Abstract: This invention provides a mold comprising a first mold half which works in conjunction with a second mold half for forming ophthalmic devices wherein said first mold half comprises at least one changeable cassette comprising inserts for forming said ophthalmic devices. The mold is particularly well-suited for use in an injection molding machine.

Abstract: An improved method of cast molding contact lenses, wherein a lens forming mixture is cured in the lens-shaped cavity formed between molding surfaces of a male and female mold sections, wherein the improvement comprises at least one of sections is injection molded from a metallocene-catalyzed thermoplastic polyolefin.

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: The mold half-block possesses at least one mold recess defined transversely by the working face of a shell provided with heat-transfer means that are intrinsic and both-way (both heating and cooling), said shell comprising a base that receives all of the heat-transfer means of said shell and a removable insert fitted on the base and carrying the working face, said insert having no intrinsic heat-transfer means and being thermally regulated solely by heat transfer with said base. The insert is in the form of a cap which fits over at least a head portion of the base, and the heat-transfer means of the base are allocated to the head portion of the base having the insert fitted thereover.

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.

Abstract: A method for molding a plastic ophthalmic lens which comprises introducing a liquid polymerizable composition in a molding cavity of a two-piece mold through a filling nozzle in flow communication with the upper half of the molding cavity and spaced apart from the central vertical axis of the molding cavity up to the time the lower half of the molding cavity is filled. Then, tilting the mold to bring the filling in register with the central axis of the molding cavity and achieving full filling of the molding cavity. Thereafter, polymerizing the composition and recovering the lens.

Abstract: A handling assembly for ophthalmic mold parts between processing stations of a manufacturing line comprises a planar mold cartridge adapted to hold about 1000 mold parts at a time.

Abstract: Disclosed is an injection molding method. The method comprises injecting a melt of thermoplastic material at a temperature higher than the glass transition temperature (Tg) of the thermoplastic material in a molding cavity defined by a two-piece mold insert. The article is recovered after cooling and disassembling of the two piece mold insert. Each of the two pieces of the mold insert comprise at least one portion partly defining the mold cavity which is made of a material or combination of materials, other than glass, the thermal diffusivity &agr; of which fulfills the condition: 1<&agr;/&agr;g<11, wherein &agr;g is the thermal diffusivity of a borosilicate glass and is equal to 6.20×10−7 m2 s−1. The portion is at least 1 mm thick. The injection molding method can be used to form weld free minus 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: An apparatus for producing a plastic molded article or product for use in an optical device is a mold assembly. The mold assembly includes a pair of molds having an inner mold surface forming a cavity with a preselected volume into which a molten molding material is injected via a gate or sprue to fill the cavity and thereby form a molded product having a sink surface and at least one mirror surface after the molten molding material has cooled. The inner mold surface includes at least one transfer surface portion against which the at least one mirror surface of the molded product is formed, and at least one non-transfer surface portion against which the sink surface portion of the molded product is formed. The mold assembly also includes at least one vent hole, at least one bore in communication with the vent hole so that a preselected air pressure is applied to the molten molding material in the cavity via the bore and the vent hole, and at least one exhaust hole adjacent to, but spaced from the vent hole.

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: A method and an apparatus are proposed for producing mouldings, in particular ophthalmic lenses, such as contact lenses for example, in which a starting material located in a mould (100, 110; 100a, 110a) is polymerized and/or crosslinked by means of exposure to light, in particular by exposure to UV light, so that a demouldable moulding is produced. The measurement of the intensity (I) of the light takes place during the production of the mouldings.

Abstract: Apparatus and method for handling an ophthalmic lens in a manufacturing line where lenses are presented for picking and transport to a respective lens receptacle. The problem of lens fly-away is prevented by a cover which releasably couples to the lens picking means and is deposited over the lens receptacle immediately following release of the lens into the secondary receptacle and withdrawal of the lens picking means.

Abstract: An injection compression molding method of a lens is provided, where a toggle link mechanism (65) is actuated to close a molding die (50) and a movable die plate (64) is moved to a position establishing a cavity thickness of greater than a thickness of an article to be molded while the die is closed. After injecting a molten resin into the cavity, the molten resin is sealed in the cavity and the toggle link mechanism (65) is actuated to advance the movable die plate (64) toward a fixed die plate (61), the relative position of a rear die plate (62) and the movable die plate (64) is made constant at a position where extension of a tie bar (63) becomes a predetermined value, and the molten resin is cooled for a predetermined time after completion of pressurizing the resin.

Abstract: An arbor for lathe cutting lenses, especially contact lenses, from a blank, is designed for the mounting of a lens mold with a cast lens blank therein during lathing of the lens blank. The arbor is made in a manner to ensure the lens mold is axially aligned with the arbor. The arbor can be reused for lathe cutting of multiple lens blanks retained in their respective lens molds.

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 optical element having a complex structure of diffraction grating, an inclined surface, a difference in level and the like and of good optical characteristics, its manufacturing method, and an optical element manufacturing metal die capable of injection molding the optical element are disclosed. By using an optical element manufacturing metal die constituted to have nestings which have mirror surface forming portions two adjoining pairs of mirror surfaces of the optical element are molded by two adjoining pairs of mirror surface forming portions which are formed on the same nesting. The optical element manufacturing metal die is constituted to include the nesting having a diffraction grating forming portion in which a predetermined concave-convex pattern for molding the diffraction grating of the optical element is formed on one surface of a substrate.

Abstract: Ophthalmic lens are made by reacting a lens forming mixture in a mold to form a polymer. The polymer is then demolded from the mold and processed into a completed lens. The molds are made of at least two parts, a first part having a surface for forming the polymer into a portion of the lens and a second part having a surface for forming the polymer into a portion of the lens. The first and second parts of the mold each have different surface energies.

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: Mold pins for use in a mold matrix, as used in the production of electroforms, are provided with means to alter the longitudinal axis of the pins relative to that of adjacent pins so that the longitudinal axis of the pins are tapered with respect to one another towards the operative ends of the pins. In one embodiment of the invention a dowel is inserted into a sidewall of the pin and extends normal thereto to space the pin from an adjacent one. In another embodiment, a spacing member of a desired thickness is applied to the shank of the pin at a location remote from the operative end thereof.

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: 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 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 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 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 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: 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. Pursuant to a second aspect of the invention, in a preferred embodiment multiple sets of assemblies are provided for moving a multitude of lens carriers into, through, and out from the pre-cure station and the curing station. In accordance with a third aspect of the invention, the curing station is provided with an intelligent buffer.

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 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: 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: In a press molding apparatus for press molding a plurality of glass materials into a plurality of glass optical elements by the use of a pressing mold including upper and lower molds each of which has a plurality of molding surfaces, at least one of the upper and the lower molds is a heat generator within which heat is generated when the heat generator is subjected to a high-frequency induction heating by an induction heating coil. The heat generator having a plurality of shape-processed portions (130) produced by partially processing a shape of the heat generator in order that a temperature distribution of the heat generator is adjusted. The apparatus simultaneously press forms, into the glass optical elements, the glass materials supplied between the molding surfaces of the upper and the lower molds which are subjected to the high-frequency induction heating.

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

Abstract: An end face of a plastic optical fiber end is treated so as not to extrude to the core side face when the plastic optical fiber end is softened and fused. The core end face of the plastic optical fiber end is pressed intermittently on a mold that is heated to a certain temperature to soften and fuse the core end face to thereby transfer the transfer face of the mold on the core end face.

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: 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: Method comprises:

Abstract: A system for molding optical attenuators that have a lens portion and a supporting portion includes a molding machine containing a mold, an extractor robot and optical inspection portion, and a controller that assesses the inspection information and send control signals to the molding machine and mold. The mold includes a cavity and a core which define a space in which the supporting portion and the attenuator are formed. The cavity and core are separable from each other by an actuating motor of the molding machine subsequent to each injection cycle to permit removal of each molded optical attenuator. The mold also includes a core pin, movably located in the core element. The core pin has a proximal end defining a surface of the lens portion and a distal end remote from the molding space. A core pin motor is coupled to the core pin, through a number of intermediate elements, so that the core pin can be moved relative to the core element to adjust a thickness of the lens portion.

Abstract: Apparatus for clamping together contact lens molds having a polymerizable liquid monomer disposed therebetween includes a plurality of clamping assemblies each having a linearly translatable shaft member mounted to a contact lens curing table. A common mold clamp release assembly is provided through which each mold clamping assembly passes, thereby ensuring that each mold set is subjected to the same clamping and release profile. Additionally, the amount of clamping force of each clamping assembly may be individually adjusted by way of an adjustable nut mounted to the shaft member which, thereby, controls the amount of force delivered by the shaft member to the contact lens molds being clamped.

Abstract: The present invention describes a carrier set for carrying ophthalmic lens molds. The carrier set has a front curve carrier, a back curve carrier, at least one spring in the front curve carrier or the back curve carrier, at least one stabilizing hole formed in one of the front curve and back curve carriers, at least one elongated stabilizing member attached to the carrier that does not have the stabilizing hole, and at least one locking bar in the carrier that has the stabilizing hole.

Abstract: An automated method and apparatus is provided to mold, cure and package soft contact lenses. A conveyor system transports an array of molds through a plurality of automated work stations. The front curve mold halves are partially filled with a polymerizable monomer or monomer mixture and assembled and clamped to displace any excess hydrogel from the mold cavity. The assembly is precured and then transported through a cure station using UV radiation to complete polymerization, The assemblies are then pried apart in an automated station, with any excess monomer adhering to the removed mold half. The newly molded lens is then hydrated and separated from the front curve mold half in a hydration station. Following hydration the array of lens is automatically deposited into a plurality of packages with a robotic transfer device having a plurality of figures which transfer the lenses.

Abstract: The invention is a compact disc manufacturing mold which permits the mold to be used to produce a variety of non-standard sizes and shapes. A replaceable flat cavity ring which fits between the conventional mold pieces encloses the outer boundary of the disc and has an inner shape which defines the non-standard disc shape. The cavity ring includes a cylindrical projection extending from its surface which is in contact with the face of the mold piece. The extension is inserted into a groove in the mold face and is locked into the mold by threaded plugs screwed through the cylindrical sides of the mold piece.

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 method for making microlens molds and microlens array molds is described which utilizes a spinning half radius diamond cutting member operated in a plunge cut in a technique similar to milling to cut the optical surface into a diamond turnable material. The method can be used to make high sag lens molds with high accuracy. Microlens array molds can be made with a high degree of uniformity and a nearly 100% fill factor.

Abstract: A plastic trial lens having a grip portion gripped when the lens is set in trial frames for trial lenses, an injection molded product for making the trial lenses, and a mold assembly for molding the injection molded product are provided. In the injection molded product molded by means of the mold assembly in an injection compression molding machine, a grip portion and a liquid guided and collected area are molded simultaneously with a lens portion on a periphery of the lens portion. When the injection molded product is dipped into hard coat liquid, the hard coat liquid is guided in the liquid guided and collected area to drip down and the remaining liquid without dripping down is collected in the liquid guided and collected area, thereby forming a coating film of uniform thickness on the lens portion. The plastic trial lens which is integrally provided with the grip portion is finished after the liquid guided and collected area is removed.

Abstract: Method and apparatus for applying an identifying mark to a mold used for making an ophthalmic device whereby the mold may be identified at various points along a production line in a fast, reliable and automatic manner. The mark is applied to a non-optical surface of the mold and is read using a reading device and a light source positioned on either side of the mold whereby the light rays enhance the contrast between the identifying mark and the mold. In a preferred embodiment, the identifying mark is a 2D matrix which is formed on the non-optical mold tool used in the injection mold machine which makes the mold. The 2D matrix on the non-optical mold tool is then replicated on the non-optical surface of the mold.

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: Apparatus for making a plastic lens. Apparatus includes a mold cavity and a cooling fluid distributor. The apparatus is adapted to produce a plastic lens from a liquid composition.

Abstract: A mold includes a cavity and a core which define a space in which an optical attenuator and supporting portion are formed. The includes a core pin, movably located in the core element. The core pin has a proximal end defining a surface of the lens portion and a distal end remote from the molding space. A core pin motor is coupled to the core pin, through a number of intermediate elements, so that the core pin can be moved relative to the core element to adjust a thickness of the lens portion. The intermediate elements can include a ball screw, a ball screw end cap fixed to a core pin holder block, a ball screw nut fixed to an outer surface of the mold so that an outer end of the ball screw passes through the nut to a location outside the mold.

Abstract: A center touch method and apparatus for use in a contact lens station for use with a contact lens mold assembly comprising a first mold half and a second mold half. The center touch apparatus comprises a center touch engaging member having a center touch engaging surface for engaging a central portion of a non-molding surface of one of the mold halves. The center touch method comprising driving one of the mold halves toward the other mold half using the center touch engaging member to contact a central area of the non-molding surface of the one mold half.

Abstract: A method and a device for removing molded soft contact lenses, high-precision intraocular lenses and the like, from the individual molds in which they are produced. Provided is an infra-red radiation or heater device preferably constituted of silicon carbide IR-emitters, and which employs an individual infra-red emitter for each individual mold, to impart a desired thermal gradient. Also provided are infra-red emitters having improved reflectors.