Apparatus for preparing an eyeglass lens having a controller for initiation of lens curing

• US 6,752,613 B2
• Filed: 02/20/2001
• Issued: 06/22/2004
• Est. Priority Date: 02/20/2001
• Status: Expired due to Fees

• Current Assignee: Q2100, Inc.
• Original Assignee: Q2100, Inc.
• Inventors: Foreman, John T.
• Primary Examiner(s): Mackey, James P.
• Assistant Examiner(s): Heckenberg, Donald
• Application Number:
  US09/789,291
• Publication Number:
  US 20020168438A1
• Time in Patent Office: 1,218 Days
• Field of Search: 425/135, 425/145, 425/174.4, 425/808, 425/DIG.108, 264/1.38
• US Class Current: 425/145
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 33/0038 with sealing means or the like seals on envelopes used in tyre retreading B29D30/542; for injection moulding footwear B29D35/0045
• 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 33/303 centering mould parts or halves, e.g. during mounting
• CPC Class Codes: B29C 33/34 movable, e.g. to or from the moulding station
• CPC Class Codes: B29C 35/0288 Controlling heating or curing of polymers during moulding, e.g. by measuring temperatures or properties of the polymer and regulating the process controlling or regulating chemical, physical or physico- chemical processes in general B01J19/0006
• CPC Class Codes: B29C 35/08 by wave energy or particle radiation B29C64/00, B29C71/04 take precedence
• CPC Class Codes: B29C 39/006 Monomers or prepolymers by reaction injection moulding B29C67/246
• 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: B29D 11/00538 Feeding arrangements
• CPC Class Codes: B29L 2011/0016 Lenses
• CPC Class Codes: B29L 2011/0041 Contact lenses
• CPC Class Codes: Y10S 425/108 Conveyor
• 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 one or more lens curing units and a mold assembly. At least one lens curing unit may include a heating system. The apparatus may inlcude a controller. In certain embodiments, the controller may be configured to control the operation of a light source in response to the eyeglass lens prescription. In some embodiments, the apparatus may include a conveyor system configured to convey the mold assembly to, from or through at least one lens curing unit.

Claims

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;

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 controller coupled to the first curing unit, wherein the controller is configured to control the operation of the first activating light source in the first lens curing unit in response to the eyeglass lens prescription and the position of a second mold assembly in the second curing unit.

2. The apparatus of claim 1, 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 complementary to the shape of the mold assembly.

3. The apparatus of claim 1, wherein the first activating light source is an ultraviolet light source.

4. The apparatus of claim 1, wherein the second activating light source is an ultraviolet light.

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

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

7. The apparatus 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.

8. The apparatus 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.

9. The apparatus 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.

10. The apparatus 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.

11. The apparatus 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.

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

13. The apparatus 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.

14. The apparatus 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.

15. The apparatus 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.

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

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

18. The apparatus 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.

19. The apparatus 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.

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

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

22. The apparatus 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 lens curing unit to the second lens curing unit, and wherein the second conveyor is configured to convey the mold assembly through the second lens curing unit.

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

24. 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, wherein the second lens curing unit is configured to produce activating light directed toward a mold assembly during use;

a conveyor system configured to convey the mold assembly from the first lens curing unit in and through the second lens curing unit; and

a controller coupled to the first lens curing unit, wherein the controller is configured to control the operation of the first activating light source in the first lens curing unit in response to a prescription for the eyeglass lens.

25. The apparatus of claim 24, 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 complementary to the shape of the mold assembly.

26. The apparatus of claim 24, wherein the first activating light source is an ultraviolet light source.

27. The apparatus of claim 24, wherein the first activating light source has a peak light intensity at a range of about 385 nm to about 490 nm.

28. The apparatus of claim 24, 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 lens curing unit.

29. The apparatus of claim 24, 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.

30. The apparatus of claim 24, 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.

31. The apparatus of claim 24, 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.

32. The apparatus of claim 24, 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.

33. The apparatus of claim 24, further comprising a programmable controller configured to control operation of the first lens curing unit as a function of the eyeglass lens prescription.

34. The apparatus of claim 24, 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.

35. The apparatus of claim 24, wherein the first activating light source comprises two or more lamps, and wherein the lamps are independently operable.

36. The apparatus of claim 24, wherein the conveyor system comprises a flexible member configured to interact with the mold assembly, and wherein the flexible member is coupled to a motor configured to move the flexible member through the conveyor system.

37. The apparatus of claim 24, wherein the second lens curing unit further comprises a heating system, wherein the heating system is configured to heat the interior of the additional lens curing unit.

38. The apparatus of claim 24, further comprising a programmable controller wherein the programmable controller is configured to substantially simultaneously control operation of the first lens curing unit and the second lens curing unit during use.

39. The apparatus of claim 24, further comprising a controller, wherein the controller is configured to control the position of a second mold assembly in the second curing unit.

40. The apparatus of claim 24, wherein the conveyor system comprises a continuous flexible member extending from the first lens curing unit through the second lens curing unit;

and wherein the flexible member is configured to interact with the mold assembly to convey the mold assembly through the first lens curing unit, to and through the second lens curing unit.

41. The apparatus of claim 24, wherein the conveyor system comprises two discrete conveyors, wherein the first conveyor is configured to convey the mold assembly from the first lens curing unit to the second lens curing unit;

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

42. The apparatus of claim 24, wherein the conveyor system comprises a flexible member configured to interact with the mold assembly, wherein the flexible member is coupled to a motor configured to move the flexible member through the conveyor system.

43. The apparatus of claim 24, further comprising an air distributor positioned within the second lens curing unit, the air distributor being configured to circulate air within the second lens curing unit during use.

44. The apparatus of claim 24, wherein the controller is configured to control the position of a second mold assembly in the second lens curing unit during use.

45. The apparatus of claim 24, further comprising a programmable controller configured to substantially simultaneously control operation of the first lens curing unit and the second lens curing unit during use.

46. The apparatus of claim 24, 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.

47. The apparatus of claim 24, wherein the first activating light and the second activating light sources are ultraviolet lights.

48. The apparatus of claim 24, wherein the first activating light and the second activating light sources have substantially the same spectral output.

49. The apparatus of claim 24, wherein the first activating light and the second activating light sources have a peak light intensity at a range of about 385 nm to about 490 nm.

50. The apparatus of claim 24, 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.

51. The apparatus of claim 24, 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

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.