Lens casting mold and process for using same in making an optical lens

Claim 2

A casting mold for making an optical lens characterized by an arbor having tubular top (2) and bottom portions (3); a finished element (4) having a predetermined surface separating said tubular top and bottom portions and forming a cup shape container with said tubular top portion; and said tubular bottom portion (3) having interior thread means (5) for mounting said casting mold on a precision mandrel.

Claim 3

The casting mold of Claim 1, characterized in that said predetermined separating surface (4) is convex.

Claim 4

The casting mold of Claim 1, characterized in that said predetermined separating surface (4) is concave.

Claim 5

The casting mold of Claim 1, characterized in that said predetermined separating surface (4) is spherical.

Claim 6

The casting mold of Claim 1, characterized in that said predetermined separating surface (4) is toric.

Claim 7

The casting mold of Claim 1, characterized in that said predetermined separating surface (4) is aspherical.

Claim 8

The casting mold of any one of the preceding claims, characterized in that said mold (1) is of a thermoplastic material.

Claim 9

The casting mold of Claim 7, characterized in that said thermoplastic material is selected from the group consisting of polyethylene, polypropylene, ethylene vinyl acetate, propylene copolymers, polysulfones and nylons.

Claim 10

The casting mold of any one of the preceding claims, characterized in that at least a part of said mold (1) is of metal.

Claim 11

The casting mold of any one of the preceding claims, characterized in that at least part of said mold (1) is of metal alloys.

Claim 12

The casting mold of any one of the preceding claims, characterized in that said tubular bottom portion (3) includes a pair of tabs (6).

Claim 13

A process of making an optical lens which includes a casting mold comprising an arbor having tubular top and bottom portions, a finished element having a predetermined surface separating said tubular top and bottom portions and forming a cup shape container with said tubular top portion and said tubular bottom portion having interior thread means for mounting said casting mold on a precision mandrel, characterized by: filing said cup shape container with a lens forming liquid; polymerizing said lens forming liquid for form a lens blank having one optical surface formed thereon by said finished element having a predetermined surface; mounting said casting mold on a threaded rod; and generating and finishing a subsequent optical surface in said lens blank.

Claim 14

A process of making an optical lens which includes a casting mold comprising an arbor having tubular top and bottom portions, a finished element having a predetermined surface separating said tubular top and bottom portions and forming a cup shape container with said tubular top portion and said tubular bottom portion having interior thread means for mounting said casting mold on a precision mandrel, characterized by: filing said cup shape container with a lens forming liquid; polymerizing said lens forming liquid for form a lens blank having one optical surface formed thereon by said finished element having a predetermined surface; mounting said casting mold on a threaded rod; and generating and finishing a subsequent optical surface in said lens blank.

Claim 15

The process of Claim 12, characterized by generating and finishing said subsequent optical surface by cutting, grinding or laser machining.

Claim 16

The process of Claim 12 or 13, characterized in that said optical lens is an ophthalmic lens, a contact lens, an intraocular lens, or a corneal implant lens.

Claim 17

The process of any one of Claims 12 to 14, characterized in that said lens forming liquid is selected from the group consisting of hydrophilic monomers, hydrophobic monomers, catalysts, acrylic esters, silicone elastomers and cellulose esters.

Claim 18

The process of any one of Claims 12 to 15, wherein said finishing element consists of a convex polished element having a predetermined curvature, characterized by placing a plurality of said casting mold on a tray; filling each of said casting molds with said lens forming liquid; polymerizing and curing said lens forming liquid in said casting molds to form said lens blanks; mounting each of said casting molds on a threaded precision mandrel; mounting said casting molds with the precision mandrels on a device; machine cutting and polishing a second optical surface in each of said lens blank; removing each casting mold from said rods and placing it back to said tray; placing a lid over said tray to firmly hold the casting molds therein; dismounting said finished lenses from said casting molds; removing said lid from said tray; and inspecting said finished lenses.

Claim 19

The process of Claim 16, characterized in that said lens mold firmly holds said lens blank during the machine cutting and polishing the second optical surface therein and is being cut therewith.