System for preparing an eyeglass lens using colored mold holders

• US 6,702,564 B2
• Filed: 02/20/2001
• Issued: 03/09/2004
• Est. Priority Date: 02/20/2001
• Status: Expired due to Fees

• Current Assignee: Q2100, Inc.
• Original Assignee: Q2100, Inc.
• Inventors: Foreman, John T., Lattis, Matthew C., Powers, Galen R.
• Primary Examiner(s): Mackey, James P.
• Assistant Examiner(s): Heckenberg, Donald
• Application Number:
  US09/789,193
• Publication Number:
  US 20030042637A1
• Time in Patent Office: 1,113 Days
• Field of Search: 425/162, 425/174.4, 425/808, 264/1.38, 249/103, 249/104
• US Class Current: 425/162
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2071/022 Annealing
• CPC Class Codes: B29C 35/0888 using transparant moulds
• CPC Class Codes: B29C 37/0032 the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat B29C44/14 and B29C44/32 take precedence
• CPC Class Codes: B29D 11/00442 Curing the lens material
• CPC Class Codes: B29K 2105/0002 monomers or prepolymers
• CPC Class Codes: B29L 2011/0016 Lenses
• CPC Class Codes: G02B 5/23 Photochromic filters
• CPC Class Codes: Y10S 425/808 Lens mold

Abstract

A high volume lens curing system is described. The high volume lens curing system may be configured to cure multiple eyeglass lenses in a continuous manner. An embodiment of the lens curing system includes an apparatus for preparing an eyeglass lens. The apparatus may include ones or more lens curing units, a mold assembly and mold assembly holders. At least one lens curing unit may include a heating system. The mold assembly holders, in some embodiments, may be colored. The apparatus may include a conveyor system configured to convey the mold assembly through the apparatus.

Claims

1. A system for preparing an eyeglass lens, comprising:

a first lens curing unit comprising a first activating light source, wherein the first activating light source is configured to direct 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;

first and second mold assembly holders, each mold assembly holder configured to support a mold assembly, each of the mold assembly holders comprising a body and an indentation formed in the body, wherein the indentation is substantially complementary to the shape of the mold assembly, and wherein the body of the first mold assembly holder is formed of a first color, and wherein the body of the second mold assembly holder is formed of a second color, wherein the first and second colors are different from each other, and wherein the first and second colors are indicative of the type of lens being formed; and

a conveyor system configured to convey the mold assembly holder from the first lens curing unit into and through the second lens curing unit.

2. The system of claim 1, wherein the body is configured to allow activating light to reach the mold assembly.

3. The system of claim 1, wherein the indentation defines an opening, and wherein the opening is positioned such that activating light passes through the opening and onto the mold assembly during use.

4. The system of claim 1, further comprising additional indentations for holding a mold or a gasket of the mold assembly.

5. The system of claim 1, further comprising an additional indentation for holding an additional mold assembly, wherein the additional indentation has a shape that is complementary with the additional mold assembly.

6. The system of claim 1, wherein a portion of the mold assembly holder is configured to hold a job ticket.

7. The system of claim 1, wherein the indentation extends into the body to a depth such that an upper surface of the mold assembly is positioned at or below the upper surface of the body.

8. The system of claim 1, wherein the first activating light source is an ultraviolet light source.

9. The system of claim 1, wherein the second activating light source is an ultraviolet light.

10. The system of claim 1, wherein the first and second activating light sources are ultraviolet lights.

11. The system of claim 1, wherein the first and second activating light sources have substantially the same spectral output.

12. The system of claim 1, wherein the first and second activating light sources have a peak light intensity at a range of about 385 nm to about 490 nm.

13. The system of claim 1, wherein the first activating light source comprises a first set of lamps and a second set of lamps, wherein the first and second set of lamps are positioned on opposite sides of the first curing unit.

14. The system of claim 1, further comprising a filter disposed directly adjacent to the first activating light source, the filter being configured to manipulate an intensity of the activating light emanating from the first activating light source.

15. The system of claim 1, further comprising a filter disposed directly adjacent to the second activating light source, the filter being configured to manipulate an intensity of the activating light emanating from the second activating light source.

16. The system of claim 1, further comprising a first filter disposed directly adjacent to the first activating light source, the filter being configured to manipulate an intensity of the activating light emanating from the first activating light source, and further comprising a second filter disposed directly adjacent to the second activating light source, the filter being configured to manipulate an intensity of the activating light emanating from the second activating light source.

17. The system of claim 1, further comprising an air distributor positioned within the second curing unit, the air distributor being configured to circulate air within the second curing unit during use.

18. The system of claim 1, further comprising 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.

19. The system of claim 1, further comprising 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 wherein the anneal unit heating system is configured to heat the interior of the anneal unit to a temperature of up to about 250°

F.

20. The system of claim 1, further comprising 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 wherein the anneal unit further comprises an anneal unit conveyor system configured to convey the mold assembly through the anneal unit.

21. The system of claim 1, further comprising a programmable controller configured to substantially simultaneously control operation of the first curing unit and the second curing unit during use.

22. The system of claim 1, further comprising a programmable controller configured to control operation of the first curing unit as a function of the eyeglass lens prescription.

23. The system of claim 1, wherein the first activating light source comprises a fluorescent lamp, and wherein the first activating light source further comprises a flasher ballast system coupled to the fluorescent lamp.

24. The system of claim 1, wherein the second activating light source comprises a fluorescent lamp, and wherein the second activating light source further comprises a flasher ballast system coupled to the fluorescent lamp.

25. The system of claim 1, wherein the first activating light source comprises two or more lamps, and wherein the lamps are independently operable.

26. The system of claim 1, wherein the conveyor system comprises a continuous flexible member extending from the first curing unit through the second curing unit, wherein the flexible member is configured to interact with a mold assembly to convey the mold assembly through the first curing unit, to the second curing unit, and through the second curing unit.

27. The system of claim 1, wherein the conveyor system comprises two discrete conveyors, wherein the first conveyor is configured to convey the mold assembly from the first curing unit to the second curing unit, and wherein the second conveyor is configured to convey the mold assembly through the second curing unit.

28. The system of claim 1, wherein the conveyor system comprises a flexible member configured to interact with a mold assembly, and wherein the flexible member is coupled to a motor configured to move the flexible member through the conveyor system.

29. A system for preparing an eyeglass lens, comprising:

a lens curing unit comprising an activating light source, wherein the activating light source is configured to direct activating light toward a mold assembly during use;

one or more mold assembly holders, each mold assembly holder is configured to support a mold assembly, each of the mold assembly holders comprises a body and an indentation formed in the body, wherein the body of at least one mold assembly holder comprises a color, and wherein the color is indicative of the type of lens being formed.

30. The system of claim 29, wherein the body is configured to allow activating light to reach the mold assembly.

31. The system of claim 29, wherein the indentation defines an opening, and wherein the opening is positioned such that activating light passes through the opening and onto the mold assembly during use.

32. The system of claim 29, further comprising additional indentations for holding a mold or a gasket of the mold assembly.

33. The system of claim 29, further comprising an additional indentation for holding an additional mold assembly, wherein the additional indentation has a shape that is substantially complementary with the additional mold assembly.

34. The system of claim 29, wherein a portion of the mold assembly holder is configured to hold a job ticket.

35. The system of claim 29, wherein the indentation extends into the body to a depth such that an upper surface of the mold assembly is positioned at or below the upper surface of the body.

36. The apparatus of claim 29, wherein the mold assembly resides on a mold assembly holder, the mold assembly holder comprising a body and an indentation formed in the body, wherein the indentation is substantially complementary to the shape of the mold assembly.

37. The apparatus of claim 29, wherein the activating light source is an ultraviolet light source.

38. The apparatus of claim 29, wherein the activating light source has a peak light intensity at a range of about 385 nm to about 490 nm.

39. The apparatus of claim 29, wherein the activating light source comprises a first set of lamps and a second set of lamps, wherein the first and second set of lamps are positioned on opposite sides of the lens curing unit.

40. The apparatus of claim 29, wherein the activating light source comprises a fluorescent lamp, and wherein the activating light source further comprises a flasher ballast system coupled to the fluorescent lamp.

41. The apparatus of claim 29, wherein the activating light source comprises two or more lamps, and wherein the lamps are independently operable.

42. The apparatus of claim 29, further comprising a filter disposed directly adjacent to the activating light source, the filter being configured to manipulate an intensity of the activating light emanating from the activating light source.

43. The apparatus of claim 29, further comprising 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.

44. The apparatus of claim 29, further comprising 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 wherein the anneal unit heating system is configured to heat the interior of the anneal unit to a temperature of up to about 250°

F.

45. The apparatus of claim 29, further comprising 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 wherein the anneal unit further comprises an anneal unit conveyor system configured to convey the mold assembly through the anneal unit.

46. The apparatus of claim 29, further comprising a programmable controller configured to control operation of the lens curing unit as a function of a prescription for the eyeglass lens.

47. The apparatus of claim 29, further comprising a conveyor system configured to convey the mold assembly holder through the lens curing unit, wherein the conveyor system comprises a continuous flexible member configured to interact with a mold assembly holder, to convey the mold assembly holder through lens curing unit.

48. The apparatus of claim 29, further comprising an additional lens curing unit.

49. The apparatus of claim 29, further comprising an additional lens curing unit, wherein the lens curing unit and the additional lens curing unit are coupled together.

50. The apparatus of claim 29, further comprising an additional activating light source disposed in an additional lens curing unit, wherein the additional activating light source is configured to direct activating light toward the mold assembly during use.

51. The apparatus of claim 29, further comprising an additional activating light source disposed in an additional lens curing unit, wherein the additional activating light source comprises a fluorescent lamp, and wherein the additional activating light source further comprises a flasher ballast system coupled to the fluorescent lamp.

52. The apparatus of claim 29, further comprising an additional lens curing unit comprising an additional activating light source, wherein the additional activating light source is configured to direct activating light toward the mold assembly during use and wherein the activating light and the additional activating light sources are ultraviolet lights.

53. The apparatus of claim 29, further comprising an additional activating light source disposed in an additional lens curing unit, wherein the additional activating light source is configured to direct activating light toward the mold assembly during use and wherein the lens activating light and the additional activating light sources have substantially the same spectral output.

54. The apparatus of claim 29, further comprising an additional activating light source disposed in an additional lens curing unit, wherein the additional activating light source is configured to direct activating light toward the mold assembly during use;

and wherein the activating light and the additional activating light sources have a peak light intensity at a range of about 385 nm to about 490 nm.

55. The apparatus of claim 29, further comprising:

an additional activating light source disposed in an additional lens curing unit, wherein the additional activating light source is configured to direct activating light toward a mold assembly during use; and

a filter disposed directly adjacent to the additional activating light source, the filter being configured to manipulate an intensity of the activating light emanating from the additional activating light source.

56. The apparatus of claim 29, further comprising:

an additional activating light source disposed in the additional lens curing unit, wherein the additional activating light source is configured to direct activating light toward a mold assembly during use;

a first filter disposed directly adjacent to the activating light source, the filter being configured to manipulate an intensity of the activating light emanating from the activating light source;

a second filter disposed directly adjacent to the additional activating light source, the filter being configured to manipulate an intensity of the activating light emanating from the additional activating light source.

57. The apparatus of claim 29, further comprising an additional lens curing unit;

and an air distributor positioned within the lens curing unit, the air distributor being configured to circulate air within the lens curing unit during use.

58. The apparatus of claim 29, further comprising an additional lens curing unit;

and a programmable controller wherein the programmable controller is configured to substantially simultaneously control operation of the lens curing unit and the additional lens curing unit during use.

59. The apparatus of claim 29, further comprising an additional activating light source disposed in an additional lens curing unit, wherein the activating light source comprises a fluorescent lamp, and wherein the additional activating light source further comprises a flasher ballast system coupled to the fluorescent lamp.

60. The apparatus of claim 29, further comprising

an additional lens curing unit, wherein the lens curing unit comprises an additional activating light source, wherein the activating light source configured to direct activating light toward the mold assembly during use;

and

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.

61. The apparatus of claim 29, further comprising an additional lens curing unit and a conveyor system, wherein the conveyor system comprises two discrete conveyors, wherein the first conveyor is configured to convey the mold assembly holder from the lens curing unit to the additional lens curing unit;

and wherein the second conveyor is configured to convey the mold assembly holder through the additional lens curing unit.

62. The apparatus of claim 29, further comprising an additional lens curing unit, and a conveyor system configured to convey the mold assembly holder through the lens curing unit, to the additional curing unit and through the additional lens curing unit, wherein the conveyor system comprises a flexible member configured to interact with a mold assembly holder, wherein the flexible member is coupled to a motor configured to move the flexible member through the conveyor system.