System for preparing an eyeglass lens using a mold holder

• US 7,083,404 B2
• Filed: 02/20/2001
• Issued: 08/01/2006
• 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): Heckenberg, Donald
• Application Number:
  US09/788,995
• Publication Number:
  US 20020168439A1
• Time in Patent Office: 1,988 Days
• Field of Search: 425/162, 425/174.4, 425/808, 425/DIG.108, 249/103, 249/104, 249/187.1, 264/1.38
• US Class Current: 425/162
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 33/0038 with sealing means or the like seals on envelopes used in tyre retreading B29D30/542; for injection moulding footwear B29D35/0045
• CPC Class Codes: B29C 33/0077 characterised by the configuration of the mould filling gate mixing chambers situated in the mould opening B29B7/7471; accessories for connecting the mould filling gate with the filling spout
• CPC Class Codes: B29C 33/303 centering mould parts or halves, e.g. during mounting
• CPC Class Codes: B29C 33/34 movable, e.g. to or from the moulding station
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 33/56 Coatings , e.g. enameled or galvanised; Releasing, lubricating or separating agents in-mould coating B29C37/0028; using or applying separating agents B29C37/0067
• 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 39/006 Monomers or prepolymers by reaction injection moulding B29C67/246
• 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. The system may include ones or more lens curing units, a mold assembly, mold assembly holders and/or a conveyor system. At least one lens curing unit may include a heating system.

Claims

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

a first lens curing unit comprising a first activating light source, wherein the 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 mold assembly holder configured to support a mold assembly, the mold assembly holder comprising a body and an indentation formed in the body, wherein the indentation is substantially complementary to the shape of the mold assembly; and

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

2. The system of claim 1, wherein the body comprises indicia, wherein the indicia is representative of the type of lens being formed by the mold assembly.

3. The system of claim 1, wherein the body comprises indicia, wherein the indicia is representative of the type of lens being formed by the mold assembly, and wherein the indicia comprises a colored body.

4. The system of claim 1, wherein the body comprises indicia, wherein the indicia is representative of the type of lens being formed by the mold assembly, and wherein the indicia comprises alphanumeric characters.

5. The system of claim 1, wherein the body comprises indicia, wherein the indicia is representative of the type of lens being formed by the mold assembly, and wherein the indicia comprises a label having alphanumeric information coupled to the body.

6. The system of claim 1, wherein the body comprises indicia, wherein the indicia is representative of the type of lens being formed by the mold assembly, and wherein the indicia comprises alphanumeric information molded into the body.

7. The system of claim 1, wherein the body comprises indicia, wherein the indicia is representative of the type of lens being formed by the mold assembly, and wherein the indicia comprises a colored body, and wherein the lens type comprises clear or photochromic, and wherein the body has a first color to designate use for forming photochromic lenses, and a second color, different from the first color, to designate use for forming clear lenses.

8. The system of claim 1, wherein the body comprises indicia, wherein the indicia is representative of the type of lens being formed by the mold assembly, and wherein the indicia comprises a colored body, and wherein the lens type comprises clear or photochromic, and wherein the color of the body is indicative of the type of lens being formed.

9. The system of claim 1, wherein the body comprises indicia, wherein the indicia is representative of the type of lens being formed by the mold assembly, and wherein the indicia comprises a colored body, and wherein the lens type comprises spheric single vision, aspheric single vision, flattop bifocal, asymmetrical progressive, and wherein the body has a first color to designate use for forming photochromic lenses, and a second color, different from the first color, to designate use for forming clear lenses.

10. The system of claim 1, wherein the body comprises indicia, wherein the indicia is representative of the type of lens being formed by the mold assembly, and wherein the body is configured to allow activating light to reach the mold assembly.

11. The system of claim 1, wherein an opening is positioned in the body such that activating light passes through the opening and onto the mold assembly during use.

12. The system of claim 1, wherein the mold assembly holder further comprises additional indentations for holding a mold or a gasket of the mold assembly.

13. The system of claim 1, wherein the mold assembly holder further comprises an additional indentation for holding an additional mold assembly, wherein the additional indentation has a shape that is substantially complementary to the shape of the additional mold assembly.

14. The system of claim 1, wherein a portion of the mold assembly holder is configured to hold a job ticket.

15. The system of claim 1, wherein the indentation extends into the body to a depth such that an upper surface of the mold assembly is positioned at or below the upper surface of the body.

16. The system of claim 1, wherein the first activating light source is an ultraviolet light source.

17. The system of claim 1, wherein the second activating light source is an ultraviolet light.

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

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

20. The system 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.

21. The system 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.

22. The system 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.

23. The system 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.

24. The system 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.

25. The system 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.

26. The system 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.

27. The system 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.

28. The system 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.

29. The system of claim 1, further comprising a programmable controller configured to substantially simultaneously control operation of the first lens curing unit and the second lens curing unit during use.

30. The system of claim 1, further comprising a programmable controller configured to control operation of the first lens curing unit as a function of the eyeglass lens prescription.

31. The system 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.

32. The system 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.

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

34. The system of claim 1, 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.

35. The system 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 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.

36. The system 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.

72. The system of claim 1, wherein the mold assembly holder is removably positionable on the conveyor system.

37. A system for preparing an eyeglass lens, comprising:

a lens curing unit configured to direct activating light toward a mold assembly during use;

a mold assembly holder configured to support a mold assembly, the mold assembly holder comprising a body and an indentation formed in the body, the indentation being substantially complementary to the shape of the mold assembly, and wherein the body comprises indicia, the indicia being representative of the type of lens being formed by the mold assembly, and wherein the indicia comprises a colored body; and

a conveyor system configured to convey the mold assembly holder through the lens curing unit.

38. The system of claim 37, wherein the indicia comprises alphanumeric characters.

39. The system of claim 37, wherein the indicia comprises a label having alphanumeric information coupled to the body.

40. The system of claim 37, wherein the indicia comprises alphanumeric information molded into the body.

41. The system of claim 37, wherein the lens type comprises clear or photochromic, and wherein the body has a first color to designate use for forming photochromic lenses, and a second color, different from the first color, to designate use for forming clear lenses.

42. The system of claim 37, wherein the lens type comprises clear or photochromic, and wherein the color of the body is indicative of the type of lens being formed.

43. The system of claim 37, wherein the lens type comprises spheric single vision, aspheric single vision, flattop bifocal, asymmetrical progressive, and wherein the body has a first color to designate use for forming photochromic lenses, and a second color, different from the first color, to designate use for forming clear lenses.

44. The system of claim 37, and wherein the body is configured to allow activating light to reach the mold assembly.

45. The system of claim 37, wherein an opening is positioned in the body such that activating light passes through the opening and onto the mold assembly during use.

46. The system of claim 37, wherein the mold assembly holder further comprises additional indentations for holding a mold or a gasket of the mold assembly.

47. The system of claim 37, wherein the mold assembly holder further comprises an additional indentation for holding an additional mold assembly, wherein the additional indentation has a shape that is substantially complementary to the shape of the additional mold assembly.

48. The system of claim 37, wherein a portion of the mold assembly holder is configured to hold a job ticket.

49. The system of claim 37, wherein the indentation extends into the body to a depth such that an upper surface of the mold assembly is positioned at or below the upper surface of the body.

50. The system of claim 37, wherein the lens curing unit comprises a first activating light source, wherein the first activating light source is an ultraviolet light source.

51. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, wherein the second activating light source is an ultraviolet light.

52. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, and wherein the first and second activating light sources are ultraviolet lights.

53. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, and wherein the first and second activating light sources have substantially the same spectral output.

54. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, and wherein the first and second activating light sources have a peak light intensity at a range of about 385 nm to about 490 nm.

55. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, and 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 lens curing unit.

56. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, and 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.

57. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, and 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.

58. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, 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.

59. The system of claim 37, wherein the lens curing unit further comprises an air distributor positioned within the lens curing unit, the air distributor being configured to circulate air within the lens curing unit during use.

60. The system of claim 37, 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.

61. The system of claim 37, 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.

62. The system of claim 37, 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.

63. The system of claim 37, further comprising a programmable controller configured to substantially simultaneously control operation of the lens curing unit and an additional lens curing unit during use.

64. The system of claim 37, further comprising a programmable controller configured to control operation of the lens curing unit as a function of the eyeglass lens prescription.

65. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, and 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.

66. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, 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.

67. The system of claim 37, wherein the lens curing unit comprises a first activating light source and a second activating light source, and wherein the first activating light source comprises two or more lamps, and wherein the lamps are independently operable.

68. The system of claim 37, wherein the conveyor system comprises a continuous flexible member extending from the lens curing unit, wherein the flexible member is configured to interact with a mold assembly to convey the mold assembly through the lens curing unit.

69. The system of claim 37, 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.

70. The system of claim 37, further comprising a heating system, wherein the heating system is configured to heat at least a portion of the interior of the lens curing unit.

71. The system of claim 37, wherein the mold assembly holder is removably positionable on the conveyor system.