Method for side-fill lens casting

• US 6,391,231 B1
• Filed: 11/22/1999
• Issued: 05/21/2002
• Est. Priority Date: 11/23/1998
• Status: Expired due to Term

• Current Assignee: Younger Manufacturing Co
• Original Assignee: Younger Manufacturing Co
• Inventors: Yamasaki, Nancy L. S., Balch, Thomas, Evans, Russell E.
• Primary Examiner(s): Vargot, Mathieu D.
• Application Number:
  US09/447,445
• Time in Patent Office: 911 Days
• Field of Search: 264/1.1, 264/1.7, 264/2.5, 425/808
• US Class Current: 264/1.7
• CPC Class Codes: B29C 33/0061 characterised by the configuration of the material feeding channel sprue channels for injection moulding B29C45/27
• CPC Class Codes: B29C 33/0077 characterised by the configuration of the mould filling gate mixing chambers situated in the mould opening B29B7/7471; accessories for connecting the mould filling gate with the filling spout
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: B29C 39/123 Making multilayered articles
• CPC Class Codes: B29D 11/00413 made by moulding between two mould parts which are not in direct contact with one another, e.g. comprising a seal between or on the edges B29D11/00019 - B29D11/00355, B29D11/00423, B29D11/00432 take precedence
• CPC Class Codes: B29D 11/00432 Auxiliary operations, e.g. machines for filling the moulds B29D11/00125 takes precedence
• CPC Class Codes: B29D 11/00528 Consisting of two mould halves joined by an annular gasket
• CPC Class Codes: B29D 11/00538 Feeding arrangements
• CPC Class Codes: Y10S 425/808 Lens mold

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.

Claims

1. A method for making a polymer lens comprising:

assembling a mold comprising first and second mold members spaced apart from one another by a gasket to define a chamber, the gasket having an annular body defining a first port hole and a second port hole adjacent thereto;

placing an embedded layer within the chamber, wherein the port holes are at a location selected from above, below, or a combination thereof, the embedded layer;

injecting a first composition through one of the two port holes to fill the chamber, wherein the port holes are disposed about the embedded layer such that the first composition is injected above the embedded layer and a second composition is injected below the embedded layer; and

curing said first and second composition to form a lens having an embedded layer therein.

2. The method of claim 1, wherein said port holes are round-shaped, oval-shaped, slot-shaped, or a combination thereof.

3. The method of claim 1, wherein at least one of the holes extends through said annular body at an angle between about 0 and −

90 degrees.

4. The method of claim 3, wherein the angle is between about −

20 and −

90 degrees.

5. The method of claim 1, wherein said first composition comprises a combination of a thermosetting material and at least one of impact-resistant material, abrasion-resistant material, photochromic material, tinted material, high viscosity material, low refractive index material, high refractive index material.

6. The method of claim 1, wherein said embedded layer is a film.

7. The method of claim 6, wherein said film is a polarizer, photochromic material, tinted material, impact-resistant material, material having light adsorption characteristics, or a material having light-controlling characteristics.

8. The method of claim 1, wherein said port holes are linearly aligned along said embedded layer.

10. The method of claim 1, wherein said second composition comprises a combination of a thermosetting material and at least one of impact-resistant material, abrasion-resistant material, photochromic material, tinted material, high viscosity material, low refractive index material, high refractive index material.

9. A method for making a polymer lens comprising:

providing a mold assembly for casting plastic lenses, said assembly including a first and second mold members spaced apart from one another by a gasket to define a chamber within which a lens is to be cast, said gasket comprising an annular body having at least three port holes therethrough, an embedded layer, at least one port hole is in fluid communication with said chamber below said embedded layer and at least one port hole is in fluid communication with the chamber above said embedded layer;

placing said composition in at least one of the port holes, whereby to fill said mold while venting gases through another of the port holes; and

curing said composition whereby to form said lens.

11. A method for making a polymer lens comprising:

assembling a mold comprising first and second mold members spaced apart from one another by a gasket to define a chamber, the gasket having an annular body defining a first port hole and a second port hole;

placing an embedded layer within the chamber, wherein one port hole is above the embedded layer and the other port hole is below the embedded layer;

injecting a composition through one of the two port holes to fill the chamber while venting gases through the other port hole; and

curing the composition to form a lens having an embedded layer therein.

12. The method of claim 11, wherein the port holes are round-shaped, oval-shaped, slot-shaped, or a combination thereof.

13. The method of claim 11, wherein at least one of the port holes extends through the annular body at an angle between about 0 and −

90 degrees.

14. The method of claim 11, wherein the composition comprises a combination of a thermosetting material and at least one of impact-resistant material, abrasion-resistant material, photochromic material, tinted material, high viscosity material, low refractive index material, high refractive index material.

15. The method of claim 11, wherein at least one of the holes extends through the annular body at an angle between about −

20 and −

90 degrees.

16. The method of claim 11, wherein the embedded layer is a film.

17. The method of claim 16, wherein the film is a polarizer, photochromic material, tinted material, impact-resistant material, material having light adsorption characteristics, or a material having light-controlling characteristics.