Apparatus for preparing an eyeglass lens having a computer system controller

• US 6,893,245 B2
• Filed: 02/20/2001
• Issued: 05/17/2005
• Est. Priority Date: 02/20/2001
• Status: Expired due to Fees

• Current Assignee: Q2100, Inc.
• Original Assignee: Q2100, Inc.
• Inventors: Foreman, John T., Lattis, Matthew C., Powers, Galen R.
• Primary Examiner(s): Mackey, James P.
• Assistant Examiner(s): Heckenberg, Donald
• Application Number:
  US09/789,190
• Publication Number:
  US 20030049343A1
• Time in Patent Office: 1,547 Days
• Field of Search: 425/135, 425/155, 425/174.4, 425/808, 425/DIG.108, 264/1.38
• US Class Current: 425/135
• 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 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 37/0032 the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat B29C44/14 and B29C44/32 take precedence
• CPC Class Codes: B29D 11/00442 Curing the lens material
• CPC Class Codes: B29L 2011/0016 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 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. One or more computer systems may be coupled to one or more lens curing units. At least one computer system may receive prescription information for the eyeglass lens. At least one computer may control at least one lens curing unit in response to the prescription information. In some embodiments, the apparatus may include a conveyor system configured to convey the mold assembly to, through or from the apparatus. In some embodiments, the apparatus may include an annealing unit, an air distributor and/or 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 activating light source is configured to direct activating light 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 first computer system for receiving a prescription for the eyeglass lens; and

a second computer system coupled to the first lens curing unit, the second lens curing unit, and the first computer system, wherein the second computer system is configured to control the operation of the first and second lens curing units in response to the eyeglass lens prescription entered into the first computer system.

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 lens 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, 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.

17. 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.

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

19. The apparatus of claim 1, further comprising a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit, and 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 a mold assembly to convey the mold assembly through the first lens curing unit, to the second lens curing unit, and through the second lens curing unit.

20. The apparatus of claim 1, further comprising a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second 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 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.

21. The apparatus of claim 1, further comprising a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit, and 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.

22. An apparatus for preparing an eyeglass lens, comprising:

a first lens curing unit comprising first activating light source, wherein the first activating light source is configured to direct activating light toward a mold assembly during use;

a second lens curing unit comprising a second activating light source, wherein the second activating light source is configured to direct activating light to toward a mold assembly during use;

a conveyor system, wherein the conveyor system is configured to convey a mold assembly from the first lens curing unit into and through the second lens curing unit during use;

a first computer system for receiving an eyeglass lens prescription; and

a second computer system coupled to at least the first lens curing unit and the first computer system.

23. The apparatus of claim 22, 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.

24. The apparatus of claim 22, wherein the first activating light source is an ultraviolet light source.

25. The apparatus of claim 22, wherein the first activating light source has a peak light intensity at a range of about 385 nm to about 490 nm.

26. The apparatus of claim 22, 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.

27. The apparatus of claim 22, 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.

28. The apparatus of claim 22, 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.

29. The apparatus of claim 22, 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.

30. The apparatus of claim 28, 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.

31. The apparatus of claim 22, 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.

32. The apparatus of claim 22, wherein the first activating light source comprises two or more lamps, and wherein the lamps are independently operable.

33. The apparatus of claim 22, 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.

34. The apparatus of claim 22, wherein the second lens curing unit comprises a heating system, wherein the heating system is configured to heat the interior of the second lens curing unit.

35. The apparatus of claim 22, wherein at least one computer system is configured to substantially simultaneously control operation of the first lens curing unit and the second lens curing unit during use.

36. The apparatus of claim 22, wherein at least one computer system is configured to control the position of a second mold assembly in the second lens curing unit.

37. The apparatus of claim 22, 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 a mold assembly to convey the mold assembly through the first lens curing unit, to the second lens curing unit and through the second lens curing unit.

38. The apparatus of claim 22, wherein the conveyor system comprises two discrete conveyors, wherein a first conveyor of the conveyor system is configured to convey the mold assembly from the first lens curing unit to the second lens curing unit;

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

39. The apparatus of claim 22, 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.

40. The apparatus of claim 22, 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.

41. The apparatus of claim 22, wherein at least one computer system is configured to substantially simultaneously control operation of the first lens curing unit and the second lens curing unit during use.

42. The apparatus of claim 22, 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.

43. The apparatus of claim 22, wherein the first activating light and the second activating light sources are ultraviolet lights.

44. The apparatus of claim 22, wherein the first activating light and the second activating light sources have substantially the same spectral output.

45. The apparatus of claim 22, 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.

46. The apparatus of claim 22, 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.

47. The apparatus of claim 22, 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;

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 form second activating light source.