US5286419A — Process for making a light polarizing spectacle l…

Claim 1

Independent Claim 340 words

A process for making a light polarizing spectacle lens using a lens mold, comprising: drying a polarizing film at a temperature and a time effective to drive any transport media from the polarizing film; testing the dried polarizing film for delamination; accepting the polarizing film if the film does not delaminate in the test after drying; shaping the dried polarizing film into a wafer having a pair of opposing straight edges after accepting the dried polarizing film; curving the polarizing film wafer after shaping the dried polarizing film with the proviso that when the plarizing film wafer is curved to a diopter listed below, the wafer is curved substantially at a temperature in degrees Fahrenheit for a time substantially indicated as follows; ______________________________________ Diopter Temperature °F. Time ______________________________________ 2 208.4° F. 100 seconds 4 208.4° F. 200 seconds 5 235.4° F. 900 seconds 6 235.4° F. 1020 seconds 7 235.4° F. 1080 seconds 8 235.4° F. 1200 seconds ______________________________________ and when the polarizing film wafer is positioned in a lens having a front element concave surface curve having substantially the following curvature in diopters, that the wafer is curved to a curvature substantially within one of the following ranges of diopters; ______________________________________ Curvature Range Diopters ______________________________________ 2.00-2.37 2.00 4.08-4.43 4.08 6.34-6.65 6.20 8.20-8.57 8.32 ______________________________________ and when the polarized film wafer is positioned in a progressive lens substantially having one of the curvatures listed below, the wafer is curved to a curvature substantially within one of the following ranges; ______________________________________ Curvature Range Diopters ______________________________________ 2.53-2.70 2.54 5.10-5.28 5.16 7.30-7.46 7.26 8.00-8.38 8.32 ______________________________________ positioning the wafer within the lens mold; filling the lens mold with a lens resin mixture comprising a pregelled monomer with a weight percent of about 65-75% of the mixture, a conventional monomer of about 25-35% by weight of the mixture and IPP of about 2.70-2.90% by weight of the mixture; permitting the resin to cure; and drying the polarizing film within an approximate range of 140° F. to 160° F. for about 2 to 12 hours.

Claim 2

Dependent Claim 340 words

A process for making a light polarizing spectacle lens using a lens mold, comprising: drying a polarizing film at a temperature and a time effective to drive any transport media from the polarizing film; testing the dried polarizing film for delamination; accepting the polarizing film if the film does not delaminate in the test after drying; shaping the dried polarizing film into a wafer having a pair of opposing straight edges after accepting the dried polarizing film; curving the polarizing film wafer after shaping the dried polarizing film with the proviso that when the plarizing film wafer is curved to a diopter listed below, the wafer is curved substantially at a temperature in degrees Fahrenheit for a time substantially indicated as follows; ______________________________________ Diopter Temperature °F. Time ______________________________________ 2 208.4° F. 100 seconds 4 208.4° F. 200 seconds 5 235.4° F. 900 seconds 6 235.4° F. 1020 seconds 7 235.4° F. 1080 seconds 8 235.4° F. 1200 seconds ______________________________________ and when the polarizing film wafer is positioned in a lens having a front element concave surface curve having substantially the following curvature in diopters, that the wafer is curved to a curvature substantially within one of the following ranges of diopters; ______________________________________ Curvature Range Diopters ______________________________________ 2.00-2.37 2.00 4.08-4.43 4.08 6.34-6.65 6.20 8.20-8.57 8.32 ______________________________________ and when the polarized film wafer is positioned in a progressive lens substantially having one of the curvatures listed below, the wafer is curved to a curvature substantially within one of the following ranges; ______________________________________ Curvature Range Diopters ______________________________________ 2.53-2.70 2.54 5.10-5.28 5.16 7.30-7.46 7.26 8.00-8.38 8.32 ______________________________________ positioning the wafer within the lens mold; filling the lens mold with a lens resin mixture comprising a pregelled monomer with a weight percent of about 65-75% of the mixture, a conventional monomer of about 25-35% by weight of the mixture and IPP of about 2.70-2.90% by weight of the mixture; permitting the resin to cure; and drying the polarizing film within an approximate range of 140° F. to 160° F. for about 2 to 12 hours.

Claim 3

Dependent Claim 213 words

The process of claim 1 and further comprising notching the polarizing wafer to form two notches separated by 180° before positioning the wafer in the lens mold to orient the wafer once the wafer is positioned within the lens mold; positioning the wafer in the lens mold by fitting the wafer in an annular groove of a gasket having a pair of protrusions positioned about 180° apart and wherein the notches of the wafers are aligned within 6° of the gasket protrusions; making the pregelled monomer by a method comprising; mixing a quantity of allyl glycol carbonate and isopropyl percarbonate (IPP) to form a mixture having an IPP concentration of about 0.1% by weight of the mixture; heating the mixture to a temperature of not more than 120° F. in order to form the pregelled monomer; sampling and testing the pregelled monomer for viscosity; and cooling the pregelled monomer to a temperature range of about 65° F. to 70° F., wherein the monomer has a viscosity of about 110 cps for at least 45 minutes prior to adding the lens resin to the lens mold; and curing the lens by a time of heating lens temperature profile substantially comprising; ______________________________________ 0 hrs 107.6° F. 2 127.4 4 136.4 14 170.6 22 131.0. ______________________________________

Claim 4

Dependent Claim 38 words

The process of claim 1 and further including removing the lens from the lens mold following curing of the lens and post curing the light polarizing lens by heating the lens to 200° F. for about 6 hours.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1997-02-14	1997-08-16	1998-02-15	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2001-02-14	2001-08-16	2002-02-15	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2005-02-14	2005-08-16	2006-02-15	$7700.00	Window Closed / Lapsed

Process for making a light polarizing spectacle lens

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