Abstract: A non-planar Fresnel reflector array mold pattern and fabrication method are described which can be utilized to manufacture integral non-planar Fresnel reflector arrays which are not subject to molding inclusions. The Fresnel reflector segments comprising the mold pattern are joined at angles to one another and incorporate off-axis Fresnel segments at segment positions in which the optical axis of the segment is not sufficiently parallel to the intended pull direction of the associated mold. The focal point of each off-axis segment lies along a path that is angularly offset from the optical axis of said segment. The use of properly oriented off-axis Fresnel segments within the non-planar Fresnel array result in the elimination of molding inclusions. The mold pattern thus created may be positive or negative, and provides the three-dimensional pattern from which the final manufacturing molds or tools are created.

Abstract: A pedestal for inverting a soft contact lens has been invented. The pedestal of the invention has an inner surface, an outer surface, a dome shape capable of supporting the back surface of the contact lens or the front surface of that contact lens which has been inverted, is made from an elastic material which allows a negative pressure gradient to be generated from the outer surface to the inner surface, and has an elastic top which is capable of collapsing in to invert the contact lens.

Abstract: A mold assembly for forming an ophthalmic lens article includes a first mold and a second mold. The first and second molds are assembled together to define a mold cavity therebetween having a profile corresponding to that of the ophthalmic lens article to be formed. The mold cavity is filled with a polymeric material which is polymerized to form the ophthalmic lens article. At least one of the first and second molds is a resin mold which is formed from a resin material, and a portion of at least a molding surface of the resin mold is directly irradiated with UV radiation so as to provide a UV-treated surface. The ophthalmic lens article formed in the mold cavity is held on the resin mold such that the ophthalmic lens article adheres to the UV-treated surface upon separating the first and second molds away from one another.

Abstract: A light guide plate which is made of a transparent resin and has a first main surface and a second main surface opposite to said first main surface, said first main surface having a surface portion provided with convex portions having a height of 5×10−7 m to 6×10−5 m each and a pitch of 5×10−7 m to 4×10−4 m, each convex portion having a tip portion, and the convex portions of at least 80% of the total convex portions having the tip portions having a radius of curvature of 2×10−6 m or less.

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: 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: 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 and method for the production of ophthalmic lenses, and particularly contact lenses, which minimizes damage of the lens in removal from the mold. The ophthalmic lens is produced in a mold having a male part and a female part that are placed in proximate relation to each other to create a lens-forming cavity. At least the female surface of the female part mold is preferably coated with plasma and is irradiated for a predetermined time such that the female surface and/or surface coating is at least partially cured. Once the female surface, and alternately the male surface and other surfaces of the mold, is at least partially cured, a curable lens-forming material is placed into the lens-forming cavity and cured to form an ophthalmic lens.

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: A method and apparatus for producing a contact lens material having two opposite lens-forming surfaces is disclosed. A first resin mold having a molding surface providing one of the opposite lens-forming surfaces of the contact lens material is injection-molded by closing a first and a second die to define at least one mold cavity and injecting a resin material into the mold cavity. A second resin mold having a molding surface is injection-molded by closing a third and a fourth die to define at least one mold cavity and injecting a resin material into the second mold cavity. The dies are separate away from each other and molding material is introduced into one of the resin molds which are held on one of the respective dies. The dies holding the first and second resin molds are moved relative to each other to assemble the first and second resin molds to define a mold cavity for the contact lens material.

Abstract: A method of automatic manufacture of an astigmatic contact lens having a toric portion and a ballast portion such that said ballast portion causes the toric portion of the contact lens to properly orient in the eye of the wearer. The toric lenses are manufactured by moving a pallet containing at least half of a casting cup assembly and an information tag under a filling assembly and filling half of a casting cup assembly with liquid monomer, then moving the pallet to a closing assembly and, based on information obtained from the information tag, rotating one or both halves of the casting cup assembly and closing the casting cup assembly. The liquid monomer is then cured thereby creating a toric contact lens.

Abstract: This invention primarily relates to a method for making a retroreflective plate including the steps of: (a) making a plurality of pin units by injection molding wherein the pin units substantially include a relatively thicker portion and a relatively thinner portion which is connected to the relatively thicker portion from the bottom thereof along the longitudinal direction of the pin units, the free end of the relatively thicker portion away from the relatively thinner portion forms a tapered portion; (b) placing the pin units on a base, wherein the base has a top surface and a plurality of recessions thereon such that the relatively thinner portion of the pin units can be put into at least some of the recessions for positioning; (c) producing a master negative die with the construction thereof complementary to the tapered portion of the arranged pin units; and (d) using the master negative die to form a retroreflective plate with the construction thereof complementary to that of the master negative die.

Abstract: A plastic lens molded through a gate in a molding process has a gate-located portion on an outer peripheral surface of the plastic lens, and a concave surface provided on at least a part of the gate-located portion.

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 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 constituted of silicon carbide IR-emitters, and which employs an individual infra-red emitter for each individual mold, to impart a desired thermal gradient.

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: The invention provides molds useful for the production of lenses with contoured edges. In particular, the molds permit production of a lens with an edge shaped to avoid its impingement on the lens wearer's conjuntival membrane.

Abstract: A molding die for molding an optical element, comprises a die base body formed by shaping an amorphous alloy having a super-cooled liquid phase, wherein the composition of the amorphous alloy contains palladium.

Abstract: An apparatus for the automated production of ophthalmic lenses, particularly compound lenses having a plastic coating on a plastic lens is described. A mold, after rotational orientation, is placed in a gimbal assembly to provide for the proper tilt. This gimbal assembly forms part of a fixture attached to an indexing means which moves for complete assembly of a molding fixture and then moves the molding fixture through a chamber to cure the resin. A preform, after rotational orientation, is held, by a preform gripper placed above the mold, and with sufficient clearance between the mold and the preform to allow the correct resin thickness during the curing portion of the process. The fixture is also provided with members to firmly grip the preform gripper so as to maintain its orientation throughout the curing process.

Abstract: There is provided an apparatus for manufacturing lenses for vehicle lamps, wherein the lenses are formed from at least first and second types of synthetic resins by molding the first and second synthetic resins integrally with each other. The apparatus includes a first mold having a common mold and a first stationary mold and defining a first cavity in which the first synthetic resin is injection molded, and a second mold constructed from the common mold and a second stationary mold and defining a second cavity in which the first synthetic resin and the second synthetic resin are molded integrally with each other with the first synthetic resin being contained within the second cavity. A partition wall is provided on the first stationary mold in such a manner as to protrude therefrom for preventing the first synthetic resin from intruding into any place other than the first cavity when the first mold is closed.

Abstract: A lens molding apparatus basically includes a lens molding tool in which a pair of lens forming molds for forming outer shapes of both surfaces of a molded lens are oppositely arranged on both sides of an annular forming frame in the thickness direction to form a target space therebetween, and a molding resin is injected in the target space to form an unhardened molded lens, wherein the unhardened molded lens is hardened by irradiating the unhardened molded lens with ultraviolet rays, to form a hardened molded lens. This lens molding apparatus is characterized in that optical characteristics of the unhardened molded lens are measured by a measuring system.

Abstract: A method for separating one mold section from another mold section and a contact lens molded in the two mold sections provides improved reliability that the lens is not damaged during this operation and that the lens is retained selectively on the desired. Various embodiments of apparatus for carrying out the method are disclosed.

Abstract: This invention provides a mold for forming a contact lens comprising an overflow collector, which causes the overflow reactive mixture to be accumulated, and not to spread out as it would upon the typically flat surface of a prior art mold. This invention further provides a method of preventing the formation of contaminating pieces of overflow reactive mixture comprising the step of: preventing the overflow reactive mixture from spreading out on the mold.

Abstract: Described is a mold for producing optical lenses from a polymerizable material and a method for such production. Said mold comprises a gasket (1) enclosing an aperture (2), which aperture (2) extends along an axis (14), and providing a contact surface (3) radially extending from said aperture (2), a first molding shell (4) abutting against said contact surface (3), a second molding shell (5) arranged within said aperture (2) at a distance from said first molding shell (4), means (6) for pressing said first molding shell against said contact surface, means (7) for radially pressing said gasket against said second molding shell, and a filling opening, thereby forming a molding cavity (8) that can be filled with molding material between said first (4) and said second (5) molding shell and said gasket (1).

Abstract: A mold assembly for forming an ophthalmic lens, or a lens blank from which one ophthalmic lens is produced by effecting a cutting operation on at least one of a front surface and a back surface of the lens blank, the mold assembly consisting of a first mold having a molding surface and a second mold having a molding surface, which first and second molds are assembled together so as to define therebetween a mold cavity having a profile corresponding to that of the ophthalmic lens or the lens blank, the mold cavity being filled with a polymeric material which is polymerized to form the ophthalmic lens or the lens blank, wherein at least one of the first and second molds is a layered mold which is constituted by a composite sheet comprising a metal sheet layer and at least one resin layer which are laminated on each other, the at least one resin layer of the composite sheet providing the molding surface of the layered mold which partially defines the mold cavity.

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: A flow cell 2, a composite lens 15, and first to third detectors 16 to 18 are arranged in this sequence in the light pathway of light emitted from a laser light source 1. The composite lens 15 is configured by a convex lens 15a, and lens elements 15b and 15c. These lenses have different focal lengths. When the posture of the composite lens is correct, light impinging on the convex lens forms an image on the first detector. Therefore, the positioning of the composite lens is enabled. When particles in the flow cell are irradiated with laser light, forward scatter is produced. Forward small angle scatter having a small scattering angle impinges on the first lens element 15b to be collected thereby, and is then received by the second detector 17. Forward large angle scatter having a large scattering angle impinges on the second lens element 15c in the outermost periphery to be collected thereby, and is then received by the third detector 18 which is remotest from the composite lens.

Abstract: A cast mould for use in the manufacture of a contact lens by the polymerisation of a flowable precursor comprises a female mould part and a male mould part. The female mould part has a concave first surface region adapted to receive the flowable precursor in use, and a second surface region. The male mould part has a convex first surface region and a second surface region. The male mould part is engageable with the female mould part to define a lens-forming recess between the concave and convex surface regions and to define a first overflow cavity between said second surface regions. The first overflow cavity is adapted to receive excess flowable precursor displaced from the lens-forming recess in use, and the first overflow cavity is provided with first retaining means such that, in use, after polymerisation, polymer in the first overflow cavity is mechanically interlocked with a single one of the mould parts after separation of the mould parts.

Abstract: A rear signal lamp of an automotive vehicle comprising a lamp housing and a curved cover lens for enclosing a thin light managing system. The thin light managing systems includes a plurality of backlight light-emitting diodes mounted in a light mounting substrate and secured to the lamp housing. A control module operatively connected to the light-emitting diodes for controlling the operation and illumination of the light-emitting diodes. A reflector matrix having a plurality of reflector cones corresponding to each of the light-emitting diodes in the mounting substrate and a hybrid optics panel having a direct lensing section covering the reflector matrix and light-emitting diodes and a double redirecting light pipe section surrounding the lensing section. A single light-emitting diodes is coupled along spaced apart quadrants of the redirecting light pipe.

Abstract: NK1717 The present invention provides a resin-cemented optical element comprising a base member 10 and a resin layer 11 formed on the surface of the base member; the resin layer 11 being in a thickness of 300 &mgr;m or smaller at least at some part of a peripheral portion (i.e., a region within 1 mm from the peripheral edge face 17 of the resin layer 11, or a region outside an effective-diameter region), and being in a thickness 12 of 850 &mgr;m or larger at a position which is thickest in the resin layer; a mold therefore; a manufacturing method thereof; and an optical article having this optical element.

Abstract: A forming mold for a lens sheet is to be used for molding ionizing radiation curing type resin into the lens sheet by applying the resin in the form of liquid on the upper surface of the forming mold, placing a substrate on the resin and pressing the substrate and the resin against the forming mold from a pressing-starting side of the forming mold to a pressing-finishing side thereof by means of a pressing roller. The forming mold comprises a mold body and a receiving member. The receiving member receives a superfluous amount of the ionizing radiation curing type resin. The receiving member is provided on at least pressing-finishing side of a periphery of the mold body.

Abstract: Unique side-fill mold assembly and method for making a lens wherein the mold assembly includes a gasket having a plurality of side port holes which allow filling of the mold assembly with a thermosetting resin and allow egress of air trapped within the mold assembly.

Abstract: A method for applying resin for forming a lens sheet comprises the steps (a) to (c). The step (a) is to apply ionizing radiation curing type resin in a form of liquid on an entirety of an upper surface of a forming die through a multiple nozzle to form a first uncured resin layer on the upper surface of the forming die. The step (b) is to apply the ionizing radiation curing type resin in the form of liquid on one side of the first uncured resin layer through a nozzle to form an uncured resin pool thereon. The step (c) is to spread the uncured resin pool from the one side of the first uncured resin layer toward the other side thereof to form a second uncured resin layer on the first uncured resin layer.

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: Methods of cast molding toric contact lenses are provided including the steps of providing a first contact lens mold section; providing a molding apparatus and an insert tool adapted to be fixed to the molding apparatus at a plurality of different rotational orientations relative to the molding apparatus; fixing, at one of a plurality of different rotational orientations relative to the molding apparatus, the insert tool in a molding apparatus and producing a second mold section in the molding apparatus with the insert tool fixed thereto, wherein the second mold section includes a contour which corresponds to a toric optical zone of a contact lens; assembling the first and second mold sections; and cast molding a toric contact lens product between the mold sections. Sets of mold sections useful for molding toric contact lenses as provided.

Abstract: Methods of cast molding toric contact lenses are provided including the steps of providing a first contact lens mold section; providing a molding apparatus and an insert tool adapted to be fixed to the molding apparatus at a plurality of different rotational orientations relative to the molding apparatus; fixing, at one of a plurality of different rotational orientations relative to the molding apparatus, the insert tool in a molding apparatus and producing a second mold section in the molding apparatus with the insert tool fixed thereto, wherein the second mold section includes a contour which corresponds to a toric optical zone of a contact lens; assembling the first and second mold sections; and cast molding a toric contact lens product between the mold sections. Sets of mold sections useful for molding toric contact lenses as provided.

Abstract: A method for manufacturing a synthetic resin thermoplastic ophthalmic lens by injecting a thermoplastic material immediately adjacent to each side of a light polarizing wafer situated within a mold cavity. The light polarizing wafer includes tab appendages which are positionable into registration notches in the mold cavity in order to maintain the wafer in a desired position in the mold during lens formation. The thermoplastic material is then injected around the light polarizing wafer, whereupon a compression procedure is implemented where the contents of the mold cavity are compressed. The mold cavity is compressed to a predetermined position to achieve a desired shape of the lens. Uniform compression is exerted over the entire surface of lens during the compression procedure, resulting in all stresses being uniformly distributed over the lens surface to significantly negate stress-inducted birefringence in the formed ophthalmic lens.

Abstract: An apparatus and method for filling a mold for casting optical lens. Two molding shells and a closure member form a mold with a molding cavity. To fill the mold a fluid lens-forming material is introduced into the molding cavity through a casting opening formed in the closure member. Air is venting out during the filling process through a venting opening also formed in the closure member. Both the casting opening and the venting opening are located in the upper portion of the molding cavity but spaced apart from each other at an acute angle.

Abstract: Apparatus and method for removing unwanted excess material from a mold section is particularly adapted for removing a monomer ring adhered within a reservoir of a female mold section used to mold a contact lens. The invention involves piercing the monomer ring and rotating the piercing members (e.g., annularly spaced pins) relative to the mold section whereby the monomer ring is sheared from the mold section to which it was adhered while the molded lens is left intact in the mold section.

Abstract: The fixture of the invention provides a bottom portion into which a mold half is placed. Movably mounted above the bottom portion is a top portion having two horizontal plates adapted to slide relative to each other to control the X direction and Y direction and hold a preform or wafer. The top portion is further adapted to allow for the adjustment of the relative angle between the preform or wafer and mold half, as well as adjustment of the distance between the top portion and bottom portion.

Abstract: A method for labeling an identification mark on a lens for inventory control. The identification mark is placed onto the facing inside surface of a mold by an ink jet printer and is remained there when the lens-forming liquid is cured. Once the lens is formed, but before the demolding, the identification mark is transferred from the mold to the lens. The identification mark contains information identifying the lens' properties such as the power of the lens and can be used for inventory control.

Abstract: An injection compression molding method for injecting and compressing molten resin to obtain molding product using a molding die internally having a lens-forming cavity includes a pair of relatively movable inserts; a gate; a runner; and a sprue. The molten resin is injected and filled into the cavity and volume of the cavity is reduced by moving one insert toward the other insert after a time period prior to completion of injecting and filling the molten resin. At the time, a gate shut pin is protruded into the gate in synchronization with the movement of the insert to gradually close the opening of the gate. Accordingly, two demands, i.e. lower resistance in filling the cavity with the molten resin and shutting in the molten resin after the molten resin is packed in the cavity, can both be satisfied. This improves productivity and enables the production of mold products having highly accurate configuration and high quality.

Abstract: A method of molding an ophthalmic lens product by using a mold assembly which has a mold cavity, the lens product having a configuration corresponding to that of an ophthalmic lens or a precursor of the ophthalmic lens and being obtained by polymerizing a liquid monomer composition in the mold cavity to provide a polymer product which gives the lens product, the method comprising the steps of: preparing the mold assembly having a monomer storage space for storing the liquid monomer composition, which storage space is held in fluid communication with the mold cavity; filling the mold cavity of the mold assembly with the liquid monomer composition while the liquid monomer composition is accommodated in the monomer storage space; and polymerizing the liquid monomer composition at a temperature of 10-80° C. while a pressure higher than the atmospheric pressure is applied directly to a liquid surface of a mass of the liquid monomer composition accommodated in the monomer storage space.

Abstract: A method of forming an ophthalmic lens using a composite ophthalmic lens vacuum mold to quickly and inexpensively produce, on-site, multi-focal, prescription and non-prescription optical quality eyeglasses, with or without photochromic, and photochromic non-prescription (e.g., sunglasses, safety glasses, reading glasses, etc.) optical quality eyeglass via a vacuum remolding. The method further includes a rigid remolding process for forming the composite ophthalmic lens.

Abstract: A mold assembly for forming an ophthalmic lens, the mold assembly comprising a first mold and a second mold which cooperate with each other to define therebetween a mold cavity having a profile following that of the ophthalmic lens, wherein the improvement comprises: at least one of the first and second molds being a coated mold consisting of a body portion including a backing surface having rigidity and mechanical strength enough to withstand a molding operation for forming the ophthalmic lens in the mold cavity, and a thermoplastic film retained on the body portion such that the thermoplastic film covers the backing surface of the body portion, the thermoplastic film having a molding surface which partially defines the mold cavity and which gives a corresponding one of opposite surfaces of the ophthalmic lens.

Abstract: A mold is disclosed for making rotationally asymmetric contact lenses. The mold comprises a first concave or convex surface that is rotationally asymmetric for forming the surface of the contact lens thereagainst, a second concave or convex surface opposed to the first surface that is also rotationally asymmetric, and a segment of the mold between the first and second surfaces having a substantially uniform thickness.

Abstract: Hard to fill large-surface-area parts and/or thinwalled configurations of optical lenses and reflective optical elements are among the difficult-to-mold thermoplastic products which require precision replication of the molding surfaces, in micro detail. We combine multiple opposing gates (to reduce the meltflow pathlength) with non-isothermal steps of firstly, heating these mold surfaces (with circulating heat transfer fluids supplied by a hot side supply system, to a temperature setpoint sufficiently high to retard solidification), then secondly, injecting the melt through these opposing gates, then thirdly, rapidly cooling to solidification (by circulating heat transfer fluids of much lower temperature, supplied from a cold side supply system).