stations, the desired movement of the carriers can be achieved without increasing the footprint of the station. Pursuant to a second aspect of the invention, a complete set of assemblies is provided for moving a multitude of lens carriers into, through, and out from the pre-cure station and the curing station. This set of assemblies accomplishes this movement in a completely automated, high speed, mass production basis. In accordance with a third aspect of the invention, the curing station is provided with an intelligent buffer.

Abstract: A lens molding die for producing a lens, which comprises a base member made of a hard material and having one surface of a predetermined shape; and a resin-molded layer formed on the one surface of the base member and having a surface shape corresponding to a predetemined shape of a lens to be molded. The resin-molded surface is to be made of a resin material which is inactive with a material which is to be molded by the lens molding die. The resin-molded layer is formed by introducing the material into the space formed between the one surface of the base member and a transfer surface formed on a transfer die correspondingly to the surface of a lens to be produced to be cured by heat or ultraviolet rays.

Abstract: The present invention discloses an apparatus for cleaning ophthalmic devices. The apparatus has a conveying system for transporting lens mold carriers to a cleaning station. The cleaning station has at least one movable cleaning assembly which is situated above the lens mold carrier and has a recess. When the cleaning assembly is lowered to the lens mold carrier, a substantially enclosed or enclosed cavity containing the lens mold is created by the carrier and the recess of the cleaning assembly. Compressed gas is injected into the cavity to dislodge any debris that may be present on the lens molds, and a vacuum is employed to remove gas and debris from the cavity.

Abstract: In one embodiment, the invention is directed to an injection molding tool that has improved grounding. The injection molding process creates significant amounts of static electricity in the molten thermoplastic. This static electricity can be more adequately dissipated from the system through the addition of one or more paths to ground. In this manner, a significant reduction in charge passing between the stamper and the mirror block can be achieved. By reducing or eliminating the amount of charge passing between the stamper and the mirror block, erosion of the mirror block can be reduced or avoided.

Abstract: This invention provides an apparatus and method for assembling first and second mold parts having contact lens forming surfaces, wherein said first mold part has a reaction mixture on said contact lens forming surface, said apparatus comprising movement preventing means which prevents said first mold part from moving while said second mold part is controllably moved from a first position wherein said second mold part is not in contact with said reaction mixture on said first mold part to a position wherein the majority of said contact lens forming surface of said second mold part has been wetted by said reaction mixture on said first mold part.

Abstract: A molding apparatus for lenses includes first and second molding units, each of which has a mold core holder, a plurality of mold cores disposed in the mold core holder, and a clamp unit provided within the mold core holder. The mold core holder has an abutment surface, and a plurality of cavities extending inwardly from the abutment surface and receiving respectively the mold cores. The cavities include cavity walls, respectively. The clamp unit includes a plurality of clamp elements attached to the clamp unit to clamp respectively the mold cores against the cavity walls. Individual removal of the mold cores of the molding units for replacement is permitted by operating the clamp elements.

Abstract: A high volume lens curing system is described. The high volume lens curing system may be configured to cure multiple eyeglass lenses in a continuous manner. An embodiment of the lens curing system includes an apparatus for preparing an eyeglass lens. The apparatus may include ones or more lens curing units, a mold assembly and mold assembly holders. At least one lens curing unit may include a heating system.

Abstract: A casting mold half (5, 5a) for producing contact lenses comprises a mount (50) and an insert (51, 51a), which is arranged at one end of the mount (50) and can be connected to the mount (50) and which has a shaping surface (510) for the shaping of the front or rear surface of the contact lens to be produced. The insert (51, 51a) consists in the region of the shaping surface (510) of a material which is permeable to the energy crosslinking the starting material of the contact lens. Finally, a mask made of a material impermeable to the energy crosslinking the starting material is provided for spatially delimiting this energy. The mask comprises a separate surround (512) made of a material impermeable to the energy crosslinking the starting material of the contact lens, which surrounds the edge region of the shaping surface (510) of the insert (51, 51a).

Abstract: An ophthalmic lens mold includes a first mold half having a front side and a back side. The front side defines an optical surface. A second mold half has a front side defining an optical surface. Upon alignment of the first mold half with respect to the second mold half so that the front sides oppose each other, a mold cavity is formed between the front sides to form an ophthalmic lens therein from a moldable material. The first mold half includes a first section that transmits curing light and that extends from the back side to the front side. The first section includes at an area of the first mold half optical surface enclosed by an outermost circumference of the ophthalmic lens. A second section is co-molded with the first section and blocks the light.

Abstract: An apparatus and a method for molding optical lenses are disclosed. The apparatus comprises a first molding shell with a first diameter, a sealing element surrounding the first molding shell, and means for radially clamping the sealing element against the first molding shell, a second molding shell having a second diameter greater than the first diameter, and means for axially clamping the second molding shell with its inner shell surface against a radial front surface of the sealing element. This is done such a hollow cavity is enclosed between the molding shells and the sealing element. The radially clamping means and the axial clamping means are structurally distinct and independent one from the other. The axially clamping means are arranged on an outer shell surface of the second molding shell, opposite to the inner shell surface.

Abstract: This invention relates to a method for preparing at least one mold part of a two-part mold useful for transferring a hydrophobic top coat from a mold onto an optical substrate. Further, the invention relates to a method for easily transferring a hydrophobic top coat from a mold onto the anti-reflecting coating of a coated optical substrate. Additionally, the invention relates to a method which provides improved adhesion of the hydrophobic top coat onto an optical substrate and in particular onto an anti-reflecting coating of a coated optical substrate. The invention also discloses a mold part useful in such methods.

Abstract: This invention provides an apparatus and method for assembling first and second mold parts having contact lens forming surfaces, wherein said first mold part has a reaction mixture on said contact lens forming surface, said apparatus comprising movement preventing means which prevents said first mold part from moving while said second mold part is controllably moved from a first position wherein said second mold part is not in contact with said reaction mixture on said first mold part to a position wherein the majority of said contact lens forming surface of said second mold part has been wetted by said reaction mixture on said first mold part.

Abstract: An injection valve includes an injection channel (17) that opens outwards via an outlet (18) and has a specific inlet for the arrival of the molding material (19A) remote from the outlet (18), in addition to a slider unit (20) that is moveably mounted in the injection channel (17) and controls the outlet thereof (18). The injection channel (17) has a specific outlet (19B) for discharging the molding material. The invention can be used to mold an optical lens made from a polymerizable synthetic material.

Abstract: A lens forming apparatus for preparing a plastic eyeglass lens includes a first lens curing unit, a second lens curing unit and a conveyor system for moving mold assemblies between the two units. The apparatus may also include an anneal unit configured to apply heat to a substantially polymerized lens. The apparatus may be used to form an eyeglass lens from a lens forming composition that may include an aromatic containing polyether polyethylenic functional monomer, a photoinitiator, and a coinitiator. The lens forming composition may be cured by the application of activating light or activating light and heat.

Abstract: A molding apparatus for generating toric contact lenses, comprises a convex inserter, a front convex inserter carrier, a rear convex inserter carrier, and a first and a second fasteners. The convex inserter, used to form a convex outer surface of toric contact lens, has positioning lines on its convex head. It is embedded in the front convex inserter carrier which also has positioning lines on its upper brim, jointing with the convex inserter, and an angle pointing line on its cylindrical surface. A first fastener is used to helically tighten the convex inserter to the front convex inserter carrier while a second fastener joining the front convex inserter carrier with the rear convex inserter carrier. The front convex inserter carrier is embedded in the rear convex inserter carrier which has a number of lines representing angles of astigmatism on its cylindrical surface.

Abstract: Method and apparatus for molding an IOL comprising first and second mold halves each having an optic forming surface and haptic forming surfaces which together define a mold cavity in the shape of the IOL to be molded therein when the mold halves are assembled together. An injection port is formed and connects to one of said haptic forming surfaces or the optic forming surface wherethrough a polymerizable material is injected into the mold cavity. A venting port is formed and connects to another haptic wherethrough air escapes from the mold cavity as the polymerizable material is injected through the injection port.

Abstract: A method and apparatus for making a lens includes a front mold (90) which has a reflective, UV absorptive surface, a back mold (50) which is UV light transmissive and a gasket (60) which holds the molds and defines a lens forming cavity (78) therebetween which receives polymerizable resin material (130). The resin (130) in the lens forming cavity (78) is exposed to a source of UV light (20) to cure the resin (130) and form the lens. Photochromatic coatings can be applied to the lens and cured.

Abstract: Holographic lines are formed directly on products by holding a holographic plate and a block under a lip on a frame and mounting the frame for limited movement within a recess in a mold half. As a mold cavity is filled, the frame, block and plate and heating tubes connected to the block move in the recess. As the product sets, springs push the frame, block and plate toward the shrinking product controlling the fine holographic lines. Lateral frame recesses receive bolt ends to limit frame travel. Partially withdrawing bolts and removing the tubes releases the frame for withdrawing the block and replacing the holographic plate.

Abstract: This invention relates generally to opthalmic molds and methods useful for casting opthalmic moldings. In one aspect, the invention relates to a mold for casting an opthalmic molding formed from a first mold half detachably affixed to a second mold half, whereby the mold has a top and a bottom; and a cavity formed by the first and second mold halves, wherein the cavity receives a lens forming material through an opening at the bottom of the mold and vents gas and excess lens forming material from an opening at the top of the mold. In another aspect, this invention relates to methods for casting opthalmic moldings, particularly intraocular lenses.

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

Abstract: This invention relates to the preparation of molds for the production of contact lenses and other ophthalmic articles. By using an inorganic material to coat the optical surfaces and sidewalls of mold parts made from clear-resin materials, manufacturers can produce lens molds with greater dimensional stability and chemical resistance. In addition to protecting the clear resin from interaction with otherwise reactive monomers from which the molded article is made, such coatings can also be used to achieve preferential release of the molded article. The resulting mold is especially useful for providing an economical way to improve manufacturing quality of contact lenses.

Abstract: The object of this invention is to provide a mold releasing method for a diffraction optical element, which enables stable mass production of a diffraction optical element free from deformation or damage due to mold release. In order to achieve this object, a mold releasing method for a diffraction optical element, of releasing from a mold a diffraction optical element formed by using the mold and having a convex lens function, includes the steps of pressing a central portion of the diffraction optical element toward the mold, and pushing a periphery of the diffraction optical element in a direction to separate from the mold, so that mold release progresses from the periphery toward the central portion of the diffraction optical element. The method also includes the step of adjusting the balance with a plurality of hydraulic cylinders without pressing the central portion, so that mold release progresses toward the center.

Abstract: A high volume lens curing system is described. The high volume lens curing system may be configured to cure multiple eyeglass lenses in a continuous manner. An embodiment of the lens curing system includes an apparatus for preparing an eyeglass lens. The apparatus may include one or more lens curing units and a mold assembly. At least one lens curing unit may include a heating system. One or more computer systems may be coupled to one or more lens curing units. At least one computer system may receive prescription information for the eyeglass lens. At least one computer may control at least one lens curing unit in response to the prescription information. In some embodiments, the apparatus may include a conveyor system configured to convey the mold assembly to, through or from the apparatus. In some embodiments, the apparatus may include an annealing unit, an air distributor and/or filters.

Abstract: The mold comprises two dies mounted in a sheath to slide along the axis of the sheath and each presenting a forming face facing the other. The two dies and the sheath are provided with intrinsic heat transfer means. A parison or preform of said thermoplastic material is placed between the two dies and the assembly is enclosed in the sheath; the dies and the sheath are heated by their intrinsic heat transfer means up to a forming temperature; The dies are moved towards each other to shape the material by plastic deformation until a predetermined relative position is reached corresponding to the thickness desired for the lens; the dies and the sheath are cooled by their intrinsic heat transfer means down to an unmolding temperature; and the finished lens is extracted from the mold.

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

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

Abstract: A high volume lens curing system is described. The high volume lens curing system may be configured to cure multiple eyeglass lenses in a continuous manner. An embodiment of the lens curing system includes an apparatus for preparing an eyeglass lens. The apparatus may include one or more lens curing units and a mold assembly. At least one lens curing unit may include a heating system. In some embodiments, the apparatus may include a conveyor system configured to convey the mold assembly to, from or through the apparatus. The conveyor system may include a gating device configured to inhibit movement the mold assembly. In some embodiments, the apparatus may include an annealing unit, an air distributor and filters.

Abstract: An apparatus and method for holding a mold assembly and molding an optical lens using the same. In one aspect, the present invention provides an apparatus for holding a mold assembly, wherein the mold assembly includes a front mold, a back mold and a strip wrapping around the edges of the front mold and back mold to form a sleeve. In one embodiment, the apparatus includes a first portion and a second portion. The first portion has a top part, a bottom part, and a middle part connecting the top part and the bottom part, the middle part including a base and a holder coupled to the base. The second portion has a top part, a bottom part, and a middle part connecting the top part and the bottom part, the middle part including a base and a holder coupled to the base.

Abstract: A method including: dropping the ultraviolet-curable resin fluid onto the aspheric face of a metallic mold set horizontally, the aspheric face having a desired concave face; bringing a convex lens close to the metallic mold and stopping the movement of the lens just before it comes into contact with the ultraviolet-curable resin fluid; inclining the metallic mold and the lens together to cause the ultraviolet-curable resin fluid to flux; after bringing the convex face of the lens into point contact with this fluxed and swelled ultraviolet-curable resin fluid, moving the lens to a prescribed position relative to the metallic mold to place the ultraviolet-curable resin fluid between the lens and the metallic mold; returning the lens and the metallic mold together from the inclined state to the horizontal state, thereby irradiating the ultraviolet-curable resin fluid with ultraviolet rays to cure the resin fluid and form a molded resin layer.

Abstract: This invention provides a method and a mold for improving the release of a molded ophthalmic device from a mold. The method comprises the steps of: providing a first mold half and second mold half each having opposing top surfaces at least one of which has been hollowed out to define a cavity for forming said ophthalmic device and at least said first mold half further defining a boundary for a release element, said boundary is part of said cavity, said release element comprising a ramped surface, said cavity having a corresponding ramped surface, and said release element having its widest part near the top surface of said at least said first mold half that defines said release element therein. The mold of this invention has a hollowed-out portion as part of the cavity to provide a release element to the molded ophthalmic device.

Abstract: A mold assembly for producing a plurality of contact lenses includes a front curve fixture assembly, a base curve fixture assembly and a plurality of mold cavities. The plurality of mold cavities are defined by a surface on either the front or the base curve fixture assembly and is disposed in a zig-zag manner relative to each other. Each of the plurality of mold cavities includes a retention edge for complimentary engagement with a mold. The retention edge of a first subset of the plurality of mold cavities is spaced apart from a selected fixture mating surface at a first distance and the retention edge of a second subset of the plurality of mold cavities being spaced apart from the selected fixture mating surface at a different second distance so that a plurality of molds may be placed in adjacent cavities so as to overlap the mold flanges.

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

Abstract: A high volume lens curing system is described. The high volume lens curing system may be configured to cure multiple eyeglass lenses in a continuous manner. An embodiment of a system may include a mold assembly, a lens curing apparatus, a mold filling apparatus and/or a controller.

Abstract: A method for making an organic glass lens or lens blank which comprises providing a two-piece mold defining a molding cavity having a vertical axis which is part of a fixed reference system comprising said vertical axis and a horizontal axis which intersects at the center of the mold, a liquid tight annular closure member disposed at the periphery of the mold pieces for maintaining the two mold pieces and closing the molding cavity, wherein the annular closure member comprises at least a portion thereof made of a material that is initially gas permeable but becomes gas impermeable when in contact with a liquid polymerizable composition.

Abstract: A high volume lens curing system is described. The high volume lens curing system may be configured to cure multiple eyeglass lenses in a continuous manner. An embodiment of the lens curing system includes an apparatus for preparing an eyeglass lens. The apparatus may prepare greater than about 25 eyeglasses lenses per hour.