Mold filing apparatus having multiple fill stations

• US 6,863,518 B2
• Filed: 02/20/2001
• Issued: 03/08/2005
• Est. Priority Date: 02/20/2001
• Status: Expired due to Fees

• Current Assignee: Q2100, Inc.
• Original Assignee: Q2100, Inc.
• Inventors: Powers, Galen R.
• Primary Examiner(s): Davis, Robert
• Assistant Examiner(s): Heckenberg, Donald
• Application Number:
  US09/789,192
• Publication Number:
  US 20020175428A1
• Time in Patent Office: 1,477 Days
• Field of Search: 435/145, 435/169, 435/174.4, 435/256, 435/808, 264/1.38, 141/82, 141/94, 141/369, 141/383
• US Class Current: 425/145
• CPC Class Codes: B29C 2035/0827 using UV radiation
• 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 37/005 Compensating volume or shape change during moulding, in general
• 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: B29D 11/00538 Feeding arrangements
• CPC Class Codes: B29L 2011/0016 Lenses
• CPC Class Codes: B29L 2011/0041 Contact lenses
• CPC Class Codes: Y10S 425/808 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 a system may include a mold assembly, a lens curing apparatus, a mold filling apparatus and/or a controller.

Claims

1. A mold filling apparatus comprising:

a body;

at least two chambers disposed in the body, the chambers being configured to hold a lens forming composition, the chambers comprising an opening for receiving a fluid container and an outlet;

a heating system positioned within each of the chambers for heating the lens forming composition; and

a valve positioned proximate the outlet of each of the chambers, 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 through the outlet during use.

2. The apparatus 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 elongated member can be varied from the first position to the second position.

3. The apparatus of claim 1, wherein the chamber inhibits the lens forming composition from contacting the heating system.

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

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

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

7. The apparatus of claim 1, further comprising a thermostat coupled to at least one chamber, the thermostat being configured to measure a temperature of the lens forming composition within the chamber, and wherein the thermostat is further configured to control the heating system in response to the measured temperature.

8. The apparatus of claim 1, further comprising a thermocouple coupled to at least one chamber, the thermocouple being configured to measure a temperature of the lens forming composition, and wherein the system further comprises a controller coupled to the thermocouple and the heating apparatus, the controller configured to control the heating system in response to the temperature measured by the thermocouple.

9. The apparatus of claim 1, further comprising a fluid level monitor disposed within at least one chamber, wherein the fluid level monitor is configured to measure the level of the lens forming composition disposed within the chamber.

10. The apparatus of claim 1, further comprising a fluid level monitor disposed within at least one chamber and a controller coupled to the fluid level monitor and the heating system, wherein the fluid level monitor is configured to measure the level of the lens forming composition disposed within the chamber, and 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 apparatus of claim 1, wherein the heating apparatus is electrically coupleable to a controller of a lens forming apparatus.

12. The apparatus of claim 1, further comprising at least one mold assembly holder coupled to the body, wherein the mold assembly holder is configured to hold a mold assembly in a position such that the outlet of at least one chamber is positioned proximate an inlet of the mold assembly.

13. The apparatus of claim 1, wherein the fluid container comprises:

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; and

wherein the fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the heating apparatus body.

14. The apparatus of claim 1, wherein the fluid container comprises:

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 fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers; and

wherein the body further comprises a projection extending toward the opening, and wherein the projection is positioned such that the projection forces the fluid control member away from the top inner surface of the cap when the bottle is inserted into the opening.

15. The apparatus of claim 1, wherein the fluid container comprises

a fluid container body and a cap, wherein the cap is removable from the fluid container body;

and 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 fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers.

16. The apparatus of claim 1, wherein the fluid container comprises:

a fluid container body and a cap, wherein the cap is coupled to the fluid container body with an adhesive and 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 fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers.

17. The apparatus of claim 1, wherein the fluid container comprises:

a fluid container body and a cap, wherein the cap comprises a fluid control member and an elastic member, wherein the fluid control member is substantially spherical and 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; and

wherein the fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers.

18. The apparatus of claim 1, wherein the fluid container comprises:

a fluid container body and a cap, wherein the cap comprises a fluid control member, wherein the fluid control member is substantially spherical and an elastic member wherein the elastic member is a spring and 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; and

wherein the fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers.

19. A mold filling apparatus comprising:

a body;

at least two chambers disposed in the body, the chambers being configured to hold a lens forming composition, the chambers comprising an opening for receiving a fluid container and an outlet;

a heating system positioned within at least one chamber for heating the lens forming composition, wherein the heating system is electrically coupleable to a controller of a lens forming apparatus; and

a valve positioned proximate the outlet of each chamber, wherein the valve is configured to allow or inhibit flow of the lens forming composition through the outlet during use.

20. The apparatus of claim 19, wherein the valve comprises an elongated member and a movable member, wherein the movable member is coupled to the elongated member, wherein the elongated member contacts the movable member at a first position such that the elongated member is positionable within the outlet to inhibit flow of the lens forming composition through the outlet, and wherein the elongated member contacts the movable member at a second position such that the elongated member is positionable within the outlet to allow flow of the lens forming composition through the outlet 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.

21. The apparatus of claim 19, wherein at least one chamber inhibits the lens forming composition from contacting the heating system.

22. The apparatus of claim 19, wherein the heating system comprises a resistive heating system.

23. The apparatus of claim 22, wherein the elongated member extends substantially completely through the outlet when the elongated member is in the closed position.

24. The apparatus of claim 22, wherein the elongated member extends partially into the outlet when the elongated member is an open position.

25. The apparatus of claim 22, further comprising a thermostat coupled to at least one chamber, the thermostat being configured to measure a temperature of the lens forming composition within the chamber, and wherein the thermostat is further configured to control the heating system in response to the measured temperature.

26. The apparatus of claim 22, further comprising a thermocouple coupled to at least one chamber, the thermocouple being configured to measure a temperature of the lens forming composition, and wherein the apparatus further comprises a controller coupled to the thermocouple and the heating system, the controller configured to control the heating system in response to the temperature measured by the thermocouple.

27. The apparatus of claim 19, further comprising a fluid level monitor disposed within at least one chamber, wherein the fluid level monitor is configured to measure the level of the lens forming composition disposed within the chamber.

28. The apparatus of claim 19, further comprising a fluid level monitor disposed within at least one chamber and a controller coupled to the fluid level monitor and the heating system, wherein the fluid level monitor is configured to measure the level of the lens forming composition disposed within the chamber, and wherein the controller is configured to control the heating system in response to the level of fluid measured by the fluid level monitor.

29. The apparatus of claim 19, further comprising a mold assembly holder coupled to the body, wherein the mold assembly holder is configured to hold a mold assembly in a position such that the outlet of at least one chamber is positioned proximate an inlet of the mold assembly.

30. The apparatus of claim 19, wherein the fluid container comprises:

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; and

wherein the fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the heating apparatus body.

31. The apparatus of claim 19, wherein the fluid container comprises:

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 fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers; and

wherein the body further comprises a projection extending toward the opening, and wherein the projection is positioned such that the projection forces the fluid control member away from the top inner surface of the cap when the bottle is inserted into the opening.

32. The apparatus of claim 19, wherein the fluid container comprises

a fluid container body and a cap, wherein the cap is removable from the fluid container body;

and 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 fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers.

33. The apparatus of claim 19, wherein the fluid container comprises:

a fluid container body and a cap, wherein the cap is coupled to the fluid container body with an adhesive and 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 fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers.

34. The apparatus of claim 19, wherein the fluid container comprises:

a fluid container body and a cap, wherein the cap comprises a fluid control member and an elastic member, wherein the fluid control member is substantially spherical and 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; and

wherein the fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers.

35. The apparatus of claim 19, wherein the fluid container comprises:

a fluid container body and a cap, wherein the cap comprises a fluid control member, wherein the fluid control member is substantially spherical and an elastic member wherein the elastic member is a spring and 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; and

wherein the fluid container is insertable into the opening of the chambers, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the chambers.