Production of optical elements

• US 6,814,896 B2
• Filed: 06/26/2002
• Issued: 11/09/2004
• Est. Priority Date: 03/03/1995
• Status: Expired due to Term

• Current Assignee: Hoya Optical Labs Of America, Inc. (Hoya Corporation)
• Original Assignee: Vision-Ease Lens Inc.
• Inventors: Bhalakia, Sujal, Moravec, Thomas J.
• Primary Examiner(s): Vargot, Mathieu D.
• Application Number:
  US10/183,088
• Publication Number:
  US 20020196408A1
• Time in Patent Office: 867 Days
• Field of Search: 264/1.32, 264/1.7, 264/1.8, 425/808
• US Class Current: 264/1.32
• CPC Class Codes: B29D 11/00028 Bifocal lenses; Multifocal lenses
• CPC Class Codes: B29D 11/00653 photochromic
• CPC Class Codes: B29D 11/0073 Optical laminates
• CPC Class Codes: B29K 2995/0034 Polarising
• CPC Class Codes: B29L 2011/0016 Lenses
• CPC Class Codes: B29L 2011/0033 Multifocal lenses
• CPC Class Codes: B32B 27/00 Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: G02B 1/041 Lenses
• CPC Class Codes: G02C 2202/16 Laminated or compound lenses
• CPC Class Codes: G02C 7/06 bifocal; multifocal ; progressive G02C7/041 takes precedence
• CPC Class Codes: G02C 7/102 Photochromic filters
• CPC Class Codes: G02C 7/12 Polarisers
• CPC Class Codes: Y10T 428/269 including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/31515 As intermediate layer
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A method of making an optical element that includes a thermoplastic power portion, the method including laminating a first thermoplastic sheet to one side of a functional film, laminating a second thermoplastic sheet to a second side of the functional film, and affixing either the first thermoplastic sheet or the second thermoplastic sheet to the power portion, with the other of the first or second thermoplastic sheets being open to atmosphere.

Claims

1. A method of making an eye lens comprising:

providing a mold having at least one mold cavity;

inserting a functional laminate film into said at least one mold cavity;

sealing said functional laminate film against said at least one mold cavity;

pre-heading said mold to a predetermined mold temperature;

injecting a molten material into said mold cavity against said functional laminate film;

maintaining said molten material at a material temperature that is at least twice said predetermined mold temperature during the injecting of said molten material; and

,

allowing said molten material to cool in said cavity so as to provide a lens wherein said material and said functional film are bonded together.

2. A method as set forth in claim 1, wherein said film is preformed into a predetermined curvature prior to insertion of said film into said mold.

3. A method as set forth in claim 1, wherein said film is formulated to include a polarizing layer prior to insertion of said film into said mold.

4. A method as set forth in claim 1, wherein said film is formulated to include a photochromic layer prior to insertion of said film into said mold.

5. A method as set forth in claim 1, wherein the injection of molten material includes injecting molten polycarbonate.

6. A method as set forth in claim 5, further comprising the making of a prescription polycarbonate eye lens.

17. A method as set forth in claim 1, wherein the sealing of said functional laminate film comprises pneumatic sealing.

18. A method as set forth in claim 1, wherein the sealing of said functional laminate film comprises mechanical sealing.

19. A method as set forth in claim 1, wherein the sealing of said functional laminate film comprises a combination of mechanical and pneumatic sealing.

7. A method of making an eye lens comprising:

providing a mold cavity;

inserting a functional laminate film into said mold cavity;

sealing said functional laminate film in said mold cavity;

injecting a molten material into said mold cavity against said functional film;

maintaining said molten material and said mold cavity at predetermined temperatures during the injecting such that said functional laminate film is a sufficiently softened so as to permanently conform to a shape of said mold cavity; and

allowing said molten material to cool, thereby providing a lens wherein said material is bonded to said functional laminate film.

8. A method set forth in claim 7, wherein said functional film is formulated to include a polarizing layer prior to insertion of said functional film into said mold cavity.

10. A method as set forth in claim 7, wherein injecting a molten material include injecting molten polycarbonate.

11. A method as set forth in claim 10, further comprising the making of a prescription lens.

20. A method as set forth in claim 7, wherein the sealing of said functional laminate film comprises pneumatic sealing.

21. A method as set forth in claim 7, wherein the sealing of said functional laminate film comprises mechanical sealing.

22. A method as set forth in claim 7, wherein the sealing of said functional laminate film comprises a combination of mechanical and pneumatic sealing.

9. A method as set forth in clam 7, wherein said functional film is formulated to include a photochromic layer prior to insertion of said functional film into sale mold cavity.

12. A method of making an eye lens comprising:

providing a mold having a mold cavity;

inserting a laminate film into a recess of said mold cavity, said laminate film including a functional layer interposed between a first and second resinous layer;

sealing said laminate film in said recess so as to adequately secure said laminate film in said cavity; and

injecting a molten material into said mold cavity and allowing said molten material to cool, thereby providing a lens.

13. A method as set forth in claim 12, wherein said laminate is formulated to include a polarizing layer prior to insertion of said laminate film into said recess.

14. A method as set forth in claim 12, wherein said laminate is formulated to include a photochromic layer prior to insertion of said laminate film into said mold cavity.

15. A method asset forth in claIm 12, wherein injecting a molten material includes injecting molten polycarbonate.

16. A method as set further in claim 15, further comprising making a prescription lens.

23. A method as set forth in claim 12, wherein the sealing of said laminate film comprises pneumatic sealing.

24. A method as set forth in claim 12, wherein the sealing of said laminate film comprises mechanical sealing.

25. A method as set forth in claim 12, wherein the sealing of said laminate film comprises a combination of mechanical and pneumatic sealing.