US5364256A — Apparatus for the production of plastic lenses

Claim 1

Independent Claim 155 words

Apparatus for making a plastic eyeglass lens, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor comprising an air jet having a substantially cylindrical bore, the bore having a plurality of openings disposed about the circumference thereof, and the bore position in relationship to the first mold member so as to direct air from the openings to the non-casting face of the first mold member during use; and wherein the apparatus is adaptable to make a plastic eyeglass lens during use.

Claim 2

Dependent Claim 155 words

Apparatus for making a plastic eyeglass lens, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor comprising an air jet having a substantially cylindrical bore, the bore having a plurality of openings disposed about the circumference thereof, and the bore position in relationship to the first mold member so as to direct air from the openings to the non-casting face of the first mold member during use; and wherein the apparatus is adaptable to make a plastic eyeglass lens during use.

Claim 3

Dependent Claim 164 words

Apparatus for making a plastic eyeglass lens, comprising: a first mold member having a casting face and a non-casting face with a center and edges; a second mold member having a casting face and a non-casting face with a center and edges, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor positioned in relationship to the first and second mold members so as to direct air from the edges to the center of the non-casting face of the first mold member during use, and from the edges to the center of the non-casting face of the second mold member during use; and wherein the apparatus is adaptable to make a plastic eyeglass lens during use.

Claim 4

Dependent Claim 164 words

Apparatus for making a plastic eyeglass lens, comprising: a first mold member having a casting face and a non-casting face with a center and edges; a second mold member having a casting face and a non-casting face with a center and edges, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor positioned in relationship to the first and second mold members so as to direct air from the edges to the center of the non-casting face of the first mold member during use, and from the edges to the center of the non-casting face of the second mold member during use; and wherein the apparatus is adaptable to make a plastic eyeglass lens during use.

Claim 5

Dependent Claim 60 words

The apparatus of claim 2 wherein the air distributor comprises an air jet having a substantially cylindrical bore, the bore having a plurality of openings dispersed about the circumference thereof, and the bore positioned in relationship to the first mold member so as to direct air from the openings to the non-casting face of the first mold member during use.

Claim 6

Dependent Claim 22 words

The apparatus of claim 1 wherein the diameter of the openings in the air jet varies about the circumference of the bore.

Claim 7

Dependent Claim 55 words

The apparatus of claim 4 wherein the air jet comprises an air inlet and the diameter of the openings is at a minimum adjacent the air inlet, and the diameter of the openings is at a maximum at a point along the circumference of the bore that is opposite the bores having a minimum diameter.

Claim 8

Dependent Claim 35 words

The apparatus of claim 1, further comprising an ultraviolet light filter disposed between the light generator and the first mold member during use, and between the light generator and the second mold member during use.

Claim 9

Dependent Claim 35 words

The apparatus of claim 2, further comprising an ultraviolet light filter disposed between the light generator and the first mold member during use, and between the light generator and the second mold member during use.

Claim 10

Dependent Claim 26 words

The apparatus of claim 3 wherein the apparatus further comprises an air cooler connected to provide air below ambient temperature to the air distributor during use.

Claim 11

Dependent Claim 206 words

Apparatus for making a plastic eyeglass lens, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air cooler for cooling air to a temperature below ambient temperature during use; an air distributor connected to direct cooled air from the air cooler across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use; and wherein the apparatus is adaptable to make a plastic eyeglass lens during use, and wherein the air distributor comprises an air jet having a substantially cylindrical bore, the bore having a plurality of openings disposed about the circumference thereof, and the bore positioned in relationship to the first mold member so as to direct air from the openings to the non-casting face of the first mold member during use.

Claim 12

Dependent Claim 206 words

Apparatus for making a plastic eyeglass lens, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air cooler for cooling air to a temperature below ambient temperature during use; an air distributor connected to direct cooled air from the air cooler across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use; and wherein the apparatus is adaptable to make a plastic eyeglass lens during use, and wherein the air distributor comprises an air jet having a substantially cylindrical bore, the bore having a plurality of openings disposed about the circumference thereof, and the bore positioned in relationship to the first mold member so as to direct air from the openings to the non-casting face of the first mold member during use.

Claim 13

Dependent Claim 206 words

Apparatus for making a plastic eyeglass lens, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air cooler for cooling air to a temperature below ambient temperature during use; an air distributor connected to direct cooled air from the air cooler across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use; and wherein the apparatus is adaptable to make a plastic eyeglass lens during use, and wherein the air distributor is positioned in relationship to the first and second mold members so as to direct air from the edges to the center of the non-casting face of the first mold member during use, and from the edges to the center of the non-casting face of the second mold member during use.

Claim 14

Dependent Claim 206 words

Apparatus for making a plastic eyeglass lens, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air cooler for cooling air to a temperature below ambient temperature during use; an air distributor connected to direct cooled air from the air cooler across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use; and wherein the apparatus is adaptable to make a plastic eyeglass lens during use, and wherein the air distributor is positioned in relationship to the first and second mold members so as to direct air from the edges to the center of the non-casting face of the first mold member during use, and from the edges to the center of the non-casting face of the second mold member during use.

Claim 15

Independent Claim 36 words

The apparatus of any one of claims 1-2, wherein the mold cavity is substantially cylindrical and the distance between the first mold member and the second mold member varies across a diameter of the mold cavity.

Claim 16

Independent Claim 26 words

The apparatus of any one of claims 6-7 wherein the filter directs ultraviolet light of varying intensity against the first and second mold members during use.

Claim 17

Independent Claim 45 words

The apparatus of any one of claims 6-7 wherein the filter comprises a disk of opaque material for reducing the intensity of ultraviolet light reaching the center of the mold members relative to the intensity of ultraviolet light reaching the edges of the mold members.

Claim 18

Independent Claim 45 words

The apparatus of any one of claims 6-7 wherein the filter comprises a ring of opaque material for reducing the intensity of ultraviolet light reaching the edges of the mold members relative to the intensity of ultraviolet light reaching the center of the mold members.

Claim 19

Independent Claim 27 words

The apparatus of any one of claims 6-7 wherein the filter comprises a substantially transparent sheet material having a plurality of ultraviolet light absorbing shapes printed thereon.

Claim 20

Independent Claim 91 words

The apparatus of any one of claims 6-7 wherein the filter comprises a substantially transparent sheet material having a plurality of ultraviolet light absorbing shapes printed thereon, and wherein the density per unit area of the shapes is at a minimum at a point corresponding to the greatest distance between the first mold member and the second mold member, and wherein the density per unit area of the shapes is at a maximum at a point corresponding to the smallest distance between the first mold member and the second mold member.

Claim 21

Independent Claim 40 words

The apparatus of any one of claims 1, 2, 3, 9, or 10 wherein the apparatus is operable to cure a liquid lens composition to form an ophthalmic quality eyeglass lens in a time period of less than one hour.

Claim 22

Independent Claim 34 words

The apparatus of any one of claims 1, 2, 3, 9, or 10 wherein the apparatus further comprises an air cooler connected to provide air below 20° C. to the air distributor during use.

Claim 23

Independent Claim 229 words

A system for making a plastic eyeglass lens, comprising: (i) a lens forming apparatus, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor connected to direct air across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use, and wherein the air distributor comprises an air jet having a substantially cylindrical bore, the bore having a plurality of openings disposed about the circumference thereof, and the bore positioned in relationship to the first mold member so as to direct air from the openings to the non-casting face of the first mold member during use; and (ii) a lens forming composition adaptable to cure to form a solid ophthalmic quality lens when cured in the apparatus; and wherein the system is adaptable to cure the lens forming composition to form a solid ophthalmic quality lens in a time period of less than one hour.

Claim 24

Independent Claim 229 words

A system for making a plastic eyeglass lens, comprising: (i) a lens forming apparatus, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor connected to direct air across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use, and wherein the air distributor comprises an air jet having a substantially cylindrical bore, the bore having a plurality of openings disposed about the circumference thereof, and the bore positioned in relationship to the first mold member so as to direct air from the openings to the non-casting face of the first mold member during use; and (ii) a lens forming composition adaptable to cure to form a solid ophthalmic quality lens when cured in the apparatus; and wherein the system is adaptable to cure the lens forming composition to form a solid ophthalmic quality lens in a time period of less than one hour.

Claim 25

Independent Claim 250 words

A system for making a plastic eyeglass lens, comprising: (i) a lens forming apparatus, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor connected to direct air across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use, and wherein the air distributor comprises an air cooler for cooling the air to a temperature below ambient temperature during use, and wherein the air distributor comprises an air jet having a substantially cylindrical bore, the bore having a plurality of openings disposed about the circumference thereof, and the bore positioned in relationship to the first mold member so as to direct air from the openings to the non-casting face of the first mold member during use; and (ii) a lens forming composition adaptable to cure to form a solid ophthalmic quality lens when cured in the apparatus; and wherein the system is adaptable to cure the lens forming composition to form a solid ophthalmic quality lens in a time period of less than one hour.

Claim 26

Independent Claim 250 words

A system for making a plastic eyeglass lens, comprising: (i) a lens forming apparatus, comprising: a first mold member having a casting face and a non-casting face; a second mold member having a casting face and a non-casting face, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor connected to direct air across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use, and wherein the air distributor comprises an air cooler for cooling the air to a temperature below ambient temperature during use, and wherein the air distributor comprises an air jet having a substantially cylindrical bore, the bore having a plurality of openings disposed about the circumference thereof, and the bore positioned in relationship to the first mold member so as to direct air from the openings to the non-casting face of the first mold member during use; and (ii) a lens forming composition adaptable to cure to form a solid ophthalmic quality lens when cured in the apparatus; and wherein the system is adaptable to cure the lens forming composition to form a solid ophthalmic quality lens in a time period of less than one hour.

Claim 27

Independent Claim 192 words

A system for making a plastic eyeglass lens, comprising: (i) a lens forming apparatus, comprising: a first mold member having a casting face and a non-casting face with a center and an edge; a second mold member having a casting face and a non-casting face with a center and an edge, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor connected to direct air across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use, and wherein the air distributor is positioned in relationship to the first and second mold members so as to direct air from the edges to the center of the non-casting face of the first mold member during use, and from the edges to the center of the non-casting face of the second mold member during use.

Claim 28

Independent Claim 192 words

A system for making a plastic eyeglass lens, comprising: (i) a lens forming apparatus, comprising: a first mold member having a casting face and a non-casting face with a center and an edge; a second mold member having a casting face and a non-casting face with a center and an edge, the second mold member being spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member define a mold cavity; a light generator for generating and directing ultraviolet light against at least one of the first and second mold members during use; an air distributor connected to direct air across the non-casting face of the first mold member during use, and across the non-casting face of the second mold member during use, and wherein the air distributor is positioned in relationship to the first and second mold members so as to direct air from the edges to the center of the non-casting face of the first mold member during use, and from the edges to the center of the non-casting face of the second mold member during use.

Claim 29

Independent Claim 79 words

The system of any one of claims 19-20 wherein the non-casting faces of the first and second mold members have centers and edges, and wherein the air distributor is positioned in relationship to the first and second mold members so as to direct air from the edges to the center of the non-casting face of the first mold member during use, and from the edges to the center of the non-casting face of the second mold member during use.

Claim 30

Dependent Claim 22 words

The system of claim 19 wherein the diameter of the openings in the air jet varies about the circumference of the bore.

Claim 31

Dependent Claim 55 words

The system of claim 23 wherein the air jet comprises an air inlet and the diameter of the openings is at a minimum adjacent the air inlet, and the diameter of the openings is at a maximum at a point along the circumference of the bore that is opposite the bores having a minimum diameter.

Claim 32

Dependent Claim 23 words

The system of claim 20 wherein the air cooler is connected to provide air below 20° C. to the air distributor during use.

Claim 33

Dependent Claim 25 words

The system of claim 21, wherein the air distributor comprises an air cooler for cooling the air to a temperature below ambient temperature during use.

Claim 34

Independent Claim 61 words

The system of any one of claims 19-21 and 26 wherein the composition comprises a photoinitiator and at least one polyethylenic-functional monomer containing at least two ethylenically unsaturated groups selected from acrylyl and methacrylyl, and wherein the composition is curable by exposure to ultraviolet light to form a substantially clear eyeglass lens in a time period of less than one hour.

Claim 35

Independent Claim 67 words

The system of any one of claims 19-21 and 26 wherein the composition contains a photoinitiator, at least one polyethylenic-functional monomer containing at least two ethylenically unsaturated groups selected from acrylyl and methacrylyl, and an aromatic containing bis(allyl carbonate)-functional monomer, and wherein the composition is curable by exposure to ultraviolet light to form a substantially clear eyeglass lens in a time period of less than one hour.

Claim 36

Independent Claim 71 words

The system of any one of claims 19-21 and 26 wherein the composition is curable to form a substantially clear eyeglass lens that is greater than 1.5 mm thick, that is substantially free of distortions, cracks, patterns and striations, and that has negligible yellowing and negligible haziness, all in less than one hour when exposed to less than ten milliwatts per square centimeter of ultraviolet light while in the mold cavity.

Claim 37

Independent Claim 31 words

The system of any one of claims 19-21 and 26 wherein the composition, when cured, can be manually removed from a glass mold in the absence of a mold release agent.

Claim 38

Independent Claim 40 words

The system of any one of claims 19-21 and 26, further comprising an ultraviolet light filter disposed between the light generator and the first mold member during use, and between the light generator and the second mold member during use.

Claim 39

Dependent Claim 42 words

The system of claim 31 wherein the filter comprises a disk of opaque material for reducing the intensity of ultraviolet light reaching the center of the mold members relative to the intensity of ultraviolet light reaching the edges of the mold members.

Claim 40

Dependent Claim 42 words

The system of claim 31 wherein the filter comprises a ring of opaque material for reducing the intensity of ultraviolet light reaching the edges of the mold members relative to the intensity of ultraviolet light reaching the center of the mold members.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1997-11-14	1998-05-16	1998-11-15	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2001-11-14	2002-05-16	2002-11-15	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2005-11-14	2006-05-16	2006-11-15	$7700.00	Window Closed / Lapsed

Apparatus for the production of plastic lenses

Abstract

Inventors

Bibliographic Details

Claims Analysis

References Cited (Backward Citations)

USPTO Annuity & Maintenance Windows

Assigned Categories & Tags

Assign Category Tag