Method and apparatus for making optical devices

Claim 1

A method for the manufacture of optical devices from reactive precursors comprising the steps of: I. providing A. a mold which has a) a first mold portion 12 which has a first molding surface 41 with a first principal longitudinal axis; b) a second mold portion 13 which has a second molding surface 45 with a second principal longitudinal axis and which is adapted to cooperate with said first mold portion to form said optical device; B. a top mold support 10 comprising a first planar surface 14 for securing said first mold portion thereto so that said first principal longitudinal axis is maintained at right angle to said first planar surface; C. a bottom mold support 11 comprising a second planar surface 16 for holding said second mold portion thereto, said second planar surface being maintained in parallel relationship to said first planar surface; II. placing the first and second mold portions together and supporting the first mold portion on the first planar surface and the second mold portion on the second planar surface to place the first and second principal longi­tudinal axes of the first and second molding surfaces in coincident alignment; III. securing the first mold portion to the first planar surface; IV. removing the first mold portion from the second mold portion by moving the mold supports linearly away from one another while maintaining the coincident alignment; V. injecting reactive material into said second mold portion; VI. inserting said first mold portion into said second mold portion while said first mold portion remains attached to said first planar surface while maintaining said first and second principal longitudinal axes in coincident alignment; VII. reacting said reactive material; and VIII. recovering said optical device from said mold.

Claim 2

A method for the manufacture of optical devices from reactive precursors comprising the steps of: I. providing A. a mold which has a) a first mold portion 12 which has a first molding surface 41 with a first principal longitudinal axis; b) a second mold portion 13 which has a second molding surface 45 with a second principal longitudinal axis and which is adapted to cooperate with said first mold portion to form said optical device; B. a top mold support 10 comprising a first planar surface 14 for securing said first mold portion thereto so that said first principal longitudinal axis is maintained at right angle to said first planar surface; C. a bottom mold support 11 comprising a second planar surface 16 for holding said second mold portion thereto, said second planar surface being maintained in parallel relationship to said first planar surface; II. placing the first and second mold portions together and supporting the first mold portion on the first planar surface and the second mold portion on the second planar surface to place the first and second principal longi­tudinal axes of the first and second molding surfaces in coincident alignment; III. securing the first mold portion to the first planar surface; IV. removing the first mold portion from the second mold portion by moving the mold supports linearly away from one another while maintaining the coincident alignment; V. injecting reactive material into said second mold portion; VI. inserting said first mold portion into said second mold portion while said first mold portion remains attached to said first planar surface while maintaining said first and second principal longitudinal axes in coincident alignment; VII. reacting said reactive material; and VIII. recovering said optical device from said mold.

Claim 10

A method for the manufacture of a vision correcting optical device comprising the steps of: A. providing a mold which has a) a male mold portion 12 having a first principal longitudinal axis and an exterior molding surface 41 capable of forming a first optical surface on said optical device; b) a female mold portion 13 having a second principal longitudinal axis and an interior molding surface 45 capable of forming a second optical surface on said optical device; B. inserting said male mold portion into said female mold portion; C. contacting said male mold portion to a first planar surface 14 and contacting said female mold portion to a second planar surface 16 maintained in a parallel relationship to said first parallel surface so as to place said first and second principal longitudinal axes in coincident alignment; D. securing said male mold portion to said first planar surface; E. opening said mold by removing said male mold portion from said female mold portion while said male mold portion remains secured to said first planar surface in said coincident alignment; F. charging a quantity of reactive material to said female mold portion; G. closing said mold by inserting said male mold portion into said female mold portion while said male mold portion remains secured to said first planar surface in said coincident alignment; H. reacting said reactive material; and I. recovering said optical device from said mold.

Claim 11

A method for the manufacture of a vision correcting optical device comprising the steps of: A. providing a mold which has a) a male mold portion 12 having a first principal longitudinal axis and an exterior molding surface 41 capable of forming a first optical surface on said optical device; b) a female mold portion 13 having a second principal longitudinal axis and an interior molding surface 45 capable of forming a second optical surface on said optical device; B. inserting said male mold portion into said female mold portion; C. contacting said male mold portion to a first planar surface 14 and contacting said female mold portion to a second planar surface 16 maintained in a parallel relationship to said first parallel surface so as to place said first and second principal longitudinal axes in coincident alignment; D. securing said male mold portion to said first planar surface; E. opening said mold by removing said male mold portion from said female mold portion while said male mold portion remains secured to said first planar surface in said coincident alignment; F. charging a quantity of reactive material to said female mold portion; G. closing said mold by inserting said male mold portion into said female mold portion while said male mold portion remains secured to said first planar surface in said coincident alignment; H. reacting said reactive material; and I. recovering said optical device from said mold.

Claim 12

An apparatus for molding optical devices comprising top and bottom mold supports 10 and 11 which are moveable with respect to one another, wherein said top mold support has a first planar surface 14 thereon for securing a first mold portion 12 thereto so that the principal longitudinal axis of said first mold portion is maintained at a right angle to said first planar surface; said bottom mold support has a second planar surface 16 thereon parallel to said first planar surface and which holds a second mold portion 13 thereon so that the principal longitudinal axis of said second mold portion is maintained at a right angle to said second planar surface.

Claim 13

An apparatus for molding optical devices comprising top and bottom mold supports 10 and 11 which are moveable with respect to one another, wherein said top mold support has a first planar surface 14 thereon for securing a first mold portion 12 thereto so that the principal longitudinal axis of said first mold portion is maintained at a right angle to said first planar surface; said bottom mold support has a second planar surface 16 thereon parallel to said first planar surface and which holds a second mold portion 13 thereon so that the principal longitudinal axis of said second mold portion is maintained at a right angle to said second planar surface.

Claim 14

An apparatus for molding optical devices comprising A. a top mold support 10 having a first planar surface 14 thereon which has means 15 for positioning a first mold portion 12 thereto; B. a bottom mold support 11 having a second planar surface 16 thereon which is parallel to said first planar surface and which has means 17 for locating a second mold support thereon; C. a driving means for moving said top and bottom mold supports vertically with respect to one another so as to open and close said mold supports.

Claim 15

An apparatus for molding optical devices comprising A. a top mold support 10 having a first planar surface 14 thereon which has means 15 for positioning a first mold portion 12 thereto; B. a bottom mold support 11 having a second planar surface 16 thereon which is parallel to said first planar surface and which has means 17 for locating a second mold support thereon; C. a driving means for moving said top and bottom mold supports vertically with respect to one another so as to open and close said mold supports.

Claim 16

An apparatus for molding optical devices comprising top and bottom mold supports 10 and 11 wherein said top mold support has a first planar surface, said bottom mold support has a second planar surface 16, said first and second planar surfaces are in confronting parallel relationship, and said first and second parallel surfaces are adapted to hold first and second mold portions 12 and 13 in coincident alignment with one another.

Claim 17

An apparatus for molding optical devices comprising top and bottom mold supports 10 and 11 wherein said top mold support has a first planar surface, said bottom mold support has a second planar surface 16, said first and second planar surfaces are in confronting parallel relationship, and said first and second parallel surfaces are adapted to hold first and second mold portions 12 and 13 in coincident alignment with one another.