Apparatus for preparing an eyeglass lens having a gating device

• US 6,875,005 B2
• Filed: 02/20/2001
• Issued: 04/05/2005
• Est. Priority Date: 02/20/2001
• Status: Expired due to Fees

• Current Assignee: Q2100, Inc.
• Original Assignee: Q1200 Incorporated
• Inventors: Foreman, John T.
• Primary Examiner(s): Mackey, James P.
• Assistant Examiner(s): HECKENBERG JR, DONALD H
• Application Number:
  US09/789,121
• Publication Number:
  US 20030194462A1
• Time in Patent Office: 1,505 Days
• Field of Search: 425/145, 425/150, 425/174.4, 425/185, 425/186, 425/808, 425/DIG.108, 425/161, 264/1.38
• US Class Current: 425/145
• 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 11/00538 Feeding arrangements
• 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. In some embodiments, the apparatus may include a conveyor system configured to convey the mold assembly to, from or through the apparatus. The conveyor system may include a gating device configured to inhibit movement the mold assembly. In some embodiments, the apparatus may include an annealing unit, an air distributor and filters.

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;

a gating device coupled to the conveyor system, wherein the gating device is configured to inhibit movement of the mold assembly from the first curing unit to the second curing unit during use; and

a controller coupled to the gating device, the controller being configured to control the operation of the gating device, and wherein the controller is configured to operate the gating device to control the flow of mold assembly from the first curing unit to the second curing unit during use.

2. The apparatus of claim 1, wherein the gating device comprises an air actuated elongated member, wherein the elongated member inhibits movement of the mold assembly in an extended position during use.

3. The apparatus of claim 1, further comprising a sensor coupled to the first curing unit, wherein the sensor is configured to sense the location of a mold assembly, and wherein the controller is configured to operate the gating device in response to the position of the mold assembly.

4. The apparatus of claim 1, wherein the gating device comprises an elongated member, wherein the elongated member inhibits movement of the mold assembly in an extended position during use, and wherein the elongated member is retracted in response to a control signal from the controller to release the mold assembly into the second curing unit during use.

5. 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.

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

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

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

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

10. 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.

11. 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.

12. 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.

13. 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.

14. 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.

15. The apparatus 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.

16. 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.

17. 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.

18. 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.

19. The apparatus 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.

20. The apparatus 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.

21. 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.

22. 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.

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

24. The apparatus 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.

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

26. The apparatus 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.

27. An apparatus 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;

a conveyor system configured to convey the mold assembly through the apparatus; and

a gating device coupled to the conveyor system, wherein the gating device is configured to inhibit, at one or more selected times, movement of the mold assembly to, from or through the apparatus.

28. The apparatus of claim 27, wherein the gating device comprises an air actuated elongated member, wherein the elongated member inhibits movement of the mold assembly in an extended position during use.

29. The apparatus of claim 27, further comprising a controller coupled to the gating device, wherein the controller is configured to operate the gating device to control the flow of the mold assembly to, from or through the apparatus.

30. The apparatus of claim 27, further comprising a sensor coupled to the lens curing unit, wherein the sensor is configured to sense the location of a mold assembly, and wherein the controller is configured to operate the gating device in response to the position of the mold assembly.

31. The apparatus of claim 27, further comprising a controller coupled to the gating device, the controller configured to operate the gating device to control the flow of the mold assembly through the apparatus;

and wherein the gating device comprises an elongated member, wherein the elongated member inhibits movement of the mold assembly in an extended position during use, and wherein the elongated member is retracted in response to a control signal from the controller to release the mold assembly into the second curing unit during use.

32. The apparatus of claim 27, 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.

33. The apparatus of claim 27, wherein the activating light source is an ultraviolet light source.

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

35. The apparatus of claim 27, 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.

36. The apparatus of claim 27, 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.

37. The apparatus of claim 27, 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.

38. The apparatus of claim 27, 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.

39. The apparatus of claim 27, 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.

40. The apparatus of claim 27, further comprising a programmable controller configured to substantially control operation of the lens curing unit.

41. The apparatus of claim 27, further comprising a programmable controller configured to control operation of the lens curing unit as a function of the eyeglass lens prescription.

42. The apparatus of claim 27, 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.

43. The apparatus of claim 27, wherein the activating light source comprises two or more lamps, and wherein the lamps are independently operable.

44. The apparatus of claim 27, 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.

45. The apparatus of claim 27, further comprising an additional lens curing unit.

46. The apparatus of claim 27, further comprising an additional lens curing unit, the additional lens curing unit comprising:

an additional activating light source, where the activating light source is configured to direct activating light toward a mold assembly during use; and

a heating system, wherein the heating system is configured to heat the interior of the additional lens curing unit.

47. The apparatus of claim 27, 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.

48. The apparatus of claim 27, further comprising an additional lens curing unit, and a controller coupled to the gating device, wherein the controller is configured to operate the gating device to control the flow of the mold assembly from the lens curing unit to the additional lens curing unit during use.

49. The apparatus of claim 27, further comprising an additional lens curing unit, and a controller coupled to the gating device, wherein the controller is configured to operate the gating device to control the flow of the mold assembly from the lens curing unit to the additional lens curing unit during use;

and wherein the gating device is configured to inhibit movement of the mold assembly from the lens curing unit to the additional lens curing unit during use.

50. The apparatus of claim 27, further comprising an additional lens curing unit and wherein the conveyor system comprises a continuous flexible member extending from the lens curing unit through the additional lens curing unit;

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

51. The apparatus of claim 27, further comprising an additional lens curing unit and wherein the conveyor system comprises two discrete conveyors, wherein the first conveyor is configured to convey the mold assembly from the lens curing unit to the additional lens curing unit;

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

52. The apparatus of claim 27, further comprising an additional lens curing unit, and wherein the conveyor system is further configured to convey the mold assembly from the lens curing unit into and through the additional lens curing unit, and wherein the conveyor system comprises a flexible member configured to interact with a mold assembly, wherein the flexible member is coupled to a motor configured to move the flexible member through the conveyor system.

53. The apparatus of claim 27, further comprising an additional lens curing unit;

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

54. The apparatus of claim 27, 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.

55. The apparatus of claim 27, 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 conveyor system is configured to convey the mold assembly from the lens curing unit into and through the additional lens curing unit.

56. The apparatus of claim 27, 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 ass,embly during use;

a controller coupled to the gating device, the controller configured to operate the gating device to control the flow of the mold assembly from the lens curing unit to the additional lens curing unit during use; and

wherein the conveyor system is configured to convey the mold assembly from the lens curing unit into and through the additional lens curing unit.

57. The apparatus of claim 27, further comprising a programmable controller configured to substantially simultaneously control operation of the lens curing unit and the additional lens curing unit during use.

58. The apparatus of claim 27, 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.

59. The apparatus of claim 27, 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.

60. The apparatus of claim 27, 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.

61. The apparatus of claim 27, further comprising an additional activating light source is 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.

62. The apparatus of claim 27, 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.

63. The apparatus of claim 27, 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.

64. The apparatus of claim 27, 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.