Apparatus and method for heating a polymerizable composition

• US 6,716,375 B1
• Filed: 03/30/2000
• Issued: 04/06/2004
• Est. Priority Date: 03/30/2000
• Status: Expired due to Fees

• Current Assignee: Q2100, Inc.
• Original Assignee: Q2100, Inc.
• Inventors: Triplett, John T., Lattis, Matthew C., Powers, Galen R.
• Primary Examiner(s): Vargot, Mathieu D.
• Application Number:
  US09/539,420
• Time in Patent Office: 1,468 Days
• Field of Search: 264/1.1, 264/2.5, 264/1.36, 264/1.38, 264/40.4, 425/808
• US Class Current: 264/1.36
• CPC Class Codes: B29C 39/24 Feeding the material into the mould
• CPC Class Codes: B29C 39/38 Heating or cooling
• CPC Class Codes: B29C 39/44 Measuring, controlling or regulating
• 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 11/00442 Curing the lens material
• CPC Class Codes: B29D 11/00528 Consisting of two mould halves joined by an annular gasket
• CPC Class Codes: H05B 41/2988 for protecting the lamp against abnormal operating conditions

Abstract

A system for dispensing a heated polymerizable lens forming composition is described. The dispensing system includes a body configured to hold the lens forming composition, a heating system coupled to the body for heating the monomer solution, and a valve positioned proximate an outlet of the body for controlling the flow of the lens forming composition out of the body.

Claims

1. A method for making a plastic eyeglass lens, comprising

heating a lens forming composition in a heating apparatus comprising:

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;

placing the liquid lens forming composition in a mold cavity of a mold assembly, wherein the mold assembly comprises a front mold member and a back mold member, the lens forming composition comprising a monomer composition and a photoinitiator;

directing activating light toward at least one of the mold members to initiate curing of the lens forming composition; and

directing activating light and heat toward at least one of the mold members subsequent to initiating curing of the lens to form the eyeglass lens.

2. The method of claim 1, wherein the valve comprises a movable member coupled to the elongated member, wherein the elongated member contacts the movable member at a first position such that the elongated member is in the closed position, and wherein the elongated member contacts the movable member at a second position such that the elongated member is in the open position, and wherein the movable member is movable such that the position of the elongated member can be varied from the first position to the second position.

3. The method of claim 1, wherein the body further comprises a chamber positioned within the body, and wherein the heating system is positioned within the chamber, and wherein the chamber inhibits the lens forming composition from contacting the heating system.

4. The method of claim 1, wherein the heating system comprises a resistive heating system.

5. The method of claim 1, wherein the elongated member extends substantially completely through the outlet when the elongated member is in the closed position.

6. The method of claim 1, wherein the elongated member extends partially into the outlet when the elongated member is an open position.

7. The method of claim 1, further comprising measuring a temperature of the lens forming composition with a thermostat coupled to the body of the heating apparatus, and further comprising operating the heating system in response to the temperature measured by the thermostat.

8. The method of claim 1, further comprising measuring a temperature of the lens forming composition with a thermocouple coupled to the body of the heating apparatus, wherein the heating apparatus further comprises a controller coupled to the thermocouple and the heating system, and wherein the controller is configured to control the heating system in response to the temperature measured by the thermocouple.

9. The method of claim 1, further comprising measuring the level of the lens forming composition disposed with the body with a fluid level monitor disposed within the body.

10. The method of claim 1, further comprising measuring the level of the lens forming composition disposed within the body with a fluid level monitor disposed within the body, wherein the heating apparatus further comprises a controller coupled to the fluid monitor and the heating system, wherein the controller is configured to control the heating system in response to the level of fluid measured by the fluid level monitor.

11. The method of claim 1, wherein the apparatus is electrically coupleable to a controller of a lens forming apparatus.

12. The method of claim 1, further comprising introducing the lens forming composition into the body of the heating apparatus.

13. The method of claim 12, wherein the lens forming composition is stored in a fluid containers the fluid container comprising a fluid container body and a cap, wherein the cap comprises a fluid control member and an elastic member, wherein the elastic member is coupled to the fluid control member such that the elastic member exerts a force on the fluid control member such that the fluid control member is forced against a top inner surface of the cap, wherein the introducing the lens forming composition into the body comprises inserting the cap of the fluid container into the opening of the heating apparatus.

14. The method of claim 1, wherein the heating apparatus further comprises a mold assembly holder coupled to the body of the heating apparatus, wherein the mold assembly holder is configured to hold the mold assembly in a position such that the outlet of the heating apparatus body is positioned proximate an inlet of the mold assembly, and wherein the method further comprises placing the mold assembly on the mold assembly holder prior to placing the lens forming composition in the mold cavity.

15. The method of claim 1, wherein curing of the lens forming composition is initiated by directing activating light toward at least one of the mold members for less than 100 seconds.

16. The method of claim 1, wherein treating the lens forming composition with activating light and heat comprises directing activating light toward at least one of the mold members and applying heat to both mold members.

17. The method of claim 1, further comprising applying heat to the lens in the absence of activating light, subsequent to directing activating light and heat toward at least one of the mold members.

18. The method of claim 1, further comprising heating the lens forming composition prior to placing the lens forming composition in a mold cavity.

19. The method of claim 1, further comprising placing the mold members in a mold assembly holder, wherein the mold assembly holder is configured to fit within a first lens curing unit and a second lens curing unit and wherein directing activating light toward at least one of the mold members to initiate curing is performed in the first lens curing unit, and wherein directing activating light and heat toward at least one of the mold members subsequent to initiating curing is performed in the second lens curing unit.

20. The method of claim 19, wherein the first lens curing unit is coupled to the second lens curing unit by a conveyor system and further comprising transferring the mold assembly holder from the first curing unit to the second curing unit along the conveyor system subsequent to initiating curing of the lens forming composition.

21. The method of claim 1, wherein the photoinitiator comprises an acylphosphine oxide.

22. The method of claim 1, wherein the lens forming composition further comprises an ultraviolet/visible light absorbing compound.

23. The method of claim 1, wherein the monomer comprises an aromatic containing polyethylenic polyether functional monomer.

24. The method of claim 1, wherein the monomer composition comprises a polyethylenic functional monomer.

25. The method of claim 1, wherein the lens forming composition further comprises a co-initiator composition, wherein the co-initiator composition comprises an amine.

26. The method of claim 1, wherein the lens forming composition further comprises a co-initiator composition, wherein the co-initiator composition comprises an acrylyl amine.

27. The method of claim 1, wherein the lens forming composition further comprises a co-initiator composition, wherein the co-initiator composition comprises an acrylyl amine, the acrylyl amine comprising monoacrylated amines, diacrylated amines, or mixtures thereof.

28. The method of claim 1, wherein the lens forming composition further comprises a photochromic compound.

29. The method of claim 1, wherein the light absorbing compound comprises a photochromic compound, and wherein the photochromic compound comprises one or more spiropyrans.

30. The method of claim 1, wherein the light absorbing compound comprises a photochromic compound, and wherein the photochromic compound comprises one or more spirooxazines.

31. The method of claim 1, wherein the light absorbing compound comprises a photochromic compound, and wherein the photochromic compound comprises one or more spiropyrans and one or more spirooxazines.

32. The method of claim 1, wherein the light absorbing compound comprises a photochromic compound, and wherein the photochromic compound comprises one or more spironaphthoxazines, one or more spiropyridobenzoxazines, one or more spirobenzoxazines, one or more naphthopyrans, one or more benzopyrans, one or more spironaphthopyrans, one or more indolinospironaphthoxazines, one or more indolinospironaphthopyrans, one or more diarylnaphthopyrans, or mixtures thereof.

33. A method for making a plastic eyeglass lens, comprising

heating a lens forming composition in a heating apparatus;

wherein the heating apparatus comprises a body being configured to hold the lens forming composition;

the body comprising an opening for receiving a fluid container and an outlet;

placing the heated liquid lens forming composition in a mold cavity of a mold assembly, wherein the mold assembly comprises a front mold member and a back mold member, the lens forming composition comprising a monomer composition and a photoinitiator;

directing activating light toward the mold assembly to initiate curing of the lens forming composition.

34. The method of claim 33, wherein the heating apparatus further comprises:

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.

35. The method of claim 34, wherein the valve comprises a movable member coupled to the elongated member, wherein the elongated member contacts the movable member at a first position such that the elongated member is in the closed position, and wherein the elongated member contacts the movable member at a second position such that the elongated member is in the open position, and wherein the movable member is movable such that the position of the elongated member can be varied from the first position to the second position.

36. The method of claim 33, wherein the body further comprises a chamber positioned within the body, and wherein a heating system is positioned within the chamber, and wherein the chamber inhibits the lens forming composition from contacting the heating system.

37. The method of claim 33, wherein the heating apparatus further comprises a heating system for heating the lens forming composition and wherein the heating system comprises a resistive heating system.

38. The method of claim 34, wherein the elongated member extends substantially completely through the outlet when the elongated member is in the closed position.

39. The method of claim 33, further comprising measuring a temperature of the lens forming composition with a thermostat coupled to the body of the heating apparatus, and further comprising operating a heating system positioned in the body in response to the temperature measured by the thermostat.

40. The method of claim 33, further comprising measuring the level of the lens forming composition disposed within the body with a fluid level monitor disposed within the body, wherein the heating apparatus further comprises a controller coupled to the fluid monitor and a heating system positioned in the body, wherein the controller is configured to control the heating system in response to the level of fluid measured by the fluid level monitor.

41. The method of claim 33, wherein the lens forming composition is stored in a fluid container, the fluid container comprising a fluid container body and a cap, wherein the cap comprises a fluid control member and an elastic member, wherein the elastic member is coupled to the fluid control member such that the elastic member exerts a force on the fluid control member such that the fluid control member is forced against a top inner surface of the cap, the method further comprising introducing the lens forming composition into the body by inserting the cap of the fluid container into the opening of the heating apparatus.

42. The method of claim 33, wherein the heating apparatus further comprises a mold assembly holder coupled to the body of the heating apparatus, wherein the mold assembly holder is configured to hold the mold assembly in a position such that the outlet of the heating apparatus body is positioned proximate an inlet of the mold assembly, and wherein the method further comprises placing the mold assembly on the mold assembly holder prior to placing the lens forming composition in the mold cavity.

43. The method of claim 33, further comprising directing activating light and heat toward the mold assembly subsequent to initiating curing of the lens to form the eyeglass lens.

44. The method of claim 43, further comprising applying heat to the eyeglass lens in the absence of activating light, subsequent to directing activating light and heat toward at least one of the mold members.

45. The method of claim 33, wherein the photoinitiator comprises an acylphosphine oxide.

46. The method of claim 33, wherein the lens forming composition further comprises an ultraviolet/visible light absorbing compound.

47. The method of claim 33, wherein the monomer comprises an aromatic containing polyethylenic polyether functional monomer.

48. The method of claim 33, wherein the monomer composition comprises a polyethylenic functional monomer.

49. The method of claim 33, wherein the lens forming composition further comprises a co-initiator composition, wherein the co-initiator composition comprises an amine.

50. The method of claim 33, wherein the lens forming composition further comprises a co-initiator composition, wherein the co-initiator composition comprises an acrylyl amine.

51. The method of claim 33, wherein the lens forming composition further comprises a co-initiator composition, wherein the co-initiator composition comprises an acrylyl amine, the acrylyl amine comprising monoacrylated amines, diacrylated amines, or mixtures thereof.

52. The method of claim 33, wherein the lens forming composition further comprises a photochromic compound.

53. The method of claim 33, wherein the light absorbing compound comprises a photochromic compound, and wherein the photochromic compound comprises one or more spiropyrans.

54. The method of claim 33, wherein the light absorbing compound comprises a photochromic compound, and wherein the photochromic compound comprises one or more spirooxazines.

55. The method of claim 33, wherein the light absorbing compound comprises a photochromic compound, and wherein the photochromic compound comprises one or more spiropyrans and one or more spirooxazines.

56. The method of claim 33, wherein the light absorbing compound comprises a photochromic compound, and wherein the photochromic compound comprises one or more spironaphthoxazines, one or more spiropyridobenzoxazines, one or more spirobenzoxazines, one or more naphthopyrans, one or more benzopyrans, one or more spironaphthopyrans, one or more indolinospironaphthoxazines, one or more indolinospironaphthopyrans, one or more diarylnaphthopyrans, or mixtures thereof.