Apparatus and system for the production of plastic lenses
First Claim
Patent Images
1. An apparatus for preparing an eyeglass lens, comprising:
- a first lens curing unit comprising a first activating light source, wherein the first lens curing unit is configured to produce activating light directed toward a mold assembly during use;
a second lens curing unit comprising a second activating light source and heating system, wherein the second activating light source is configured to direct activating light toward a mold assembly during use; and
wherein the heating system is configured to heat the interior of the second lens curing unit; and
a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit;
wherein the apparatus is configured such that a substantially clear eyeglass lens is formed in a time period of less than 1 hour.
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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.
243 Citations
139 Claims
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1. An apparatus for preparing an eyeglass lens, comprising:
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a first lens curing unit comprising a first activating light source, wherein the first lens curing unit is configured to produce activating light directed toward a mold assembly during use;
a second lens curing unit comprising a second activating light source and heating system, wherein the second activating light source is configured to direct activating light toward a mold assembly during use; and
wherein the heating system is configured to heat the interior of the second lens curing unit; and
a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit;
wherein the apparatus is configured such that a substantially clear eyeglass lens is formed in a time period of less than 1 hour. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
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34. An apparatus for preparing an eyeglass lens, comprising:
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a first lens curing unit comprising a first activating light source, wherein the first lens curing unit is configured to produce activating light directed toward a mold assembly during use;
a second lens curing unit comprising a second activating light source and heating system, wherein the second activating light source is configured to direct activating light toward a mold assembly during use; and
wherein the heating system is configured to heat the interior of the second lens curing unit;
an anneal unit, the anneal unit comprising an anneal unit heating system, wherein the anneal unit heating system is configured to heat the interior of the anneal unit; and
a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit;
wherein the apparatus is configured such that a substantially clear eyeglass lens is formed in a time period of less than 1 hour.
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35. A system for preparing an eyeglass lens, comprising:
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a mold assembly comprising;
a first mold member having a casting face and a non-casting face;
a second mold member having a casting face and a non-casting face, the second mold member being configured to be spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member at least partially define a mold cavity;
an apparatus for curing a lens forming composition, comprising;
a first lens curing unit comprising a first activating light source, wherein the first lens curing unit is configured to produce activating light toward a mold assembly during use;
a second lens curing unit comprising a second activating light source and heating system, wherein the second activating light source is configured to direct activating light toward a mold assembly during use; and
wherein the heating system is configured to heat the interior of the second lens curing unit; and
a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit. - View Dependent Claims (36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81)
a body, wherein the body is configured to allow activating light to reach the mold assembly;
an indentation formed in the body, wherein the indentation is complementary to the shape of the mold assembly.
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75. The system of claim 74, wherein the indentation defines an opening, and wherein the opening is positioned such that activating light from the first activating light source passes through the opening and onto the mold assembly when the mold assembly is positioned within the first lens curing unit.
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76. The system of claim 74, wherein the indentation defines an opening, and wherein the opening is positioned such that activating light from the second activating light source passes through the opening and onto the mold assembly when the mold assembly is positioned within the second lens curing unit.
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77. The system of claim 74, wherein the indentation defines an opening, and wherein the opening is positioned such that activating light from the first activating light source passes through the opening and onto the mold assembly when the mold assembly is positioned within the first lens curing unit, and wherein the opening is positioned such that activating light from the second activating light source passes through the opening and onto the mold assembly when the mold assembly is positioned within the second lens curing unit.
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78. The system of claim 74, wherein the mold assembly holder further comprises additional indentations for holding a mold or a gasket of the mold assembly.
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79. The system of claim 74, wherein the mold assembly holder further comprises a ridge disposed on the bottom surface, wherein the ridge is configured to interact with a conveyor system.
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80. The system of claim 35, further comprising a monomer heating apparatus for dispensing a heated polymerizable lens forming composition comprising:
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a body, the body being configured to hold the lens forming composition, the body comprising an opening for receiving a fluid container and an outlet;
a heating system positioned within the body for heating the lens forming composition;
a valve positioned proximate the outlet, wherein the valve comprises an elongated member, wherein the elongated member is positionable within the outlet in a closed position, wherein the elongated member in the closed position inhibits flow of the lens forming composition through the outlet, and wherein the elongated member is positionable within the outlet in an open position, wherein the elongated member in an open position allows flow of the lens forming composition flows through the outlet during use.
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81. The system of claim 80, further comprising a programmable controller, wherein the programmable controller is configured to control the operation of the first curing unit, the second curing unit, and the monomer heating apparatus.
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53. The system of 52, wherein the anneal unit heating system is configured to heat the interior of the anneal unit to a temperature of up to about 250°
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82. A system for preparing an eyeglass lens, comprising:
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a mold assembly comprising;
a first mold member having a casting face and a non-casting face;
a second mold member having a casting face and a non-casting face, the second mold member being configured to be spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member at least partially define a mold cavity;
an apparatus for curing a lens forming composition, comprising;
a first lens curing unit comprising a first activating light source, wherein the first lens curing unit is configured to produce activating light toward a mold assembly during use;
a second lens curing unit comprising a second activating light source and heating system, wherein the second activating light source is configured to direct activating light toward a mold assembly during use; and
wherein the heating system is configured to heat the interior of the second lens curing unit; and
a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit; and
a lens forming composition configured to be disposed within the mold cavity during use, comprising;
a monomer that cures by exposure to activating light to form the eyeglass lens during use; and
a photoinitiator that initiates curing of the monomer in response to being exposed to activating light during use. - View Dependent Claims (83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139)
a body, wherein the body is configured to allow activating light to reach the mold assembly;
an indentation formed in the body, wherein the indentation is complementary to the shape of the mold assembly.
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133. The system of claim 132, wherein the indentation defines an opening, and wherein the opening is positioned such that activating light from the first activating light source passes through the opening and onto the mold assembly when the mold assembly is positioned within the first lens curing unit.
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134. The system of claim 132, wherein the indentation defines an opening, and wherein the opening is positioned such that activating light from the second activating light source passes through the opening and onto the mold assembly when the mold assembly is positioned within the second lens curing unit.
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135. The system of claim 132, wherein the indentation defines an opening, and wherein the opening is positioned such that activating light from the first activating light source passes through the opening and onto the mold assembly when the mold assembly is positioned within the first lens curing unit, and wherein the opening is positioned such that activating light from the second activating light source passes through the opening and onto the mold assembly when the mold assembly is positioned within the second lens curing unit.
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136. The system of claim 132, wherein the mold assembly holder further comprises additional indentations for holding a mold or a gasket of the mold assembly.
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137. The system of claim 132, wherein the mold assembly holder further comprises a ridge disposed on the bottom surface, wherein the ridge is configured to interact with a conveyor system.
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138. The system of claim 82, further comprising a monomer heating apparatus for dispensing a heated polymerizable lens forming composition comprising:
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a body, the body being configured to hold the lens forming composition, the body comprising an opening for receiving a fluid container and an outlet;
a heating system positioned with the body for heating the monomer solution;
a valve positioned proximate the outlet, wherein the valve comprises an elongated member, wherein the elongated member is positionable within the in a closed position, wherein the elongated member in the closed position inhibits flow of the lens forming composition through the outlet, and wherein the elongated member is positionable within the conduit in an open position, wherein the elongated member in an open position allows flow of the lens forming composition flows through the outlet during use.
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139. The system of claim 138, further comprising a programmable controller, wherein the programmable controller is configured to control the operation of the first curing unit, the second curing unit, and the monomer heating apparatus.
Specification