Methods for the production of plastic lenses

• US 6,960,312 B2
• Filed: 10/15/2002
• Issued: 11/01/2005
• Est. Priority Date: 03/30/2000
• Status: Expired due to Fees

• Current Assignee: Q2100, Inc.
• Original Assignee: Q2100, Inc.
• Inventors: Buazza, Omar M., Triplett, John T., Foreman, John T., Lattis, Matthew C., Luetke, Stephen C., Lossman, Loren C., Powers, Galen R., Joel, Larry H.
• Primary Examiner(s): Vargot, Mathieu D.
• Application Number:
  US10/271,692
• Publication Number:
  US 20030146527A1
• Time in Patent Office: 1,113 Days
• Field of Search: 264/1.1, 264/1.36, 264/1.38, 264/1.6, 264/406, 264/2.5, 425/808
• US Class Current: 264/1.38
• CPC Class Codes: B29C 39/24 Feeding the material into the mould
• CPC Class Codes: B29C 39/38 Heating or cooling
• CPC Class Codes: B29C 39/44 Measuring, controlling or regulating
• 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: H05B 41/2988 for protecting the lamp against abnormal operating conditions
• CPC Class Codes: Y10S 425/808 Lens mold

Abstract

A lens forming apparatus for preparing a plastic eyeglass lens includes a first lens curing unit, a second lens curing unit and a conveyor system for moving mold assemblies between the two units. The apparatus may also include an anneal unit configured to apply heat to a substantially polymerized lens. The apparatus may be used to form an eyeglass lens from a lens forming composition that may include an aromatic containing polyether polyethylenic functional monomer, a photoinitiator, and a coinitiator. The lens forming composition may be cured by the application of activating light or activating light and heat.

Claims

1. A method for preparing an eyeglass lens, comprising:

placing a lens forming composition in a mold cavity of a mold assembly;

placing the mold assembly onto a lens forming apparatus, the lens forming apparatus comprising;

a lens curing unit comprising an activating light source;

a conveyor system configured to convey the mold assembly through the lens curing unit; and

a controller configured to receive eyeglass lens prescription information and control the lens curing unit;

receiving prescription information with the controller;

operating the conveyor system such that the mold assembly is conveyed through the lens curing unit;

controlling the lens curing unit based on the received eyeglass prescription; and

applying activating light to the lens forming composition disposed in the mold assembly as the mold assembly is conveyed through the lens curing unit.

2. The method of claim 1, wherein the lens forming composition comprises a monomer and a photoinitiator that initiates curing of the monomer in response to being exposed to activating light.

3. The method of claim 1, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a photochromic compound.

4. The method of claim 1, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and an ultraviolet/visible light absorbing compound.

5. The method of claim 1, wherein the lens forming composition comprises a monomer and a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, wherein the monomer comprises an aromatic containing polyethylenic polyether functional monomer.

6. The method of claim 1, wherein the lens forming composition comprises a monomer and a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, wherein the monomer comprises a polyethylenic functional monomer.

7. The method of claim 1, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator.

8. The method of claim 1, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator, wherein the co-initiator comprises an amine.

9. The method of claim 1, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator, wherein the co-initiator comprises an acrylyl amine.

10. The method of claim 1, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator, wherein the co-initiator comprises an acrylyl amine, the acrylyl amine comprising monoacrylated amines, diacrylated amines, or mixtures thereof.

11. The method of claim 1, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator, wherein the photoinitiator comprises an acyl phosphine oxide.

12. The method of claim 1, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a dye to form a background color within the lens.

13. The method of claim 1, wherein the activating light source is an ultraviolet light source.

14. The method of claim 1, wherein the activating light source has a spectral output in the range of about 385 nm to about 490 nm.

15. The method of claim 1, wherein applying activating light to the lens forming composition is performed for a time sufficient to cure at least a portion of the lens forming composition.

16. The method of claim 1, wherein applying activating light to the lens forming composition is performed for a time sufficient to cure at least a portion of the lens forming composition, and wherein the method further comprises:

removing the at least partially cured lens from the mold assembly; and

applying heat to the at least partially cured lens.

17. The method of claim 1, 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.

18. The method of claim 1, wherein the conveyor system comprises a continuous flexible member extending through the curing unit, wherein the flexible member is configured to interact with a mold assembly to convey the mold assembly through the curing unit.

19. The method of claim 1, wherein the mold assembly comprises a first mold member and a second mold member.

20. The method of claim 1, wherein the mold assembly comprises a first mold member, a second mold member, and a gasket configured to engage the first mold member and the second mold member, the gasket comprising at least four discrete projections for spacing the mold members, and wherein the projections are arranged on an interior surface of the gas gasket.

21. The method of claim 1, further comprising placing the mold assembly on a mold assembly holder, wherein the mold assembly holder comprises:

a body, wherein the body is configured to allow activating light to reach the mold assembly; and

an indentation formed in the body, wherein the indentation is complementary to the shape of the mold assembly.

22. The method of claim 1, further comprising heating the lens forming composition prior to placing the lens forming composition in a mold cavity.

23. A method for preparing an eyeglass lens, comprising:

placing a lens forming composition in a mold cavity of a mold assembly;

placing the mold assembly onto a lens forming apparatus, the lens forming apparatus comprising;

a first lens curing unit comprising a first activating light source;

a second lens curing unit comprising a second activating light source and heating system; and

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

operating the conveyor system such that the mold assembly is conveyed into the first lens curing unit;

applying activating light to the lens forming composition disposed in the mold assembly while the mold assembly is disposed in the first lens curing unit; and

operating the conveyor system such that the mold assembly is transferred from the first lens curing unit into the second lens curing unit;

operating the conveyor system such that the mold assembly is moved through the second lens curing unit; and

applying activating light and heat to the lens forming composition while the mold assembly is conveyed through the second lens curing unit.

24. The method of claim 23, wherein the lens forming composition comprises a monomer and a photoinitiator that initiates curing of the monomer in response to being exposed to activating light.

25. The method of claim 23, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a photochromic compound.

26. The method of claim 23, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and an ultraviolet/visible light absorbing compound.

27. The method of claim 23, wherein the lens forming composition comprises a monomer and a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, wherein the monomer comprises an aromatic containing polyethylenic polyether functional monomer.

28. The method of claim 23, wherein the lens forming composition comprises a monomer and a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, wherein the monomer comprises a polyethylenic functional monomer.

29. The method of claim 23, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator.

30. The method of claim 23, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator, wherein the co-initiator comprises an amine.

31. The method of claim 23, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator, wherein the co-initiator comprises an acrylyl amine.

32. The method of claim 23, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator, wherein the co-initiator comprises an acrylyl amine, the acrylyl amine comprising monoacrylated amines, diacrylated amines, or mixtures thereof.

33. The method of claim 23, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a co-initiator, wherein the photoinitiator comprises an acylphosphine oxide.

34. The method of claim 23, wherein the lens forming composition comprises a monomer, a photoinitiator that initiates curing of the monomer in response to being exposed to activating light, and a dye to form a background color within the lens.

35. The method of claim 23, wherein the first activating light source is an ultraviolet light source.

36. The method of claim 23, wherein the second activating light source is an ultraviolet light source.

37. The method of claim 23, wherein the first and second activating light sources are ultraviolet light sources.

38. The method of claim 23, wherein the first and second activating light sources have substantially the same spectral output.

39. The method of claim 23, wherein the first and second activating light sources have a spectral output in the range of about 385 nm to about 490 nm.

40. The method of claim 23, 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.

41. The method of claim 23, wherein the lens forming apparatus further comprises a filter disposed proximate 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.

42. The method of claim 23, wherein the lens forming apparatus further comprises an air distributor positioned within the second lens curing unit, the air distributor being configured to circulate air within the second lens curing unit as the mold is conveyed through the second lens curing unit.

43. The method of claim 23, wherein applying activating light to the lens forming composition while the mold assembly is disposed within the first lens curing unit is performed for a time sufficient to initiate curing of the lens forming composition.

44. The method of claim 23, wherein applying activating light and beat to the lens forming composition while the mold assembly is disposed within the second lens curing unit is performed for a time sufficient to substantially cure the lens forming composition.

45. The method of claim 23, wherein the application of activating light and heat to the mold assembly in the second unit substantially cures the lens forming composition, wherein the method further comprises:

removing the cured lens from the mold assembly after the mold assembly is conveyed through the second lens curing unit; and

placing the cured lens into an anneal unit;

applying heat to the cured lens while the cured lens is in the anneal unit, wherein the anneal unit comprises an anneal unit heating system configured to heat an interior of the anneal unit.

46. The method of claim 45, wherein the anneal unit further comprises an anneal unit conveyor system configured to convey the mold assembly through the anneal unit, wherein the method further comprises applying heat to the cured lens while the cured lens is conveyed through the anneal unit.

47. The method of claim 23, 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.

48. The method of claim 23, 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.

49. The method of claim 23, 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, and 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.

50. The method of claim 23, 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.

51. The method of claim 23, 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 assemblies through the second lens curing unit.

52. The method of claim 23, 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.

53. The method of claim 23, wherein the mold assembly comprises a first mold member and a second mold member.

54. The method of claim 23, wherein the mold assembly comprises a first mold member, a second mold member, and a gasket configured to engage the first mold member and the second mold member, the gasket comprising at least four discrete projections for spacing the mold members, and wherein the projections are arranged on an interior surface of the gasket.

55. The method of claim 23, further comprising placing the mold assembly on a mold assembly holder, wherein the mold assembly holder comprises:

a body, wherein the body is configured to allow activating light to reach the mold assembly; and

an indentation formed in the body, wherein the indentation is complementary to the shape of the mold assembly.

56. The method of claim 23, further comprising heating the lens forming composition prior to placing the lens forming composition in a mold cavity.

57. A method for preparing an eyeglass lens, comprising:

placing a lens forming composition in a mold cavity of a mold assembly;

placing the mold assembly onto a lens forming apparatus, the lens forming apparatus comprising;

a first lens curing unit comprising a first activating light source;

a second lens curing unit comprising a second activating light source and heating system; and

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

operating the conveyor system such that the mold assembly is conveyed into the first lens curing unit;

applying activating light to the lens forming composition disposed in the mold assembly while the mold assembly is disposed in the first lens curing unit; and

operating the conveyor system such that the mold assembly is transferred from the first lens curing unit into the second lens curing unit.