Method for molding glass lenses

Claim 1

A method of molding glass comprising the steps of: providing a molding surface of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing the glass in proximity to or in contact with the molding surface; heating the glass and molding surface while they are in proximity or contact; and pressing the glass against the molding surface.

Claim 2

A method of molding glass comprising the steps of: providing a molding surface of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing the glass in proximity to or in contact with the molding surface; heating the glass and molding surface while they are in proximity or contact; and pressing the glass against the molding surface.

Claim 3

A method of molding glass comprising the steps of: providing a mold which includes a molding surface of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with the molding surface; heating the glass and mold while the glass and the molding surface are in proximity or contact; and pressing the glass against the molding surface.

Claim 4

A method of molding glass comprising the steps of: providing a mold which includes a molding surface of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with the molding surface; heating the glass and mold while the glass and the molding surface are in proximity or contact; and pressing the glass against the molding surface.

Claim 5

A method of molding glass into a finished lens comprising the steps of: providing a mold which includes a surface of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and a surface of the glasslike carbon having been finished to provide a molding surface which is specular and which has a high surface accuracy and a high surface quality; placing glass in proximity to or in contact with the molding surface; heating the glass and mold while the glass and the molding surface are in proximity or contact; and pressing the glass against the molding surface.

Claim 6

A method of molding glass into a finished lens comprising the steps of: providing a mold which includes a surface of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and a surface of the glasslike carbon having been finished to provide a molding surface which is specular and which has a high surface accuracy and a high surface quality; placing glass in proximity to or in contact with the molding surface; heating the glass and mold while the glass and the molding surface are in proximity or contact; and pressing the glass against the molding surface.

Claim 7

A method of molding glass comprising the steps of: providing relatively separable mold members, at least one of the mold members including a molding surface of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with the molding surface; heating the glass and mold members while the glass and the molding surface are in proximity or contact; and pressing the glass against the molding surface.

Claim 8

A method of molding glass comprising the steps of: providing relatively separable mold members, at least one of the mold members including a molding surface of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with the molding surface; heating the glass and mold members while the glass and the molding surface are in proximity or contact; and pressing the glass against the molding surface.

Claim 9

A method of molding glass comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their cooperating position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organiC polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with at least one of the molding surfaces; heating the mold members and glass while the glass is in proximity to or in contact with the molding surface; and urging the mold members toward their cooperating position to press the glass against the molding surfaces.

Claim 10

A method of molding glass comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their cooperating position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organiC polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with at least one of the molding surfaces; heating the mold members and glass while the glass is in proximity to or in contact with the molding surface; and urging the mold members toward their cooperating position to press the glass against the molding surfaces.

Claim 15

A method of molding glass into a finished lens which comprises the steps of: providing mold members which are relatively movable to a cooperating position and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surface quality and a high surface accuracy and which define a mold cavity when the mold members are in their cooperating position; placing glass in proximity to or in contact with at least one of the molding surfaces; heating the mold members and the glass while the glass is in proximity to or contact with the molding surface; and pressing the glass against the molding surfaces.

Claim 16

A method of molding glass into a finished lens which comprises the steps of: providing mold members which are relatively movable to a cooperating position and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surface quality and a high surface accuracy and which define a mold cavity when the mold members are in their cooperating position; placing glass in proximity to or in contact with at least one of the molding surfaces; heating the mold members and the glass while the glass is in proximity to or contact with the molding surface; and pressing the glass against the molding surfaces.

Claim 17

A method of molding glass comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their cooperating position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with at least one of the molding surfaces; heating the mold members and the glass while the glass is in proximity to or in contact with the molding surface; urging the mold members toward their cooperating position to contact the glass with the molding surfaces and to press the glass into the configuration of the mold cavity; and cooling the mold members and the glass while urging the mold members toward their cooperating position.

Claim 18

A method of molding glass comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their cooperating position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with at least one of the molding surfaces; heating the mold members and the glass while the glass is in proximity to or in contact with the molding surface; urging the mold members toward their cooperating position to contact the glass with the molding surfaces and to press the glass into the configuration of the mold cavity; and cooling the mold members and the glass while urging the mold members toward their cooperating position.

Claim 22

A method of molding a finished glass lens comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surfaCe accuracy and a high surface quality and which define a mold cavity when the mold members are in their cooperating position; placing glass in proximity to or in contact with at least one of the molding surfaces; heating the mold members and the glass while the glass is in proximity to or in contact with the molding surface; urging the mold members toward their cooperating position to contact the glass with the molding surfaces and to press the glass into the configuration of the mold cavity; and cooling the mold members and the glass while urging the mold members toward their cooperating position.

Claim 23

A method of molding a finished glass lens comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surfaCe accuracy and a high surface quality and which define a mold cavity when the mold members are in their cooperating position; placing glass in proximity to or in contact with at least one of the molding surfaces; heating the mold members and the glass while the glass is in proximity to or in contact with the molding surface; urging the mold members toward their cooperating position to contact the glass with the molding surfaces and to press the glass into the configuration of the mold cavity; and cooling the mold members and the glass while urging the mold members toward their cooperating position.

Claim 24

A method of molding glass comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their cooperating position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with at least one of the molding surfaces; establishing a non-oxidizing atmosphere around the glass and mold members; moving the mold members toward their cooperating position to bring the molding surfaces into proximity or contact with the glass; and applying heat and pressure to the mold members to move the mold members to their cooperating position and to press the glass into the configuration of the mold cavity defined by the molding surfaces.

Claim 25

A method of molding glass comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their cooperating position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with at least one of the molding surfaces; establishing a non-oxidizing atmosphere around the glass and mold members; moving the mold members toward their cooperating position to bring the molding surfaces into proximity or contact with the glass; and applying heat and pressure to the mold members to move the mold members to their cooperating position and to press the glass into the configuration of the mold cavity defined by the molding surfaces.

Claim 28

A method of molding glass into a finished lens comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surface quality and a high surface accuracy and which define a mold cavity when the mold members are in their cooperating position; placing glass in proximity to or in contact with at least one of the molding surfaces; establishing a non-oxidizing atmosphere around the glass and mold members; moving the mold members toward their cooperating position to bring the molding surfaces into proximity or contact with the glass; and applying heat and pressure to the mold members to move the mold members to their cooperating position and to press the glass into the configuration of the mold cavity defined by the molding surfaces.

Claim 29

A method of molding glass into a finished lens comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surface quality and a high surface accuracy and which define a mold cavity when the mold members are in their cooperating position; placing glass in proximity to or in contact with at least one of the molding surfaces; establishing a non-oxidizing atmosphere around the glass and mold members; moving the mold members toward their cooperating position to bring the molding surfaces into proximity or contact with the glass; and applying heat and pressure to the mold members to move the mold members to their cooperating position and to press the glass into the configuration of the mold cavity defined by the molding surfaces.

Claim 30

A method of molding glass comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their cooperating position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with at least one of the molding surfaces; moving the mold members toward their cooperating position to bring the molding surfaces into proximity or contact with the glass; applying heat and pressure to the mold members to move the mold members to their cooperating position and to press the glass into the configuration of the mold cavity defined by the molding surfaces; and reducing The temperature of the mold members and glass while maintaining pressure on the mold members.

Claim 31

A method of molding glass comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their cooperating position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing glass in proximity to or in contact with at least one of the molding surfaces; moving the mold members toward their cooperating position to bring the molding surfaces into proximity or contact with the glass; applying heat and pressure to the mold members to move the mold members to their cooperating position and to press the glass into the configuration of the mold cavity defined by the molding surfaces; and reducing The temperature of the mold members and glass while maintaining pressure on the mold members.

Claim 34

A method of molding glass into a finished lens comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surface quality and a high surface accuracy and which define a mold cavity when the mold members are in their cooperating position; placing glass in proximity to or in contact with at least one of the molding surfaces; moving the mold members toward their cooperating position to bring the molding surfaces into proximity or contact with the glass; applying heat and pressure to the mold members to move the mold members to their cooperating position and to press the glass into the configuration of the mold cavity defined by the molding surfaces; and reducing the temperature of the mold members and glass while maintaining pressure on the mold members.

Claim 35

A method of molding glass into a finished lens comprising the steps of: providing mold members which are relatively movable to a cooperating position and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surface quality and a high surface accuracy and which define a mold cavity when the mold members are in their cooperating position; placing glass in proximity to or in contact with at least one of the molding surfaces; moving the mold members toward their cooperating position to bring the molding surfaces into proximity or contact with the glass; applying heat and pressure to the mold members to move the mold members to their cooperating position and to press the glass into the configuration of the mold cavity defined by the molding surfaces; and reducing the temperature of the mold members and glass while maintaining pressure on the mold members.

Claim 36

A method of molding glass comprising the steps of: providing an upper mold member and a lower mold member which are relatively movable between open and closed positions and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their closed position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; moving the mold members to their open positions and placing glass on the molding surface of the lower mold member; bringing the upper mold member into proximity or contact with the glass and heating the mold members and the glass to soften the glass; moving the mold members to their closed position to bring both molding surfaces into contact with the softened glass; applying sufficient force to the mold members to press the glass into the configuration of the mold cavity defined by the molding surfaces; cooling the glass and mold members to reduce the temperature of the glass below its transformation temperature; removing the force from the mold members and further cooling the glass and the mold members; and moving the mold members to their open positions to permit removal of the molded glass.

Claim 37

A method of molding glass comprising the steps of: providing an upper mold member and a lower mold member which are relatively movable between open and closed positions and which include molding surfaces of glasslike carbon that define a mold cavity when the mold members are in their closed position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; moving the mold members to their open positions and placing glass on the molding surface of the lower mold member; bringing the upper mold member into proximity or contact with the glass and heating the mold members and the glass to soften the glass; moving the mold members to their closed position to bring both molding surfaces into contact with the softened glass; applying sufficient force to the mold members to press the glass into the configuration of the mold cavity defined by the molding surfaces; cooling the glass and mold members to reduce the temperature of the glass below its transformation temperature; removing the force from the mold members and further cooling the glass and the mold members; and moving the mold members to their open positions to permit removal of the molded glass.

Claim 39

A method of molding glass into a finished lens comprising the steps of: providing upper and lower mold members which are relatively movable between open and closed positions and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surface quality and a high surface accuracy and which define a mold cavity when the mold members are in their closed position; moving the mold members to their open positions and placing glass on the molding surface of the lower mold member; bringing the upper mold member into proximity or contact with the glass and heating the mold members and the glass to soften the glass; moving the mold members to their closed position to bring both molding surfaces into contact with the softened glass; applying sufficient force to the mold members to press the glass into the configuration of the mold cavity defined by the molding surfaces; cooling the glass and mold members to reduce the temperature of the glass below its transformation temperature; removing the force from the mold members and further cooling the glass and the mold members; and moving the mold members to their open positions to permit removal of the molded glass.

Claim 40

A method of molding glass into a finished lens comprising the steps of: providing upper and lower mold members which are relatively movable between open and closed positions and which include surfaces of glasslike carbon, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic and selected surfaces of the glasslike carbon having been finished to provide molding surfaces which are specular, which have a high surface quality and a high surface accuracy and which define a mold cavity when the mold members are in their closed position; moving the mold members to their open positions and placing glass on the molding surface of the lower mold member; bringing the upper mold member into proximity or contact with the glass and heating the mold members and the glass to soften the glass; moving the mold members to their closed position to bring both molding surfaces into contact with the softened glass; applying sufficient force to the mold members to press the glass into the configuration of the mold cavity defined by the molding surfaces; cooling the glass and mold members to reduce the temperature of the glass below its transformation temperature; removing the force from the mold members and further cooling the glass and the mold members; and moving the mold members to their open positions to permit removal of the molded glass.

Claim 41

A method of molding glass having a softening temperature within the range of 700*C to 800*C and an annealing temperature within the range of 600*C to 700*C, comprising the steps of: providing a set of mold assemblies which are movable between an open and closed position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold assemblies are in their closed position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing the mold assemblies within a chamber that may be substantially hermetically sealed; placing glass between the molding surfaces; hermetically sealing and evacuating the chamber; heating the mold assemblies to a temperature within the range of 200*C to 300*C to outgas the mold members; adding a gas of 95% N2 and 5% H2 to the chamber and maintaining the gas under a slight overpressure; heating the mold assemblies to a temperature within the range of from 700*C to 800*C; moving the mold assemblies towards their closed position and holding the molding surfaces in proximity with the glass for one to five minutes; moving the mold assemblies toward their closed position until the molding surfaces are brought into contact with the glass; adding a load of from 10 pounds to 200 pounds to the mold assemblies to press the glass into the shape of the mold cavity defined by the molding surfaces and maintaining the load for one minute; cooling the mold assemblies to between 500*C and 600*C while maintaining a load on the mold assemblies; removing the load from the mold assemblies and reducing the temperature of the mold assemblies to below 300*C; unsealing the chamber; and moving the mold assemblies to their open position to permit removal of the molded glass.

Claim 42

A method of molding glass having a softening temperature within the range of 700*C to 800*C and an annealing temperature within the range of 600*C to 700*C, comprising the steps of: providing a set of mold assemblies which are movable between an open and closed position and which include molding surfaces of glasslike carbon that define a mold cavity when the mold assemblies are in their closed position, the glasslike carbon being a form of carbon which has been prepared by the thermal degradation of an organic polymer, which is substantially chemically inert with heated glass and which is isotropic; placing the mold assemblies within a chamber that may be substantially hermetically sealed; placing glass between the molding surfaces; hermetically sealing and evacuating the chamber; heating the mold assemblies to a temperature within the range of 200*C to 300*C to outgas the mold members; adding a gas of 95% N2 and 5% H2 to the chamber and maintaining the gas under a slight overpressure; heating the mold assemblies to a temperature within the range of from 700*C to 800*C; moving the mold assemblies towards their closed position and holding the molding surfaces in proximity with the glass for one to five minutes; moving the mold assemblies toward their closed position until the molding surfaces are brought into contact with the glass; adding a load of from 10 pounds to 200 pounds to the mold assemblies to press the glass into the shape of the mold cavity defined by the molding surfaces and maintaining the load for one minute; cooling the mold assemblies to between 500*C and 600*C while maintaining a load on the mold assemblies; removing the load from the mold assemblies and reducing the temperature of the mold assemblies to below 300*C; unsealing the chamber; and moving the mold assemblies to their open position to permit removal of the molded glass.