Method for injection molding a curvilinear lens

• US 6,383,417 B1
• Filed: 09/23/1999
• Issued: 05/07/2002
• Est. Priority Date: 12/26/1997
• Status: Expired due to Term

• Current Assignee: Paulson Manufacturing Corporation
• Original Assignee: Paulson Manufacturing Corporation
• Inventors: Reiterman, Donald R., Paulson, Roy V.
• Primary Examiner(s): Vargot, Mathieu D.
• Application Number:
  US09/404,557
• Time in Patent Office: 957 Days
• Field of Search: 264/1.1, 264/328.1, 243/1, 243/6, 243/9
• US Class Current: 264/1.1
• CPC Class Codes: A61F 9/027 Straps; Buckles; Attachment of headbands
• CPC Class Codes: A61F 9/029 Additional functions or features, e.g. protection for other parts of the face such as ears, nose or mouth; Screen wipers or cleaning devices
• CPC Class Codes: Y10T 24/1371 Eyeglass holder including retaining means
• CPC Class Codes: Y10T 24/4736 Buckle connected

Abstract

Goggles for protecting the eyes of a wearer in ultra-hazardous conditions. The goggles comprise a frame that seals to the face of the wearer so that the wearer'"'"'s eyes are enveloped. An adjustable strap is attached to the goggles and goes around the head of the wearer in order to secure the goggles over the wearer'"'"'s face. Indirect ventilation is utilized to eliminate fogging, and drains are used in the frame to evacuate trapped moisture, A curvilinear lens with multiple optical zones is secured within the frame of the goggles and angled for increased lower peripheral vision. The materials with which the goggles are constructed are capable of withstanding a temperature of at least about 550° F. for a minimum of five minutes without oozing or dripping or otherwise deforming.

Claims

1. A method for forming a curvilinear lens by injection molding, the method comprising the steps of:

using a tool die capable of being parted, the die having walls, said walls defining a hollow, said hollow shaped to generally reflect a negative embodiment of said curvilinear lens to be formed, said embodiment including;

a curvilinear first surface, said first surface corresponding to said inner surface of said lens;

a curvilinear second surface, said second surface corresponding to said outer surface of said lens;

a perimeter; and

multiple zones integral to said embodiment, said multiple zones comprising;

a central zone positioned at a center of said embodiment, said curvilinear second surface diverging with said curvilinear first surface about said central zone so that a thickness between said first surface and said second surface is maximized toward said center of said central zone;

curvilinear side zones separated by said central zone, said side zones comprising;

a first side zone contiguous to said central zone; and

a second side zone contiguous to said central zone; and

curvilinear rear zones spaced from said central zone by said side zones, said rear zones comprising;

a first rear zone contiguous to said first side zone, wherein said curvature of said first side zone is equal to a curvature of said first rear zone at said contiguous location; and

a second rear zone contiguous to said second side zone, wherein said curvature of said second side zone is equal to a curvature of said second rear zone at said contiguous location;

the die being shaped and configured to provide a curvilinear lens having a shape minimizing optical distortion at each contiguous interface between adjacent zones of said lens;

flowing a fluid optically transparent material into said hollow of said die to form said curvilinear lens;

allowing said transparent material to obtain a stable substantially non-fluid state, said material being physically shaped by said walls into said curvilinear lens, said curvilinear shape of said lens minimizing optical distortion at each contiguous interface between adjacent zones of said lens; and

removing said lens from said hollow of said die.

2. A method for forming a curvilinear lens by injection molding, the method comprising the steps of:

using a tool die to form a curvilinear lens by injection molding, the die capable of being parted;

defining a hollow in the die, the die having walls shaped to generally reflect an embodiment of the curvilinear lens, the embodiment comprising;

a curvilinear first surface corresponding to an inner surface of the lens;

a curvilinear second surface corresponding to an outer surface of the lens;

a central zone positioned substantially at a center of the embodiment, the curvilinear second surface diverging with the curvilinear first surface about the central zone so that a thickness between the first surface and the second surface is generally maximized toward the center of the central zone;

curvilinear side zones separated by the central zone, the side zones comprising;

a first side zone contiguous to the central zone; and

a second side zone contiguous to the central zone;

the curvilinear shape of the die being configured to minimize the optical distortion at each contiguous interface between zones of the lens formed thereby; and

inserting a material into the hollow of the die to form the curvilinear lens.

3. A method for forming a curvilinear lens by injection molding, the method comprising the steps of:

using a tool die to form a curvilinear lens by injection molding, the die capable of being parted;

defining a hollow in the die, the die having walls shaped to generally reflect an embodiment of the curvilinear lens, the embodiment comprising;

a curvilinear first surface corresponding to an inner surface of the lens;

a curvilinear second surface corresponding to an outer surface of the lens;

a central zone positioned substantially at a center of the embodiment, the curvilinear second surface diverging with the curvilinear first surface about the central zone so that a thickness between the first surface and the second surface is generally maximized toward the center of the central zone;

curvilinear side zones separated by the central zone, the side zones comprising;

a first side zone contiguous to the central zone; and

a second side zone contiguous to the central zone,

curvilinear rear zones spaced from the central zone by the side zones, the rear zones comprising;

a first rear zone contiguous to the first side zone, wherein a curvature of the first side zone is substantially equal to a curvature of the first rear zone around the contiguous location; and

a second rear zone contiguous to the second side zone, wherein a curvature of the second side zone is substantially equal to a curvature of the second rear zone around the contiguous location;

the die being shaped and configured to provide a curvilinear lens with minimal optical distortion at each contiguous interface of the lens zones; and

inserting a material into the hollow of the die to form the curvilinear lens.