U.S. patent application number 11/433849 was filed with the patent office on 2006-09-14 for method of forming an anti-reflective coating on an eyeglass lens.
This patent application is currently assigned to Q2100, Inc.. Invention is credited to John T. Foreman, Matthew C. Lattis, Galen R. Powers.
Application Number | 20060202369 11/433849 |
Document ID | / |
Family ID | 28039427 |
Filed Date | 2006-09-14 |
United States Patent
Application |
20060202369 |
Kind Code |
A1 |
Foreman; John T. ; et
al. |
September 14, 2006 |
Method of forming an anti-reflective coating on an eyeglass
lens
Abstract
Methods of coating a lens mold are described. One or more
methods may include coupling a mold to a mold holder of an eyeglass
lens mold coating apparatus. The mold holder may be rotatably
coupled to a transport device of the mold coating apparatus. The
mold may be moved to a coating process unit. The mold may be
rotated while a coating composition is applied to the casting face
of the mold. The mold with the coating composition applied may be
moved to a curing process unit. Activating light may be applied to
the coating composition to initiate curing of the coating
composition.
Inventors: |
Foreman; John T.;
(Louisville, KY) ; Powers; Galen R.; (Louisville,
KY) ; Lattis; Matthew C.; (Louisville, KY) |
Correspondence
Address: |
MEYERTONS, HOOD, KIVLIN, KOWERT & GOETZEL, P.C.
700 LAVACA, SUITE 800
AUSTIN
TX
78701
US
|
Assignee: |
Q2100, Inc.
|
Family ID: |
28039427 |
Appl. No.: |
11/433849 |
Filed: |
May 12, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10098736 |
Mar 15, 2002 |
7044429 |
|
|
11433849 |
May 12, 2006 |
|
|
|
Current U.S.
Class: |
264/1.32 ;
264/1.7 |
Current CPC
Class: |
B29D 11/00173 20130101;
Y10S 425/808 20130101 |
Class at
Publication: |
264/001.32 ;
264/001.7 |
International
Class: |
B29D 11/00 20060101
B29D011/00 |
Claims
1-471. (canceled)
472. A method of forming an antireflective coating stack on a lens,
comprising: providing an eyeglass lens mold; coupling the eyeglass
lens mold to a rotatable mold holder of an eyeglass lens mold
coating apparatus, wherein the mold holder is coupled to a
transport device of the coating apparatus; moving the eyeglass lens
mold into a desired operational relationship with a coating process
unit; rotating the eyeglass lens mold while applying a first mold
coating composition to a casting face of the eyeglass lens mold;
moving the eyeglass lens mold into a desired operational
relationship with a curing process unit; applying activating light
to the first mold coating composition to cure the first mold
coating composition; moving the eyeglass lens mold into a desired
operational relationship with the coating process unit; rotating
the eyeglass lens mold while applying a second mold coating
composition over the cured first mold coating composition on the
casting face of the eyeglass lens mold; moving the eyeglass lens
mold into a desired operational relationship with a curing process
unit; applying activating light to the second mold coating
composition to cure the second mold coating composition; wherein
the first mold coating composition comprises a refractive index
lower than the second mold coating composition when both
compositions are cured; and casting an eyeglass lens using at least
the coated eyeglass lens mold.
473. The method of claim 472, wherein moving the eyeglass lens mold
is controlled by a controller.
474. The method of claim 472, wherein coupling the eyeglass lens
mold to the rotatable mold holder is controlled by a
controller.
475. The method of claim 472, wherein rotating the eyeglass lens
mold is controlled by a controller.
476. The method of claim 472, wherein applying a coating
composition to the eyeglass lens mold is controlled by a
controller.
477. The method of claim 472, wherein applying activating light is
controlled by a controller.
478. A method of forming an antireflective coating stack on an
eyeglass lens, comprising: providing an eyeglass lens mold;
coupling the eyeglass lens mold to a rotatable mold holder of an
eyeglass lens mold coating apparatus, wherein the mold holder is
coupled to a transport device of the eyeglass lens mold coating
apparatus; forming an antireflective coating stack on the casting
surface of the eyeglass lens mold; and casting an eyeglass lens
using at least the coated eyeglass lens mold.
479. The method of claim 478, wherein coupling the eyeglass lens
mold to the rotatable mold holder is controlled by a
controller.
480. The method of claim 478, wherein forming an antireflective
coating stack on the casting surface of the eyeglass lens mold is
controlled by a controller.
481. The method of claim 478, wherein coupling the mold to the
rotatable mold holder comprises inserting the mold into a vacuum
chuck of the mold holder.
482. The method of claim 478, wherein forming an antireflective
coating stack on the casting surface of the eyeglass lens mold
comprises rotating the lens mold while applying at least one mold
coating composition.
483. The method of claim 478, wherein forming an antireflective
coating stack on the casting surface of the eyeglass lens mold
comprises rotating the lens mold at a predetermined rotation while
applying at least one mold coating composition.
484. The method of claim 478, wherein forming an antireflective
coating stack on the casting surface of the eyeglass lens mold
comprises rotating the lens mold at between about 200 rpm and about
2000 rpm while applying at least one mold coating composition.
485. The method of claim 478, wherein applying at least one coating
layer of the antireflective coating stack to the casting surface of
the mold comprises dispensing at least one coating composition from
a coating applicator of a coating process unit onto the casting
surface of the mold while the mold is rotating to form a uniform
coating layer.
486. The method of claim 478, wherein applying at least one layer
of the antireflective coating stack to the casting face of the mold
comprises selecting a coating to be applied and controlling one or
more process parameters based on the coating selected.
487. The method of claim 478, wherein applying at least one layer
of the antireflective coating stack to the casting surface of the
mold comprises selecting a coating to be applied and controlling
the rate of rotation of the mold based on the coating selected.
488. The method of claim 478, wherein applying at least one layer
of the antireflective coating stack to the casting surface of the
mold comprises selecting a coating to be applied and controlling a
delay time after application of the coating and before curing of
the coating based on the coating selected.
489. The method of claim 478, wherein applying at least one layer
of the antireflective coating stack comprises applying activating
light pulses to a coating composition applied to the casting
surface of the eyeglass lens mold.
490. The method of claim 478, wherein applying at least one layer
of the antireflective coating stack comprises applying activating
light pulses to a coating composition applied to the casting
surface of the eyeglass lens mold and rotating the mold between one
or more activating light pulses.
491. The method of claim 478, wherein at least one coating layer of
the antireflective coating stack is less than about 1000 nm
thick.
492. The method of claim 478, wherein at least one coating layer of
the antireflective coating stack is less than about 500 nm
thick.
493. The method of claim 478, further comprising cleaning the
eyeglass lens mold before applying the antireflective coating
stack.
494. The method of claim 493, wherein cleaning the eyeglass lens
mold comprises: moving the mold into a desired operational
relationship with a cleaning process unit; and rotating the
eyeglass lens mold while applying a cleaning fluid to the casting
face of the eyeglass lens mold.
495. The method of claim 493, further comprising rotating the
eyeglass lens mold after cleaning to facilitate drying of the
eyeglass lens mold.
496. The method of claim 493, further comprising applying a drying
agent the eyeglass lens mold after cleaning to facilitate drying of
the eyeglass lens mold.
497. The method of claim 493, further comprising applying a
chemical drying agent to the eyeglass lens mold after cleaning the
eyeglass lens mold.
498. The method of claim 497, wherein the chemical drying agent
comprises isopropyl alcohol.
499. The method of claim 478, further comprising receiving input
comprising eyeglass lens information.
500. The method of claim 499, further comprising selecting at least
one eyeglass lens mold to coat based on the received input, wherein
at least one selected eyeglass lens mold is usable for forming an
eyeglass lens substantially conforming to the eyeglass lens
information.
501. The method of claim 499, wherein the eyeglass lens information
comprises an identification of at least one coating desired to be
present on a lens substantially conforming to the eyeglass lens
information.
502. The method of claim 499, further comprising determining one or
more operating parameters of an eyeglass lens mold coating
apparatus based on the eyeglass lens information.
503. The method of claim 502, wherein at least one operating
parameter determined based on the eyeglass lens information are
selected from the group consisting of: mold rotation time during a
cleaning process, mold rotation rate during the cleaning process,
and dispense time of a cleaning fluid during the cleaning
process.
504. The method of claim 502, wherein at least one operating
parameter determined based on the eyeglass lens information is
selected from the group consisting of: mold rotation time during
coating, mold rotation rate during coating, a coating composition
applied, and amount of coating composition dispensed during
coating.
505. The method of claim 502, wherein at least one operating
parameter determined based on the eyeglass lens information is
selected from the group consisting of: mold rotation time during a
mold drying process, mold rotation rate during the mold drying
process, and selection of a drying agent applied during the mold
drying process.
506. The method of claim 502, wherein at least one operating
parameter determined based on the eyeglass lens information is
selected from the group consisting of: mold rotation time during
curing, intensity of activating light applied, duration of
application of activating light, flash rate of activating light
source, and flash duration of activating light source.
507. The method of claim 478, further comprising moving the mold
along a travel path of the transport device while applying at least
one mold coating composition of at least one coating layer of the
antireflective coating stack to ensure a uniform coating on the
casting face of the mold.
508. The method of claim 478, further comprising rotating the mold
for a predetermined period of time after applying at least one mold
coating composition of at least one coating layer of the
antireflective coating stack to promote drying of the coating
composition.
509. The method of claim 478, further comprising promoting
evaporation of a coating composition of at least one coating layer
of the antireflective coating stack solvent before applying
activating light to at least one coating composition.
510. The method of claim 478, further comprising decoupling the
mold from the mold holder at a transfer station after applying at
least one coating layer of the antireflective coating stack.
511. The method of claim 510, further comprising coupling the mold
to a second rotatable mold holder at the transfer station.
Description
PRIORITY CLAIM
[0001] This application is a continuation of U.S. patent
application Ser. No. 10/098,736 entitled "METHODS AND SYSTEMS FOR
COATING EYEGLASS LENS MOLDS" filed on Mar. 15, 2002.
BACKGROUND
[0002] 1. Field of the Invention
[0003] Embodiments presented herein generally relate to eyeglass
lenses. More particularly, embodiments relate to systems and
methods for the location, storage, identification, and coating of
eyeglass mold members used in the production of eyeglass lenses.
Further embodiments relate to methods and systems for separating a
cast lens from a lens mold.
[0004] 2. Description of the Related Art
[0005] It is conventional in the art to produce eyeglass lenses by
thermal curing techniques from the monomer of diethylene glycol
bis(allyl)-carbonate (DEG-BAC). Eyeglass lenses may also be made
using radiation curing techniques. In general, radiation techniques
to form eyeglass lens may use one or more lens molds. Additionally,
a mold gasket may be used. Lens molds may include spherical
surfaces, toric surfaces or aspherical surfaces, and may contain
other features as well in order to impart desired optical
properties to a formed lens. Due to the lens thickness differences
and other features, different mold gaskets may be required for
different lens mold sets. A typical eyeglass lens manufacturer may
have a large number of eyeglass lens mold members available in
order to produce the large variety of lenses requested. As a
result, locating specific eyeglass mold members to produce a
particular eyeglass lens may be time consuming. It may be difficult
to visually distinguish one mold member from another. Productivity
may be lost if a mold is misplaced or cannot be located in a timely
manner. Accuracy may be lost if a mold member is misidentified.
Thus, it may be advantageous to be able to accurately and
efficiently identify a mold member's appropriate storage
location.
[0006] A common method of storing lens molds may involve placing
the molds in a storage drawer. Within the drawer, molds may be
separated by tabs. The tabs may include an identification of an
adjacent mold. An operator seeking a desired lens mold may look
through the tabs to find the mold storage location. When the
operator has finished using the lens mold, he or she may look
through the tabs again to find the appropriate storage
location.
[0007] Ophthalmic eyeglass lenses may include one or more coatings.
For example, coatings may be applied to improve durability of the
lenses, to change the appearance of the lenses, to improve the
function of the lenses and/or to improve the manufacturability of
the lenses. Various methods have been used to apply one or more
coatings after forming a lens. Alternately, one or more coatings
may also be applied to lens molds before casting a lens. Coatings
applied to lens molds before casting a lens may adhere to or be
integrated with the lens after casting the lens.
[0008] After forming an eyeglass lens using a lens casting
technique, separating the cast lens from one or more of the lens
molds may be problematic. Methods of demolding a cast lens may
include applying force at an intersection of the lens and lens
mold. Commonly, a sharp object, such as a knife blade, may be used
to apply the force at the intersection of the lens and lens mold.
Liquid bath demolding, wherein the cast lens mold assembly is
immersed in a liquid to facilitate separation of the lens mold from
the cast lens, may also be used. Demolding may result in damage to
the lens and/or one or more lens molds.
SUMMARY
[0009] Embodiments disclosed herein, may allow mold members to be
stored in an organized fashion. A controller may be utilized for
processing and filing information about mold members, and their
storage locations.
[0010] Systems and methods are disclosed for the location, storage,
and identification of eyeglass mold members to be used in the
production of eyeglass lenses. Such a system may employ a mold
member storage system body including a plurality of mold member
storage locations. In an embodiment, a mold member storage location
may include a plurality of separating devices to inhibit mold
members within the storage location from contacting one another. In
an embodiment, an eyeglass mold member storage system may include
one or more indicators proximate one or more mold member storage
locations. The indicators may assist an operator in locating a
desired mold member. In an embodiment, a controller may be coupled
to the eyeglass mold member storage system. In such an embodiment,
the controller may be configured to determine a mold member storage
location associated with a desired mold member type. The controller
may assist an operator in locating a desired mold member. For
example, the controller may receive input relating to a desired
mold member. The controller may activate an indicator proximate a
mold member storage location of a desired mold member based the
received input. The input may include, but is not limited to:
eyeglass lens information. The operator may select a mold member
from the indicated storage location and use the mold member to form
an eyeglass lens. In an embodiment, the controller may be
configured to maintain an inventory of mold members in the eyeglass
mold member storage system. In such an embodiment, a mold member
selection method may include determining whether a desired mold
member is available in the eyeglass mold member storage system. The
method may also provide output to the operator indicating whether a
desired mold member is available or not. If a desired mold member
is not available, the method may include putting a job associated
with the received input on hold. If a desired mold member is
available, the method may include receiving input from the operator
regarding a selected mold member. The mold member inventory may be
adjusted based on the input regarding the selected mold member. In
an embodiment, the controller may provide a graphical display to
assist an operator with the mold member selection process. For
example, the graphical display may include a depiction of a mold
assembly tray. A mold member to be selected may be indicated in the
graphical display. The display may allow the operator to provide
input regarding the selection of the desired mold member. If a
desired mold member has been selected, the graphical display may
indicate another mold member to be selected. A selected mold member
may be used to form an eyeglass lens. In an embodiment, forming an
eyeglass lens may include coating one or more lens molds. A lens
mold may be coated in an apparatus including a plurality of process
units and a transport device. For example, the process units may
include one or more coating process units and one or more curing
process units. The process units may also include one or more
cleaning process units. In an embodiment, a curing process unit may
include at least one coating applicator and a coating basin.
Similarly, a cleaning process unit may include at least one
cleaning applicator and a cleaning basin. As used herein, a "basin"
may refer to any structure configured to restrict spreading of a
process fluid. For example, a basin may include but is not limited
to: a bowl, an enclosure, a berm, a box, a cover, a cylinder, etc.
An embodiment of a curing process unit may include an activating
light source. A transport device may include a rotation device. In
an embodiment, an eyeglass lens mold coating apparatus may also
include one or more mold staging areas. To coat a lens mold, the
lens mold may be placed in a mold staging area and coating
apparatus may be initiated. Coating and/or cleaning applicators may
be disposed along a travel path of the transport device.
[0011] In an embodiment, a method of coating a lens mold may
include coupling a mold to a mold holder of an eyeglass lens mold
coating apparatus. In such an embodiment, the mold holder may be
rotatably coupled to a transport device of the mold coating
apparatus. The mold may be moved to a coating process unit. The
mold may be rotated while a coating composition is applied to the
casting face of the mold. The mold with the coating composition
applied may be moved to a curing process unit. Activating light may
be applied to the coating composition to initiate curing of the
coating composition. In some embodiments, the coating and curing
may be repeated until all of the desired lens coating layers have
been formed on the lens mold. For example, to form an
antireflective coating stack on a lens, a first coating composition
and a second coating composition may be applied to the lens mold.
The first coating composition may have a lower refractive index
than the second coating layer when both are cured. The lens mold
may then be used to form a lens.
[0012] In an embodiment, after forming a lens using a lens mold,
the lens and the lens mold may need to be separated. In an
embodiment, the lens and lens mold may be separated by a method
including applying force to an edge of the lens mold. The force
applied may be sufficient to elastically deform the mold. A
separating force may then be applied to separate the lens and the
lens mold.
[0013] In an embodiment, a demolding device may be used to assist
the operator in separating the lens from the lens mold. The
demolding device may include a clamping mechanism configured to
engage an edge of a lens mold. For example, the clamping mechanism
may include two or more clamping members. The demolding device may
also include an urging means for urging the clamping members toward
one another.
[0014] After use, a mold member may be placed back into an eyeglass
mold member storage system. In an embodiment, a controller of an
eyeglass mold member storage system may assist an operator in
identifying a storage location associated with a mold member to be
stored. For example, the operator may provide input to the
controller identifying a mold member to be stored. The controller
may determine a mold member storage location appropriate for
storing the mold member. An indicator associated with a determined
mold member storage location may be activated.
[0015] In an embodiment, a lens mold may include a machine-readable
data code disposed thereon. The data code may include identifying
information. For example, the data code may include or be
associated with information related to the shape of the casting
face of the lens mold. In an embodiment, an operator may provide
input to a controller regarding a mold member to be stored using a
mold reader. A mold reader may include a light source and a light
detection device. The light detection device may be coupled to a
controller. The light detection device may be configured to detect
a light pattern formed by illumination of the data code on the lens
mold. The light detector may send a signal to the controller
corresponding to the detected light pattern. The controller may
determine the identification of the mold member based on the light
pattern.
[0016] In an embodiment, a data code may be formed on a lens mold
by a method including directing laser light toward a determined
location on the surface of the lens mold. The surface may then be
allowed to cool. Directing laser light toward the surface and
cooling the surface may continue until a provided data code is
formed on the lens mold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above brief description as well as further objects,
features and advantages of the methods and apparatus of the present
invention will be more fully appreciated by reference to the
following detailed description of presently preferred but
nonetheless illustrative embodiments in accordance with the present
invention when taken in conjunction with the accompanying drawings
in which:
[0018] FIG. 1 depicts a perspective view of a plastic lens forming
apparatus;
[0019] FIG. 2 depicts a perspective view of a spin coating
unit;
[0020] FIG. 3 depicts a cut-away side view of a spin coating
unit;
[0021] FIG. 4 depicts a perspective view of a plastic lens forming
apparatus with a portion of the body removed;
[0022] FIG. 5 depicts a perspective view of the components of a
lens curing unit;
[0023] FIG. 6 depicts a perspective view of a plastic lens forming
apparatus with a portion of the body removed and the coating units
removed;
[0024] FIG. 7 depicts a schematic of a fluorescent light ballast
system;
[0025] FIG. 8 depicts a mold assembly;
[0026] FIG. 9 depicts an isomeric view of an embodiment of a
gasket;
[0027] FIG. 10 depicts a top view of the gasket of FIG. 9;
[0028] FIG. 11 depicts a cross-sectional view of an embodiment of a
mold/gasket assembly;
[0029] FIG. 12 depicts an isometric view of an embodiment of a
gasket;
[0030] FIG. 13 depicts a top view of the gasket of FIG. 12;
[0031] FIG. 14 depicts a side view of a cured lens and molds after
removal of a gasket;
[0032] FIG. 15 depicts a post-cure unit;
[0033] FIG. 16 depicts chemical structures of acrylated amines;
[0034] FIGS. 17-19 depict a front panel of a controller with a
display screen depicting various display menus;
[0035] FIG. 20 depicts an isometric view of a heated polymerizable
lens forming composition dispensing system;
[0036] FIG. 21 depicts a side view of a heated polymerizable lens
forming composition dispensing system;
[0037] FIGS. 22 and 23 depict cross-sectional side views of a
heated polymerizable lens forming composition dispensing
system;
[0038] FIG. 24 depicts a mold assembly for making flat-top bifocal
lenses;
[0039] FIG. 25 depicts a front view of a lens curing unit;
[0040] FIG. 26 depicts a top view of a lens curing unit;
[0041] FIG. 27 depicts an isometric view of a high-volume lens
curing apparatus;
[0042] FIG. 28 depicts a cross-sectional side view of a high-volume
lens curing apparatus;
[0043] FIG. 29 depicts a cross-sectional top view of a first curing
unit of a high-volume lens curing apparatus;
[0044] FIG. 30 depicts an isometric view of a mold assembly
holder;
[0045] FIG. 31 depicts an isometric view of a conveyor system for a
high-volume lens curing apparatus;
[0046] FIG. 32 depicts a cross sectional top view of a high-volume
lens curing apparatus;
[0047] FIG. 33 depicts a side view of a portion of a conveyor
system for a high-volume lens curing apparatus;
[0048] FIG. 34 depicts a side view of a high-volume lens curing
apparatus;
[0049] FIG. 35 depicts a cross-sectional front view of a
high-volume lens curing apparatus;
[0050] FIG. 36 depicts a schematic front view of an embodiment of a
mold member storage array coupled to a controller computer;
[0051] FIGS. 37a and 37b depict schematic perspective views of
embodiments of indicators positioned on eyeglass mold member
storage locations;
[0052] FIG. 38 depicts a schematic perspective view of an
embodiment of a vertical mold member storage array;
[0053] FIG. 39 depicts a partial cross-sectional view of an
embodiment of the vertical mold member storage array of FIG.
38;
[0054] FIG. 40 depicts a partial cross-sectional view of an
embodiment of a mold member storage unit in which mold members
interact with the separating devices;
[0055] FIGS. 41A through 41D depict schematic perspective views of
various embodiments of cams that may be employed in a mold storage
array;
[0056] FIG. 42 depicts a schematic view of an embodiment of a
system configured to collect and transmit eyeglass lens information
over a computer network;
[0057] FIG. 43 depicts a flow chart illustrating an embodiment of a
method for collecting and transmitting eyeglass lens information
over a computer network;
[0058] FIGS. 44, 45, and 46 depict embodiments of graphical user
interfaces which may display eyeglass lens forming-related
information;
[0059] FIG. 47 depicts an embodiment of a graphical user interface
which may include a prescription input menu;
[0060] FIG. 48 depicts an embodiment of a graphical user interface
which may include a prescription viewer display;
[0061] FIG. 49 depicts an embodiment of a graphical user interface
which may include an alarm viewer display;
[0062] FIG. 50 depicts an embodiment of a graphical user interface
which may include a maintenance viewer display;
[0063] FIG. 51 depicts an embodiment of a graphical user interface
which may include a machine setup menu;
[0064] FIGS. 52 and 53 depict embodiments of graphical user
interfaces which may include a configuration setup menu;
[0065] FIG. 54 depicts a perspective side view of an embodiment of
a mold member storage array;
[0066] FIG. 55 depicts a detailed view of the dispensing end of the
mold member storage panel depicted in FIG. 56 according to one
embodiment;
[0067] FIG. 56 depicts a perspective side view of an embodiment of
a panel of a mold member storage array;
[0068] FIG. 57 depicts a front view of an embodiment of an end
panel of a mold member storage array;
[0069] FIG. 58 depicts a perspective view of the back of an
embodiment of an end panel of a mold member storage array;
[0070] FIG. 59 depicts a schematic view of an embodiment of an
eyeglass mold member storage system coupled to another computer via
a network;
[0071] FIG. 60A depicts an embodiment of a mold member selection
graphical display during a selection process;
[0072] FIG. 60B depicts an embodiment of a mold member selection
display after a mold member has been rejected;
[0073] FIG. 60C depicts an embodiment of a mold member selection
display when a desired mold member is not available;
[0074] FIG. 60D depicts an embodiment of a mold member selection
display indicating that mold members needed for an on-hold job are
available;
[0075] FIG. 60E depicts an embodiment of a mold member selection
display initiating a re-inventory process;
[0076] FIG. 61 depicts a flowchart of a method of identifying a
mold member according to one embodiment;
[0077] FIG. 62 depicts a flowchart of a pick process of a mold
member inventory method according to one embodiment;
[0078] FIG. 63 depicts a flowchart of a hold job process of a mold
member inventory method according to one embodiment;
[0079] FIG. 64 depicts a flowchart of a mold member selection
process of a mold member inventory method according to one
embodiment;
[0080] FIG. 65 depicts a flowchart of a method of updating a mold
member inventory according to one embodiment;
[0081] FIG. 66A depicts a perspective side view of a first
embodiment of a lens mold coating apparatus;
[0082] FIG. 66B depicts a cutaway side view of the lens mold
coating apparatus of FIG. 66A
[0083] FIG. 66C depicts a top view of a processing area of the lens
mold coating apparatus of FIG. 66A;
[0084] FIG. 67A depicts a perspective side view of a second
embodiment of a lens mold coating apparatus;
[0085] FIG. 67B depicts a schematic top view of a processing area
of the lens mold coating apparatus of FIG. 68A;
[0086] FIG. 67C depicts a perspective front view of an embodiment
of several process unit modules;
[0087] FIG. 67D depicts a perspective view of an embodiment of a
transport device;
[0088] FIG. 68 depicts a perspective side view of a third
embodiment of a lens mold coating apparatus;
[0089] FIG. 69 depicts a flowchart of a method of coating a lens
mold according to one embodiment;
[0090] FIG. 70 depicts a partial cut-away perspective side view of
an embodiment of a demolding apparatus;
[0091] FIG. 71 depicts a perspective side view of a lens mold;
[0092] FIG. 72 depicts a flowchart of a method of applying a data
code to a lens mold according to one embodiment;
[0093] FIG. 73 depicts a cut-away perspective side view of an
embodiment of a mold reader;
[0094] FIG. 74 depicts a flowchart of a method of determining the
identification of a lens mold according to one embodiment; and
[0095] FIG. 75 depicts a flowchart of a method of storing a mold
member according to one embodiment.
DETAILED DESCRIPTION
[0096] Apparatus, operating procedures, equipment, systems,
methods, and compositions for lens coating and curing using
activating light are available from Optical Dynamics Corporation in
Louisville, Ky.
[0097] Referring now to FIG. 1, a plastic lens curing apparatus is
generally indicated by reference numeral 10. As shown in FIG. 1,
lens forming apparatus 10 includes at least one coating unit 20, a
lens curing unit 30, a post-cure unit 40, and a controller 50. In
one embodiment, apparatus 10 includes two coating units 20. Coating
unit 20 may be configured to apply a coating layer to a mold member
or a lens. Coating unit 20 may be a spin coating unit. Lens curing
unit 30 includes an activating light source for producing
activating light. As used herein "activating light" means light
that may affect a chemical change. Activating light may include
ultraviolet light (e.g., light having a wavelength between about
300 nm to about 400 nm), actinic light, visible light or infrared
light. Generally, any wavelength of light capable of affecting a
chemical change may be classified as activating. Chemical changes
may be manifested in a number of forms. A chemical change may
include, but is not limited to, any chemical reaction that causes a
polymerization to take place. In some embodiments, the chemical
change causes the formation of an initiator species within the lens
forming composition, the initiator species being capable of
initiating a chemical polymerization reaction. The activating light
source may be configured to direct light toward a mold assembly.
Post-cure unit 40 may be configured to complete the polymerization
of plastic lenses. Post-cure unit 40 may include an activating
light source and a heat source. Controller 50 may be a programmable
logic controller. Controller 50 may be coupled to coating units 20,
lens curing unit 30, and post-cure unit 40, such that the
controller is capable of substantially simultaneously operating the
three units 20, 30, and 40. Controller 50 may be a computer. A
coating unit for applying a coating composition to a lens or a mold
member and then curing the coating composition is described in U.S.
Pat. No. 4,895,102 to Kachel et al., U.S. Pat. No. 3,494,326 to
Upton, and U.S. Pat. No. 5,514,214 to Joel et al. (all of which are
incorporated herein by reference). In addition, the apparatus shown
in FIGS. 2 and 3 may also be used to apply coatings to lenses or
mold members.
[0098] FIG. 2 depicts a pair of spin coating units 102 and 104.
These spin coating units may be used to apply a scratch resistant
coating or a tint coating to a lens or mold member. Each of the
coating units includes an opening through which an operator may
apply lenses and lens mold assemblies to a holder 108. Holder 108
may be partially surrounded by barrier 114. Barrier 114 may be
coupled to a dish 115. As shown in FIG. 3, the dish edges may be
inclined to form a peripheral sidewall 121 that merges with barrier
114. The bottom 117 of the dish may be substantially flat. The flat
bottom may have a circular opening that allows an elongated member
109 coupled to lens holder 108 to extend through the dish 115.
[0099] Holder 108 may be coupled to a motor 112 via elongated
member 109. Motor 112 may be configured to cause rotation of holder
108. In such a case, motor 112 may be configured to cause rotation
of elongated member 109, that in turn causes the rotation of holder
108. The coating unit 102/104, may also include an electronic
controller 140. Electronic controller 140 may be coupled to motor
112 to control the rate at which holder 108 is rotated by motor
112. Electronic controller 140 may be coupled to a programmable
logic controller, such as controller 50, shown in FIG. 1. The
programmable logic controller may send signals to the electronic
controller to control the rotational speed of holder 108. In one
embodiment, motor 112 is configured to rotate holder 108 at
different rates. Motor 112 may be capable of rotating the lens or
mold member at a rate of up to 1500 revolutions per minute
("RPM").
[0100] In one embodiment, barrier 114 has an interior surface that
may be made or lined with an absorbent material such as foam
rubber. This absorbent material may be disposable and removable.
The absorbent material may be configured to absorb any liquids that
fall off a lens or mold member during use. Alternatively, the
interior surface of barrier 114 may be substantially non-absorbent,
allowing any liquids used during the coating process to move down
barrier 114 into dish 115.
[0101] Coating units 20, in one embodiment, are positioned in a top
portion 12 of lens forming apparatus 10, as depicted in FIG. 1. A
cover 22 may be coupled to body 14 of the lens forming apparatus to
allow top portion 12 to be covered during use. A light source 23
may be positioned on an inner surface of cover 22. The light source
may include at least one lamp 24, preferably two or more lamps,
positioned on the inner surface of cover 22. Lamps 24 may be
positioned such that the lamps are oriented above the coating units
20 when cover 22 is closed. Lamps 24 emit activating light upon the
lenses or mold members positioned within coating units 20. Lamps
may have a variety of shapes including, but not limited to, linear
(as depicted in FIG. 1), square, rectangular, circular, or oval.
Activating light sources emit light having a wavelength that will
initiate curing of various coating materials. For example, most
currently used coating materials may be curable by activating light
having wavelengths in the ultraviolet region, therefore the light
sources should exhibit strong ultraviolet light emission. The light
sources may also be configured to produce minimal heat during use.
Lamps that exhibit strong ultraviolet light emission have a peak
output at a wavelength in the ultraviolet light region, between
about 200 nm to about 400 nm, preferably the peak output is between
about 200 nm to 300 nm, and more preferably at about 254 nm. In one
embodiment, lamps 24 may have a peak output in the ultraviolet
light region and have relatively low heat output. Such lamps are
commonly known as "germicidal" lamps and any such lamp may be used.
A "germicidal" light emitting light with a peak output in the
desired ultraviolet region is commercially available from Voltarc,
Inc. of Fairfield, Conn. as model UV-WX G10T5.
[0102] An advantage of using a spin coating unit is that lamps of a
variety of shapes may be used (e.g., linear lamps) for the curing
of the coating materials. In one embodiment, a coating material is
preferably cured in a substantially uniform manner to ensure that
the coating is formed uniformly on the mold member or lens. With a
spin coating unit, the object to be coated may be spun at speeds
high enough to ensure that a substantially uniform distribution of
light reaches the object during the curing process, regardless of
the shape of the light source. The use of a spin coating unit
preferably allows the use of commercially available linear light
sources for the curing of coating materials.
[0103] A switch may be incorporated into cover 22. The switch is
preferably electrically coupled to light source 23 such that the
switch must be activated prior to turning the light source on.
Preferably, the switch is positioned such that closing the cover
causes the switch to become activated. In this manner, the lights
will preferably remain off until the cover is closed, thus
preventing inadvertent exposure of an operator to the light from
light source 23.
[0104] During use a lens or lens mold assembly may be placed on the
lens holder 108. The lens holder 108 may include a suction cup
connected to a metal bar. The concave surface of the suction cup
may be attachable to a face of a mold or lens, and the convex
surface of the suction cup may be attached to a metal bar. The
metal bar may be coupled to motor 112. The lens holder may also
include movable arms and a spring assembly that may be together
operable to hold a lens against the lens holder with spring tension
during use.
[0105] As shown in FIG. 4, the curing unit 30 may include an upper
light source 214, a lens drawer assembly 216, and a lower light
source 218. Lens drawer assembly 216 preferably includes a mold
assembly holder 220, more preferably at least two mold assembly
holders 220. Each of the mold assembly holders 220 is preferably
configured to hold a pair of mold members that together with a
gasket form a mold assembly. The lens drawer assembly 216 is
preferably slidingly mounted on a guide. During use, mold
assemblies may be placed in the mold assembly holders 220 while the
lens drawer assembly is in the open position (i.e., when the door
extends from the front of the lens curing unit). After the mold
assemblies have been loaded into the mold holder 220 the door may
be slid into a closed position, with the mold assemblies directly
under the upper light source 214 and above the lower light source
218. Vents (not shown) may be placed in communication with the lens
curing unit to allow a stream of air to be directed toward the mold
members when the mold members are positioned beneath the upper
lamps. An exhaust fan (not shown) may communicate with the vents to
improve the circulation of air flowing through the lens curing
unit.
[0106] As shown in FIGS. 4 and 5, it is preferred that the upper
light source 214 and lower light source 216 include a plurality of
activating light generating devices or lamps 240. Preferably, the
lamps are oriented proximate each other to form a row of lights, as
depicted in FIG. 4. Preferably, three or four lamps are positioned
to provide substantially uniform radiation over the entire surface
of the mold assembly to be cured. The lamps 240, preferably
generate activating light. Lamps 240 may be supported by and
electrically connected to suitable fixtures 242. Lamps 240 may
generate either ultraviolet light, actinic light, visible light,
and/or infrared light. The choice of lamps is preferably based on
the monomers used in the lens forming composition. In one
embodiment, the activating light may be generated from a
fluorescent lamp. The fluorescent lamp preferably has a strong
emission spectra in the 380 to 490 nm region. A fluorescent lamp
emitting activating light with the described wavelengths is
commercially available from Philips as model TLD-15W/03. In another
embodiment, the lamps may be ultraviolet lights.
[0107] In one embodiment, the activating light sources may be
turned on and off quickly between exposures. Ballasts 250, depicted
in FIG. 6, may be used for this function. The ballasts may be
positioned beneath the coating unit. Power supply 252 may also be
located proximate the ballasts 250, underneath the coating
unit.
[0108] Typically, when a fluorescent lamp is turned off the
filaments in the lamp will become cool. When the lamp is
subsequently turned on, the lamp intensity may fluctuate as the
filaments are warmed. These fluctuations may effect the curing of a
lens forming compositions. To minimize the intensity fluctuations
of the lamps, a ballasts 250 may allow the startup of a fluorescent
lamp and minimizes the time required to stabilize the intensity of
the light produced by the fluorescent lamp.
[0109] A number of ballast systems may be used. Ballasts for
fluorescent lamps typically serve two purposes. One function is to
provide an initial high voltage arc that will ionize the gases in
the fluorescent lamp (known herein as the "strike voltage"). After
the gases are ionized, a much lower voltage will be required to
maintain the ionization of the gases. In some embodiments, the
ballast will also limit the current flow through the lamp. In some
ballast systems, the filaments of a lamp may be preheated before
the starting voltage is sent through the electrodes.
[0110] An instant start ballast typically provides a strike voltage
of between 500-600 V. The electrodes of fluorescent lamps that are
used with an instant start ballast are usually designed for
starting without preheating. Instant start ballast allow the
fluorescent lamp to be turned on quickly without a significant
delay. However, the intensity of light produced by the fluorescent
lamp may fluctuate as the temperature of the filaments
increases.
[0111] Rapid start ballasts include a high voltage transformer for
providing the strike voltage and additional windings that supply a
low voltage (between about 2 to 4 V) to the filaments to heat the
filaments before the lamp is started. Because the filaments are
already heated, the strike voltage required to ionize the gases in
the lamp are lower than those used with an instant start ballast. A
rapid start ballast typically produces a strike voltage of 250 to
400 V. A rapid start ballast may be used to minimize fluctuations
in the intensity of the light produced by the lamp. Since the
filaments are preheated before the lamp comes on, the time required
to heat up the filaments to their normal operating temperature is
minimal.
[0112] Rapid start ballasts typically continually run the heating
voltage through the filaments during operation of the lamp and when
the lamps are switched off. Thus, during long periods when the
lamps are not used, the filaments will be maintained in a heated
state. This tends to waste power and increase the operating costs
of the apparatus.
[0113] To allow more control over the heating of the filaments, a
flasher ballast system may be used. A schematic drawing of an
embodiment of a flasher ballast system is depicted in FIG. 7. In a
flasher ballast system a fluorescent lamp 712 is electrically
coupled to a high frequency instant start ballast 714 and one or
more transformers 716. The high frequency instant start ballast 714
may provide the strike voltage and perform the current limiting
functions once the lamp is lighted. High frequency instant start
ballasts are available from many different manufacturers including
Motorola, Inc. and Hatch Transformers, Inc. Tampa, Fla. The
transformers 716 may be electrically coupled to one or both of the
filaments 718 to provide a low voltage (between about 2 to about 4
V) to the filaments. This low voltage may heat the filaments 718 to
a temperature that is close to the operating temperature of the
filaments 718. By heating the filaments before turning the lamp on,
the intensity of light produced by the lamp may be stable because
the filaments of the lamp are kept close to the optimum operating
temperature. Transformers are available from many different
manufacturers. In one embodiment, toroidal transformers may be used
to supply low voltage to the filaments. Toroidal transformers may
be obtained from Plitron Manufacturing Inc. Toronto, Ontario,
Canada or Toroid Corporation of Maryland, Salisbury, Md.
[0114] Because the instant start ballast 714 and the transformers
716 are separate units they may be operated independently of each
other. A controller 711 may be coupled to both the instant start
ballast 714 and the transformers 716 to control the operation of
these devices. The transformers 716 may be left on or off when the
striking voltage is applied to the lamp. In some embodiments,
controller 711 may turn off the transformers 716 just before the
strike voltage is applied to the lamp. The controller 711 may also
monitor the operation of the lamp. The controller 711 may be
programmed to turn the transformers 716 on when the lamps are
switched off, thus maintaining the lamps in a state of readiness.
To conserve power, the filaments 718 may be warmed only prior to
turning on the lamp. Thus, when the controller 711 receives a
signal to turn the lamp on, the controller may turn on the
transformers 716 to warm the filaments 718, and subsequently turn
on the lamp by sending a striking voltage from the instant start
ballast 714. The controller may be configured to turn the
transformer off after a predetermined amount of inactivity of the
lamps. For example, the controller may be configured to receive
signals when the lamps are used in a curing process. If no such
signals are received, the controller may turn off the lamps (by
turning off the instant start ballast), but leave the transformer
on. The lamps may be kept in a state of readiness for a
predetermined amount of time. If no signals are received by the
controller to turn on the lamp, the controller may turn the
transformer off to conserve energy.
[0115] In one embodiment, an upper light filter 254 may be
positioned between upper light source 214 and lens drawer assembly
216, as depicted in FIG. 5. A lower light filter 256 may be
positioned between lower light source 218 and lens drawer assembly
216. The upper light filter 254 and lower light filter 256 are
shown in FIG. 5 as being made of a single filter member, however,
those of ordinary skill in the art will recognize that each of the
filters may include two or more filter members. The components of
upper light filter 254 and lower light filter 256 are preferably
modified depending upon the characteristics of the lens to be
molded. For instance, in an embodiment for making negative lenses,
the upper light filter 254 includes a plate of Pyrex glass that may
be frosted on both sides resting upon a plate of clear Pyrex glass.
The lower light filter 256 includes a plate of Pyrex glass, frosted
on one side, resting upon a plate of clear Pyrex glass with a
device for reducing the intensity of activating light incident upon
the center portion relative to the edge portion of the mold
assembly.
[0116] Conversely, in a an alternate arrangement for producing
positive lenses, the upper light filter 254 includes a plate of
Pyrex glass frosted on one or both sides and a plate of clear Pyrex
glass resting upon the plate of frosted Pyrex glass with a device
for reducing the intensity of activating light incident upon the
edge portion in relation to the center portion of the mold
assembly. The lower light filter 256 includes a plate of clear
Pyrex glass frosted on one side resting upon a plate of clear Pyrex
glass with a device for reducing the intensity of activating light
incident upon the edge portion in relation to the center portion of
the mold assembly. In this arrangement, in place of a device for
reducing the relative intensity of activating light incident upon
the edge portion of the lens, the diameter of the aperture 250 may
be reduced to achieve the same result, i.e., to reduce the relative
intensity of activating light incident upon the edge portion of the
mold assembly.
[0117] It should be apparent to those skilled in the art that each
filter 254 or 256 could be composed of a plurality of filter
members or include any other means or device effective to reduce
the light to its desired intensity, to diffuse the light and/or to
create a light intensity gradient across the mold assemblies.
Alternately, in certain embodiments no filter elements may be
used.
[0118] In one embodiment, upper light filter 254 or lower light
filter 256 each include at least one plate of Pyrex glass having at
least one frosted surface. Also, either or both of the filters may
include more than one plate of Pyrex glass each frosted on one or
both surfaces, and/or one or more sheets of tracing paper. After
passing through frosted Pyrex glass, the activating light is
believed to have no sharp intensity discontinuities. By removing
the sharp intensity distributions, a reduction in optical
distortions in the finished lens may be achieved. Those of ordinary
skill in the art will recognize that other means may be used to
diffuse the activating light so that it has no sharp intensity
discontinuities. In another embodiment, a plastic filter may be
used. The plastic filter may be formed from a substantially clear
sheet of plastic. The plastic filter may frosted or non-frosted.
The substantially clear sheet of plastic is formed from a material
that does not significantly absorb wavelengths of light that
initiate the polymerization reaction. In one embodiment, the
plastic filter may be formed from a sheet of polycarbonate. An
example of a polycarbonate that may be used is LEXAN polycarbonate,
commercially available from General Electric Corporation. In
another embodiment, the filter may be formed from a borosilicate
type glass.
[0119] In operation, the apparatus may be appropriately configured
for the production of positive lenses which are relatively thick at
the center or negative lenses which are relatively thick at the
edge. To reduce the likelihood of premature release, the relatively
thick portions of a lens are preferably polymerized at a faster
rate than the relatively thin portions of a lens.
[0120] The rate of polymerization taking place at various portions
of a lens may be controlled by varying the relative intensity of
activating light incident upon particular portions of a lens. For
positive lenses, the intensity of incident activating light is
preferably reduced at the edge portion of the lens so that the
thicker center portion of the lens polymerizes faster than the
thinner edge portion of the lens.
[0121] It is well known by those of ordinary skill in the art that
lens forming materials tend to shrink as they cure. If the
relatively thin portion of a lens is allowed to polymerize before
the relatively thick portion, the relatively thin portion will tend
to be rigid at the time the relatively thick portion cures and
shrinks and the lens will either release prematurely from or crack
the mold members. Accordingly, when the relative intensity of
activating light incident upon the edge portion of a positive lens
is reduced relative to the center portion, the center portion may
polymerize faster and shrink before the edge portion is rigid so
that the shrinkage is more uniform.
[0122] The variation of the relative intensity of activating light
incident upon a lens may be accomplished in a variety of ways.
According to one method, in the case of a positive lens, a metal
plate having an aperture disposed in a position over the center of
the mold assembly may be placed between the lamps and the mold
assembly. The metal plate is positioned such that the incident
activating light falls mainly on the thicker center portion of the
lens. In this manner, the polymerization rate of the center of a
positive lens may be accelerated with respect to the outer edges of
the positive lens, which receive less activating light. The metal
plate may be inserted manually or may be inserted by an automatic
device that is coupled to the controller. In one embodiment, the
prescription entered into the controller determines whether the
metal plate is placed between the lamps and the mold assembly.
[0123] As shown in FIG. 7, the mold assembly 352 may include
opposed mold members 378, separated by an annular gasket 380 to
define a lens molding cavity 382. The opposed mold members 378 and
the annular gasket 380 may be shaped and selected in a manner to
produce a lens having a desired diopter.
[0124] The mold members 378 may be formed of any suitable material
that will permit the passage of activating light. The mold members
378 are preferably formed of glass. Each mold member 378 has an
outer peripheral surface 384 and a pair of opposed surfaces 386 and
388 with the surfaces 386 and 388 being precision ground.
Preferably the mold members 378 have desirable activating light
transmission characteristics and both the casting surface 386 and
non-casting surface 388 preferably have no surface aberrations,
waves, scratches or other defects as these may be reproduced in the
finished lens.
[0125] As noted above, the mold members 378 are preferably adapted
to be held in spaced apart relation to define a lens molding cavity
382 between the facing surfaces 386 thereof. The mold members 378
are preferably held in a spaced apart relation by a T-shaped
flexible annular gasket 380 that seals the lens molding cavity 382
from the exterior of the mold members 378. In use, the gasket 380
may be supported on a portion of the mold assembly holder 220
(shown in FIG. 4).
[0126] In this manner, the upper or back mold member 390 has a
convex inner surface 386 while the lower or front mold member 392
has a concave inner surface 386 so that the resulting lens molding
cavity 382 is preferably shaped to form a lens with a desired
configuration. Thus, by selecting the mold members 378 with a
desired surface 386, lenses with different characteristics, such as
focal lengths, may be produced.
[0127] Rays of activating light emanating from lamps 240 preferably
pass through the mold members 378 and act on a lens forming
material disposed in the mold cavity 382 in a manner discussed
below so as to form a lens. As noted above, the rays of activating
light may pass through a suitable filter 254 or 256 before
impinging upon the mold assembly 352.
[0128] The mold members 378, preferably, are formed from a material
that will not transmit activating light having a wavelength below
approximately 300 nm. Suitable materials are Schott Crown, S-1 or
S-3 glass manufactured and sold by Schott Optical Glass Inc., of
Duryea, Pa. or Corning 8092 glass sold by Corning Glass of Corning,
N.Y. A source of flat-top or single vision molds may be Augen Lens
Co. in San Diego, Calif.
[0129] The annular gasket 380 may be formed of vinyl material that
exhibits good lip finish and maintains sufficient flexibility at
conditions throughout the lens curing process. In an embodiment,
the annular gasket 380 is formed of silicone rubber material such
as GE SE6035 which is commercially available from General Electric.
In another preferred embodiment, the annular gasket 380 is formed
of copolymers of ethylene and vinyl acetate which are commercially
available from E.I. DuPont de Nemours & Co. under the trade
name ELVAX7. Preferred ELVAX7 resins are ELVAX7 350 having a melt
index of 17.3-20.9 dg/min and a vinyl acetate content of 24.3-25.7
wt. %, ELVAX7 250 having a melt index of 22.0-28.0 dg/min and a
vinyl acetate content of 27.2-28.8 wt. %, ELVAX7 240 having a melt
index of 38.0-48.0 dg/min and a vinyl acetate content of 27.2-28.8
wt. %, and ELVAX7 150 having a melt index of 38.0-48.0 dg/min and a
vinyl acetate content of 32.0-34.0 wt. %. In another embodiment,
the gasket may be made from polyethylene. Regardless of the
particular material, the gaskets 380 may be prepared by
conventional injection molding or compression molding techniques
which are well-known by those of ordinary skill in the art.
[0130] FIGS. 9 and 10 present an isometric view and a top view,
respectively, of a gasket 510. Gasket 510 may be annular, and is
preferably configured to engage a mold set for forming a mold
assembly. Gasket 510 is preferably characterized by at least four
discrete projections 511. Gasket 510 preferably has an exterior
surface 514 and an interior surface 512. The projections 511 are
preferably arranged upon inner surface 512 such that they are
substantially coplanar. The projections are preferably evenly
spaced around the interior surface of the gasket. Preferably, the
spacing along the interior surface of the gasket between each
projection is about 90 degrees. Although four projections are
preferred, it is envisioned that more than four could be
incorporated. For example, a fifth projection may be incorporated
into the gasket which may be configured to contact one of the mold
members. The gasket 510 may be formed of a silicone rubber material
such as GE SE6035 which is commercially available from General
Electric. In another embodiment, the gasket 510 may be formed of
copolymers of ethylene and vinyl acetate which are commercially
available from E.I. DuPont de Nemours & Co. under the trade
name ELVAX7. In another embodiment, the gasket 510 may be formed
from polyethylene. In another embodiment, the gasket may be formed
from a thermoplastic elastomer rubber. An example of a
thermoplastic elastomer rubber that may be used is, DYNAFLEX G-2780
commercially available from GLS Corporation.
[0131] As shown in FIG. 11, projections 511 are preferably capable
of spacing mold members 526 of a mold set. Mold members 526 may be
any of the various types and sizes of mold members that are well
known in the art. A mold cavity 528 at least partially defined by
mold members 526 and gasket 510, is preferably capable of retaining
a lens forming composition. Preferably, the seal between gasket 510
and mold members 526 is as complete as possible. The height of each
projection 511 preferably controls the spacing between mold members
526, and thus the thickness of the finished lens. By selecting
proper gaskets and mold sets, lens cavities may be created to
produce lenses of various powers.
[0132] A mold assembly consists of two mold members. A front mold
member 526a and a back mold member 526b, as depicted in FIG. 11.
The back mold member is also known as the convex mold member. The
back mold member preferably defines the concave surface of a convex
lens. Referring back to FIGS. 9 and 10, locations where the steep
axis 522 and the flat axis 524 of the back mold member 526b
preferably lie in relation to gasket 510 have been indicated. In
conventional gaskets, a raised lip may be used to space mold
members. The thickness of this lip varies over the circumference of
the lip in a manner appropriate with the type of mold set a
particular gasket is designed to be used with. In order to have the
flexibility to use a certain number of molds, an equivalent amount
of conventional gaskets is typically kept in stock.
[0133] However, within a class of mold sets there may be points
along the outer curvature of a the back mold member where each
member of a class of back mold members is shaped similarly. These
points may be found at locations along gasket 510, oblique to the
steep and flat axes of the mold members. In a preferred embodiment,
these points are at about 45 degree angles to the steep and flat
axes of the mold members. By using discrete projections 511 to
space the mold members at these points, an individual gasket could
be used with a variety of mold sets. Therefore, the number of
gaskets that would have to be kept in stock may be greatly
reduced.
[0134] In addition, gasket 510 may include a recession 518 for
receiving a lens forming composition. Lip 520 may be pulled back in
order to allow a lens forming composition to be introduced into the
cavity. Vent ports 516 may be incorporated to facilitate the escape
of air from the mold cavity as a lens forming composition is
introduced.
[0135] Gasket 510 may also include a projection 540. Projection 540
may extend from the side of the gasket toward the interior of the
mold cavity when a first and second mold are assembled with the
gasket. The projection is positioned such that a groove is formed
in a plastic lens formed using the mold assembly. The groove may be
positioned near an outer surface of the formed lens. In this manner
the groove is formed near the interface between the mold members
and the formed lens. FIG. 14 depicts a side view of an lens 550
disposed between two mold members 526 after curing and the removal
of the gasket. A variety of indentations/grooves may be seen along
the outer surface of the lens caused by the various projections
from the gasket. Grooves 544 may be caused by the projections 511
of a gasket used to space the mold members at the appropriate
distance. Groove 546 may be caused by the projection 540. The
groove is positioned at the interface of the mold members and the
formed lens. While depicted as near the interface of the upper mold
member, it should be understood that the groove may also be
positioned at the interface between the lower mold member and the
formed lens. In one embodiment, the fill port 538 (see FIGS. 12 and
13) may produce a groove near the interface of the upper mold
member and the formed lens. The projection 511 may therefore be
positioned at the interface between the lower mold member and the
formed lens. In this manner, two grooves may be created at the
interfaces between the formed lens and each of the mold
members.
[0136] After the gasket is been removed, the molds may adhere to
the formed lens. In some instances a sharp object may be inserted
between the mold members and the formed lens to separate the formed
lens from the mold members. The groove 546 may facilitate the
separation of the mold members from the formed lens by allowing the
insertion of a sharp object to pry the molds away from the formed
lens.
[0137] FIGS. 12 and 13 present an isometric view and a top view,
respectively, of an improved gasket. Gasket 530 may be composed of
similar materials as gasket 510. Like gasket 510, gasket 530 is
preferably annular, but may be take a variety of shapes. In
addition, gasket 530 may incorporate projections 531 in a manner
similar to the projections 511 shown in FIG. 9. Alternatively,
gasket 530 may include a raised lip along interior surface 532 or
another method of spacing mold members that is conventional in the
art.
[0138] Gasket 530 preferably includes a fill port 538 for receiving
a lens forming composition while gasket 530 is fully engaged to a
mold set. Fill port 538 preferably extends from interior surface
532 of gasket 530 to an exterior surface 534 of gasket 530.
Consequently, gasket 530 need not be partially disengaged from a
mold member of a mold set in order to receive a lens forming
composition. In order to introduce a lens forming composition into
the mold cavity defined by a conventional mold/gasket assembly the
gasket must be at least partially disengaged from the mold members.
During the process of filling the mold cavity, lens forming
composition may drip onto the backside of a mold member. Lens
forming composition on the backside of a mold member may cause
activating light used to cure the lens to become locally focused,
and may cause optical distortions in the final product. Because
fill port 538 allows lens forming composition to be introduced into
a mold cavity while gasket 530 is fully engaged to a mold set,
gasket 530 preferably avoids this problem. In addition, fill port
538 may be of sufficient size to allow air to escape during the
introduction of a lens forming composition into a mold cavity;
however, gasket 530 may also incorporate vent ports 536 to
facilitate the escape of air.
[0139] A method for making a plastic eyeglass lenses using either
gasket 510 or 530 is presented. The method preferably includes
engaging gasket 510 with a first mold set for forming a first lens
of a first power. The first mold set preferably contains at least a
front mold member 526a and a back mold member 526b. A mold cavity
for retaining a lens forming composition may be at least partially
defined by mold members 526a and 526b, and gasket 510. Gasket 510
is preferably characterized by at least four discrete projections
511 arranged on interior surface 512 for spacing the mold members.
Engaging gasket 510 with the mold set preferably includes
positioning the mold members such that each of the projections 511
forms an oblique angle with the steep and flat axis of the back
mold member 526b. In a preferred embodiment, this angle is about 45
degrees. The method preferably further includes introducing a lens
forming composition into mold cavity 528 and curing the lens
forming composition. Curing may include exposing the composition to
activating light and/or thermal radiation. After the lens is cured,
the first mold set may be removed from the gasket and the gasket
may then be engaged with a second mold set for forming a second
lens of a second power. When using the gasket 530, the method
further includes introducing a lens forming composition through
fill port 538, wherein the first and second mold members remain
fully engaged with the gasket during the introduction of the lens
forming composition. The lens forming composition may then be cured
by use of activating light and/or thermal radiation.
[0140] After curing of the lens in lens curing unit 30, the lens
may be de-molded and post-cured in the post-cure unit 40. Post-cure
unit 40 is preferably configured to apply light, heat, or a
combination of light and heat to the lens. As shown in FIG. 15,
post-cure unit 40 may include a light source 414, a lens drawer
assembly 416, and a heat source 418. Lens drawer assembly 416
preferably includes a lens holder 420, more preferably at least two
lens holders 420. Lens drawer assembly 416 is preferably slidingly
mounted on a guide. Preferably, lens drawer assembly 416 is made
from a ceramic material. Cured lenses may be placed in lens holders
420 while the lens drawer assembly 416 is in the open position
(i.e., when the door extends from the front of post-cure unit 40).
After the lenses have been loaded into lens holders 420, the door
may be slid into a closed position, with the lenses directly under
light source 414 and above heat source 418.
[0141] As shown in FIG. 15, it is preferred that the light source
414 includes a plurality of light generating devices or lamps 440.
Preferably, lamps 440 may be oriented above each of the lens
holders when the lens drawer assembly is closed. The lamps 440,
preferably, generate activating light. The lamps 440 may be
supported by and electrically connected to suitable fixtures 442.
The fixtures may be at least partially reflective and concave in
shape to direct light from the lamps 440 toward the lens holders.
The lamps may generate either ultraviolet light, actinic light,
visible light, and/or infrared light. The choice of lamps is
preferably based on the monomers used in the lens forming
composition. In one embodiment, the activating light may be
generated from a fluorescent lamp. The fluorescent lamp preferably
has a strong emission spectra from about 200 nm to about 800 nm,
more preferably between about 200 nm to about 400 nm. A fluorescent
lamp emitting activating light with the described wavelengths is
commercially available from Voltarc as model SNEUV RPR 4190. In
another embodiment, the lamp may generate ultraviolet light.
[0142] In one embodiment, the activating light source may be turned
on and off quickly between exposures. A ballast may be used for
this function. The ballast may be positioned beneath the post-cure
unit. Alternatively, a ballast and transformer system, as depicted
in FIG. 7 and described above may be used to control the activating
light source.
[0143] Heat source 418 may be configured to heat the interior of
the post-cure unit. Preferably, heat source 418 is a resistive
heater. Heat source 418 may be made up of one or two resistive
heaters. The temperature of heat source 418 may be thermostatically
controlled. By heating the interior of the post-cure unit, the
lenses which are placed in post-cure unit 40 may be heated to
complete curing of the lens forming material. Post-cure unit 40 may
also include a fan to circulate air within the unit. The
circulation of air within the unit may help maintain a relatively
uniform temperature within the unit. The fan may also be used to
cool the temperature of post-cure unit 40 after completion of the
post cure process.
[0144] In an embodiment, a lens cured by exposure to activating
light may be further processed by conductive heating. The use of a
conductive heating post-cure procedure is described in detail in
U.S. Pat. No. 5,928,575 to Buazza, which is incorporated by
reference.
[0145] In another embodiment, the edges of a lens may be treated to
cure or remove incompletely cured lens forming material (see above
description) before a post-cure heat is applied. Techniques for
further curing of incompletely cured lens forming material are
described in U.S. Pat. No. 5,976,423 to Buazza, which is
incorporated herein by reference.
[0146] In another embodiment, a lens may be tinted after receiving
conductive heat postcure treatment in a mold cavity. During tinting
of the lens, the lens is preferably immersed in a dye solution.
[0147] The operation of the lens curing system may be controlled by
a microprocessor based controller 50 (FIG. 1). Controller 50
preferably controls the operation of coating unit 20, lens curing
unit 30, and post-cure unit 40. Controller 50 may be configured to
substantially simultaneously control each of these units. In
addition, the controller may include a display 52 and an input
device 54. The display and input device may be configured to
exchange information with an operator.
[0148] Controller 50 preferably controls a number of operations
related to the process of forming a plastic lens. Many of the
operations used to make a plastic lens (e.g., coating, curing and
post-cure operations) are preferably performed under a
predetermined set of conditions based on the prescription and type
of lens being formed (e.g., ultraviolet/visible light absorbing,
photochromic, colored, etc.). Controller 50 is preferably
programmed to control a number of these operations, thus relieving
the operator from having to continually monitor the apparatus.
[0149] In some embodiments, the lens or mold members may be coated
with a variety of coatings (e.g., a scratch resistant or tinted
coating). The application of these coatings may require specific
conditions depending on the type of coating to be applied.
Controller 50 is preferably configured to produce these conditions
in response to input from the operator.
[0150] When a spin coating unit is used, controller 50 may be
configured to control the rotation of the lens or mold member
during the coating process. Controller 50 is preferably
electronically coupled to the motor of the spin coating unit. The
controller may send electronic signals to the motor to turn the
motor on and/or off. In a typical coating process, the rate at
which the mold or lens is rotated is preferably controlled to
achieve a uniform and defect free coating. The controller is
preferably configured to control the rate of rotation of the mold
or lens during a curing process. For example, when a coating
material is being applied, the mold or lens is preferably spun at
relatively high rotational rates (e.g., about 900 to about 950
RPM). When the coating material is being cured, however, a much
slower rotational rate is preferably used (e.g., about 200 RPM).
The controller is preferably configured to adjust the rotational
rate of the lens or mold depending on the process step being
performed.
[0151] The controller is also preferably configured to control the
operation of lamps 24. The lamps are preferably turned on and off
at the appropriate times during a coating procedure. For example,
during the application of the coating material activating lights
are typically not used, thus the controller may be configured to
keep the lamps off during this process. During the curing process,
activating light may be used to initiate the curing of the coating
material. The controller is preferably configured to turn the lamps
on and to control the amount of time the lamps remain on during a
curing of the coating material. The controller may also be
configured to create light pulses to affect curing of the coating
material. Both the length and frequency of the light pulses may be
controlled by the controller.
[0152] The controller is also preferably configured to control
operation of the lens-curing unit. The controller may perform some
and/or all of a number of functions during the lens curing process,
including, but not limited to: (i) measuring the ambient room
temperature; (ii) determining the dose of light (or initial dose of
light in pulsed curing applications) required to cure the lens
forming composition, based on the ambient room temperature; (iii)
applying the activating light with an intensity and duration
sufficient to equal the determined dose; (iv) measuring the
composition's temperature response during and subsequent to the
application of the dose of light; (v) calculating the dose required
for the next application of activating light (in pulsed curing
applications); (vi) applying the activating light with an intensity
and duration sufficient to equal the determined second dose; (vii)
determining when the curing process is complete by monitoring the
temperature response of the lens forming composition during the
application of activating light; (viii) turning the upper and lower
light sources on and off independently; (ix) monitoring the lamp
temperature, and controlling the temperature of the lamps by
activating cooling fans proximate the lamps; and (x) turning the
fans on/off or controlling the flow rate of an air stream produced
by a fan to control the composition temperature. Herein, "dose"
refers to the amount of light energy applied to an object, the
energy of the incident light being determined by the intensity and
duration of the light. A controller that is configured to alter the
dose activating light applied to a lens forming composition in
response to the temperature of lens forming composition is
described in U.S. Pat. No. 5,989,462 to Buazza et al., which is
incorporated herein by reference.
[0153] In an embodiment, a shutter system may be used to control
the application of activating light rays to the lens forming
material. The shutter system preferably includes air-actuated
shutter plates that may be inserted into the curing chamber to
prevent activating light from reaching the lens forming material.
The shutter system may be coupled to the controller, which may
actuate an air cylinder to cause the shutter plates to be inserted
or extracted from the curing chamber. The controller preferably
allows the insertion and extraction of the shutter plates at
specified time intervals. The controller may receive signals from
temperature sensors allowing the time intervals in which the
shutters are inserted and/or extracted to be adjusted as a function
of a temperature of the lens forming composition and/or the molds.
The temperature sensor may be located at numerous positions
proximate the mold cavity and/or casting chamber.
[0154] In some embodiments, the lens may require a post-curing
process. The post-cure process may require specific conditions
depending on the type of lens being formed. The controller is
preferably configured to produce these conditions in response to
input from the operator.
[0155] The controller is preferably configured to control the
operation of lamps in the post-cure unit. The lamps are preferably
turned on and off at the appropriate times during the post-cure
procedure. For example, in some post-cure operations the lights may
not be required, thus the controller would keep the lights off
during this process. During other processes, the lights may be used
to complete the curing of the lens. The controller is preferably
configured to turn the lights on and to control the amount of time
the lights remain on during a post-cure procedure. The controller
may also be configured to create light pulses during the post-cure
procedure. Both the length and frequency of the light pulses may be
controlled by the controller.
[0156] The controller is preferably configured to control operation
of the heating device 418 during the post-cure operation. Heating
device 418 is preferably turned on and off to maintain a
predetermined temperature within the post-cure unit. Alternatively,
when a resistive heater is used, the current flow through the
heating element may be altered to control the temperature within
the post-cure unit. Preferably, both the application of light and
heat are controlled by the controller. The operation of fans,
coupled to the post-cure unit, is also preferably controlled by the
controller. The fans may be operated by the controller to circulate
air within or into/out of the post-cure unit.
[0157] Additionally, the controller may provide system diagnostics
to determine if the system is operating properly. The controller
may notify the user when routine maintenance is due or when a
system error is detected. The system monitors the following
conditions to warn the user when the machine has malfunctioned,
requires standard maintenance, or is drifting out of its suggested
operating envelope: I.sup.2C network errors; line voltage; top rack
light intensity; bottom rack light intensity; post-cure rack light
intensity; top activating light ballast current; bottom activating
light ballast current; post-cure activating light ballast current;
germicidal light ballast current; post-cure heater current; top
activating light filament heat transformer current; bottom
activating light filament heat transformer current; germicidal
light filament heat transformer current; the number of times the
top activating light is turned on; the number of times the bottom
activating light is turned on; the number of times the post-cure
activating light is turned on; the number of times the germicidal
light is turned on; top activating light on time; bottom activating
light on time; post cure activating light on time; germicidal light
on time; top lamp temperature; bottom lamp temperature; spin board
temperature; post-cure temperature.
[0158] For example, the controller may monitor the current passing
through lamps of the coating, lens curing, or post-cure unit to
determine if the lamps are operating properly. The controller may
keep track of the number of hours that the lamps have been used.
When a lamp has been used for a predetermined number of hours, a
message may be transmitted to an operator to inform the operator
that the lamps may require changing. The controller may also
monitor the intensity of light produced by the lamp. A photodiode
may be placed proximate the lamps to determine the intensity of
light being produced by the lamp. If the intensity of light falls
outside a predetermined range, the current applied to the lamp may
be adjusted to alter the intensity of light produced (either
increased to increase the intensity; or decreased to decrease the
intensity). Alternatively, the controller may transmit a message
informing the operator that a lamp needs to be changed when the
intensity of light produced by the lamp drops below a predetermined
value.
[0159] When the machine encounters an error in these areas, the
following error messages may be displayed: [0160] post cure
temperature The temperature of your post cure is out of its
suggested operating range. If the lens drawer is closed, the unit
has had sufficient warm-up time, and the problem continues after a
system restart, your machine may need service. [0161] light
intensity Your ______ light source output has dropped below its
recommended range. If the problem continues after a system restart,
you may need to replace your ______lamps. [0162] lamp power Your
______ lamps are not functioning properly. If the problem continues
after a system restart, you may need to replace your ______ lamps.
[0163] filament heat power Your ______ lamps are not functioning
properly. If the problem continues after a system restart, you may
need to replace your ______ lamps. [0164] lamp on time Your ______
lamps have exceeded their expected life. Please replace your ______
lamps. [0165] PC heaters The heaters in your post cure unit are not
functioning properly. If the problem continues after a system
restart, your machine may need service
[0166] The controller may also manage an interlock system for
safety and energy conservation purposes. If the lens drawer
assembly from the coating or post-cure units are open the
controller is preferably configured to prevent the lamps from
turning on. This may prevent the operator from inadvertently
becoming exposed to the light from the lamps. Lamps 24 for the
coating unit 20 are preferably positioned on cover 22 (See FIG. 1).
In order to prevent inadvertent exposure of the operator to light
from lamps 24 a switch is preferably built into the cover, as
described above. The controller is preferably configured to prevent
the lamps 24 from turning on when the cover is open. The controller
may also automatically turn lamps 24 off if the cover is opened
when the lenses are on. Additionally, the controller may conserve
energy by keeping fans and other cooling devices off when the lamps
are off. [0167] The controller may display a number of messages
indicating problems that prevent further operation of the lens
forming apparatus. Process tips appear in the appropriate location
on the display (over a button when related to that function, at the
top and flashing when important, etc.). The controller uses the
following list of tips to instruct the user during machine use. The
list is in order of priority (i.e. the tip at the top of the list
is displayed if both it and the second item need to be displayed
simultaneously).
[0168] WARNING JOBS RUNNING,
[0169] CONFIRM PURGE
[0170] WARNING JOBS RUNNING, CONFIRM RERUN
[0171] ROTATE ENCODER TO CONFIRM PURGE
[0172] NOT ALLOWED WHILE JOBS RUNNING
[0173] MOVE CAVITY TO POST-CURE & PRESS THE KEY
[0174] CLOSE LID
[0175] PRESS & HOLD TO RERUN POST-CURE PROCESS
[0176] PRESS & HOLD TO RERUN CURE PROCESS
[0177] PRESS & HOLD TO RERUN ANNEAL PROCESS
[0178] PRESS & HOLD TO CANCEL
[0179] PRESS & HOLD TO RERUN COAT PROCESS
[0180] PRESS THE CURE KEY TO START JOB
[0181] MUST WAIT FOR POST-CURE TO COMPLETE
[0182] MUST WAIT FOR POST-CURE TO START
[0183] MUST SPIN LEFT AND RIGHT BOWLS
[0184] NO JOBS CURRENTLY IN MEMORY
[0185] ROTATE ENCODER TO SELECT JOB
[0186] NO CURED JOBS AVAILABLE TO POST-CURE
[0187] NO JOBS READY TO ANNEAL
[0188] LEFT MOLD DOES NOT EXIST, RE-ENTER RX
[0189] RIGHT MOLD DOES NOT EXIST, RE-ENTER RX
[0190] MOLDS NOT IN KIT, ACCEPT OR RE-ENTER RX
[0191] ROTATE ENCODER TO SELECT SAVE OR DISCARD
[0192] PRESS ENCODER WHEN READY
[0193] PLEASE WAIT WHILE COMPUTING
[0194] ANNEAL COMPLETE
[0195] COAT COMPLETE
[0196] POST-CURE COMPLETE, DEMOLD & ANNEAL
[0197] MOLDS DO NOT EXIST, RE-ENTER RX
[0198] RIGHT MOLD NOT 1N KIT, ACCEPT | RE-ENTER
[0199] LEFT MOLD NOT 1N KIT, ACCEPT | RE-ENTER
[0200] THERE ARE NO STORED Rx's TO EDIT
[0201] THERE ARE NO JOBS TO PURGE/RERUN
[0202] THERE ARE NO STORED JOBS TO VIEW
[0203] THERE ARE NO STORED JOBS TO EDIT
[0204] The controller may also be configured to interact with the
operator. The controller preferably includes an input device 54 and
a display screen 52. The input device may be a keyboard (e.g., a
full computer keyboard or a modified keyboard), a light sensitive
pad, a touch sensitive pad, or similar input device. A number the
parameters controlled by the controller may be dependent on the
input of the operator. In the initial set up of the apparatus, the
controller may allow the operator to input the type of lens being
formed. This information may include type of lens (clear,
ultraviolet absorbing, photochromic, colored, etc.), prescription,
and type of coatings (e.g., scratch resistant or tint).
[0205] Based on this information the controller is preferably
configured to transmit information back to the operator. The
operator may be instructed to select mold members for the mold
assembly. The mold members may be coded such that the controller
may indicate to the operator, which molds to select by transmitting
the code for each mold member. The controller may also determine
the type of gasket required to properly seal the mold members
together. Like the mold members, the gaskets may also be coded to
make the selection of the appropriate gasket easier.
[0206] The lens forming compositions may also be coded. For the
production of certain kinds of lenses, a specific lens forming
composition may be required. The controller may be configured to
determine the specific composition required and transmit the code
for that composition to the operator. The controller may also
signal to the operator when certain operations need to be performed
or when a particular operation is completed (e.g., when to place
the mold assembly in the lens curing unit, when to remove the mold
assembly, when to transfer the mold assembly, etc.).
[0207] The controller may also display Help functions to instruct
the user on machine use and give general process guidance. The
following paragraphs are examples of some of the help files that
may be available to an operator:
[0208] 1) Navigation and Data Entry [0209] The information entry
knob is used for most data selection and entry. Rotating the knob
moves the cursor in menus and scrolls through choices on data entry
screens. Pressing the knob down enters the selection. [0210]
Prompts at the top of the screen help the user through the process.
The arrow keys allow for correction of previously entered data and
can be used as an alternative to the data entry knob during
navigation. [0211] The menu key returns the user to the previous
menu. [0212] The help key gives general process help and also shows
machine malfunctions when there is a problem with the system. When
an error is present, the user will be given information about any
errors and suggested courses of action to remedy them.
[0213] 2) Screen Descriptions [0214] NEW Rx Prescription
information is entered in this screen. The availability of molds is
displayed on this screen in real time. Molds that are available
have a checkmark next to them. Molds that can be added to your kit
are displayed with a box next to them. Powers that are out of the
range of the machine will produce dashes in the area where the mold
information is normally shown. When all prescription information is
entered, the data entry knob is pressed and the job is saved in
memory. The view screen displays the data for cavity creation. If
the data was entered in plus cylinder format, it will be transposed
and shown in minus cylinder form. If you need to see the data as it
was input, it is available in the EDIT Rx screen in both plus and
minus cylinder forms. [0215] VIEW and EDIT Allow the user to see
and modify jobs that are in memory. Once the view or edit selection
is made on the main menu, the user can scroll through all jobs that
have been saved. When using edit, pressing the data entry knob will
move the cursor into an edit screen where the displayed job's
prescription can be modified. In the view menu, pressing the knob
will put the user at the main menu. [0216] PURGE/RERUN JOB Allows
the user to delete and rerun jobs if necessary. When a single lens
of a pair needs to be rerun, edit job can be used to change the job
type to left or right only after rerun is selected for that job.
Purge all jobs clears all jobs from the memory. If you would like
to start your job numbering back at zero, this feature is used.
[0217] INSTRUMENT STATUS Shows the current status of individual
sections of the machine--spin speeds, current being delivered to a
device, network errors etc. These screens are useful when
diagnosing errors. The system's serial numbers and software version
numbers are also in the status screens. [0218] ADVANCED The
advanced menu contains all user adjustable settings, program upload
options, and mold kit selections. This menu is password protected
to minimize the risk that changes will be made by accident. When
password is displayed, pressing the data entry knob lets the user
enter a password by rotating the data entry knob. Press the knob
when the proper password is dialed in. Incorrect passwords will
return the user to the password screen. The proper password will
take the user to the advanced menu which functions like the main
menu. Within these menus, when the desired field is highlighted,
the data entry knob is pressed and parentheses appear around the
field indicating that it is changeable by rotating the data entry
knob. When the proper value is selected, pressing the knob again
removes the parentheses and sets the field to the value selected.
In the date and time setting screen, changes will not be saved
until the save settings field is highlighted and the data entry
knob is pressed. The kit menu allows the user to select the
available mold package and power range.
[0219] 3) Running a Job [0220] Making lenses is a 3 part process.
Applying a scratch resistant coating is optional and is covered at
the end of this section. [0221] When the user enters a prescription
and saves the job, the view screen displays the data required to
retrieve the molds and gasket necessary for each lens. The system
is designed for minus cylinder format prescriptions. If the Rx
information is entered in plus cylinder format, it will be
transposed and returned in minus cylinder form. The cavity must be
assembled based on the view screen data (the axis will be
90.degree. different from the plus cylinder input). The original
prescription can be viewed at the Edit Rx screen along with its
transposed return information. [0222] Before assembling a cavity,
the molds and gasket must be thoroughly cleaned. Any contaminants
on the molds or gasket may be included in the finished lens
rendering it undispensable. Spin clean the casting side of each
mold with IPA and acetone. Assemble the cavity next, ensuring that
the axis is set properly. Fill the cavity with the appropriate
monomer. A filled cavity should not be exposed to room light for
more than 3 minutes. High ambient light levels caused by windows or
high intensity room lighting can significantly shorten the
allowable room light exposure time. [0223] CURING Press the cure
button to initiate a curing cycle. Rotating the data entry knob
will allow the user to select the job to be run. The necessary
filters for the cycle are displayed with the job number. When the
correct job is displayed, press the cure key. The area over the key
instructs you to put in the pair or the left or right lens only.
Ensure that the left and right lenses are always on the proper side
of the chamber. Put the cavity in the initial curing drawer and
press the cure button. When the initial cure is done, transfer the
cavity, or cavities to the front part of the post cure drawer and
press the post cure key. If the job was split because of power
differences in the left and right lenses, the area over the cure
button will instruct the user to insert the second cavity in the
initial cure drawer and press the cure key again (the first cavity
should be in the post cure when performing the initial curing step
on the second cavity). When prompted, move the cavity to the post
cure section and press the post cure button again. [0224] POST
CURING The front openings in the post cure oven drawer are used to
post cure the cavities. When the post cure cycle is over, press the
post cure key, remove the cavities from the post cure chamber, and
allow them to cool for 1 to 2 minutes. After the cooling period,
remove the gasket and separate one mold from each assembly with the
demolding tool. The tool is inserted in the gap created by the tab
on the gasket and the mold is gently pried off the assembly. Place
the remaining lens and mold in the Q-Soak container to separate the
mold from the lens. Clean the lenses and proceed to the annealing
step. [0225] ANNEALING If more than one job is available for
annealing, the user can choose which job they would like to anneal
by rotating the data entry knob when the area over the anneal
button displays a job number. Press the anneal button when the
proper job is displayed. The cleaned lens is placed over the rear
openings of the post cure chamber drawer. Press the anneal key when
prompted at the end of the annealing cycle. [0226] COATING Scratch
coating is optional and is applied in the spin bowls of the main
chamber. The timed buttons by the spin bowls initiate the coat
curing cycle. When the front molds are cleaned and coated, the hood
is closed and a 90 second curing cycle is started for the coatings.
When the cycle is complete, the light turns off, the motors stop,
and the controller signals the user that the molds are ready. The
cavity is assembled in the normal fashion and the lens monomer is
dispensed into the cavity. [0227] Lens coating is also available
and is applied to the finished lens after the annealing step is
complete.
[0228] 4) Tinting Tips
[0229] After edging, lenses may be tinted by conventional means. As
with many modern lens materials, tinting results may be improved
with slightly modified handling procedures. First, when mounting
the lenses in the dye holders, do not use spring-type holders or
apply excessive pressure to the lenses. Lenses become somewhat
flexible at dye tank temperatures and may bend. Faster and more
uniform dye absorption will be achieved if the lenses are agitated
in a slow back and forth motion while in the dye tank.
[0230] In some embodiments, the controller may be a computer
system. A computer system may include a memory medium on which
computer programs configured to perform the above described
operations of the controller are stored. The term "memory medium"
is intended to include an installation medium, e.g., a CD-ROM, or
floppy disks, a computer system memory such as DRAM, SRAM, EDO RAM,
Rambus RAM, etc., or a non-volatile memory such as a magnetic
media, e.g., a hard drive, or optical storage. The memory medium
may comprise other types of memory as well, or combinations
thereof. In addition, the memory medium may be located in a first
computer in which the programs are executed, or may be located in a
second different computer that connects to the first computer over
a network. In the latter instance, the second computer provides the
program instructions to the first computer for execution. Also, the
computer system may take various forms, including a personal
computer system, mainframe computer system, workstation, network
appliance, Internet appliance, personal digital assistant (PDA),
television system, or other device. In general, the term "computer
system" can be broadly defined to encompass any device having a
processor, which executes instructions from a memory medium.
[0231] The memory medium preferably stores a software program for
controlling the operation of a lens forming apparatus. The software
program may be implemented in any of various ways, including
procedure-based techniques, component-based techniques, and/or
object-oriented techniques, among others. For example, the software
program may be implemented using ActiveX controls, C++ objects,
JavaBeans, Microsoft Foundation Classes (MFC), or other
technologies or methodologies, as desired. A CPU, such as the host
CPU, executing code and data from the memory medium comprises a
means for creating and executing the software program according to
the methods or flowcharts described below.
[0232] Various embodiments further include receiving or storing
instructions and/or data implemented in accordance with the
foregoing description upon a carrier medium. Suitable carrier media
include memory media or storage media such as magnetic or optical
media, e.g., disk or CD-ROM, as well as signals such as electrical,
electromagnetic, or digital signals, conveyed via a communication
medium such as networks and/or a wireless link.
Lens Forming Compositions
[0233] The lens forming material may include any suitable liquid
monomer or monomer mixture and any suitable photosensitive
initiator. As used herein "monomer" is taken to mean any compound
capable of undergoing a polymerization reaction. Monomers may
include non-polymerized material or partially polymerized material.
When partially polymerized material is used as a monomer, the
partially polymerized material preferably contains functional
groups capable of undergoing further reaction to form a new
polymer. The lens forming material preferably includes a
photoinitiator that interacts with activating light. In one
embodiment, the photoinitiator absorbs ultraviolet light having a
wavelength in the range of 300 to 400 nm. In another embodiment,
the photoinitiator absorbs actinic light having a wavelength in the
range of about 380 nm to 490 mm. The liquid lens forming material
is preferably filtered for quality control and placed in the lens
molding cavity 382 by pulling the annular gasket 380 away from one
of the opposed mold members 378 and injecting the liquid lens
forming material into the lens molding cavity 382 (See FIG. 8).
Once the lens molding cavity 382 is filled with such material, the
annular gasket 380 is preferably replaced into its sealing relation
with the opposed mold members 378.
[0234] Those skilled in the art will recognize that once the cured
lens is removed from the lens molding cavity 382 by disassembling
the opposed mold members 378, the lens may be further processed in
a conventional manner, such as by grinding its peripheral edge.
[0235] A polymerizable lens forming composition includes an
aromatic-containing bis(allyl carbonate)-functional monomer and at
least one polyethylenic-functional monomer containing two
ethylenically unsaturated groups selected from acrylyl or
methacrylyl. In a preferred embodiment, the composition further
includes a suitable photoinitiator. In other preferred embodiments,
the composition may include one or more polyethylenic-functional
monomers containing three ethylenically unsaturated groups selected
from acrylyl or methacrylyl, and a dye. The lens forming
composition may also include activating light absorbing compounds
such as ultraviolet light absorbing compounds and photochromic
compounds. Examples of these compositions are described in more
detail in U.S. Pat. No. 5,989,462 to Buazza et al., which is
incorporated by reference.
[0236] In another embodiment, an eyeglass lens may be made from a
lens forming composition comprising a monomer composition and a
photoinitiator composition.
[0237] The monomer composition preferably includes an aromatic
containing polyethylenic polyether functional monomer. In an
embodiment, the polyether employed is an ethylene oxide derived
polyether, propylene oxide derived polyether, or mixtures thereof.
Preferably, the polyether is an ethylene oxide derived polyether.
The aromatic polyether polyethylenic functional monomer preferably
has the general structure (V), depicted below where each R.sub.2 is
a polymerizable unsaturated group, m and n are independently 1 or
2, and the average values of j and k are each independently in the
range of from about 1 to about 20. Common polymerizable unsaturated
groups include vinyl, allyl, allyl carbonate, methacrylyl, acrylyl,
methacrylate, and acrylate.
R.sub.2--[CH.sub.2--(CH.sub.2).sub.m--O].sub.j-A.sub.1-[O--(CH.sub.2).sub-
.n--CH.sub.2].sub.k--R.sub.2
[0238] A.sub.1 is the divalent radical derived from a dihydroxy
aromatic-containing material. A subclass of the divalent radical
A.sub.1, which is of particular usefulness, is represented by
formula (II): ##STR1## in which each R.sub.1 is independently alkyl
containing from 1 to about 4 carbon atoms, phenyl, or halo; the
average value of each (a) is independently in the range of from 0
to 4; each Q is independently oxy, sulfonyl, alkanediyl having from
2 to about 4 carbon atoms, or alkylidene having from 1 to about 4
carbon atoms; and the average value of n is in the range of from 0
to about 3. PREFERABLY, Q is methylethylidene, viz.,
isopropylidene.
[0239] Preferably, the value of n is zero, in which case A.sub.1 is
represented by formula (III): ##STR2## in which each R.sub.1, each
a, and Q are as discussed with respect to Formula II. Preferably,
the two free bonds are both in the ortho or para positions. The
para positions are especially preferred.
[0240] In an embodiment, when para, para-bisphenols are chain
extended with ethylene oxide, the central portion of the aromatic
containing polyethylenic polyether functional monomer may be
represented by the formula: ##STR3## where each R.sub.1, each a,
and Q are as discussed with respect to Formula II, and the average
values of j and k are each independently in the range of from about
1 to about 20.
[0241] In another embodiment, the polyethylenic functional monomer
is an aromatic polyether polyethylenic functional monomer
containing at least one group selected from acrylyl or methacrylyl.
Preferably the aromatic polyether polyethylenic functional monomer
containing at least one group selected from acrylate and
methacrylate has the general structure (VI), depicted below where
R.sub.0 is hydrogen or methyl, where each R.sub.1, each a, and Q
are as discussed with respect to Formula II, where the values of j
and k are each independently in the range of from about 1 to about
20, and where R.sub.2 is a polymerizable unsaturated group (e.g.,
vinyl, allyl, allyl carbonate, methacrylyl, acrylyl, methacrylate,
or acrylate). ##STR4##
[0242] In one embodiment, the aromatic containing polyether
polyethylenic functional monomer is preferably an ethoxylated
bisphenol A di(meth)acrylate. Ethoxylated bisphenol A
di(meth)acrylates have the general structure depicted below where
each R.sub.0 is independently hydrogen or methyl, each R.sub.1,
each a, and Q are as discussed with respect to Formula II, and the
values of j and k are each independently in the range of from about
1 to about 20. ##STR5##
[0243] Preferred ethoxylated bisphenol A dimethacrylates include
ethoxylated 2 bisphenol A diacrylate (where j+k=2, and R.sub.0 is
H), ethoxylated 2 bisphenol A dimethacrylate (where j+k=2, and
R.sub.0 is Me), ethoxylated 3 bisphenol A diacrylate (where j+k=3,
and R.sub.0 is H), ethoxylated 4 bisphenol A diacrylate (where
j+k=4, and R.sub.0 is H), ethoxylated 4 bisphenol A dimethacrylate
(where j+k=4, and R.sub.0 is Me), ethoxylated 6 bisphenol A
dimethacrylate (where j+k=6, and R.sub.0 is Me), ethoxylated 8
bisphenol A dimethacrylate (where j+k=8, and R.sub.0 is Me),
ethoxylated 10 bisphenol A diacrylate (where j+k=10, and R.sub.0 is
H), ethoxylated 10 bisphenol A dimethacrylate (where j+k=10, and
R.sub.0 is Me), ethoxylated 30 bisphenol A diacrylate (where
j+k=30, and R.sub.0 is H), ethoxylated 30 bisphenol A
dimethacrylate (where j+k=30, and R.sub.0 is Me). These compounds
are commercially available from Sartomer Company under the trade
names PRO-631, SR-348, SR-349, SR-601, CD-540, CD-541, CD-542,
SR-602, SR-480, SR-9038, and SR-9036 respectively. Other
ethoxylated bisphenol A dimethacrylates include ethoxylated 3
bisphenol A dimethacrylate (where j+k=3, and R.sub.0 is Me),
ethoxylated 6 bisphenol A diacrylate (where j+k=30, and R.sub.0 is
H), and ethoxylated 8 bisphenol A diacrylate (where j+k=30, and
R.sub.0 is H). In all of the above described compounds, Q is
C(CH.sub.3).sub.2.
[0244] The monomer composition preferably may also include a
polyethylenic functional monomer. Polyethylenic functional monomers
are defined herein as organic molecules, which include two or more
polymerizable unsaturated groups. Common polymerizable unsaturated
groups include vinyl, allyl, allyl carbonate, methacrylyl, acrylyl,
methacrylate, and acrylate. Preferably, the polyethylenic
functional monomers have the general formula (VII) or (VIII)
depicted below, where each R.sub.0 is independently hydrogen, halo,
or a C.sub.1-C.sub.4 alkyl group and where A.sub.1 is as described
above. It should be understood that while general structures (VII)
and (VIII) are depicted as having only two polymerizable
unsaturated groups, polyethylenic functional monomers having three
(e.g., tri(meth)acrylates), four (e.g., tetra(meth)acrylates), five
(e.g., penta(meth)acrylates), six (e.g., hexa(meth)acrylates) or
more groups may be used. ##STR6##
[0245] Preferred polyethylenic functional monomers which may be
combined with an aromatic containing polyethylenic polyether
functional monomer to form the monomer composition include, but are
not limited to, ethoxylated 2 bisphenol A dimethacrylate,
tris(2-hydroxyethyl)isocyanurate triacrylate, ethoxylated 10
bisphenol A dimethacrylate, ethoxylated 4 bisphenol A
dimethacrylate, dipentaerythritol pentaacrylate, 1,6-hexanediol
dimethacrylate, isobornyl acrylate, pentaerythritol triacrylate,
ethoxylated 6 trimethylolpropane triacrylate, and bisphenol A bis
allyl carbonate.
[0246] According to one embodiment, the liquid lens forming
composition includes ethoxylated 4 bisphenol A dimethacrylate.
Ethoxylated 4 bisphenol A dimethacrylate monomer, when cured to
form an eyeglass lens, typically produces lenses that have a higher
index of refraction than comparable lenses produced using DEG-BAC.
Lenses formed from such a mid-index lens forming composition which
includes ethoxylated 4 bisphenol A dimethacrylate may have an index
of refraction of about 1.56 compared to the non-ethoxylated monomer
compositions which tend to have an index of refraction of about
1.51. A lens made from a higher index of refraction polymer may be
thinner than a lens made from a lower index of refraction polymer
because the differences in the radii of curvature between the front
and back surface of the lens do not have to be as great to produce
a lens of a desired focal power. Lenses formed from a lens forming
composition, which includes ethoxylated, 4-bisphenol A
dimethacrylate may also be more rigid than lenses formed from
non-ethoxylated monomer based compositions.
[0247] The monomer composition may include additional monomers,
which, when combined with ethoxylated 4 bisphenol A dimethacrylate,
may modify the properties of the formed eyeglass lens and/or the
lens forming composition. Tris(2-hydroxyethyl)isocyanurate
triacrylate, available from Sartomer under the trade name SR-368,
is a triacrylate monomer that may be included in the composition to
provide improved clarity, high temperature rigidity, and impact
resistance properties to the finished lens. Ethoxylated 10
bisphenol A dimethacrylate, available from Sartomer under the trade
name SR-480, is a diacrylate monomer that may be included in the
composition to provide impact resistance properties to the finished
lens. Ethoxylated 2 bisphenol A dimethacrylate, available from
Sartomer under the trade name SR-348, is a diacrylate monomer that
may be included in the composition to provide tintability
properties to the finished lens. Dipentaerythritol pentaacrylate,
available from Sartomer under the trade name SR-399, is a
pentaacrylate monomer that may be included in the composition to
provide abrasion resistance properties to the finished lens.
1,6-hexanediol dimethacrylate, available from Sartomer under the
trade name SR-239, is a diacrylate monomer that may be included in
the composition to reduce the viscosity of the lens forming
composition. Isobornyl acrylate, available from Sartomer under the
trade name SR-506, is an acrylate monomer that may be included in
the composition to reduce the viscosity of the lens forming
composition and enhance tinting characteristics. Bisphenol A bis
allyl carbonate may be included in the composition to control the
rate of reaction during cure and also improve the shelf life of the
lens forming composition. Pentaerythritol triacrylate, available
from Sartomer under the trade name SR-444, is a triacrylate monomer
that may be included in the composition to promote better adhesion
of the lens forming composition to the molds during curing.
Ethoxylated 6 trimethylolpropane triacrylate, available from
Sartomer under the trade name SR-454, may also be added.
[0248] Photoinitiators, which may be used in the lens forming
composition, have been described in previous sections. In one
embodiment, the photoinitiator composition preferably includes
phenyl bis(2,4,6-trimethylbenzoyl) phosphine oxide (IRG-819), which
is commercially available from Ciba Additives under the trade name
of Irgacure 819. The amount of Irgacure 819 present in a lens
forming composition preferably ranges from about 30 ppm by weight
to about 2000 ppm by weight. In another embodiment, the
photoinitiator composition may include a mixture of photoinitiator.
Preferably, a mixture of Irgacure 819 and 1-hydroxycyclohexylphenyl
ketone, commercially available from Ciba Additives under the trade
name of Irgacure 184 (IRG-184), is used. Preferably, the total
amount of photoinitiators in the lens forming composition ranges
from about 50 ppm to about 1000 ppm.
[0249] In another embodiment, an eyeglass lens may be made from
lens forming composition comprising a monomer composition, a
photoinitiator composition, and a co-initiator composition. The
lens forming composition, in liquid form, is preferably placed in a
mold cavity defined by a first mold member and a second mold
member. It is believed that activating light, which is directed
toward the mold members to activate the photoinitiator composition,
causes the photoinitiator to form a polymer chain radical. The
co-initiator may react with a fragment or an active species of
either the photoinitiator or the polymer chain radical to produce a
monomer initiating species. The polymer chain radical and the
monomer initiating species may react with the monomer to cause
polymerization of the lens forming composition.
[0250] The monomer composition preferably includes an aromatic
containing polyethylenic polyether functional monomer having a
structure as shown above. Preferably, the polyethylenic functional
monomer is an aromatic polyether polyethylenic functional monomer
containing at least one group selected from acrylyl or
methacrylyl.
[0251] More preferably, the polyethylenic functional monomer is an
ethoxylated bisphenol A di(meth)acrylate. The monomer composition
may include a mixture of polyethylenic functional monomers, as
described above. The photoinitiators, which may be present in the
lens forming composition, have been described above.
[0252] The lens forming composition preferably includes a
co-initiator composition. The co-initiator composition preferably
includes amine co-initiators. Amines are defined herein as
compounds of nitrogen formally derived from ammonia (NH.sub.3) by
replacement of the hydrogens of ammonia with organic substituents.
Co-initiators include acrylyl amine co-initiators commercially
available from Sartomer Company under the trade names of CN-381,
CN-383, CN-384, and CN-386, where these co-initiators are
monoacrylyl amines, diacrylyl amines, or mixtures thereof. Other
co-initiators include ethanolamines. Examples of ethanolamines
include but are not limited to N-methyldiethanolamine (NMDEA) and
triethanolamine (TEA) both commercially available from Aldrich
Chemicals. Aromatic amines (e.g., aniline derivatives) may also be
used as co-initiators. Example of aromatic amines include, but are
not limited to, ethyl-4-dimethylaminobenzoate (E4-DMAB),
ethyl-2-dimethylaminobenzoate (E-2-DMAB),
n-butoxyethyl-4-dimethylaminobenzoate, p-dimethylaminobenzaldehyde,
N,N-dimethyl-p-toluidine, and octyl-p-(dimethylamino)benzoate
commercially available from Aldrich Chemicals or The First Chemical
Group of Pascagoula, Miss.
[0253] Preferably, acylated amines are included in the co-initiator
composition. Acrylyl amines may have the general structures
depicted in FIG. 16, where R.sub.0 is hydrogen or methyl, n and m
are 1 to 20, preferably 14, and R.sub.1 and R.sub.2 are
independently alkyl containing from 1 to about 4 carbon atoms or
phenyl. Monoacrylyl amines may include at least one acrylyl or
methacrylyl group (see compounds (A) and (B) in FIG. 16). Diacrylyl
amines may include two acrylyl, two methacrylyl, or a mixture of
acrylyl or methacrylyl groups (see compounds (C) and (D) in FIG.
16). Acrylyl amines are commercially available from Sartomer
Company under the trade names of CN-381, CN-383, CN-384, and
CN-386, where these co-initiators are monoacrylyl amines, diacrylyl
amines, or mixtures thereof. Other acrylyl amines include
dimethylaminoethyl methacrylate and dimethylaminoethyl acrylate
both commercially available from Aldrich. In one embodiment, the
co-initiator composition preferably includes a mixture of CN-384
and CN-386. Preferably, the total amount of co-initiators in the
lens forming composition ranges from about 50 ppm to about 7% by
weight.
[0254] An advantage to lens forming compositions, which include a
co-initiator, is that less photoinitiator may be used to initiate
curing of the lens forming composition. Typically, plastic lenses
are formed from a lens forming composition, which includes a
photoinitiator and a monomer. To improve the hardness of the formed
lenses the concentration of photoinitiator may be increased.
Increasing the concentration of photoinitiator, however, may cause
increased yellowing of the formed lens, as has been described
previously. To offset this increase in yellowing, a permanent dye
may be added to the lens forming composition. As the amount of
yellowing is increased, the amount of dye added may also be
increased. Increasing the concentration of the dye may cause the
light transmissibility of the lens to decrease.
[0255] A lens forming composition that includes a co-initiator may
be used to reduce the amount of photoinitiator used. To improve the
hardness of the formed lenses a mixture of photoinitiator and
co-initiator may be used to initiate curing of the monomer. The
above-described co-initiators typically do not significantly
contribute to the yellowing of the formed lens. By adding
co-initiators to the lens forming composition, the amount of
photoinitiator may be reduced. Reducing the amount of
photoinitiator may decrease the amount of yellowing in the formed
lens. This allows the amount of dyes added to the lens forming
composition to be reduced and light transmissibility of the formed
lens may be improved without sacrificing the rigidity of the
lens.
[0256] The lens forming composition may also include activating
light absorbing compounds. These compounds may absorb at least a
portion of the activating light, which is directed toward the lens
forming composition during curing. One example of activating light
absorbing compounds are photochromic compounds. Photochromic
compounds, which may be added to the lens forming composition, have
been previously described. Preferably, the total amount of
photochromic compounds in the lens forming composition ranges from
about 1 ppm to about 1000 ppm. Examples of photochromic compounds
which may be used in the lens forming composition include, but are
not limited to Corn Yellow, Berry Red, Sea Green, Plum Red,
Variacrol Yellow, Palatinate Purple, CH-94, Variacrol Blue D,
Oxford Blue and CH-266. Preferably, a mixture of these compounds is
used. Variacrol Yellow is a napthopyran material, commercially
available from Great Lakes Chemical in West Lafayette, Ind. Corn
Yellow and Berry Red are napthopyrans and Sea Green, Plum Red and
Palatinate Purple are spironaphthoxazine materials commercially
available from Keystone Aniline Corporation in Chicago, Ill.
Variacrol Blue D and Oxford Blue are spironaphthoxazine materials,
commercially available from Great Lakes Chemical in West Lafayette,
Ind. CH-94 and CH-266 are benzopyran materials, commercially
available from Chroma Chemicals in Dayton, Ohio. The composition of
a Photochromic Dye Mixture, which may be added to the lens forming
composition, is described in Table 1. TABLE-US-00001 TABLE 1
Photochromic Dye Mixture Corn Yellow 22.3% Berry Red 19.7% Sea
Green 14.8% Plum Red 14.0% Variacrol Yellow 9.7% Palatinate Purple
7.6% CH-94 4.0% Variacrol Blue D 3.7% Oxford Blue 2.6% CH-266
1.6%
[0257] The lens forming composition may also include other
activating light absorbing compounds such as UV stabilizers, UV
absorbers, and dyes. UV stabilizers, such as Tinuvin 770 may be
added to reduce the rate of degradation of the formed lens caused
by exposure to ultraviolet light. UV absorbers, such as
2-(2H-benzotriazol-2-yl)-4-(1,1,3,3,-tetmethylbutyl)phenol, may be
added to the composition to provide UV blocking characteristics to
the formed lens. Small amounts of dyes, such as Thermoplast Blue
684 and Thermoplast Red from BASF may be added to the lens forming
composition to counteract yellowing. These classes of compounds
have been described in greater detail in previous sections.
[0258] In an embodiment, a UV absorbing composition may be added to
the lens forming composition. The UV absorbing composition
preferably includes a photoinitiator and a UV absorber.
Photoinitiators and UV absorbers have been described in greater
detail in previous sections. Typically, the concentration of UV
absorber in the lens forming composition required to achieve
desirable UV blocking characteristics is in the range from about
0.1 to about 0.25% by weight. For example,
2-(2H-benzotriazol-2-yl)-4-(1,1,3,3,-tetramethylbutyl)phenol may be
added to the lens forming composition as a UV absorber at a
concentration of about 0.17%.
[0259] By mixing a photoinitiator with a UV absorbing compound the
combined concentration of the photoinitiator and the UV absorber
required to achieve the desired UV blocking characteristics in the
formed lens may be lower than the concentration of UV absorber
required if used alone. For example,
2-(2H-benzotriazol-2-yl)-4-(1,1,3,3,-tetramethylbutyl)phenol may be
added to the lens forming composition as a UV absorber at a
concentration of about 0.17% to achieve the desired UV blocking
characteristics for the formed lens. Alternatively, a UV absorbing
composition may be formed by a combination of
2-(2H-benzotriazol-2-yl)-4-(1,1,3,3,-tetramethylbutyl)phenol with
the photoinitiator 2-isopropyl-thioxanthone (ITX), commercially
available from Aceto Chemical in Flushing, N.Y. To achieve similar
UV blocking characteristics in the formed lens, significantly less
of the UV absorbing composition may be added to the lens forming
composition, compared to the amount of UV absorber used by itself.
For example,
2-(2H-benzotriazol-2-yl)-4-(1,1,3,3,-tetramethylbutyl)phenol at a
concentration of about 700 ppm, with respect to the lens forming
composition, along with 150 ppm of the photoinitiator
2-isopropyl-thioxanthone (2-ITX) may be used to provide UV blocking
characteristics. Thus, a significant reduction, (e.g., from 0.15%
down to less than about 1000 ppm), in the concentration of UV
absorber may be achieved, without a reduction in the UV blocking
ability of the subsequently formed lens. An advantage of lowering
the amount of UV absorbing compounds present in the lens forming
composition is that the solubility of the various components of the
composition may be improved. Tables 2-6 list some examples of
mid-index lens forming compositions. The UV absorber is
2-(2H-benzotriazol-2-yl)-4-(1,1,3,3,-tetramethylbutyl)phenol.
TABLE-US-00002 TABLE 2 Ingredient Formula 1 Formula 2 Formula 3
Formula 4 Formula 5 Formula 6 Irgacure 819 694.2 ppm 486 ppm 480
ppm 382 ppm 375 ppm 414 ppm Irgacure 184 CN 384 0.962% 0.674%
0.757% 0.62% 0.61% 0.66% CN386 0.962% 0.674% 0.757% 0.62% 0.61%
0.66% SR-348 97.98% 68.65% 98.2% 81.2% 79.6% 86.4% SR-368 SR-480
29.95% CD-540 SR-399 SR-239 2.0% 2.08% SR-506 CR-73 17.2% 16.9%
10.0% PRO-629 Tinuvin 770 290 ppm UV Absorber 0.173% Thermoplast
0.534 ppm 0.374 ppm 0.6 ppm 0.5 ppm 4.5 ppm 4.58 ppm Blue
Thermoplast 0.019 ppm 0.0133 ppm 0.015 ppm 0.012 ppm 0.58 ppm 0.58
ppm Red Mineral Oil 136 ppm 65 ppm Photochromic 470 ppm 507 ppm Dye
Mixture
[0260] TABLE-US-00003 TABLE 3 Ingredient Formula 7 Formula 8
Formula 9 Formula 10 Formula 11 Formula 12 Irgacure 819 531.2 ppm
462 ppm 565.9 ppm 226 ppm 443 ppm 294 ppm Irgacure 184 18.7 ppm 144
ppm CN 384 0.77% 0.887% 0.78% 0.40% 0.61% CN386 0.77% 0.887% 0.78%
0.53% 0.61% SR-348 72.4% 70.36% 58.20% 41.5% 88.70% SR-368 24.1%
23.87% 21.4% 7.0% SR-480 CD-540 18.7% 0.74% 97.76% SR-399 46.8%
SR-239 1.86% 3.65% 20.1% 2.00% SR-506 10.0% CR-73 20.1% 2.9%
PRO-629 0.05% Tinuvin 770 UV Absorber Thermoplast 0.567 ppm 3.62
ppm 0.70 ppm 0.255 ppm 0.6 ppm 4.3 ppm Blue Thermoplast Red 0.0147
ppm 0.576 ppm 0.014 ppm 0.006 ppm 0.028 ppm 0.24 ppm Photochromic
450 ppm Dye Mixture
[0261] TABLE-US-00004 TABLE 4 Ingredient Formula 13 Formula 14
Formula 15 Formula 16 Formula 17 Formula 18 Irgacure 819 760 ppm
620 ppm 289 ppm 105 ppm 343 ppm Irgacure 184 CN 384 0.73% 0.34%
0.475% CN 386 0.73% 0.34% 1.00% 0.70% 0.475% 2-ITX 188 ppm 141 ppm
SR-348 89.00% 92.00% 98.90% SR-368 SR-480 CD-540 97.57% 96.20 %
99.28% 0.34% SR-399 SR-239 2.30% 2.30% 0.01% SR-506 SR-444 SR-454
10.00% 6.9% CR-73 PRO-629 Tinuvin 770 UV Absorber 785 ppm
Thermoplast 4.9 ppm 5.1 ppm 0.508 ppm 0.35 ppm 0.69 ppm Blue
Thermoplast 0.276 ppm 0.285 ppm 0.022 ppm 0.002 ppm 0.034 ppm Red
Dioctyl- 125 ppm phthalate Butyl stearate Photochromic 499 ppm Dye
Mixture
[0262] TABLE-US-00005 TABLE 5 Ingredient Formula 19 Formula 20
Formula 21 Formula 22 Formula 23 Formula 24 Irgacure 819 490 ppm
635 ppm 610 ppm 735 ppm 320 ppm 600 ppm Irgacure 184 CN 384 0.680%
0.746% 0.705% 0.60% CN 386 0.680% 0.746% 0.705% 0.60% 2-ITX SR-348
69.30% 68.60% SR-368 74.0% 22.10% SR-480 CD-540 98.45% 92.60%
98.50% 1.0% 1.97% SR-399 SR-239 0.01% 3.86% 0.16% SR-506 0.10%
SR-444 29.30% SR-454 25.0% 7.40% CR-73 PRO-629 0.007% 2.06% Tinuvin
770 UV Absorber Thermoplast 0.37 ppm 0.507 ppm 3.07 ppm 4.3 ppm
0.15 ppm 0.29 ppm Blue Thermoplast 0.013 ppm 0.0126 ppm 0.336 ppm
0.41 ppm 0.006 ppm 0.012 ppm Red Dioctyl- phthalate Butyl stearate
Photochromic 442 ppm 497 ppm Dye Mixture
[0263] TABLE-US-00006 TABLE 6 Ingredient Formula 25 Formula 26
Formula 27 Formula 28 Formula 29 Formula 30 Formula 31 Irgacure 819
650 ppm 464 ppm 557 ppm 448 ppm 460 ppm Irgacure 184 300 ppm CN 384
0.650% 0.70% CN 386 0.650% 0.70% 2-ITX 600 ppm 120 ppm SR-348
39.10% SR-368 13.00% 19.60% 20.70% SR-480 10.70% CD-540 88.96%
41.90% 1.60% 1.30% 99.94% 99.96% SR-399 SR-239 SR-506 98.30% 79.00%
67.24% SR-444 9.70% 4.60% SR-454 CR-73 PRO-629 Tinuvin 770 UV
Absorber Thermoplast Blue 0.566 ppm 0.52 ppm 0.24 ppm 0.19 ppm
0.467 ppm Thermoplast Red 0.02 ppm 0.013 ppm 0.01 ppm 0.008 ppm
0.024 ppm Dioctyl-phthalate Butyl stearate 75 ppm 35 ppm
Photochromic Dye Mixture
[0264] In one embodiment, plastic lenses may be formed by disposing
a mid-index lens forming composition into the mold cavity of a mold
assembly and irradiating the mold assembly with activating light.
Coating materials may be applied to the mold members prior to
filling the mold cavity with the lens forming composition.
[0265] After filing the mold cavity of the mold assembly the mold
assembly is preferably placed in the lens curing unit and subjected
to activating light. Preferably, actinic light is used to irradiate
the mold assembly. A clear polycarbonate plate may be placed
between the mold assembly and the activating light source. The
polycarbonate plate preferably isolates the mold assembly from the
lamp chamber, thus preventing airflow from the lamp cooling fans
from interacting with the mold assemblies. The activating light
source may be configured to deliver from about 0.1 to about 10
milliwatts/cm2 to at least one non-casting face, preferably both
non-casting faces, of the mold assembly. Depending on the
components of the lens forming composition used the intensity of
activating light used may be <1 milliwatt/cm2. The intensity of
incident light at the plane of the lens curing unit drawer is
measured using an International Light IL-1400 radiometer equipped
with an XRL140A detector head. This particular radiometer
preferably has a peak detection wavelength at about 400 nm, with a
detection range from about 310 nm to about 495 nm. The
International Light IL-1400 radiometer and the XRL140A detector
head are both commercially available International Light,
Incorporated of Newburyport, Mass.
[0266] After the mold assembly is placed within the lens curing
unit, the mold assemblies are preferably irradiated with activating
light continuously for 30 seconds to thirty minutes, more
preferably from one minute to five minutes. Preferably, the mold
assemblies irradiated in the absence of a cooling air stream. After
irradiation, the mold assemblies were removed from the lens curing
unit and the formed lens demolded. The lenses may be subjected to a
post-cure treatment in the post-cure unit.
[0267] In general, it was found that the use of a photoinitiator
(e.g., IRG-819 and IRG-184) in the lens forming composition
produces lenses with better characteristics than lens formed using
a co-initiator only. For example, formula 15, described in the
Table 4, includes a monomer composition (a mixture of SR-348 and
SR454) and a co-initiator (CN-386). When this lens forming
composition was exposed to activating light for 15 min. there was
no significant reaction or gel formation. It is believed that the
co-initiator requires an initiating species in order to catalyze
curing of the monomer composition. Typically this initiating
species is produced from the reaction of the photoinitiator with
activating light.
[0268] A variety of photoinitiators and photoinitiators combined
with co-initiators may be used to initiate polymerization of the
monomer composition. One initiator system, which may be used,
includes photoinitiators IRG-819 and 2-ITX and a co-initiator, see
Formulas 17-18. Such a system is highly efficient at initiating
polymerization reactions. The efficiency of a polymerization
catalyst is a measurement of the amount of photoinitiator required
to initiate a polymerization reaction. A relatively small amount of
an efficient photoinitiator may be required to catalyze a
polymerization reaction, whereas a greater amount of a less
efficient photoinitiator may be required to catalyze the
polymerization reaction. The IRG-819/2-ITX/co-initiator system may
be used to cure lenses forming compositions, which include a UV
absorbing compound. This initiator system may also be used to form
colored lenses.
[0269] An initiator system that is less efficient than the
IRG-819/2-ITX/co-initiator system includes a mixture of the
photoinitiators IRG-819 and 2-ITX, see Formula 31. This system is
less efficient at initiating polymerization of lens forming
compositions than the IRG-819/2-ITX/co-initiator system. The
IRG-819/2-ITX system may be used to cure very reactive monomer
compositions. An initiator system having a similar efficiency to
the IRG-819/2-ITX system includes a mixture of IRG-819 and
co-initiator, see Formulas 1-6,8-9, 11, 14-15, 19-22, and 25-26.
The IRG-819/co-initiator system may be used to cure clear lenses,
which do not include a UV blocking compound, and photochromic lens
forming compositions.
[0270] Another initiator system, which may be used, includes the
photoinitiator 2-ITX and a co-initiator. This initiator system is
much less efficient at initiating polymerization reactions than the
IRG-819/co-initiator system. The 2-ITX/co-initiator system is
preferably used for curing monomer compositions, which include
highly reactive monomers.
[0271] The use of the above described mid-index lens forming
compositions may minimize or eliminate a number of problems
associated with activating light curing of lenses. One problem
typical of curing eyeglass lenses with activating light is
pre-release. Pre-release may be caused by a number of factors. If
the adhesion between the mold faces and the shrinking lens forming
composition is not sufficient, pre-release may occur. The
propensity of a lens forming composition to adhere to the mold
face, in combination with its shrinkage, determine how the process
variables are controlled to avoid pre-release. Adhesion is affected
by such factors as geometry of the mold face (e.g., high-add
flat-top bifocals tend to release because of the sharp change in
cavity height at the segment line), the temperature of the mold
assembly, and the characteristics of the in-mold coating material.
The process variables which are typically varied to control
pre-release include the application of cooling fluid to remove
exothermic heat, controlling the rate of heat generation by
manipulating the intensities and timing of the activating
radiation, providing differential light distribution across the
thin or thick sections of the mold cavity manipulating the
thickness of the molds, and providing in-mold coatings which
enhance adhesion. An advantage of the above described mid-index
lens forming compositions is that the composition appears to have
enhanced adhesion characteristics. This may allow acceptable lenses
to be produced over a greater variety of curing conditions. Another
advantage is that higher diopter lenses may be produced at
relatively low pre-release rates, broadening the achievable
prescription range.
[0272] Another advantage of the above described mid-index lens
forming compositions is that they tend to minimize problems
associated with dripping during low intensity curing of lenses
(e.g., in the 1 to 6 milliwatt range). Typically, during the
irradiation of the lens forming composition with activating light,
small amounts of monomer may be squeezed out of the cavity and run
onto the non-casting faces of the molds. Alternatively, during
filling of the mold assembly with the lens forming composition, a
portion of the lens forming composition may drip onto the
non-casting faces of the mold assembly. This "dripping" onto the
non-casting faces of the mold assembly tends to cause the
activating light to focus more strongly in the regions of the
cavity located underneath the drippings. This focusing of the
activating light may affect the rate of curing. If the rate of
curing underneath the drippings varies significantly from the rate
of curing throughout the rest of the lens forming composition,
optical distortions may be created in the regions below the
drippings.
[0273] It is believed that differences in the rate of gelation
between the center and the edge regions of the lens forming
composition may cause dripping to occur. During the curing of a
lens forming composition, the material within the mold cavity tends
to swell slightly during the gel phase of the curing process. If
there is enough residual monomer around the gasket lip, this liquid
will tend to be forced out of the cavity and onto the non-casting
faces of the mold. This problem tends to be minimized when the lens
forming composition undergoes fast, uniform gelation. Typically, a
fast uniform gelation of the lens forming composition may be
achieved by manipulating the timing, intensities, and distribution
of the activating radiation. The above described mid-index lens
forming compositions, however, tend to gel quickly and uniformly
under a variety of curing conditions, thus minimizing the problems
caused by dripping.
[0274] Another advantage of the above described mid-index lens
forming compositions is that the compositions tend to undergo
uniform curing under a variety of curing conditions. This uniform
curing tends to minimize optical aberrations within the formed
lens. This is especially evident during the formation of high plus
power flattop lenses which tend to exhibit optical distortions
after the lens forming composition is cured. It is believed that
the activating radiation may be reflected off of the segment line
and create local differences in the rate of gelation in the regions
of the lens forming composition that the reflected light reaches.
The above described mid-index lens forming compositions tend to
show less optical distortions caused by variations of the intensity
of activating radiation throughout the composition.
[0275] Other advantages include drier edges and increased rigidity
of the formed lens. An advantage of drier edges is that the
contamination of the optical faces of the lens by uncured or
partially cured lens forming composition is minimized.
[0276] In an embodiment, a lens forming composition may be cured
into a variety of different lenses. The lens forming composition
includes an aromatic containing polyether polyethylenic functional
monomer, a co-initiator composition configured to activate curing
of the monomer, and a photoinitiator configured to activate the
co-initiator composition in response to being exposed to activating
light. The lens forming composition may include other components
such as ultraviolet light absorbers and photochromic compounds.
Lenses, which may be cured using the lens forming composition,
include, but are not limited to, spheric single vision, aspheric
single vision lenses, flattop bifocal lenses, and asymmetrical
progressive lenses.
[0277] One lens forming composition includes a mixture of the
following monomers. TABLE-US-00007 98.25%
Ethoxylated.sub.(4)bisphenol A dimethacrylate (CD-540) 0.75%
Difunctional reactive amine coinitiator (CN-384) 0.75%
Monofunctional reactive amine coinitiator (CN-386) 0.15% Phenyl
bis(2,4,6-trimethylbenzoyl) phosphine oxide (Irgacure-819) 0.10%
2-(2H-Benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)phenol 0.87
ppm Thermoplast Blue 684 0.05 ppm Thermoplast Red LB 454
[0278] Another lens forming composition includes a mixture of the
following monomers. The presence of photochromic compounds in this
composition allows the composition to be used to form photochromic
lenses. TABLE-US-00008 97.09% Ethoxylated(4)bisphenol A
dimethacrylate (CD-540) 1.4% Difunctional reactive amine
coinitiator (CN-384) 1.4% Monofunctional reactive amine coinitiator
(CN-386) 0.09% Phenyl bis(2,4,6-trimethylbenzoyl) phosphine oxide
(Irgacure-819) 0.9 ppm Thermoplast Red LB 454 50 ppm Variacrol Blue
D 73.5 ppm Variacrol Yellow 145 ppm Berry Red 29 ppm Palatinate
Purple 55.5 ppm Corn Yellow 62 ppm Sea Green 85 ppm Plum Red
[0279] A lens forming composition which includes an aromatic
containing polyether polyethylenic functional monomer, a
co-initiator composition and a photoinitiator may be used to form a
variety of prescription eyeglass lenses, including eyeglass lenses
which have a sphere power ranging from about +4.0 diopter to about
-6.0 diopter. The lenses formed from this lens forming composition
are substantially free of distortions, cracks, patterns and
striations, and that have negligible yellowing, in less than thirty
minutes by exposing the lens forming composition to activating
light and heat. An advantage of the lens forming composition is
that it exhibits increased adhesion to the molds. This may reduce
the incidence of premature release of the formed lens from the
molds. Additionally, the use of adhesion promoting agents,
typically applied to the molds to prevent premature release, may no
longer be necessary.
[0280] The increased adhesion of the lens forming composition to
the molds allows curing of the lens forming composition at higher
temperatures. Typically, control of the temperature of the lens
forming composition may be necessary to prevent premature release
of the lens from the molds. Premature release may occur when the
lens forming composition shrinks as it is cured. Shrinkage
typically occurs when the lens forming composition is rapidly
heated during curing. Lens forming compositions, which include an
aromatic containing polyether polyethylenic functional monomer, a
co-initiator composition and a photoinitiator, may reduce the
incidence of premature release. The increased adhesion of this lens
forming composition may allow higher curing temperatures to be used
without increasing the incidence of premature release. It is also
believed that this lens forming composition may exhibit less
shrinkage during curing which may further reduce the chance of
premature release.
[0281] An advantage of curing at higher temperatures is that an
eyeglass lens having a high crosslink density may be formed. The
crosslink density of an eyeglass lens is typically related to the
curing temperature. Curing a lens forming composition at a
relatively low temperature leads to a lower crosslink density than
the crosslink density of a lens cured at a higher temperature.
Lenses, which have a higher crosslink density generally, absorb
tinting dyes substantially evenly without blotching or streaking.
Lenses, which have a high crosslink density, also may exhibit
reduced flexibility.
Methods of Forming Plastic Lenses
[0282] Plastic lenses may be formed by disposing a lens forming
composition into the mold cavity of a mold assembly and irradiating
the mold assembly with activating light. Coating materials may be
applied to the mold members prior to filling the mold cavity with
the lens forming composition. The lens may be treated in a
post-cure unit after the lens-curing process is completed.
[0283] The operation of the above described system to provide
plastic lenses involves a number of operations. These operations
are preferably coordinated by the controller 50, which has been
described above. After powering the system, an operator is
preferably signaled by the controller to enter the prescription of
the lens, the type of lens, and the type of coating materials for
the lens. Based on these inputted values the controller will
preferably indicate to the operator which molds and gaskets will be
required to form the particular lens.
[0284] The formation of lenses involves: 1) preparing the mold
assembly; 2) filling the mold assembly with the lens forming
composition; 3) curing the lens; 4) post-curing the lens; and 5)
annealing the lens. Optionally, the lens may be coated before use.
The formation of lenses may be accomplished using the plastic lens
curing apparatus described above.
[0285] The preparation of a mold assembly includes selecting the
appropriate front and back molds for a desired prescription and
lens type, cleaning the molds, and assembling the molds to form the
mold assembly. The prescription of the lens determines which front
mold, back mold, and gasket are used to prepare the mold assembly.
In one embodiment, a chart, which includes all of the possible lens
prescriptions, may be used to allow a user to determine the
appropriate molds and gaskets. Such a chart may include thousands
of entries, making the determination of the appropriate molds and
gaskets somewhat time consuming.
[0286] In an embodiment, the controller 50 of the plastic lens
curing apparatus 10 (see FIG. 1) will display the appropriate front
mold, back mold, and gasket identification markings when a
prescription is submitted to the controller. The controller will
prompt the user to enter the 1) the monomer type; 2) the lens type;
3) spherical power; 4) cylindrical power; 5) axis; 6) add power,
and 7) the lens location (i.e., right or left lens). Once this
information is entered, the computer will determine the correct
front mold, back mold and gasket to be used. The controller may
also allow a user to save and recall prescription data.
[0287] FIG. 17 shows an embodiment of a front panel for the
controller 50. The controller includes an output device 610 and at
least one input device. A variety of input devices may be used.
Some input devices include pressure sensitive devices (e.g.,
buttons), movable data entry devices (e.g., rotatable knobs, a
mouse, a trackball, or moving switches), voice data entry devices
(e.g., a microphone), light pens, or a computer coupled to the
controller. Preferably, the input devices include buttons 630, 640,
650 and 660 and a selection knob 620. The display panel preferably
displays the controller data requests and responses. The output
device may be a cathode ray tube, an LCD panel, or a plasma display
screen.
[0288] When initially powered, the controller will preferably
display a main menu, such as the menu depicted in FIG. 17. If the
main menu is not displayed, a user may access the main menu by
pressing button 650, which may be labeled Main Menu. In response to
activating the Main Menu button 650, the controller will cause the
main menu screen to be displayed. As depicted in FIG. 17, a display
screen offers a number of initial options on the opening menu. The
options may include 1) NEW Rx; 2) EDIT Rx; and 3) VIEW Rx. The main
menu may also offer other options, which allow the operator to
access machine status information and instrument setup menus. The
scrolling buttons 630 preferably allow the user to navigate through
the options by moving a cursor 612, which appears, on the display
screen to the appropriate selection. Selection knob 620 is
preferably configured to be rotatable to allow selection of options
on the display screen. Knob 620 is also configured to allow entry
of these items. In one embodiment, selection knob 620 may be
depressed to allow data entry. That is, when the appropriate
selection is made, the knob may be pushed down to enter the
selected data. In the main menu, when the cursor 612 is moved to
the appropriate selection, the selection may be made by depressing
the selection knob 620.
[0289] Selection of the NEW Rx menu item will cause the display
screen to change to a prescription input menu, depicted in FIG. 18.
The prescription input menu will preferably allow the user to enter
data pertaining to a new lens type. The default starting position
will be the lens monomer selection box. Once the area is
highlighted, the selection knob 620 is rotated to make a choice
among the predetermined selections. When the proper selection is
displayed, the selection knob may be pushed down to enter the
selection. Entry of the selection may also cause the cursor to move
to the next item on the list. Alternatively, a user may select the
next item to be entered using the scrolling arrows 630.
[0290] Each of the menu items allows entry of a portion of the lens
prescription. The lens prescription information includes 1) the
monomer type; 2) the lens type; 3) lens location (i.e., left lens
or right lens); 4) spherical power; 5) cylindrical power; 6) axis;
and 7) add power. The monomer selection may include choices for
either clear or photochromic lenses. The lens type item may allow
selection between spheric single vision, aspheric single vision
lenses, flattop bifocal lenses, and asymmetrical progressive
lenses. The sphere item allows the sphere power of the lens to be
entered. The cylinder item allows the cylinder power to be entered.
The axis item allows the cylinder axis to be entered. The add item
allows the add power for multifocal prescriptions to be added.
Since the sphere power, cylinder power, cylinder axis, and add
power may differ for each eye, and since the molds and gaskets may
be specific for the location of the lens (i.e., right lens or left
lens), the controller preferably allows separate entries for right
and left lenses. If an error is made in any of the entry fields,
the scrolling arrows 630 preferably allow the user to move the
cursor to the incorrect entry for correction.
[0291] After the data relating to the prescription has been added,
the controller may prompt the user to enter a job number to save
the prescription type. This preferably allows the user to recall a
prescription type without having to renter the data. The job number
may also be used by the controller to control the curing conditions
for the lens. The curing conditions typically vary depending on the
type and prescription of the lens. By allowing the controller
access to the prescription and type of lens being formed, the
controller may automatically set up the curing conditions without
further input from the user.
[0292] After the job is saved, the display screen will preferably
display information, which allows the user to select the
appropriate front mold, back mold and gasket for preparing the
lens, as depicted in FIG. 19. This information is preferably
generated by the use of a stored database, which correlates the
inputted data to the appropriate lenses and gasket. The
prescription information is also summarized to allow the user to
check that the prescription has been entered correctly. The mold
and gasket information may be printed out for the user. A printer
may be incorporated into the controller to allow print out of this
data. Alternatively, a communication port may be incorporated into
the controller to allow the data to be transferred to a printer or
personal computer. Each of the molds and gaskets has a
predetermined identification marking. Preferably, the
identification markings are alphanumeric sequences. The
identification markings for the molds and gasket preferably
correspond to alphanumeric sequences for a library of mold members.
The user, having obtained the mold and gasket identification
markings, may then go to the library and select the appropriate
molds and gaskets.
[0293] The controller is preferably configured to run a computer
software program, which, upon input of the eyeglass prescription,
will supply the identification markings of the appropriate front
mold, back mold and gasket.
[0294] The computer program includes a plurality of instructions
configured to allow the controller to collect the prescription
information, determine the appropriate front mold, back mold, and
gasket required to a form a lens having the inputted prescription,
and display the appropriate identification markings for the front
mold, back mold and gasket. In one embodiment, the computer program
may include an information database. The information database may
include a multidimensional array of records. Each record may
include data fields corresponding to identification markings for
the front mold, the back mold, and the gasket. When the
prescription data is entered, the computer program is configured to
look up the record corresponding to the entered prescription. The
information from this record may be transmitted to the user,
allowing the user to select the appropriate molds and gasket.
[0295] In one embodiment the information database may be a three
dimensional array of records. An example of a portion of a three
dimensional array of records is depicted in Table 7. The three
dimensional array includes array variables of sphere, cylinder, and
add. A record of the three dimensional array includes a list of
identification markings. Preferably, this list includes
identification markings for a front mold (for either a left or
right lens), a back mold and a gasket. When a prescription is
entered, the program includes instructions, which take the
cylinder, sphere, and add information and look up the record, which
is associated with that information. The program obtains from the
record the desired information and transmits the information to the
user. For example, if a prescription for left lens having a sphere
power of +1.00, a cylinder power of -0.75 and an add power of 2.75
is entered, the front mold identification marking will be FT-34,
the back mold identification marking will be TB-101, and the gasket
identification marking will be G25. These values will be
transmitted to the user via an output device. The output device may
include a display screen or a printer. It should be understood that
the examples shown in Table 7 represent a small portion of the
entire database. The sphere power may range from +4.00 to 4.00 in
0.25 diopter increments, the cylinder power may range from 0.00
diopters to -2.00 diopters in 0.25 diopter increments, and the add
power may range from +1.00 to +3.00 in 0.25 diopter increments.
TABLE-US-00009 TABLE 7 IDENTIFICATION MARKINGS ARRAY VARIABLES
Front Front Sphere Cylinder Add (Right) (Left) Back Gasket +1.00
-0.75 +1.25 FT-21 FT-22 TB-101 G25 +1.00 -0.75 +1.50 FT-23 FT-24
TB-101 G25 +1.00 -0.75 +1.75 FT-25 FT-26 TB-101 G25 +1.00 -0.75
+2.00 FT-27 FT-28 TB-101 G25 +1.00 -0.75 +2.25 FT-29 FT-30 TB-101
G25 +1.00 -0.75 +2.50 FT-31 FT-32 TB-101 G25 +1.00 -0.75 +2.75
FT-33 FT-34 TB-101 G25 +1.00 -0.75 +3.00 FT-35 FT-36 TB-101 G25
+0.75 -0.75 +1.00 FT-19 FT-20 TB-102 G25 +0.75 -0.75 +1.25 FT-21
FT-22 TB-102 G25 +0.75 -0.75 +1.50 FT-23 FT-24 TB-102 G25 +0.75
-0.75 +1.75 FT-25 FT-26 TB-102 G25 +0.75 -0.75 +2.00 FT-27 FT-28
TB-102 G25 +0.75 -0.75 +2.25 FT-29 FT-30 TB-102 G25 +0.75 -0.75
+2.50 FT-31 FT-32 TB-102 G25 +0.75 -0.75 +2.75 FT-33 FT-34 TB-102
G25 +0.75 -0.75 +3.00 FT-35 FT-36 TB-102 G25 +0.50 -0.75 +1.00
FT-19 FT-20 TB-103 G25 +0.50 -0.75 +1.25 FT-21 FT-22 TB-103 G25
[0296] A second information database may include information
related to curing the lens forming composition based on the
prescription variables. Each record may include information related
to curing clear lenses (i.e., non-photochromic lenses) and
photochromic lenses. The curing information may include filter
information, initial curing dose information, postcure time and
conditions, and anneal time. An example of a portion of this
database is depicted in Table 8. Curing conditions typically depend
on the sphere power of a lens, the type of lens being formed
(photochromic or non-photochromic), and whether the lens will be
tinted or not. Curing information includes type of filter being
used, initial dose conditions, postcure time, and anneal time. A
filter with a 50 mm aperture (denoted as "50 mm") or a clear plate
filter (denoted as "clear") may be used. Initial dose is typically
in seconds, with the irradiation pattern (e.g., top and bottom,
bottom only) being also designated. The postcure time represents
the amount of time the mold assembly is treated with activating
light and heat in the postcure unit. The anneal time represents the
amount of time the demolded lens is treated with heat after the
lens is removed from the mold assembly. While this second database
is depicted as a separate database, the database may be
incorporated into the mold and gasket database by adding the lens
curing information to each of the appropriate records.
[0297] The controller may also be configured to warn the user if
the lens power is beyond the range of the system or if their mold
package does not contain the necessary molds to make the desired
lens. In these cases, the user may be asked to check the
prescription information to ensure that the proper prescription was
entered.
[0298] The controller may also be used to control the operation of
the various components of the plastic lens curing apparatus. A
series of input devices 640 may allow the operation of the various
components of the system. The input devices may be configured to
cause the commencement of the lens coating process (640a), the cure
process (640b), the postcure process (640c), and the anneal process
(640d).
[0299] In an embodiment, activating any of the input devices 640
may cause a screen to appear requesting a job number corresponding
to the type of lenses being formed. The last job used may appear as
a default entry. The user may change the displayed job number by
cycling through the saved jobs. When the proper job is displayed
the user may enter the job by depressing the selection knob.
TABLE-US-00010 TABLE 8 LENS INFORMATION CURING INFORMATION Lens
Initial Postcure Anneal Sphere Type Tinted Filter Dose Time Time
+2.25 Clear No 50 mm 90 Sec. 13 Min. 7 Min. Top and Bottom +2.25
Clear Yes 50 mm 90 Sec. 15 Min. 7 Min. Top and Bottom +2.25 Photo-
No 50 mm 90 Sec. 13 Min. 7 Min. chromic Top and Bottom +2.00 Clear
No Clear 7 Sec. 13 Min. 7 Min. Bottom +2.00 Clear Yes Clear 7 Sec.
15 Min. 7 Min. Bottom +2.00 Photo- No Clear 15 Sec. 13 Min. 7 Min.
chromic Bottom
[0300] After the job has been entered, the system will be ready to
commence the selected function. Activating the same input device
again (e.g., depressing the button) will cause the system to
commence the selected function. For example, pressing the cure
button a second time may cause a preprogrammed cure cycle to begin.
After the selected function is complete, the display screen may
display a prompt informing the user that the action is
finished.
[0301] The controller may be configured to prevent the user from
using curing cycles other than those that have been prescribed by
the programmer of the controller. After a prescription is entered,
the job enters the work stream where the controller allows only the
prescribed curing conditions. Timers (set by the algorithm picked
at prescription input) may run constantly during the lens cycle to
monitor doses and deliver both audible and visible prompts to the
user of at times of transition in the process. The system tracks
job completion and status and gives visual representation of job
status in the view job screen. Boxes at the bottom of the screen
are checked as the necessary steps are competed. In sensitive parts
of the lens cycle, no deviation from the established method is
allowed. Operator discretion is allowed when the process is not
time critical. The software warns the user during procedures that
will interrupt jobs during their execution, erase jobs that are not
finished, rerun jobs that are not finished, etc.
[0302] The system may be configured to prevent a new cure cycle
from being started until the previous job's cure is finished. This
"gatekeeper" function ensures post cure chamber availability during
time sensitive transitions. When the cure stage is finished, both
audible and visual prompts instruct the user to place the cavities
in the post cure area.
[0303] The main menu may also include selections allowing a saved
job to be edited. Returning to the main menu screen, depicted in
FIG. 17, selecting the edit menu item will cause an interactive
screen to be displayed similar to the input screen. This will allow
a user to change the prescription of a preexisting job. The view
menu item will allow a user to view the prescription information
and mold/gasket selection information from an existing job.
[0304] Once the desired mold and gasket information has been
obtained, the proper molds and gasket are selected from a
collection of molds and gaskets. The molds may be placed into the
gasket to create a mold assembly. Prior to placing the molds in the
gasket, the molds are preferably cleaned. The inner surface (i.e.,
casting surface) of the mold members may be cleaned on a spin
coating unit 20 by spraying the mold members with a cleaning
solution while spinning the mold members. Examples of cleaning
solutions include methanol, ethanol, isopropyl alcohol, acetone,
methyl ethyl ketone, or a water based detergent cleaner.
Preferably, a cleaning solution, which includes isopropyl alcohol,
is used to clean the mold members. As the mold member is contacted
with the cleaning solution, dust and dirt may be removed and
transferred into the underlying dish 115 of the curing unit. After
a sufficient amount of cleaning solution has been applied, the mold
members may be dried by continued spinning without the application
of cleaning solution.
[0305] In an embodiment, the inner surface, i.e., the casting face,
of the front mold member may be coated with one or more hardcoat
layers before the lens forming composition is placed within the
mold cavity. Preferably, two hardcoat layers are used so that any
imperfections, such as pin holes in the first hardcoat layer, are
covered by the second hardcoat layer. The resulting double hardcoat
layer is preferably scratch resistant and protects the subsequently
formed eyeglass lens to which the double hardcoat layer adheres.
The hardcoat layers are preferably applied using a spin coating
unit 20. The mold member is preferably placed in the spin coating
unit and the coating material applied to the mold while spinning at
high speeds (e.g., between about 900 to 1000 RPM). After a
sufficient amount of coating material has been applied, the coating
material may be cured by the activating light source disposed in
the cover. The cover is preferably closed and activating light is
preferably applied to the mold member while the mold member is
spinning at relatively low speeds (e.g., between about 150 to 250
RPM). Preferably control of the spinning and the application of
activating light is performed by controller 50. Controller 50 is
preferably configured to prompt the operator to place the mold
members on the coating unit, apply the coating material to the mold
member, and close the cover to initiate curing of the coating
material.
[0306] In an embodiment, the eyeglass lens that is formed may be
coated with a hydrophobic layer, e.g. a hardcoat layer. The
hydrophobic layer preferably extends the life of the photochromic
pigments near the surfaces of the lens by preventing water and
oxygen molecules from degrading the photochromic pigments.
[0307] In a preferred embodiment, both mold members may be coated
with a cured adhesion-promoting composition prior to placing the
lens forming composition into the mold cavity. Providing the mold
members with such an adhesion-promoting composition is preferred to
increase the adhesion between the casting surface of the mold and
the lens forming composition. The adhesion-promoting composition
thus reduces the possibility of premature release of the lens from
the mold. Further, it is believed that such a coating also provides
an oxygen and moisture barrier on the lens, which serves to protect
the photochromic, pigments near the surface of the lens from oxygen
and moisture degradation. Yet further, the coating provides
abrasion resistance, chemical resistance, and improved cosmetics to
the finished lens.
[0308] In an embodiment, the casting face of the back mold member
may be coated with a material that is capable of being tinted with
dye prior to filling the mold cavity with the lens forming
composition. This tintable coat preferably adheres to the lens
forming composition so that dyes may later be added to the
resulting eyeglass lens for tinting the lens. The tintable coat may
be applied using the spin coating unit as described above.
[0309] The clean molds are placed on the gasket to form a mold
assembly. The front mold is preferably placed on the gasket first.
For single vision prescriptions, the front mold does not have to be
placed in any particular alignment. For flat-top bifocal or
progressive front molds, the molds are preferably aligned with
alignment marks positioned on the gasket. Once the front mold has
been placed into the gasket, the back mold is placed onto the
gasket. If the prescription calls for cylinder power, the back mold
must be aligned with respect to the front mold. If the prescription
is spherical (e.g., the lens has no cylinder power), the back mold
may be placed into the gasket without any special alignment. Once
assembled the mold assembly will be ready for filling.
[0310] The controller may prompt the user to obtain the appropriate
lens forming composition. In one embodiment, the controller will
inform the user of which chemicals and the amounts of each chemical
that is required to prepare the lens forming composition.
Alternatively, the lens forming compositions may be preformed. In
this case the controller may indicate to the operator which of the
preformed lens forming compositions should be used.
[0311] In an embodiment, dyes may be added to the lens forming
composition. It is believed that certain dyes may be used to attack
and encapsulate ambient oxygen so that the oxygen may be inhibited
from reacting with free radicals formed during the curing process.
Also, dyes may be added to the composition to alter the color of an
unactivated photochromic lens. For instance, a yellow color that
sometimes results after a lens is formed may be "hidden" if a
blue-red or blue-pink dye is present in the lens forming
composition. The unactivated color of a photochromic lens may also
be adjusted by the addition of non-photochromic pigments to the
lens forming composition.
[0312] In a preferred technique for filling the lens molding cavity
382, the annular gasket 380 is placed on a concave or front mold
member 392 and a convex or back mold member 390 is moved into
place. The annular gasket 380 is preferably pulled away from the
edge of the back mold member 390 at the uppermost point and a lens
forming composition is preferably injected into the lens molding
cavity 382 until a small amount of the lens forming composition is
forced out around the edge. The excess is then removed, preferably,
by vacuum. Excess liquid that is not removed could spill over the
face of the back mold member 390 and cause optical distortion in
the finished lens.
[0313] The lens forming composition is typically stored at
temperatures below about 100.degree. F. At these temperatures,
however, the lens forming composition may be relatively viscous.
The viscosity of the solution may make it difficult to fill a mold
cavity without creating bubbles within the lens forming
composition. The presence of bubbles in the lens forming
composition may cause defects in the cured eyeglass lens. To reduce
the viscosity of the solution, and therefore reduce the incidence
of air bubbles during filling of the mold cavity, the lens forming
composition may be heated prior to filling the mold cavity. In an
embodiment, the lens forming composition may be heated to a
temperature of about 70.degree. F. to about 220.degree. F.,
preferably from about 130.degree. F. to about 170.degree. F. prior
to filing the mold cavity. Preferably, the lens forming composition
is heated to a temperature of about 150.degree. F. prior to filling
the mold cavity.
[0314] The lens forming composition may be heated by using an
electric heater, an infrared heating system, a hot air system, a
hot water system, or a microwave heating system. Preferably, the
lens forming composition is heated in a monomer heating system,
such as depicted in FIGS. 20 and 21. FIG. 20 depicts an isometric
view of the monomer heating system and FIG. 21 depicts a side view
of the monomer heating system depicted in FIG. 20. The monomer
heating system includes a body 1500 configured to hold the lens
forming composition and a valve 1520 for transferring the heated
lens forming composition from the body to a mold assembly. The
monomer heating system may also include a mold assembly support
1540 for holding a mold assembly 1550 proximate the valve. The
monomer heating system may also include an opening for receiving a
container 1560 that holds a monomer composition.
[0315] FIG. 22 depicts a cross sectional view of the monomer
heating system. The body includes a bottom 1502 and top 1504. The
top of the body 1504 may include an opening 1506 sized to allow a
fluid container 1560 to be inserted within the opening. The opening
may be sized such that the bottle rests at an angle when placed in
the opening, as depicted in FIG. 22. In some embodiments, the angle
of the bottle may be between about 5 and about 45 degrees. In one
embodiment, the opening is sized to receive a cap 1562 of a fluid
container 1560. The cap 1562 and the opening 1506 may be sized to
allow the cap to be easily inserted through the opening. If all of
the fluid in the fluid container 1562 will fit in the body 1500 of
the monomer heating system, the cap 1562 may be removed and the
bottle placed in the opening. The fluid container 1560 may be left
until all of the fluid has been emptied into the body 1500. The
fluid container 1560 may be removed or left in the opening after
the monomer has emptied into the body 1500.
[0316] In another embodiment, the fluid container 1560 may include
a self sealing cap 1562 coupled to the fluid container body 1569. A
cross sectional view of the fluid container 1560 with a self
sealing cap is depicted in FIG. 23. The self sealing cap 1562 may
be configured to fit within the opening 1506 in the body. The self
sealing cap 1562 may be coupleable to the fluid container body 1569
via a threaded fit (e.g., screwed onto the fluid container) or,
alternatively, may be fastened to the fluid container body using a
suitable adhesive. In another embodiment, the cap 1562 may be
fastened to the fluid container body by both a threaded fit and the
use of a suitable adhesive.
[0317] The cap 1562 includes, in one embodiment, a fluid control
member 1564 and an elastic member 1566. The fluid control member
1564 may have a size and shape to substantially fit against an
inner surface of the top of cap 1562 such that the fluid control
member inhibits the passage of fluid out of the fluid container.
The elastic member 1566 may be coupled to the fluid control member
1564 such that the elastic member exerts a force on the fluid
control member such that the fluid control member is forced against
the top inner surface of the cap. In one embodiment, the elastic
member may be a spring while the fluid control member may be a
substantially spherical object. In a normal resting position, the
elastic member 1566 exerts a force against the fluid control member
1564, forcing it against the top inner surface 1568 of the cap. The
top of the cap is sized to inhibit the passage of the spherical
object 1564 through the top 1568 of the cap. Thus, when not is use,
the fluid control member 1564 is forced against the top 1568 of the
cap 1562, forming a seal that inhibits the flow of a fluid through
the cap.
[0318] When the monomer heating station is to be filled, the fluid
container 1560 may be inserted into opening 1506 of the body 1500.
If a self sealing cap is used, as depicted in FIG. 23, the body may
be configured to force the fluid control member away from the top
of the fluid container. As the fluid control member is moved away
from the top of the cap, the fluid will flow around the fluid
control member and out of the fluid container. In one embodiment,
the body 1500 may include a projection 1508 (see FIG. 23) that
extends from the bottom 1502 of the body and toward the opening.
When the fluid container is inserted into the opening, the
projection may hit the fluid control member forcing the fluid
control member away from the top. When the bottle is removed, the
projection will move away from the fluid control member and the
fluid control member may be pushed back to its resting position,
thus inhibiting the further flow of fluid from the fluid
container.
[0319] A heating system 1510 is preferably coupled to the body. The
heating system 1510 is preferably configured to heat the lens
forming composition to a temperature of between about 80.degree. F.
to about 220.degree. F. Preferably, a resistive heater is used to
heat the lens forming composition. Other heating systems such as
hot air system, hot water systems, and infrared heating systems may
also be used. In one embodiment, the heating system may include a
silicon pad heater. A silicon pad heater includes one or more of
resistive heating elements embedded within a silicon rubber
material.
[0320] The heating system is preferably disposed within the body,
as depicted in FIG. 22. In an embodiment, the body may be divided
into a main chamber 1512 and a heating system chamber 1514. The
lens forming composition may be disposed within the main chamber
1512, while the heating system 1510 is preferably disposed within
the heating system chamber 1514. The heating system chamber 1514
preferably isolates the heating system 1510 from the main chamber
1512 such that the lens forming composition is inhibited from
contacting the heating system. Typically, the heating system 1510
may attain temperatures significantly higher than desired. If the
heating system 1510 were to come into contact with the lens forming
composition, the higher temperature of the heating system may cause
the contacted lens forming composition to become partially
polymerized. By isolating the heating system 1510 from the lens
forming composition, such partial polymerization may be avoided. To
further prevent partial polymerization, the heating system is
preferably insulated from the bottom surface of the main chamber.
An insulating material may be placed between the heating system and
the bottom of the main chamber. Alternatively, an air gap may be
formed between the heating system and the bottom of the main
chamber to prevent overheating of the bottom of the main
chamber.
[0321] A thermostat or thermocouple 1530 may be placed within the
chamber, in contact with either the lens forming composition and/or
the heating system chamber. In another embodiment, the thermostat
may be placed in the heating system chamber between the main
chamber and the heating element. When positioned in this manner,
the thermostat may be more responsive to changes in the temperature
of the monomer. The thermostat 1530 preferably monitors the
temperature of the lens forming composition. In an embodiment, the
thermostat may be a bi-metal immersion temperature switch. Such
thermostats may be obtained from Nason, West Union, S.C. The
temperature switch may be configured for a specific temperature by
the manufacturer. For example, the optimal monomer composition may
be about 150.degree. F. The temperature switch may be preset by the
manufacturer for about 150.degree. F. When the monomer solution is
below 150.degree. F., the switch may be in an "on" state, which
causes the heating system to continue operating. Once the
temperature of the monomer solution reaches about 150.degree. F.,
the temperature switch may change to an "off" state. In the off
state, the heating system may be switched off. As the temperature
of the monomer solution cools to below 150.degree. F., the switch
may cause the heating system to turn back on.
[0322] Alternatively, a controller 1570 may be coupled to a
thermocouple 1530 and the heating system 1510. The thermocouple
1530 may provide a signal to the controller that indicates a
temperature determined by the thermocouple. The thermocouple may be
positioned within an aluminum block disposed within the main
chamber and adjacent to the heating system chamber. The temperature
detected by the thermocouple may be a combination of the
temperature of the heating system chamber wall and the lens forming
composition. The controller 1570 may monitor the temperature of the
lens forming composition via the signals produced by thermocouple
1530 and controls the heating system 1510 to keep the lens forming
composition at a predetermined temperature. For example, as the
lens forming composition becomes cooler the controller may activate
the heating system 1510 to heat the lens forming composition back
to the desired temperature. The controller 1570 may be a computer,
programmable logic controller, or any of other known controller
systems known in the art. These systems may include a
proportional-integral ("PI") controller or a
proportional-integral-derivative ("PID") controller.
[0323] A body 1500 may be in the form of a small volume conduit for
transferring the lens forming composition out of the body. The use
of a small volume conduit may minimize the amount of monomer
solution that is in contact with the heating system at any given
time. Monomer solution passes through the body and exits the body
via the outlet valve 1520.
[0324] A fluid monitor 1580 may be used to monitor the level of
fluid in the body 1500. A fluid monitor 1580 may be positioned
within the body 1500. Fluid monitors are commercially available
from Gems Sensors Inc., Plainville, Conn. In one embodiment model
ELS-1100HT from Gems Sensors may be used. The fluid monitor may be
configured to monitor the level of fluid in the body 1500. If the
fluid level drops below a preselected minimum, the fluid sensor may
produce a signal to a controller. A controller may be coupled to
the monomer heating system (e.g., controller 1570) or may be part
of the lens forming apparatus (e.g., controller 50). In one
embodiment, the controller may produce a warning message when a low
fluid level signal is received from the fluid sensor.
Alternatively, the controller may determine when a fluid level may
be low in the body by monitoring the number of fills. For example,
a sensor may be coupled to the body and may send a signal to the
controller each time a fill is completed. The warning message may
be an alphanumeric readout on a controller output device (e.g., and
LCD screen) or the warning message may involve causing a light to
turn on signifying the low fluid level. The controller may also be
configured to turn the heating system 1510 off when the fluid level
within the body is too low. The warning message may also be an
alphanumeric readout on the monomer heating system. In addition,
warning messages may also be generated by the controller computer
to signify a ready state of the fill unit or a warming up state of
the fill unit.
[0325] Outlet valve 1520 is positioned near the outlet of the body.
The outlet valve includes an elongated member 1522 and a movable
member 1524 for altering the position of the elongated member, as
depicted in FIG. 22. The elongated member 1522 preferably inhibits
the flow of lens forming composition through the conduit when the
elongated member is in a closed position. The elongated member may
be moved into an open position such that the lens forming
composition may flow through the conduit.
[0326] As depicted in FIG. 22, the elongated member 1522 is in an
open position. The elongated member 1522 is preferably oriented
perpendicular to the longitudinal axis of the body 1500, as
depicted in FIG. 22. The elongated member 1522 resides in a channel
1526 extending through the top 1504 of the body 1500. When in the
open position, the elongated member 1522 is positioned away from
the outlet of the body. The end of the elongated member, as
depicted in FIG. 22, has been moved past a portion of the bottom
surface 1502 of the conduit such that the lens forming solution may
flow through the conduit and out of the body. The elongated member
may be positioned to control the flow rate of the lens forming
composition through the conduit. For example, as depicted in FIG.
22, the elongated member, although in an open position, still
partially blocks the conduit, thus partially inhibiting flow of the
lens forming composition through the conduit. As the elongated
member is moved further away from the outlet, the flow of the lens
forming composition may increase. The flow rate of the lens forming
composition may reach a maximum when the elongated member no longer
blocks the conduit.
[0327] In a closed position, the elongated member 1522 may extend
to the bottom surface 1502 near the outlet. Preferably, the
elongated member 1522 extends past the outer surface of the bottom
of the body proximate the outlet, when in the closed position.
Configuring the elongated member 1522 such that it extends past the
outer surface of the conduit may inhibit any residual lens forming
composition from building up near the outlet. As the elongated
member 1522 is extended toward the outlet any lens forming
composition present may be forced out, leaving the outlet
substantially clear of lens forming composition. The outlet may be
subsequently cleaned by removing the excess lens forming
composition from the outer surface of the conduit and the elongated
member.
[0328] The interaction of the elongated member 1522 with the
movable member 1524 allows the elongated member to be positioned in
either a closed or an open position. The top of the body 1504
preferably includes a plurality of threads that interact with
complimentary threads along the elongate member 1522. Rotation of
the movable member may cause the elongated member to move away from
or toward the outlet, depending on the direction of rotation of the
movable member.
[0329] A mold assembly holder 1540 may be coupled to the body of
the monomer heating system, as depicted in FIG. 21. The mold
assembly holder 1540 is configured to hold the mold assembly at a
preferred location with respect to the outlet of the body 1500. The
mold assembly holder may secure the mold assembly during filling.
In one embodiment, the mold assembly holder is spring mounted to
the bottom surface of the monomer heating system. The mold assembly
holder includes an arm 1542 that is coupled to the body 1500 by
hinge 1544. The hinge allows the mold assembly holder to be rotated
away from or toward the body 1500 of the monomer heating solution.
Hinge 1544 may be spring loaded such that a constant force is
exerted on the arm, forcing the arm toward the bottom of the body
1500. To place the mold assembly 1550 on the mold assembly arm
1544, the arm may be rotated away from the body and the mold
assembly placed onto a portion of the arm configured to hold the
mold assembly. The portion of the arm configured to hold the mold
assembly may include a clamping system to secure the mold
assembly.
[0330] To fill the mold assembly, the mold assembly is placed on
the mold assembly holders and positioned proximate to the outlet.
The monomer solution is preferably introduced into the body of the
fill station and heated to a temperature of about 150.degree. F.
After the mold assembly is in place, the valve of the mold fill
station is aligned with a fill port of the mold assembly. The lens
forming composition is now flowed through the valve and into the
mold assembly. The movable member 1524, may be adjusted to control
the flow rate of the monomer.
[0331] After the mold assembly is filled, any monomer, which may
have spilled on the surface of the molds, is removed using a lint
free wipe. Excess monomer that may be around the edge of the
filling port may be removed by using a micro vacuum unit. The mold
assembly may be inspected to insure that the mold cavity is filled
with monomer. The mold assembly is also inspected to insure that no
air bubbles are present in the mold cavity. Any air bubbles in the
mold cavity may be removed by rotating the mold assembly such that
the air bubbles rise to the top of the assembly.
[0332] The heating of the monomer solution may be coordinated with
the entry of a prescription using a controller. In one embodiment,
the monomer heating system may be electrically coupled to a lens
forming apparatus, such as the apparatus depicted in FIG. 1. The
monomer heating system may have ports that are appropriate for
using standard data transfer cables to couple to ports that are
disposed on the lens forming apparatus. The operation of the
monomer heating system may thus coordinate with the operation of
the lens forming apparatus. In some embodiments, it may be
desirable to minimize the amount of time a monomer solution is
heated. In these instances, it may be desirable to heat the monomer
solution just before filling the mold assembly. The controller 50
of the lens forming apparatus may be configured to coordinate the
filling operation with the needs of an operator.
[0333] When forming a prescription lens, an operator may first
enter the prescription into the controller 50 as described above.
Once the prescription has been entered, the operator typically
spends some time finding and cleaning the appropriate molds for the
prescription and assembling the molds with a gasket. In one
embodiment, the controller may signal a monomer heating system to
begin heating the monomer solution when a prescription is entered.
By the time the mold assembly has been assembled, the monomer
solution may be at or near the desired temperature. This may
minimize the amount of time required by the operator to prepare and
fill the mold assembly. In some instances the operator may, after
preparing a first prescription enter additional prescriptions to
process. In this case, the monomer heating system may be left in an
"on" state. If a prescription is not entered after a predetermined
amount of time, the controller may turn off the monomer heating
system, so that the monomer in the system does not remain in a
heated state for long periods of time. In some embodiments, the
predetermined amount of time may be about 10 or more minutes.
[0334] After filing the mold assembly, the lens forming composition
may be cured using a lens curing apparatus. In one embodiment, the
curing of the lens forming composition may be accomplished by a
procedure involving the application of heat and activating light to
the lens forming composition. Initially, activating light is
directed toward at least one of the mold members. The activating
light is directed for a sufficient time to initiate curing of the
lens forming composition. Preferably, the activating light is
directed toward at least one of the mold members for a time of less
than about 2 minutes. In some embodiments, the activating light is
directed toward at least one of the mold members for a time of less
than about 25 seconds. In other embodiments, the activating light
is directed toward at least one of the mold members for a time of
less than about 10 seconds. The activating light is preferably
stopped before the lens forming composition is completely
cured.
[0335] After the curing is initiated, the mold assembly may be
transferred to a post cure unit. In the post cure unit the mold
assembly is preferably treated with additional activating light and
heat to further cure the lens forming composition. The activating
light may be applied from the top, bottom, or from both the top and
bottom of the curing chamber during the post cure process. The lens
forming composition may exhibit a yellow color after the curing is
initiated. It is believed that the yellow color is produced by the
photoinitiator. As the lens forming composition cures, the yellow
color may gradually disappear as the photoinitiator is used up.
Preferably, the mold assembly is treated in the post cure unit for
a time sufficient to substantially remove the yellow color from the
formed eyeglass lens. The mold assembly may be treated in the post
cure unit for a time of up to about 15 minutes, preferably for a
time of between about 10 minutes to 15 minutes. After the lens is
treated in the post cure unit, the formed eyeglass lens may be
demolded and placed back into the post cure unit. TABLE-US-00011
TABLE 9 LENS INFORMATION CURING INFORMATION Lens Initial Postcure
Anneal Sphere Type Tinted Filter Dose Time Time +4.00 to Clear No
50 mm 90 Sec. 13 Min. 7 Min. +2.25 Back and Front +4.00 to Clear
Yes 50 mm 90 Sec. 15 Min. 7 Min. +2.25 Back and Front +4.00 to
Photo 50 mm 90 Sec. 13 Min. 7 Min. +2.25 Back and Front +2.00 to
Clear No Clear Plate 7 Sec. 13 Min. 7 Min. -4.00 Front +2.00 to
Clear Yes Clear Plate 7 Sec. 15 Min. 7 Min. -4.00 Front +2.00 to
Photo Clear Plate 15 Sec. 13 Min. 7 Min. plano Front -0.25 to Photo
Clear Plate 20 Sec. 13 Min. 7 Min. -4.00 Back, w/7 Sec. Front
starting @ 13 Sec. elapsed time.
[0336] In some instances, it may be desirable to subject the lens
to an anneal process. When a lens, cured by the activating light,
is removed from a mold assembly, the lens may be under a stressed
condition. It is believed that the power of the lens can be more
rapidly brought to a final resting power by subjecting the lens to
an anneal treatment to relieve the internal stresses developed
during the cure. Prior to annealing, the lens may have a power that
differs from the desired final resting power. The anneal treatment
is believed to reduce stress in the lens, thus altering the power
of the lens to the desired final resting power. Preferably, the
anneal treatment involves heating the lens at a temperature between
about 200.degree. F. to 225.degree. F. for a period of up to about
10 minutes. The heating may be performed in the presence or absence
of activating light.
[0337] The post-cure and anneal times given in Table 9 are strictly
exemplary of the particular system described herein. It should be
understood that the time for the post-cure and anneal process may
vary if the intensity of the lamps or the temperature of the
process is altered. For example, increasing the intensity of light
used during the post-cure process may allow a shorter post-cure
time. Similarly, reducing the temperature of the post-cure unit
during the annealing process may cause an increase in the anneal
time. Generally, the post-cure process is believed to be related to
the time required to substantially complete curing of the lens
forming composition. The anneal process is believed to be related
to the amount of time required to bring the formed lens to its
final resting power.
[0338] The use of a lens forming composition which includes an
aromatic containing polyether polyethylenic functional monomer, a
co-initiator composition and a photoinitiator allows much simpler
curing conditions than other lens forming compositions. While
pulsed activated light curing sequences may be used to cure the
lenses, continuous activating light sequences may also be used, as
described in Table 9. The use of continuous activating light
sequences allows the lens curing equipment to be simplified. For
example, if continuous activating light is used, rather than pulsed
light, equipment for generating light pulses is no longer required.
Thus, the cost of the lens curing apparatus may be reduced. Also,
the use of such a lens forming composition allows more general
curing processes to be used. As shown in Table 9, seven different
processes may be used to cure a wide variety of lenses. This
greatly simplifies the programming and operation of the lens curing
unit.
[0339] Furthermore, the use a lens forming composition which
includes an aromatic containing polyether polyethylenic functional
monomer, a co-initiator composition and a photoinitiator may
alleviate the need for cooling of the lens forming composition
during curing. This may further simplify the procedure since
cooling fans, or other cooling systems, may no longer be required.
Thus, the lens curing apparatus may be further simplified by
removing the mold apparatus cooling systems.
[0340] Table 9 shows the preferable curing conditions for a variety
of lenses. The sphere column refers to the sphere power of the
lens. The monomer type is either clear (i.e., non-photochromic) or
photochromic. Note that the lens type (e.g., spheric single vision,
aspheric single vision lens, flat-top bifocal lens or progressive
multifocal lens) does not significantly alter the lens curing
conditions. Tinted refers to whether the formed eyeglass lens will
be soaked in a dye bath or not.
[0341] Based on the prescription information the lens curing
conditions may be determined. There are four curing variables to be
set. The type of light filter refers to the filter placed between
the lamps and the mold assembly in the curing unit and the post
cure unit. The initial dose refers to the time that activating
light is applied to the lens forming composition in the curing
unit. The irradiation pattern (e.g., irradiation of the front mold
only, the back mold only, or both molds) is also dependent on the
lens being formed. After the initial dose is applied, the mold
assembly is transferred to the post cure unit where it is treated
with activating light and heat. The chart lists the preferred time
spent in the post cure chamber. After treatment in the post cure
chamber the formed eyeglass lens is removed from the mold assembly.
The lens may undergo an annealing process, for the time listed, in
which the lens is heated either in the presence or absence of
activating light. It should be noted that all of the lens curing
processes recited are preferably performed without any cooling of
the mold apparatus.
[0342] To further illustrate this procedure, the method will be
described in detail for the production of a clear, non-tinted lens
having sphere power of +3.00. A mold assembly is filled with a
non-photochromic monomer solution. The mold assembly is placed in a
lens curing unit to apply the initial dose to the lens forming
composition. The curing of the lens forming composition is
preferably controlled by controller 50. As shown in FIG. 17, the
controller 50 includes a number of input devices, which allow an
operator to initiate use of the various components of the plastic
lens curing apparatus 10. In an embodiment, buttons 640 may be used
to control operation of the coating process (640a), the curing
process (640b), the postcure process (640c), and the anneal process
(640d). After the mold assembly is placed in the lens curing unit,
the curing process button 640b may be pressed to set the curing
conditions. In one embodiment, an operator has preloaded the
prescription information and saved the information as described
above. Pressing the cure button may cause the controller to prompt
the user to enter a reference code corresponding to the saved
prescription information. The controller is preferably configured
to analyze the prescription information and set up the appropriate
initial dose conditions.
[0343] After determining the appropriate lens forming conditions,
the controller may inform the user of the type of filters to be
used. The controller may pause to allow the proper filters to be
installed within the lens curing unit. Typically, two types of
filters may be used for the initial cure process. The filters are
preferably configured to distribute the light so that the
activating light, which is imparted to the lens molds, is properly
distributed with respect to the prescription of the lens. A clear
plate filter refers to a plate that is substantially transparent to
activating light. The clear plate may be composed of polycarbonate
or glass. A 50 mm filter refers to filter which includes a 50 mm
aperture positioned in a central portion of the filter. The 50 mm
aperture is preferably aligned with the mold assembly when the
filter is placed in the curing unit. Preferably, two filters are
used, the first being placed between the top lamps and the mold
assembly, the second being placed between the bottom lamps and the
mold assembly.
[0344] After the filters have been placed, the user may indicate to
the controller that the filters are in place. Alternatively, the
controller may include a sensor disposed within the lens curing
unit, which informs the controller when a filter is placed within
the curing unit. After the filters are placed in the curing unit,
the controller may prompt the user to ensure that the mold assembly
is in the curing unit prior to commencing the curing process. When
the filters and mold are in place, the initial dose may be started
by the controller. For a clear, non-tinted lens having sphere power
of +3.00 the initial dose will be 90 seconds of activating light
applied to both the front and back molds. A 50 mm filter is
preferably positioned between the top and bottom lamps.
[0345] After the initial cure process is completed, the mold
assembly is transferred to the post cure unit. The completion of
the initial cure process may cause the controller to alert the
operator that the process is completed. An alarm may go off to
indicate that the process is completed. To initiate the post cure
process, the post cure button 640c may be pressed. Pressing the
post cure button may cause the controller to prompt the user to
enter a reference code corresponding to the saved prescription
information. The controller is preferably configured to analyze the
prescription information and set up the appropriate post cure
conditions. For a clear, non-tinted lens having sphere power of
+3.00 the post cure conditions will include directing activating
light toward the mold assembly in a heated post cure unit for 13
minutes. The post cure unit is preferably heated to a temperature
of about 200.degree. F. to about 225.degree. F. during the post
cure process.
[0346] After the post cure process is completed, the mold assembly
is disassembled and the formed lens is removed from the mold
members. The completion of the post cure process may cause the
controller to alert the operator that the process is completed. An
alarm may go off to indicate that the process is completed. After
the molds are removed from the post cure unit, the gasket is
removed and the molds placed in a demolding solution. A demolding
solution is commercially available as "Q-Soak Solution"
commercially available from Optical Dynamics Corporation,
Louisville, Ky. The demolding solution causes the lens to separate
from the molds. The demolding solution also aids in the subsequent
cleaning of the molds. After the lens has been demolded, the lens
is preferably cleaned of dust particles using a solution of
isopropyl alcohol and water.
[0347] In some instances it is desirable that the formed lens
undergoes an anneal process. To initiate the anneal process the
anneal button 640d may be pressed. Pressing the anneal button will
set the conditions for the anneal process. For a clear, non-tinted
lens having sphere power of +3.00 the anneal conditions will
include heating the lens in the post cure unit, in the absence of
activating light, for about 7 minutes. The post cure unit is
preferably heated to a temperature of about 200.degree. F. to about
225.degree. F. during the anneal process.
[0348] In one embodiment, the drawer of the post cure unit includes
a front row of mold assembly holders and a back row of lens
holders. For the post cure process, the mold assemblies are
preferably placed in the front row. The front row is preferably
oriented under the post cure lamps when the post cure drawer is
closed. For the anneal process the lenses are preferably placed in
the back row of the post-cure drawer. The back row may be
misaligned with the lamps such that little or no activating light
reaches the back row.
[0349] After the anneal process, the lens may be coated in the
coating unit with a scratch resistant hard coat. The lens may also
be tinted by placing in a tinting bath. It is believed that tinting
of the lens is influenced by the crosslink density of the lens.
Typically, a lens having a relatively high crosslink density
exhibits more homogenous absorption of the dye. Problems such as
blotching and streaking of the dye are typically minimized by
highly crosslinked lenses. The crosslink density of a lens is
typically controlled by the temperature of curing of the lens. A
lens, which is cured at relatively high temperatures typically,
exhibits a crosslink density that is substantially greater than a
low temperature cured lens. The curing time may also influence the
hardness of a lens. Treating a lens for a long period of time in a
post cure unit will typically produce a lens having a greater
crosslink density than lenses treated for a shorter amount of time.
Thus, to produce lenses which will be subsequently treated in a
tinting bath, the lens forming composition is treated with heat and
activating light in the post cure unit for a longer period of time
than for the production of non-tinted lenses. As shown in Table 9,
non-tinted clear lenses are treated in the postcure unit for about
13 minutes. For clear lenses, which will be subsequently tinted,
the post cure time is extended to about 15 minutes, to produce a
lens having a relatively high crosslink density.
[0350] The formation of flat-top bifocal lenses may also be
accomplished using the above described procedure. One problem
typical of curing flat-top bifocal eyeglass lenses with activating
light is premature release. Flat-top bifocals include a far vision
correction zone and a near vision correction region. The far vision
correction zone is the portion of the lens, which allows the user
to see far away objects more clearly. The near vision correction
zone is the region that allows the user to see nearby objects
clearer. The near vision correction zone is characterized by a
semicircular protrusion, which extends out from the outer surface
of an eyeglass lens. As seen in FIG. 24, the portion of the mold
cavity, which defines the near vision correction zone 1610, is
substantially thicker than the portion of the mold cavity defining
the far vision correction zone 1620. Directing activating light
toward the mold members causes the polymerization of the lens
forming composition to occur. It is believed that the
polymerization of the lens forming composition begins at the
casting face of the irradiated mold and progresses through the mold
cavity toward the opposite mold. For example, irradiation of the
front mold 1630 causes the polymerization to begin at the casting
surface of the front mold 1632 and progress toward the back mold
1640. As the polymerization reaction progresses, the lens forming
composition is transformed from a liquid state to a gel state.
Thus, shortly after the front mold 1632 is irradiated with
activating light, the portion of the lens forming composition
proximate the casting face of the front mold member 1632 will
become gelled while the portion of the lens forming composition
proximate the back mold member 1640 will remain substantially
liquid. If the polymerization is initiated from the back mold 1640,
the lens forming composition throughout the far vision correction
zone 1620 may become substantially gelled prior to gelation of the
lens forming composition in the near vision correction zone
proximate the casting surface of the front mold member 1610 (herein
referred to as the "front portion of the near vision correction
zone"). It is believed that when the gelation of the lens forming
composition in the front portion of the near vision correction zone
1610 occurs after the far vision correction zone 1620 has
substantially gelled, the resulting strain may cause premature
release of the lens.
[0351] To reduce the incidence of premature release in flat-top
bifocal lenses, it is preferred that polymerization of the lens
forming composition in the front portion of the near vision
correction zone 1610 is initiated before the portion of the lens
forming composition in the far vision correction zone proximate the
back mold member 1640 is substantially gelled. Preferably, this may
be achieved by irradiating the front mold 1630 with activating
light prior to irradiating the back mold 1640 with activating
light. This causes the polymerization reaction to begin proximate
the front mold 1630 and progress toward the back mold 1640. It is
believed that irradiation in this manner causes the lens forming
composition in the front portion of the near vision correction zone
1610 to become gelled before the lens forming composition proximate
the back mold 1640 becomes gelled. After the polymerization is
initiated, activating light may be directed at either mold or both
molds to complete the polymerization of the lens forming
composition. The subsequent post cure and anneal steps for the
production of flat-top bifocal lenses are substantially the same as
described above.
[0352] Alternatively, the incidence of premature release may also
be reduced if the front portion of the near vision correction zone
1610 is gelled before gelation of the lens forming composition
extends from the back mold member 1640 to the front mold member
1630. In this embodiment, the polymerization of the lens forming
composition may be initiated by irradiation of the back mold 1640.
This will cause the gelation to begin proximate the back mold 1640
and progress toward the front mold 1630. To reduce the incidence of
premature release, the front mold 1630 is irradiated with
activating light before the gelation of the lens forming
composition in the far vision correction zone 1620 reaches the
front mold. After the polymerization is initiated in the front
portion of the near vision correction zone 1610, activating light
may be directed at either mold or both molds to complete the
polymerization of the lens forming composition. The subsequent post
cure and anneal steps for the production of flat-top bifocal lenses
are substantially the same as described above.
[0353] In another embodiment, a single curing unit may be used to
perform the initial curing process, the post cure process, and the
anneal process. A lens curing unit is depicted in FIG. 25 and FIG.
26. The curing unit 1230 may include an upper light source 1214, a
lens drawer assembly 1216, and a lower light source 1218. Lens
drawer assembly 1216 preferably includes a mold assembly holder
1220 (see FIG. 26), more preferably at least two mold assembly
holders 1220. Each of the mold assembly holders 1220 is preferably
configured to hold a pair of mold members that together with a
gasket form a mold assembly. Preferably, the lens drawer assembly
may also include a lens holder 1221 (see FIG. 26), more preferably
at least two lens holders 1221. The lens holders 1221 are
preferably configured to hold a formed eyeglass lens. The lens
drawer assembly 1216 is preferably slidingly mounted on a guide
1217. During use, mold assemblies and/or lenses may be placed in
the mold assembly holders 1220 or lens holders 1221, respectively,
while the lens drawer assembly is in the open position (i.e., when
the drawer extends from the front of the lens curing unit). After
the holders have been loaded, the drawer may be slid into a closed
position, with the mold assemblies directly under the upper light
source 1214 and above the lower light source 1218. The lens holders
and lenses disposed upon the lens holders may not be oriented
directly under the upper and lower light sources. As depicted in
FIG. 26, the light sources 1214 and 1218 preferably extend across a
front portion of the curing unit, while no lamps are placed in the
rear portion of the curing unit. When the lens drawer assembly is
slid back into the curing unit, the mold assembly holders 1220 are
oriented under the lamps, while the lens holders 1221 are oriented
in the back portion where no lamps are present. By orienting the
holders in this manner curing process, which involve light and heat
(e.g., post cure processes) and annealing processes, which may
involve either application of heat and light or the application of
heat only, may be performed in the same unit.
[0354] The light sources 1214 and 1218, preferably generate
activating light. Light sources 1214 and 1218 may be supported by
and electrically connected to suitable fixtures 1242. Lamps 1214
may generate either ultraviolet light, actinic light, visible
light, and/or infrared light. The choice of lamps is preferably
based on the monomers and photoinitiator system used in the lens
forming composition. In one embodiment, the activating light may be
generated from a fluorescent lamp. The fluorescent lamp preferably
has a strong emission spectra in the 380 to 490 nm region. A
fluorescent lamp emitting activating light with the described
wavelengths is commercially available from Philips as model
TLD-15W/03. In another embodiment, the lamps may be ultraviolet
lights.
[0355] In one embodiment, an upper light filter 1254 may be
positioned between upper light source 1214 and lens drawer assembly
1216, as depicted in FIG. 25. A lower light filter 1256 may be
positioned between lower light source 1218 and lens drawer assembly
1216. Examples of suitable light filters have been previously
described. The light filters are used to create a proper
distribution of light with regard to the prescription of the
eyeglass lens. The light filters may also insulate the lamps from
the curing chamber. During post cure and annealing process it is
preferred that the chamber is heated to temperatures between about
200 and 225.degree. F. Such temperatures may have a detrimental
effect on the lamps such as shortening the lifetime of the lamps
and altering the intensity of the light being produced. The light
filters 1254 and 1256, when mounted into the guide 1217, will form
an inner chamber, which partially insulates the lamps from the
heated portion of the chamber. In this manner, the temperatures of
the lamps may be maintained within the usual operating
temperatures.
[0356] Alternatively, a heat barrier 1260 may be disposed within
the curing chamber. The heat barrier may insulate the lamps from
the curing chamber, while allowing the activated light generated by
the lamps to pass into the chamber. In one embodiment, the heat
barrier may include a borosilicate plate of glass (e.g., PYREX
glass) disposed between the light sources and the mold assembly. In
one embodiment, a pair of borosilicate glass plates 1264 and 1262
with an intervening air gap between the plates 1263 serves as the
heat barrier. The use of borosilicate glass allows the activating
radiation to pass from the light sources to the lamps without any
significant reduction in intensity.
[0357] Along with the heat barrier 1260 and filter 1254, an opaque
plate 1270, may be placed between the light sources and the mold
assembly. The opaque plate is substantially opaque toward the
activating light. Apertures are preferably disposed in the opaque
plate to allow light to pass through the plate onto the mold
assemblies.
[0358] In order to allow post cure and annealing procedures to be
performed, a heating system 1250 is preferably disposed within the
curing unit, as depicted in FIG. 26. The heating system 1250 may be
a resistive heating system, a hot air system, or an infrared
heating system. The heating system 1250 may be oriented along the
back side of the curing chamber. The heating system 1250 is
preferably disposed at a position between the two filters, such
that the heating system is partially insulated from the light
sources 1214 and 1218. Preferably, the heating system is configured
to heat the curing chamber to a temperature of about 200.degree. F.
to about 225.degree. F.
[0359] The incorporation of a heating system into a system which
allows irradiation of a mold assembly from both sides will allow
many of the above described operations to be performed in a single
curing unit. The use of lamps in the front portion of the curing
unit, while leaving the back portion of the curing chamber
substantially free of lamps, allows both activating light curing
steps and annealing steps to performed in the same unit at the same
time. Thus, the curing conditions described in Table 9 may be
performed in a single unit, rather than the two units as described
above.
[0360] In another embodiment, the method of producing the lenses
may be modified such that all of the initial curing process is
performed while heat is applied to the lens forming composition.
Table 10 shows alternate curing conditions, which may be used to
cure the lens forming compositions. TABLE-US-00012 TABLE 10 LENS
INFORMATION Lens CURING INFORMATION Sphere Type Tinted Filter
Curing Conditions Anneal Time +4.00 to Clear No 50 mm 90 Seconds
Front and Back 7 Min. +2.25 13 Minutes Back Temperature 225.degree.
F. +4.00 to Clear Yes 50 mm 90 Seconds Front and Back 7 Min. +2.25
15 Minutes Front Temperature 225.degree. F. +4.00 to Photo 50 mm 90
Seconds Front and Back 7 Min. +2.25 13 Minutes Front Temperature
225.degree. F. +2.00 to Clear No Clear Plate 7 Seconds Front 7 Min.
-4.00 13 Minutes Back Temperature 225.degree. F. +2.00 to Clear Yes
Clear Plate 7 Seconds Front 7 Min. -4.00 15 Minutes Back
Temperature 225.degree. F. +2.00 to Photo Clear Plate 15 Seconds
Front 7 Min. plano 13 Minutes Back Temperature 225.degree. F. -0.25
to Photo Clear Plate 20 Seconds Back 7 Min. -4.00 w/7 Sec. Front
starting @ 13 Sec. elapsed time 13 Minutes Back Temperature
225.degree. F.
[0361] After the mold assembly is filled with the appropriate
monomer solution the mold assemblies are placed in the mold
assembly holders of the drawer of the curing unit. The drawer is
slid back into the curing unit. The curing unit may be preheated to
a temperature of about 225.degree. F. prior to placing the mold
assemblies in the curing unit. The curing conditions include
applying activating light to one or both of the mold members while
substantially simultaneously applying heat to the mold assemblies.
As shown in Table 10, the light curing conditions are similar to
the previously described conditions. However, the initial dose and
the post-cure processes have been combined into a single process.
Thus, for the formation of a photochromic lens having a sphere
power of +1.50, the mold assemblies are placed in the lens curing
unit and irradiated with activating light from the bottom of the
unit for about 15 seconds. The curing unit is preferably at a
temperature of about 225.degree. F. while the activating light is
applied. After 15 seconds, the bottom light is turned off and the
mold assemblies are treated with activating light from the top
lamps for about 13 minutes. This subsequent treatment with
activating light is also performed at a curing chamber temperature
of about 225.degree. F. After the 13 minutes have elapsed, the
lights may be turned off, the lens removed from the molds and an
anneal process begun.
[0362] The anneal process may be performed in the same unit that
the cure process is performed. The demolded lens is preferably
placed in the lens holders of the curing unit drawer. The curing
unit is preferably at a temperature of about 225.degree. F., when
the lens is placed in the curing unit. Preferably, the lens holders
are positioned away from the lamps, such that little activating
light reaches the lenses when the lamps are on. This allows anneal
processed to be performed at the same time that curing processes
are performed and within the same curing unit. Lenses that have
been formed with a mixture of heating and light typically exhibit
crosslink density that are greater than lenses which are cured
using combinations of light only curing with light and heat
curing.
[0363] The mold assembly, with a lens forming composition disposed
within the mold cavity, is preferably placed within the lens curing
unit. Curing of the lens forming composition is preferably
initiated by the controller after the lens curing unit drawer is
closed. The curing conditions are preferably set by the controller
based on the prescription and type of lens being formed.
[0364] After the curing cycle has been completed, the controller
preferably prompts the user to remove the mold assembly from the
lens curing unit. In an embodiment, the cured lens may be removed
from the mold apparatus. The cured lens may be complete at this
stage and ready for use.
[0365] In another embodiment, the cured lens may require a post
cure treatment. After the lens is removed from the mold apparatus,
the edges of the lens may be dried and scraped to remove any
uncured lens forming composition near the edges. The controller may
prompt the user to place the partially cured lens into a post-cure
unit. After the lens has been placed within the post-cure unit, the
controller may apply light and/or heat to the lens to complete the
curing of the lens. In an embodiment, partially cured lenses may be
heated to about 115.degree. C. while being irradiated with
activating light. This post-treatment may be applied for about 5
minutes.
[0366] It has been determined that in some embodiments the finished
power of an activating light polymerized lens may be controlled by
manipulating the curing temperature of the lens forming
composition. For instance, for an identical combination of mold
members and gasket, the focusing power of the produced lens may be
increased or decreased by changing the intensity of activating
light across the lens mold cavity or the faces of the opposed mold
members. Methods for altering the power of a formed lens are
described in U.S. Pat. No. 5,989,462 to Buazza, which is
incorporated by reference.
[0367] In certain applications, all of the lens forming composition
may fail to completely cure by exposure to activating light when
forming the lens. In particular, a portion of the lens forming
composition proximate the gasket often remains in a liquid state
following formation of the lens. It is believed that the gaskets
may be often somewhat permeable to air, and, as a result, oxygen
permeates them and contacts the portions of the lens forming
material that are proximate the gasket. Since oxygen tends to
inhibit the polymerization process, portions of the lens forming
composition proximate the gasket tend to remain uncured as the lens
is formed. The wet edge problem has been addressed by a variety of
methods described in U.S. Pat. No. 5,529,728 to Buazza et. al. and
U.S. Pat. No. 5,989,462 to Buazza et al., which are incorporated by
reference.
[0368] Methods for curing a lens forming composition by the use of
pulses of ultraviolet light are described in U.S. Pat. No.
6,022,498, which is incorporated by reference.
[0369] Materials (hereinafter referred to as "activating light
absorbing compounds") that absorb various degrees of
ultraviolet/visible light may be used in an eyeglass lens to
inhibit ultraviolet/visible light from being transmitted through
the eyeglass lens. Such an eyeglass lens advantageously inhibits
ultraviolet/visible light from being transmitted to the eye of a
user wearing the lens. Curing of an eyeglass lens using activating
light to initiate the polymerization of a lens forming composition
that includes activating light absorbing compositions is described
in detail in U.S. Pat. No. 5,989,462 which is incorporated by
reference.
[0370] Referring now to FIG. 27, a high-volume lens forming
apparatus is generally indicated by reference numeral 800. As shown
in FIG. 27, lens forming apparatus 800 includes at least a first
lens curing unit 810 and a second lens curing unit 820. The lens
forming apparatus may, optionally, include an anneal unit 830. In
other embodiments, a post cure unit may be a separate apparatus,
which is not an integral part of the lens curing apparatus. A
housing in which first lens curing unit 810, second lens curing
unit 820, and anneal unit 830 may be disposed may be formed of an
insulating material. In this manner, the housing may be configured
to reduce heat transfer between the first lens curing unit, the
second lens curing unit and the anneal unit. The lens forming
apparatus may also include at least one monomer heating unit or
fill unit as described in any of the above embodiments. The lens
forming apparatus may also include conveyance system 850 positioned
within the first and/or second lens curing units. The conveyance
system 850 may be configured to allow a mold assembly, such as has
been described above, to be transported from the first lens curing
unit 810 to the second lens curing unit 820. For example, the
conveyance system may be configured to allow a plurality of mold
assemblies, which may be filled with a lens forming composition, to
be transported into, through, and out of the lens forming
apparatus.
[0371] The lens forming apparatus may be configured to form an
eyeglass lens in less than approximately one hour. In addition, the
lens forming apparatus may be configured to form at least 25
prescription cast eyeglass lenses per hour by application of
activating light to cure a liquid forming composition into a
prescription cast eyeglass lens. For example, the system may be
configured to form approximately 100 prescription cast eyeglass
lenses per hour by application of activating light to cure a liquid
forming composition into a prescription cast eyeglass lens. Such a
rate of production may also include a time required to anneal a
prescription cast eyeglass lens.
[0372] Lens curing units 810 and 820 include an activating light
source for producing activating light. The activating light sources
disposed in units 810 and 820 are preferably configured to direct
light toward a mold assembly. Anneal unit 830 may be configured to
apply heat to an at least partially relieve or relax the stresses
caused during the polymerization of the lens forming material.
Anneal unit 830, in one embodiment, includes a heat source. A
controller 840 may be a programmable logic controller, e.g., a
computer. Controller 840 may be coupled to lens curing units 810
and 820 and, if present, an anneal unit 830, such that the
controller is capable of substantially simultaneously operating the
three units 810, 820, and 830.
[0373] As shown in FIG. 28, first curing unit 810 may include upper
light source 812 and lower light source 814. FIG. 29 depicts a cut
away top view of first curing unit 810. As shown in FIG. 28, light
sources 812 and 814 of first curing unit 810 may include a
plurality of activating light generating devices or lamps. In one
embodiment, the lamps are oriented proximate each other to form a
row of lights, as depicted in FIG. 29. While the lamps are depicted
as substantially U-shaped, it should be understood that the lamps
may be linear, circular, or any other shape that allows a uniform
irradiation of a lens forming assembly placed in the first curing
unit. In one embodiment, three or four lamps are positioned to
provide substantially uniform radiation over the entire surface of
the mold assembly to be cured. The lamps may generate activating
light.
[0374] The lamps may be supported by and electrically connected to
suitable fixtures 811. Light sources 812 and 814 may generate
either ultraviolet light, actinic light, visible light, and/or
infrared light. The choice of lamps is preferably based on the
monomers used in the lens forming composition. In one embodiment,
the activating light may be generated from a fluorescent lamp. The
fluorescent lamp preferably has a strong emission spectra in the
380 to 490 nm region. A fluorescent lamp emitting activating light
with the described wavelengths is commercially available as model
number FB290D15/ACT/2PC from LCD Lighting, Inc. in Orange Conn.
[0375] In some embodiments, the activating light sources may be
turned on and off frequently during use. Fixture 811 may also
include electronic hardware to allow a fluorescent lamp to be
frequently turned on and off. Ballasts systems, such as the ones
previously described, may be used to operate the lamps. In some
embodiments, a barrier 815 may be placed between the lamps 811. The
barrier may be configured to inhibit the passage of activating
light from one set of lamps to the other. In this manner, the lamp
sets may be optically isolated from each other. The lamps may be
connected to separate ballast systems and a controller. In
addition, the lamps may be coupled separately to fans. Thus, the
lamps may be operated independently of each other. In addition,
operation of the fans may be controlled by a controller to coincide
with operation of the lamps. For example, if a lamp is turned on by
a controller, a fan may also be turned on by a controller. This may
be useful when lenses that require different initial curing
sequences are being processed at the same time. The barrier 815 may
inhibit the passage of light from one set of lamps to a mold
assembly positioned below the other set of lamps.
[0376] In some embodiments, at least four independently
controllable lamps or sets of lamps may be disposed in the first
curing unit. The lamps may be disposed within the first curing unit
with a sliding rack, which may maintain a position of the lamps
within the first curing unit. The lamps may be disposed in left and
right top positions and left and right bottom positions. As shown
in Table 10, a variety of different initial curing conditions may
be required depending on the prescription. In some instances, the
left eyeglass lens may require initial curing conditions that are
substantially different from the initial curing conditions of the
right eyeglass lens. To allow both lenses to be cured substantially
simultaneously, the four sets of lamps may be independently
controlled. For example, the right set of lamps may be activated to
apply light to the back face of the mold assembly only, while, at
the same time, the left set of lamps may be activated to apply
light to both sides of the mold assembly. In this manner, a pair of
eyeglass lenses whose left and right eyeglass prescriptions require
different initial curing conditions may be cured at substantially
the same time. Since the lenses may thus advantageously remain
together in the same mold assembly holder throughout the process,
the production process is simpler with minimized job tracking and
handling requirements.
[0377] To facilitate the positioning and the conveyance of mold
assemblies, a mold assembly holder may be used. An isometric view
of a mold assembly holder 900 is depicted in FIG. 30. The mold
assembly holder includes at least one, preferably two, portions 910
and 912 configured to hold a mold assembly 930. In one embodiment,
the portions 910 and 912 are indentations machined into a plastic
or metal block that is configured to hold a standard mold assembly.
The mold assembly may be placed in the indentation. An advantage of
such indentations is that the mold assemblies may be positioned in
the optimal location for curing in the first and second curing
units 810 and 820.
[0378] The indentations 910 and 912 may be sized to hold the mold
assembly such that substantially all of the molds may be exposed to
activating light when the mold assembly is positioned above or
below an activating light source. The mold assembly holder may
include an opening extending through the mold assembly holder. The
opening may be positioned in the indentations 910 and 912 such that
activating light may be shone through the mold assembly holder to
the mold assembly. In some embodiments, the opening may be of a
diameter that is substantially equal to the diameter of the molds.
The opening will therefore allow substantially all of the surface
area of the mold to be irradiated with activated light. In another
embodiment, the diameter of the opening may be substantially less
than a diameter of the molds. In this respect the opening may serve
as an aperture, which reduces the amount of light, that contacts
the outer edges of the molds. This may be particularly useful for
curing positive lenses in which curing is initiated with more
activating light being applied to the central portion of the molds
than the edges. The indentations may extend in the body to a depth
such that the mold assemblies, when placed in the indentations are
even with or below the upper surface of the mold assembly holder.
This imparts a low vertical profile to the mold assembly holder and
allows the curing units of the high volume system to be constructed
with a low vertical profile. In this manner, the size of the unit
may be minimized.
[0379] The mold assembly holder 900 may also include further
machined indentations for holding the unassembled pieces of the
mold assembly (e.g., the molds and the gasket). For example, the
mold assembly holder may be configured to hold at least two molds.
During the assembly of the mold assembly, an operator typically
will find and clean the molds and gasket before assembly. To
minimize the possibility of mixing up the molds and gaskets, and to
help minimize recontamination after the molds are cleaned, the mold
assembly holder 900 includes sections to hold the various
components. As depicted in FIG. 30, indentations 922, 924, 926, and
928 may also be formed in the mold assembly holder 900. The
indentations may be labeled to facilitate the placement of the
molds or gaskets. For example, indentation 922 may be labeled left
lens, front mold, 924 may be labeled left lens, back mold, 928 may
be labeled right lens, front mold, and 926 may be labeled right
lens, back mold. Other variations of labeling and positioning of
the indentations 922, 924, 926, and 928 may be used. This may help
prevent operators from making mistakes due to use of incorrect
molds to assemble the mold assemblies.
[0380] The mold assembly holder may also include a location for
holding a job ticket 940. Job ticket may be placed in a holder
mounted to a side of the mold assembly holder. Alternatively, the
job ticket may have an adhesive that allows the ticket to be
attached to the side of the mold assembly. The job ticket may
include information such as: the prescription information, the mold
ID numbers, the gasket ID numbers, the time, date, and type of lens
being formed. The job ticket may also include a job number; the job
number may correspond to a job number generated by the controller
when the prescription is entered into the controller. The job
number may also be depicted using a bar coding scheme. Use of a bar
code on the job ticket may allow the use of bar-code scanners to
determine the job number corresponding to the mold assemblies
placed on the mold assembly holder.
[0381] The mold assembly holder may also include at least one
indicia or an identifying mark. An indicia may include a color, at
least one alphanumeric character, at least one graphical character,
a barcode, or a radio frequency emitter. The indicia of a mold
assembly holder may vary depending on the intended use of the mold
assembly holder. For example, the color of a mold assembly holder
may vary depending on the type of lens, which may be formed within
the mold assembly holder. For example, a mold assembly holder
having a first color may be suitable for forming a photochromic
lens, and a mold assembly holder having a second color may be
suitable for forming a non-photochromic lens. In addition,
alphanumeric characters formed in, printed on, or attached to the
mold assembly unit may include, for example, "PHOTOCHROMIC LENS" or
"NON-PHOTOCHROMIC LENS" depending on the type of lens which may be
formed within the mold assembly holder. A graphical character may
also vary depending on the type of lens, which may be formed within
the mold assembly holder.
[0382] A radio frequency emitter may be commonly referred to as an
"RF tag." A radio frequency emitter may be formed within or coupled
to a mold assembly holder. A radio frequency emitter may be
configured to generate a radio frequency signal at least
periodically. The generated radio frequency signal may include a
signature, which may be characteristic of the type of lens, which
may be formed within the mold assembly holder. A radio frequency
detector may be coupled to a lens forming apparatus and may be
configured to detect a radio frequency signal generated by the
radio frequency emitter. The type of lens, which may be formed with
the mold assembly holder, may then be determined from the detected
radio frequency signal. In addition, a system may include a lens
forming apparatus and mold assemblies of at least two different
forms of at least one of the indicia described above.
[0383] The mold assembly holder 900 may be used in combination with
a conveyor system 850 to transfer mold assemblies from the first
curing unit to the second curing unit. The second curing unit is
configured to apply activating light and heat to the mold
assemblies after the curing is initiated by the first curing unit.
The use of two curing units in this manner facilitates the
application of curing sequences such as the sequences outlined in
Table 9. In these embodiments, the mold assembly is subjected to an
initiating dose of activating light, followed by a post-cure dose
of activating light and heat. The initial dose may last from about
7 to 90 seconds. After the initial dose is applied, the mold
assembly is subjected to a combination of activating light and heat
for about 5 to 15 minutes. In many instances, subjecting the mold
assembly to longer times under the post-cure conditions does not
significantly effect the quality of the formed lens. Thus, the
second curing unit is designed such that the amount of time that
the mold assemblies spend in the second unit is not less than about
5 minutes.
[0384] During operation, a mold assembly or mold assembly holder is
placed on the conveyor system and the mold assembly is moved to a
position within the first curing unit 810. In the first curing unit
810, the mold assemblies receive the initial dose of light based on
the prescription of the lens, e.g., as outlined in Table 9. After
the mold assemblies receive their initial dose, the mold assemblies
are moved by the conveyor system 850 to the second curing unit. In
the second curing unit, the mold assemblies are treated with
activating light and heat. The time it takes for the mold assembly
to pass entirely through the second curing unit may be equal to or
greater than the post-cure time.
[0385] In one embodiment, the conveyor system may be a single
continuous system extending from the first curing unit through the
second curing unit. During the operation of the lens forming
apparatus 800, it is envisioned that a continuous stream of mold
assemblies may be placed on the apparatus. FIG. 32 depicts a top
cut away of a system in which a continuous stream of mold assembly
holders 900 are moving through the first and second curing units.
Because the curing for any given prescription lens is complete in
the first curing unit in a time of 90 seconds or less, the second
unit may be constructed as a rectangular shaped unit that will hold
multiple mold assemblies, as depicted in FIG. 27. The length of the
second cure unit is determined by the time required for each mold
assembly in the first unit. Because the conveyor system is a single
continuous unit, the molds will move through the second curing unit
in increments equal to the amount of time spent in the first curing
unit. Thus, the molds move only when the curing cycle of the first
curing unit is complete and the mold assemblies or mold assembly
holder is advanced to the second curing unit.
[0386] In one embodiment, the mold assemblies are placed on a mold
assembly holder 900 as described above. The mold assembly holder
may have a predetermined length (L.sub.H). After the mold
assemblies are loaded onto the mold assembly holder, the mold
assembly holder may be placed on the conveyor system 850 and
advanced to the first curing unit. The mold assembly holder will
remain in the first curing unit for a predetermined minimum amount
of time, i.e., the initiation time (T.sub.I). For example, for most
of the lens forming compositions and prescriptions outlined above,
this maximum time will be about 90 sec. After the initial cure is
performed, the mold assembly holder is advanced to the second
curing unit and another mold assembly holder is advanced to the
first curing unit. To properly cure lens forming composition, the
mold assemblies may need to remain in the second curing unit for a
minimum amount of time, i.e., the post-cure time (T.sub.P). The
required minimum length of the second curing unit (L.sub.SC) may,
therefore be calculated by these predetermined values using the
following equation. L.sub.SC=L.sub.H.times.(T.sub.P/T.sub.I) By
constructing the second curing unit to have a length based on this
equation, the mold assembly holder will exit from the second curing
unit after the correct amount of post-curing has occurred. This
will ensure that the mold assembly will remain in a post-cure
situation even if the minimal initiation times are used.
[0387] In practice, there is a wide variation in the initiation
times based on the prescription and the type of lenses being
formed. For example, Table 9 discloses some typical initiation
times that range from about 7 sec. to about 90 sec. In order to
optimize the system, the length of the second curing unit may be
altered based on the maximum predetermined initiation time. For
example, the (T.sub.I) rather than being the minimum time will be
the maximum time possible for initiation of the curing. In
practice, the conveyor system may be configure to advance a mold
assembly holder from the first curing unit to the second curing
unit at time intervals equal to the maximum possible initial curing
cycle (e.g., about 90 sec. for the above-described compositions).
To accommodate the different initial curing cycles, a controller
may be coupled to the lamps of the first curing unit. The
controller may be configured to turn on the lamps such that the
initial curing cycle ends at the end of the maximum initial curing
time. For example, if the maximum initial curing time is 90 sec.,
however the prescription and lens type calls for only a 7 sec,
cure. The lamps are kept off until 7 sec. before the end of the 90
sec. time interval (i.e., for 83 seconds). The lamps are,
therefore, only activated for the last 7 sec. This may ensure that
the time interval between the end of the completion of the initial
cure and the entry into the second curing unit is the same
regardless of the actual initiation dosage. The length of the
second curing unit may be adjusted accordingly to accommodate this
type of curing sequence.
[0388] In another embodiment, the conveyor system may include two
independently operated conveyors. The first conveyor may be
configured to convey the mold assembly holder or mold assemblies
from the first curing unit to the second curing unit. A second
conveyor may be positioned within the second curing unit. The
second conveyor may be configured to convey the mold assemblies or
the mold assembly holder through the second curing unit. As such, a
speed of the first and second conveyors may be substantially
different. For example, a speed of the first conveyor may be
variable and a speed of the second conveyor may be substantially
constant. In this manner, the second curing unit may be designed
independently of the initial curing times. Instead, the length of
the second curing unit may be based on the time required for a
typical post-cure sequence. Thus, the length of the second curing
unit may be determined by the rate at which the second conveyor
system is operated and the amount of time required for a post-cure.
This also allows an operator to operate the curing units
independently of the other.
[0389] The conveyor system may be configured to convey either mold
assemblies or a mold assembly holder (e.g., mold assembly holder
900) through the first and second curing units. A view of the
conveyor system in which the curing units have been removed from
the lens forming apparatus is depicted in FIG. 31. The conveyor
system includes a platform for conveying a mold assembly holder.
The platform may be configured to support the mold assembly holder
900 as it passes through the first and second curing units. In one
embodiment, the platform is formed from two rails 852 that extend
the length of the lens forming apparatus. The rails, 852 may be any
width, however should be spaced apart from each other at a distance
that allows activating light to pass past the rails 852 and to the
mold assemblies on the mold assembly holder 900.
[0390] The conveyor system includes a flexible member 854 (e.g., a
belt or chain) that is configured to interact with the mold
assembly holder 900. The flexible member will interact with the
mold assembly holder and pull or push the mold assembly holder
along the platform. FIG. 33 depicts a close up view of a portion of
the flexible member. In this embodiment, the flexible member is
composed of a chain 854 that includes a number of projections 856
and 858 that are placed at predetermined positions along the chain.
The projections may be configured to interact with the mold
assembly holder. In one embodiment, the mold assembly holder may
include a ridge along the bottom surface. The ridge will interact
with the projections when the chain is moved to the appropriate
position. While depicted as a chain, it should be understood that
the flexible member may be formed of other materials such as a
rubber belt. For example, the flexible member may be formed of a
flexible material such as neoprene.
[0391] The flexible member 854 may be coupled to a pair of wheels
or gears disposed at opposite ends of the lens forming apparatus.
FIG. 33 depicts a portion of the flexible member that is resting on
a gear disposed at an end of the lens forming apparatus. The
flexible member may be moved along the lens forming apparatus by
turning either of the wheels or gears. The wheels or gears may be
manually turned or may be coupled to a motor. FIG. 34 depicts a
lens forming apparatus in which a motor 851 is coupled to an end of
the second curing unit. The motor may be coupled to the flexible
member such that the flexible member may be moved by the operation
of the motor. The motor 851 may either pull or push the flexible
member along the length of the lens forming apparatus. In addition,
the motor and the flexible member may be configured such that the
flexible member may continue to move under a mold member holder
even if movement of the mold member holder may be obstructed. In
this manner, the flexible member may "slip" under a mold member
holder if, for example, a mold member has reached a safety stop
coupled to the first or second curing units. For example, a safety
stop may be coupled to an end of each of the curing units to
prevent tray from falling off the conveyance system.
[0392] The second curing unit may be configured to apply heat and
activating light to a mold assembly as it passes through the second
curing unit. The second curing unit may be configured to apply
activating light to the top, bottom, or both top and bottom of the
mold assemblies. As depicted in FIGS. 28 and 35, the second curing
unit may include a bank of activating light producing lamps 822 and
heating systems 824. The bank of lamps may include one or more
substantially straight fluorescent lamps that extend through the
entire length of the second curing unit. The activating light
sources in the second curing unit may produce light having the same
spectral output as the activating light sources in the first curing
unit. The spectral output refers to the wavelength range of light
produced by a lamp, and the relative intensity of the light at the
specific wavelengths produced. Alternatively, a series of smaller
lamps may be disposed with the curing unit. In either case, the
lamps are positioned such that the mold assemblies will receive
activating light as they pass through the second curing unit. The
heating unit may be a resistive heater, hot air system, hot water
systems, or infrared heating systems. In this manner, a chamber
temperature may be controlled by altering the adjusting the power
to, for example, the resistive heater. An air distributor 826
(e.g., a fan) may be disposed within the heating system to aid in
air circulation within the second curing unit. By circulating the
air within the second curing unit, the temperature within the
second curing may be more homogenous.
[0393] In some embodiments, an anneal unit may also be coupled to
the lens forming apparatus. As depicted in FIG. 27, an anneal unit
830 may be placed above the second curing unit. Alternatively, the
anneal unit may be placed below or alongside of the first or second
curing units. The anneal unit is configured to apply heat and,
optionally light, to anneal a demolded lens. When a lens, cured by
the activating light, is removed from a mold assembly, the lens may
be under a stressed condition. It is believed that the power of the
lens can be more rapidly brought to a final resting power by
subjecting the lens to an anneal treatment to relieve the internal
stresses developed during the cure. Prior to annealing, the lens
may have a power that differs from the desired final resting power.
The anneal treatment is believed to reduce stress in the lens, thus
altering the power of the lens to the desired final resting power.
Preferably, the anneal treatment involves heating the lens at a
temperature between about 200.degree. F. to 225.degree. F. for a
period of up to about 10 minutes. It should be understood that the
anneal time may be varied depending on the temperature of the
anneal unit. Generally, the higher the temperature of the anneal
unit, the faster the anneal process will be completed. The anneal
process time is predetermined based on the amount of time, at a
predetermined temperature, a formed lens will need to be annealed
to be brought to its final resting power.
[0394] In the embodiment depicted in FIG. 27, the anneal unit may
be constructed in a similar manner to the second curing unit.
Turning to FIG. 35, the anneal unit may include a conveyor system
832 for moving a demolded lens through the anneal unit. The
demolded lens may be placed in the same mold assembly holder that
was used for the first and second curing units. The mold assembly
holder 900 may be configured to hold either the mold assembly
and/or a demolded lens. The anneal unit includes a heating element
834 (depicted in FIG. 28). The heating element may include a air
distributor 836 for circulating air throughout the anneal unit.
[0395] The anneal unit may have a length that is determined by the
rate at which the mold assembly holders are transported through the
anneal unit and the time required for the anneal process. For
example, in some of the compositions listed above, an anneal time
of about 10 min. may be used to bring the lens to its final resting
power. The conveyor system of the anneal unit may therefore be
configured such that the demolded lenses spend about 10 minutes
within the anneal unit as the lenses traverse the length of the
unit. A conveyor system similar to the system described above for
the first and second curing units may be used. The conveyor system
in the anneal unit may also be configured to move through the
anneal unit continuously.
[0396] The controller 840 may be configured to control operation of
the lens-curing units. The controller may perform some and/or all
of a number of functions during the lens curing process, including,
but not limited to: (i) determining the initial dose of light
required for the first curing unit based on the prescription; (ii)
applying the activating light with an intensity and duration
sufficient to equal the determined dose; (iii) applying the
activating light with an intensity and duration sufficient to equal
the determined second curing unit dose; (iv) turning the lamps
sources on and off independently and at the appropriate times; and
(v) triggering the movement of the proper light filters into the
proper position based on the prescription. These functions may be
performed in response to information read by the bar code reader
from the job ticket positioned on the mold assembly holder. This
information may include the prescription information and may be
correlated with the initial curing conditions by the controller
840.
[0397] The controller may also control the flow of the mold
assembly holder through the system. The controller may include a
monitoring device for determining the job number associated with a
mold assembly holder. FIG. 29 depicts a monitoring device 817,
which is coupled to the lens forming apparatus proximate, the first
curing unit. The monitoring device may be a laser or infra-red
reading device. In some embodiments, the monitoring device may be a
bar code reader for reading a bar code. The monitoring device may
be positioned within the first curing unit. When a mold assembly
holder is placed on the conveyer system, it may be moved to a
position such that the monitoring device may read a job number
printed on the job ticket. In one embodiment, the job number is in
the form of a bar code. The monitoring device may be coupled to the
controller. The controller may use the job number, read from the
mold assembly holder, to determine the curing conditions required
for the job that is being transferred to the first curing unit. In
addition, the controller may use the job number, read from the mold
assembly holder, to determine when to apply light to the job being
transferred to the first curing unit. As described before, the job
number may correspond to a prescription that was previously entered
into the controller. In this manner, the proper curing conditions
may be achieved without relying on the operator to input the
correct parameters.
[0398] Another advantage of the monitoring of the job number is
that accidental usage of the lamps may be avoided. If the
monitoring device is positioned within the first cure unit, the
controller may prevent the activation of the first cure unit lamps,
until a job ticket is detected. The detection of a job ticket may
indicate that a mold assembly holder is placed in the proper
position within the first curing unit. Once the mold assembly
holder is placed within the first curing unit, the lamps of the
first curing unit may be activated to initiate curing and the
conveyance system may begin to move. If no job ticket is detected,
the apparatus may wait in a stand-by mode until the mold assembly
holder is inserted into the first curing unit. In this manner, the
lifetime of a lamp of a lens forming apparatus may be extended.
[0399] Alternatively, a monitoring device positioned within the
first cure unit may include a photosensor, which may commonly be
referred to as a "photoeye". The photosensor may be configured to
determine if a mold assembly holder is placed at the entrance of an
initialization unit within the curing unit. The photosensor may,
for example, monitor an intensity of a light beam. If a mold
assembly holder is in front of the photosensor, then an intensity
of the light beam may be reduced. Such a reduction in intensity may
be detected by the photosensor and may be processed to determine
that a mold assembly holder may have been placed in the curing
unit. As described above, once a mold assembly holder may be
detected within the first curing unit, the lamps of the first
curing unit may be activated to initiate curing and the conveyance
system within the first curing unit may begin to move.
[0400] In addition, a speed of the conveyance system may increase
upon detection of a mold assembly holder within the first curing
unit. In this manner, a mold assembly holder may be moved into
position quickly once the mold assembly holder has been placed in
the curing unit. Furthermore, the photosensor may be configured to
monitor an intensity of the light beam periodically. In this
manner, the photosensor may determine how long a mold assembly
holder may be located at a position in the lens forming apparatus.
In addition, if a mold assembly holder is moved out of the light
beam of the photosensor, the photosensor may detect an increase in
an intensity of the light beam. The photosensor may be further
configured to send the detected intensity of the light beam to a
controller computer. The controller computer may be configured to
control the conveyor system in response to the detected intensity
of the light beam. In this manner, the controller computer may be
configured to prevent a mold assembly holder from entering the lens
forming apparatus until an increase in an intensity of a light beam
is received from the photosensor by controlling the conveyor
system.
[0401] Furthermore, multiple such photosensors may be positioned at
various locations throughout a curing unit. In this manner, a
presence of the mold assembly holder may be detected at various
positions through a curing unit. In addition, the output of the
multiple photosensors may be used to monitor the operation of the
curing unit. Such a photosensor, or a plurality of photosensors,
may also be positioned within the second cure unit and may also be
configured to determine a presence of a mold assembly holder in the
second cure unit. Position of a tray within a curing unit may also
be used to determine when light may be applied to the mold assembly
holder in an initialization chamber. For example, the controller
may determine delay time for applying initialization light from a
speed of the conveyance system. In this manner, application of
initialization light may be delayed until a last portion of the
time in which the mold assembly holder may be in the initialization
unit. Minimization of the delay between application of
initialization light and curing light may increase the consistency
of resulting eyeglass lenses because each lens forming composition
in each processed mold assembly holder may get the same
treatment.
[0402] It should be understood, that the above-described lens
curing system may be used in combination with any of the features
of the previously described embodiments.
[0403] Additional embodiments relate to systems and method for the
location, storage, and identification of eyeglass mold members to
be used in the production of eyeglass lenses. The system may employ
a two-dimensional or three-dimensional eyeglass mold member storage
system (also called a storage array) that may allow a user to store
and retrieve mold members in an organized fashion. The storage
array may be configured as a horizontal, vertical or angled array.
The mold members may be organized within the storage array such
that mold members with similar properties may be arranged near one
another. A controller computer may be coupled to the mold member
storage array. Additionally, an indicator or indicators may be
coupled to the mold member storage array to assist a user in
locating a desired mold member.
[0404] FIG. 36 depicts an embodiment of an eyeglass mold member
storage system including mold member storage array 1806 coupled to
controller computer 1801. Mold member storage array 1806 may
include rows or columns of mold member storage locations 1804.
Indicators 1802 may be arranged proximate each mold member storage
location 1804. In this embodiment, four indicators 1802 may
surround each mold member storage location 1804 with adjacent
storage locations sharing the indicators between them. To direct a
user to select a mold member in a storage location, controller
computer 1801 may produce a signal thereby activating indicators
1802. Mold member storage array 1806 may be configured as a
vertical, horizontal, or angled array of storage locations 1804 in
which an eyeglass mold member may be securely stored.
[0405] FIGS. 37a and 37b depicts several embodiments of mold member
storage locations 1821 and 1822. In the embodiment of FIG. 37a,
indicator 1820 may be located adjacent to each mold member storage
location 1821. In the embodiment of FIG. 37b, indicator 1823 may be
configured to encircle or illuminate each mold member storage
location 1822. The indicator, however, may include any appropriate
indicator, which may be known in the art.
[0406] FIG. 38 depicts an embodiment of an eyeglass mold member
storage array 1806. Storage array 1806 may facilitate the storage
of a large number of mold members 1830. Mold member storage array
1806 may be configured vertically, i.e. such that molds within the
array are vertical. As shown in FIG. 39, molds may be arranged on
shelf 1840. Shelf 1840 may be tilted toward the front of array 1833
at an angle of about 5 degrees to about 10 degrees.
[0407] If the stored mold members are lens molds, as shown in FIG.
38, it may be possible for individual molds 1830 to be damaged by
contact with one another. To prevent molds 1830 from contacting
each other, separating device 1832 may be coupled to the mold
storage array. A variety of cams or other separating devices may be
used to separate individual molds. Separating device 1832 (more
clearly illustrated in FIG. 39) may include one cam or a plurality
of cams. Many different types and arrangements of cams may be used.
FIGS. 40, 41A, 41B, 41C, and 41D depict a variety of cams, which
may be suitable for separating devices. Reference numerals 1852,
1853, 1861, and 1862 indicate rocking type cams. Reference numeral
1863 indicates a hinged cam as depicted in FIG. 41C. Reference
numeral 1864 indicates a reciprocating cam as depicted in FIG. 4
ID. FIG. 40 also depicts interaction of cams 1852 and 1853 with
mold members 1851 and 1855. At dispensing end 1854, cam 1853 may
retain mold member 1855 within the storage location, whereas within
the body of the storage location, cam 1852 may prevent mold members
1851 and 1855 from contacting one another. The position of the
separating devices may vary depending on the mold member storage
array and preference. As each mold 1855 is removed for use, the
separating devices 1853 may move to dispense the mold 1855.
[0408] In the embodiment of FIG. 38, molds 1830 may be removed from
array 1806 at front end 1833. When mold 1830 is removed (or
dispensed) from array 1806, separating devices 1832 may move or
disengage to allow the adjacent mold to advance into the emptied
storage location. This process may continue, with adjacent molds
advancing into empty storage locations until the empty storage
location coincides with the storage locations designated for
restocking molds into mold member storage array 1806.
[0409] Once a mold member has been used and cleaned, it may be
ready for storage. The cleaned mold member may be returned to
storage by placing the mold member in the designated restocking
location. The restocking location may be the same as the dispensing
location, or it may be different. For example, in the case where
the mold member is a lens mold, and the mold member storage array
is a vertical array, the mold member storage array may be
configured to allow the user to remove a desired mold from a first
point. The array may further be configured to allow the user to
restock the array at a second point. The second point may be on the
opposite side of the array from the first point, or it may be on a
side adjacent to the side of first point. In the embodiment of FIG.
38, the first point coincides with the front end of array 1833.
Preferably, the second point coincides with back end 1834 of the
array. However, rather than being restocked from back end 1834 of
the array, the array may be configured to allow restocking from top
end 1831 of the array. Separating devices 1832 may load and secure
returned molds 1830 into place automatically.
[0410] Controller computer 1801, as depicted in FIG. 36, may be
configured to interact with the operator. The controller computer
may include at least one input device 1805 and at least one output
device 1803. Input device 1805 may include a keyboard (e.g., a full
computer keyboard or a modified keyboard), a light sensitive pad, a
mouse, a touch sensitive pad, a bar code scanner, a microphone, or
another appropriate input device. In a preferred embodiment, input
devices 1805 may also include at least a keyboard, a mouse, and a
bar code scanner. Output device 1803 or devices may include a
display screen, a voice synthesizer, or another suitable output
device. In a preferred embodiment, output device 1803 may include
at least a display screen.
[0411] Controller computer 1801 may utilize user input to establish
some control parameters. For example, the controller computer may
allow the user to input information regarding the lens to be
formed. This information may include type of lens (clear,
ultraviolet absorbing, photochromic, colored, etc.), lens
prescription, type of coatings (e.g., scratch resistant or tint) or
other such information as may be desired to describe the lens to be
formed. Based on this information controller computer 1801 may
preferably be configured to send information back to the operator.
For example, controller computer 1801 may inform the user of
appropriate mold members to use in forming the desired lens, the
location of the mold members, or process parameters. Controller
computer 1801 may also signal an operator when certain operations
may need to be performed or when a particular operation may be
completed (e.g., when to place the mold assembly in the lens curing
unit, when to remove the mold assembly, when to transfer the mold
assembly, etc.).
[0412] In an embodiment, controller computer 1801 may be a computer
system including display screen 1803 to view data, input device
1805 such as a keyboard, keypad or scanning device to input data,
and a CPU to store and process data, and run software applications.
The controller computer may be configured to send an activation
signal to individual indicators 1802 as appropriate to instruct the
user as to the location of a desired mold member, or the
appropriate storage location for a mold member being placed into
storage array 1806.
[0413] Mold members may be marked for identification. The mark may
include a symbol, bar code, human readable code, text, or other
identifying mark. In an embodiment, each mold member may be coded
such that controller computer 1801 may indicate to a user which
mold members to select by conveying the code for each mold member.
In an embodiment, after mold member 1809 is selected, identifying
mark 1808 on mold member 1809 may be sent to controller computer
1801. Controller computer 1801 may be configured to provide
feedback to the user confirming or rejecting the selection. In an
embodiment, when mold member 1809 is to be placed back into storage
array 1806, identifying mark 1808 may be sent to controller
computer 1801. Controller computer 1801 may be configured to notify
a user of designated storage location 1804 for mold member 1809 by
activating indicators 1802 proximate to that location 1804.
[0414] In an embodiment, the controller computer may be manipulated
by utilizing software applications as described above. The software
may include applications for classifying certain eyeglass molds for
the production of prescription eyeglass lenses. The logic
controller and the software may also be configured to accept data
pertaining to certain parameters that characterize an eyeglass mold
for lens production. In a preferred embodiment, the desired
parameters may be recognized by the controller computer and a
signal may be sent from controller computer 1801 to indicators 1802
proximate mold member storage location 1804, where the mold member
possessing the desired parameters for production may be stored. In
this manner, indicators 1802 may be activated to call a user's
attention to the desired mold member.
[0415] As depicted in FIG. 36, device 1807 may be coupled to the
controller computer to ease inputting data pertaining to mold
member 1809. Device 1807 may be a scanner that reads a human
readable code or bar code 1808 attached to mold member 1809. In a
preferred embodiment, a code or marking may be assigned and
attached to each eyeglass mold member 1809. For example, bar code
1808 may be located on an outside edge of eyeglass mold 1809, as
depicted in FIG. 36. Scanning device 1807 may read bar code 1808 on
an outside edge of eyeglass mold 1809. In addition, the controller
computer 1801 may be configured to send an activation signal to
indicators 1802 adjacent to the proper mold member storage location
1804 for mold member 1809.
[0416] In an alternate embodiment, device 1807 may include a
peripheral device that may be configured to process data by way of
voice recognition. The peripheral device may include a microphone
configured to recognize voice input from the user. Once controller
computer 1801 recognizes the input data, it may send a signal to
mold member storage array 1806 or mold member storage location 1804
to indicate the proper storage location for an eyeglass mold
member.
[0417] Additional embodiments relate to a system and a
computer-implemented method for the collection and transmission of
eyeglass lens information over a computer network. The system may
also include at least one controller computer coupled to a lens
forming apparatus. The system, in some embodiments, includes
computer hardware and software operable to send and receive data
over a computer network to and from a client computer system. In an
embodiment, the computer-implemented method may be implemented by
program instructions, which may be computer-executable and may be
incorporated into a carrier medium.
[0418] Eyeglass lens information may generally refer to any data
representative of an eyeglass lens prescription, an eyeglass lens
composition, operating conditions configured to produce an eyeglass
lens, one or more lens molds appropriate to form an eyeglass lens,
one or more lens mold gaskets appropriate to form an eyeglass lens
and/or other appropriate characteristics of an eyeglass lens such
as but not limited to tint or coating. The eyeglass lens
composition information may include, for example, an identity of a
monomer-containing fluid, which may be polymerized to form an
eyeglass lens. Such information may be in the form of raw data,
including binary or alphanumeric, formatted data, or reports. In
some embodiments, eyeglass lens information relates to data
collected from a client or customer. More specifically, eyeglass
lens information may take the form of data collected from a doctor
examining a patient and/or prescribing an eyeglass lens for a
patient. Other sources of eyeglass lens information may include,
but are not limited to: an optician, an optometrist, an
ophthalmologist, a retailer of eyeglass lenses, an optical lab, or
a wholesaler of eyeglass lenses. The information may be encrypted
for security purposes.
[0419] The term "computer system" as used herein generally
describes the hardware and software components that in combination
allow the execution of computer programs. The computer programs may
be implemented in software, hardware, or a combination of software
and hardware. Computer system hardware generally includes a
processor, memory media, and input/output (I/O) devices. As used
herein, the term "processor" generally describes the logic
circuitry that responds to and processes the basic instructions
that operate a computer system. The term "memory medium" includes
an installation medium, e.g., a CD-ROM, floppy disks; a volatile
computer system memory such as DRAM, SRAM, EDO RAM, Rambus RAM,
etc.; or a non-volatile memory such as optical storage or a
magnetic medium, e.g., a hard drive. The term "memory" is used
synonymously with "memory medium" herein. The memory medium may
include other types of memory or combinations thereof. In addition,
the memory medium may be located in a first computer in which the
programs are executed, or may be located in a second computer that
connects to the first computer over a network. In the latter
instance, the second computer provides the program instructions to
the first computer for execution. In addition, the computer system
may take various forms, including a personal computer system,
mainframe computer system, workstation, network appliance, Internet
appliance, personal digital assistant (PDA), television system or
other device. In general, the term "computer system" can be broadly
defined to encompass any device having a processor that executes
instructions from a memory medium.
[0420] The memory medium preferably stores a software program or
programs for the reception, storage, analysis, and transmittal of
eyeglass lens information. The software program(s) may be
implemented in any of various ways, including procedure-based
techniques, component-based techniques, and/or object-oriented
techniques, among others. For example, the software program may be
implemented using ActiveX controls, C++ objects, JavaBeans,
Microsoft Foundation Classes (MFC), or other technologies or
methodologies, as desired. A central processing unit (CPU), such as
the host CPU, for executing code and data from the memory medium
includes a means for creating and executing the software program or
programs according to the methods, flowcharts, and/or block
diagrams described below.
[0421] A computer system's software generally includes at least one
operating system such as Windows NT, Windows 95, Windows 98, or
Windows ME (all available from Microsoft Corporation); or Mac OS
and Mac OS X Server (Apple Computer, Inc.), MacNFS (Thursby
Software), PC MACLAN (Miramar Systems), or real time operating
systems such as VXWorks (Wind River Systems, Inc.), QNX (QNX
Software Systems, Ltd.), etc. The foregoing are all examples of
specialized software programs that manage and provide services to
other software programs on the computer system. Software may also
include one or more programs configured to perform various tasks on
the computer system and various forms of data to be used by the
operating system or other programs on the computer system. Software
may also be operable to perform the functions of an operating
system ("OS"). The data may include, but is not limited to,
databases, text files, and graphics files. A computer system's
software generally is stored in non-volatile memory or on an
installation medium. A program may be copied into a volatile memory
when running on the computer system. Data may be read into volatile
memory as the data is required by a program.
[0422] A server program may be defined as a computer program that,
when executed, provides services to other computer programs
executing in the same or other computer systems. The computer
system on which a server program is executing may be referred to as
a server, though it may contain a number of server and client
programs. In the client/server model, a server program awaits and
fulfills requests from client programs in the same or other
computer systems. Examples of computer programs that may serve as
servers include: Windows NT (Microsoft Corporation), Mac OS X
Server (Apple Computer, Inc.), MacNFS (Thursby Software), PC MACLAN
(Miramar Systems), etc.
[0423] A web server is a computer system, which maintains a web
site browsable by any of various web browser software programs. As
used herein, the term `web browser` refers to any software program
operable to access web sites over a computer network.
[0424] An intranet is a network that may be contained within an
enterprise. An intranet may include many interlinked local area
networks (LANs) and may use data connections to connect LANs in a
wide area network (WAN). An intranet may also include connections
to the Internet. An intranet may use TCP/IP, HTTP, and other
Internet protocols.
[0425] An extranet, or virtual private network, is a private
network that uses Internet protocols and public telecommunication
systems to securely share part of a business' information or
operations with suppliers, vendors, partners, customers, or other
businesses. An extranet may be viewed as part of a company's
intranet that is extended to users outside the company. An extranet
may require security and privacy. Companies may use an extranet to
exchange large volumes of data, share product catalogs exclusively
with customers, collaborate with other companies on joint
development efforts, provide or access services provided by one
company to a group of other companies, and to share news of common
interest exclusively with partner companies.
[0426] Connection mechanisms included in a network may include
copper lines, optical fiber, radio transmission, satellite relays,
or any other device or mechanism operable to allow computer systems
to communicate.
[0427] As used herein, a lens forming apparatus may refer to any
device or instrument operable to form an eyeglass lens. More
particularly, a lens forming apparatus may includes a first curing
unit, which may be configured to direct light to an eyeglass lens
mold, a second curing unit, which may be configured to direct light
and heat to an eyeglass lens, and an anneal unit, which may be
configured to direct heat to an eyeglass lens, as described
herein.
[0428] As illustrated in FIG. 42, lens forming apparatus 2000 may
be operable to direct light and/or heat to an eyeglass lens mold to
form an eyeglass lens. Lens forming apparatus 2000 may be further
configured as described in any of the above embodiments. Lens
forming apparatus 2000 may include at least one controller computer
2002. Controller computer 2002 may be operable to monitor and
control the lens forming apparatus. Alternatively, multiple
controller computers may be coupled to the lens forming apparatus,
and each of the multiple controller computers may be configured to
monitor and control a subset of the equipment coupled to the lens
forming apparatus.
[0429] Controller computer 2002 may operable to connect to a
computer network 2004 such as a local area network, which may
include an Ethernet device. As used herein, "computer network" may
also refer to any type of intranet or extranet network which
connects computers and/or networks of computers together, thereby
providing connectivity between various systems for communication
there between, using various network communication protocols, such
as TCP/IP, FTP, HTTP, HTTPS, etc. Controller computer 2002 may
execute software to communicate with other computer systems
connected to network 2004. In addition, a plurality of controller
computers may be connected to network 2004. Each controller
computer may be coupled to a lens forming apparatus that may be
configured as described in above embodiments.
[0430] A receiver computer 2006 may also be connected to network
2004. Receiver computer 2006 may be configured to receive an
eyeglass lens order from a user. The user may enter the eyeglass
lens order by using a user input device such as a keyboard coupled
to receiver computer 2006. Alternatively, receiver computer 2006
may be configured to receive an eyeglass lens order from a client.
For example, a client may include a doctor, an optician, an
optometrist, an ophthalmologist, a retailer of eyeglass lenses, an
optical lab, or a wholesaler of eyeglass lenses, a franchise of a
national or local retail chain, or another enterprise which
supplies eyeglass lenses. Therefore, the client may be located
remotely from receiver computer 2006. A user at a client site such
as an employee of a doctor or an employee of a franchise may enter
an eyeglass lens order into computer system 2008 located at the
client site. The eyeglass lens order may include eyeglass lens
information as described above. Computer system 2008 at the client
site may be configured to send the eyeglass lens order to the
receiver computer.
[0431] Computer system 2008 may be a computer system, network
appliance, Internet appliance, personal digital assistant (PDA) or
other system. Computer system 2008 may execute software to
communicate with receiver unit 2006, thus facilitating transmission
of eyeglass lens data from computer system 2008 to receiver
computer 2006 and vice versa. For example, computer system 2008 may
be coupled to receiver computer 2006 by connection mechanism 2007
as described above. In one embodiment, computer system 2008 may
execute software operable to transmit eyeglass lens data via any of
various communication protocols over a network to one or more
recipient computer systems and to receive responses from the
recipient computers. These protocols may include, but are not
limited to, TCP/IP, FTP, HTTP, and HTTPS. For example, computer
system 2008 at the client site may be coupled to receiver computer
2006 by computer network 2010 such as an extranet as described
above. Alternatively, computer system 2008 at the client site may
be coupled to receiver computer 2006 by computer network 2004 as
described above. In addition, the information may be encrypted for
security purposes as described above.
[0432] Receiver computer 2006 may store the received eyeglass lens
order in a database. In addition, the database may be stored in
memory of receiver computer 2006, controller computer 2002, and/or
client computer system 2008. Therefore, the database may include a
plurality of eyeglass lens orders. Each eyeglass lens order may
include eyeglass lens information as described above. For example,
each eyeglass lens order may include a patient name, a priority
classification, a job type such as right and/or left lens, a lens
type such as aspheric, flat top, and paradigm progressive, a
monomer or tint type, and an eyeglass lens prescription. The
database may also include a sorted list of the plurality of
eyeglass lens orders. For example, the receiver computer may be
configured to sort the database by patient name, priority
classification, or job type. In addition, the receiver computer may
be configured to send such a database through network 2004 such
that the database may be stored on controller computer 2002 or
client computer system 2008.
[0433] Receiver computer 2006 may also be configured to generate a
job ticket in response to the received eyeglass lens information.
For example, a job ticket may include a barcode representative of
the received eyeglass lens information. The barcode may be
generated by the receiver computer. The job ticket may also include
a portion or any of the received eyeglass lens information as
described above. Receiver computer 2006 may also be configured to
store the generated barcode in the database as a field associated
with the received eyeglass lens information. In this manner, the
database may include a look-up-table that may be searched by
barcode or by any of the eyeglass lens information as described
above. In addition, receiver computer 2006 may be further
configured to send the generated job ticket to printer 2009.
Printer 2009 may be configured to print job tickets in addition to
any other type of document. A printed job ticket may be attached to
a mold assembly holder by a user. The mold assembly holder may be
configured to support an eyeglass lens mold during a process
performed by the lens forming apparatus.
[0434] Lens forming apparatus 2000 may include first barcode reader
2012. First barcode reader 2012 may be configured to scan a barcode
printed on a job ticket. For example, first barcode reader 2012 may
include a light source and a detector. The light source may be
configured to scan a beam of light across a barcode. The detector
may be configured to detect light reflected from the barcode. The
job ticket may be generated by the receiver computer 2006 as
described above. First barcode reader 2012 may be coupled to
controller computer 2002 and may be configured to send information
representative of the barcode such as the detected light to
controller computer 2002 over a serial line connection. The
controller computer may be configured to send the information
representative of the barcode to receiver computer 2006 over
network 2004.
[0435] In addition, receiver computer 2006 may be configured to
search the database of eyeglass lens orders using the information
representative of the barcode as described above. Alternatively,
the receiver computer may process the information representative of
the barcode to determine information representative of an eyeglass
lens order. For example, the receiver computer may search a first
database with the barcode to determine information representative
of an eyeglass lens order associated with the barcode. In addition,
the receiver computer may use the determined information
representative of an eyeglass order to search a second database.
Furthermore, receiver computer 2006 may be configured to send
results of searching the database to controller computer 2002 over
computer network 2004. Results of searching the database may
include any of the information representative of an eyeglass lens
order as described above and a barcode associated with the eyeglass
lens order. For example, results of searching the database may
include a job number, a patient name, a mold assembly holder
number, a priority, a bin location, a lens location (i.e., left
lens or right lens), a lens type, a monomer type and/or tint, a
spherical power, a cylindrical power, axis, an add power, curing
conditions. In addition, controller computer 2002 may be configured
to at least temporarily store the information in a memory coupled
to controller computer 2002.
[0436] In a further embodiment, receiver computer 2006 may be
configured to determine a front mold member identity and a back
mold member identity from the information representative of the
eyeglass lens order. In addition, receiver computer 2006 may be
configured to send the determined front mold member identity and
the determined back mold member identity to controller computer
2002. Alternatively, controller computer 2002 may be configured to
determine the front mold member identity and the back mold member
identity from information representative of an eyeglass lens order,
which may be received from receiver computer 2006.
[0437] Controller computer 2002 may be further coupled to mold
member storage array 2014. In addition, controller computer 2002
may be configured to send the determined front mold member identity
and the determined back mold member identity to mold member storage
array 2014. Mold member storage array 2014 may be configured as
described in any of the above embodiments. For example, the mold
member storage array may be configured to hold a plurality of
eyeglass lens molds. In addition, the mold member storage array may
be configured to determine a location of a front mold member and a
back mold member and to generate a signal to indicate the
determined locations. Alternatively, the location of front and back
mold members may be determined by the controller computer. The mold
member storage array may also be configured to display the
generated signal to a user. The signal may be a visual and/or
audible signal suitable for detection by a user. The mold member
storage array may also be configured to generate and/or display the
signal sequentially as described in above embodiments. As such, a
generated signal may indicate an appropriate mold member to a user.
The user may remove the appropriate mold member from the mold
member storage array and may assemble an eyeglass lens mold in the
mold assembly holder as described above. Assembly of the eyeglass
lens mold may also include filling a space between two mold members
with a lens forming composition. The lens forming composition may
include any of the lens forming compositions as described in above
embodiments.
[0438] Lens forming apparatus 2000 may be configured to receive a
mold assembly holder and an assembled eyeglass lens mold in a first
curing unit (not shown) as described in any of the above
embodiments. For example, the first curing unit may be configured
to direct light to the eyeglass lens mold to at least partially
cure the lens forming composition. In addition, first curing unit
may include second barcode reader 2016. Second barcode reader 2016
may be configured to scan a barcode on a job ticket as described in
above embodiments. The job ticket may be attached to a mold
assembly holder as described in above embodiments. In addition, the
second barcode reader may be disposed within the first curing unit
proximate to a location at which the mold assembly holder may be
placed into the first curing unit by a user. Additional barcode
readers may be disposed within the first curing unit proximate to a
location at which the mold assembly holder may be removed from the
first curing unit by a user and at various locations through the
first curing unit. As such, the second barcode reader may be
configured to scan a barcode of job ticket on a mold assembly
holder containing an assembled eyeglass lens mold prior to, during,
or subsequent to at least partial curing of a lens forming
composition disposed within the assembled eyeglass lens mold. In
addition, second barcode reader 2016 may be coupled to controller
computer 2002 and may configured to send information representative
of the barcode such as detected light to controller computer 2002
over a serial line connection. In addition, controller computer
2002 may be configured to monitor the progress of mold assembly
units through the first curing unit from output from at least one
barcode reader. Furthermore, the controller computer may be
configured to determine a throughput of the first curing unit from
the output from at least one barcode reader.
[0439] The controller computer may be configured to determine an
eyeglass lens order and/or eyeglass lens information from the
information received from the second barcode reader as described in
above embodiments. For example, the controller computer may be
configured to search a database of eyeglass lens information, which
may be sent to controller computer by the receiver computer. In
addition, the controller computer may be configured to send the
information received from the second barcode reader to receiver
computer 2006 over network 2004. Receiver computer 2006 may be
configured to determine an eyeglass lens order and/or eyeglass lens
information from the information received from the second barcode
reader as described in above embodiments. Receiver computer 2006
may be configured to send the determined eyeglass lens order and/or
the determined eyeglass lens information to controller computer
2002.
[0440] In addition, controller computer 2002 may be configured to
alter a parameter of an instrument coupled to lens forming
apparatus 2000 in response to the determined eyeglass lens order
and/or the determined eyeglass lens information. For example,
controller computer 2002 may be coupled to a first curing unit of
lens forming apparatus 2000. In addition, controller computer 2002
may be configured to alter a parameter of an instrument coupled to
the first curing unit of lens forming apparatus 2000 to alter a
duration of a light pulse generated by the first curing unit. In
this manner, the duration of the light pulse, which is provided to
an assembled eyeglass lens mold by a first curing unit, may vary
depending on the eyeglass lens being formed.
[0441] Furthermore, controller computer 2002 may be configured to
monitor a parameter of at least one instrument coupled to the first
curing unit during curing of a lens forming composition in the
first curing unit. In addition, the controller computer may be
configured to compare the monitored parameter to an acceptable
range for the parameter and to display an error message if the
monitored parameter is outside of the acceptable range. In this
manner, the controller computer may be configured to monitor a
curing process in situ and to provide real-time information to a
user of the lens forming apparatus.
[0442] Lens forming apparatus 2000 may also be configured such that
an assembled eyeglass lens mold may be transported from the
apparatus subsequent to being treated in the first curing unit. For
example, lens forming apparatus 2000 may include a conveyor system
(not shown) configured to transport mold assembly holders which may
contain eyeglass lens molds through a first curing unit as
described in above embodiments. Therefore, subsequent to treatment
in a first curing unit, a user may remove the mold assembly holder
and the assembled eyeglass lens mold contained within the mold
assembly holder from a conveyor system. Furthermore, the user may
place the mold assembly holder into a second curing unit (not
shown) of lens forming apparatus 2000.
[0443] In addition, second curing unit may include third barcode
reader 2018. Third barcode reader 2018 may be configured to scan a
barcode on a job ticket as described in above embodiments. The job
ticket may be attached to a mold assembly holder as described in
above embodiments. In addition, the third barcode reader may be
disposed within the second curing unit proximate to a location at
which the mold assembly holder may be placed into the second curing
unit by a user. An additional barcode reader may also be disposed
within the second curing unit proximate to a location at which the
mold assembly holder may be removed from the second curing unit by
a user or at various locations within the second curing unit.
[0444] As such, the third barcode reader may be configured to scan
a barcode on a job ticket attached to a mold assembly holder
containing an assembled eyeglass lens mold prior to, during, or
subsequent to curing of a lens forming composition disposed within
the assembled eyeglass lens mold. In addition, third barcode reader
2018 may be coupled to controller computer 2002 and may be
configured to send information representative of the barcode such
as detected light to controller computer 2002 over a serial line
connection. In addition, controller computer 2002 may be configured
to monitor the progress of mold assembly units through the second
curing unit from output from at least one barcode reader. The
controller computer may also be configured to alter a parameter of
an instrument coupled to the first curing unit from output from at
least the one barcode reader. In this manner, the controller
computer may be configured to control the first curing unit based
on conditions present in the second curing unit. As such, curing of
a lens forming composition in the first and the second curing unit
may be synchronized and/or optimized by the controller computer.
Furthermore, the controller computer may be configured to determine
a throughput of the second curing unit from the output from at
least one barcode reader.
[0445] The controller computer may be configured to determine an
eyeglass lens order and/or eyeglass lens information from the
information received from the third barcode reader as described in
above embodiments. In addition, the controller computer may be
configured to send the information received from the third barcode
reader to receiver computer 2006 over network 2004. Receiver
computer 2006 may be configured to determine an eyeglass lens order
and/or eyeglass lens information from the information received from
the third barcode reader as described in above embodiments.
Receiver computer 2006 may be configured to send the determined
eyeglass lens order and/or the determined eyeglass lens information
to controller computer 2002.
[0446] In addition, controller computer 2002 may be configured to
alter a parameter of an instrument coupled to lens forming
apparatus 2000 in response to the determined eyeglass lens order
and/or the determined eyeglass lens information. For example,
controller computer 2002 may be coupled to a second curing unit of
lens forming apparatus 2000. In addition, controller computer 2002
may be configured to alter a parameter of an instrument coupled to
the second curing unit of lens forming apparatus 2000 to alter an
intensity of light or a temperature of heat generated by the second
curing unit. As such, the intensity of light or the temperature of
heat, which may be provided to an assembled eyeglass lens mold by a
second curing unit, may vary depending on the eyeglass lens being
formed.
[0447] As described above, controller computer 2002 may be
configured to monitor a parameter of at least one instrument
coupled to the second curing unit during curing of a lens forming
composition in the second curing unit. For example, the controller
computer may be configured to monitor a temperature of a second
curing unit. In addition, the controller computer may be configured
to alter a speed of the conveyor system in response to the
monitored temperature. In this manner, the controller computer may
be configured to prevent a mold assembly holder from being
introduced into the second curing unit until the temperature is
within an acceptable range for curing a lens forming composition
disposed within the mold assembly holder. In addition, the
controller computer may be configured to compare the monitored
parameter to an acceptable range for the parameter and to display
an error message if the monitored parameter is outside of the
acceptable range. In this manner, the controller computer may be
configured to monitor a curing process in situ and to provide
real-time information to a user of the lens forming apparatus.
[0448] Lens forming apparatus 2000 may also be configured such that
an eyeglass lens may be transported from the apparatus subsequent
to being treated in the second curing unit. For example, lens
forming apparatus 2000 may include a conveyor system configured to
transport mold assembly holders which may contain at least
partially cured lens forming compositions through a second curing
unit as described in above embodiments. Therefore, subsequent to
treatment in a second curing unit, a user may remove the mold
assembly holder from a conveyor system and the eyeglass lens
contained within the mold assembly holder. A user may also
disassemble the eyeglass lens mold assembly and may remove the at
least partially cured lens forming composition from the eyeglass
lens mold assembly. In addition, the user may place the at least
partially cured lens forming composition into the mold assembly
holder from which the at least partially cured lens forming
composition was removed.
[0449] The user may place the at least partially cured lens forming
composition contained within the mold assembly holder into an
anneal unit. At least one barcode reader may be disposed within the
anneal unit as described in any of the above embodiments. In
addition, at least the one barcode reader within the anneal unit
may be configured as described in any of the above embodiments.
Each barcode reader within the anneal unit may also be coupled to a
controller computer. The controller computer may also be configured
as described in any of the above embodiments.
[0450] In addition, the controller computer may be configured to
alter operation of the lens forming apparatus in response to a
predetermined signal. A predetermined signal may include login by
an operator or an engineer, a predetermined time, or reception of
an eyeglass lens order. For example, an operator or an engineer may
login at the beginning of a work shift. Upon receiving the login
data, the controller computer may alter an operation of the lens
forming apparatus. In this manner, upon receiving login data, a
controller computer may supply power to lamps of a curing unit and
may supply power to a monomer heating unit. Similarly, a controller
computer may be configured to supply power to lamps of a curing
unit or a monomer heating unit at a predetermined time at which a
work shift may begin. The predetermined time may be set by an
operator or an engineer using the controller computer.
Alternatively, a controller computer may be configured to supply
power to lamps of a curing unit or a monomer heating unit upon
reception of an eyeglass lens order. In this manner, the supplied
power may vary depending on the eyeglass lens, which may be formed
in response to the order. As such, the controller computer may be
configured to "warm up" a lens forming apparatus, which may
increase throughput and decrease cost.
[0451] Lens forming apparatus 2000 may also include mold reader
2020. Mold reader 2020 may be configured to scan a mold member and
to determine a mold member identity. For example, a user may
disassemble an eyeglass lens mold subsequent to removing the
eyeglass lens mold from the second curing unit as described above.
In addition, a user may use mold reader 2020 to scan a front mold
member and a back mold member of the disassembled eyeglass lens
mold. For example, mold reader 2020 may include a light source and
a detector. The light source may be configured to scan a beam of
light across an eyeglass lens mold. The detector may be configured
to detect light reflected from the eyeglass lens mold.
[0452] Mold reader 2020 may be coupled to controller computer 2002
and may configured to send information representative of a mold
member identity such as detected light to controller computer 2002
over a serial line connection. Controller computer 2002 may be
configured to determine an identity of the front mold member and
the back mold member from the sent information. Alternatively,
controller computer 2002 may be configured to send information
generated by mold reader 2020 to receiver computer 2006 over a
computer network. Receiver computer 2006 may be configured to
determine an identity of the front mold member and the back mold
member and to send the determined identities to the controller
computer over the computer network. Alternatively, mold reader 2020
may be configured to determine an identity of a front mold member
and an identity of a back mold member. In this manner, mold reader
2020 may also be configured to send determined identities of the
front and back mold members to the controller computer.
[0453] Controller computer 2002 may be coupled to mold member
storage array 2014 as described above. Controller computer 2002 may
be configured to send the determined front mold member identity and
the determined back mold member identity to mold member storage
array 2014. In addition, the mold member storage array may be
configured to determine an appropriate location for a mold member
within the mold member storage array from a mold member identity
and to generate a signal to indicate the determined location. The
mold member storage array may also be configured to display the
generated signal to a user. The signal may be visual and/or audible
such that the signal may be detected by a user. The mold member
storage array may also be configured to generate and/or display the
signal sequentially as described in above embodiments. As such, a
generated signal may indicate, to a user, an appropriate location
for an eyeglass mold member having the determined identity. In this
manner, a user may place a mold member into an appropriate location
in a mold member storage array until an eyeglass lens order is
received which requires use of the mold member.
[0454] Various embodiments further include receiving or storing
instructions and/or data implemented in accordance with the
foregoing description upon a carrier medium. Suitable carrier media
include memory media or storage media such as magnetic or optical
media, e.g., disk or CD-ROM, as well as signals such as electrical,
electromagnetic, or digital signals, conveyed via a communication
medium such as networks and/or a wireless link.
[0455] In an alternate embodiment, the receiver computer may be
operable to upload eyeglass lens data directly to the controller
computer, for example, by a communications link such as a serial
data connection, wireless data link modem, floppy drive, etc. The
controller computer may be connected to a computer network, as may
be the client computer system. In addition, the controller computer
may have software executable to transmit eyeglass lens information
to the client computer system and to receive response information
back from the client computer system, and the client computer
system may have software executable to receive eyeglass lens
information and to transmit a response back to the controller
computer or to one or more receiver computers.
[0456] In a further embodiment, the receiver computer may connect
to a server (not shown), either directly, as with a communication
link, or remotely, via a computer network. The server may be
operable to receive and store eyeglass lens information and to make
the eyeglass lens information available to client computer systems
also connected to a network. The server may be any of a variety of
servers. For example, the server may be a web server such that the
server may be operable to maintain a web site accessible by the
client computer systems with browser software. A use of the client
computer system may include viewing and/or downloading eyeglass
lens information from a server using the browser software. As
another example, the server may be an FTP server, in which case a
user of a client computer system may be able to transfer the
eyeglass lens information from the server to the client computer
system using an FTP software program. As yet another example, a
server may allow remote login to an account by a client computer
system. The account may have been established for use by a user of
the client computer system. The user of the client computer system
may then view, edit, or transfer eyeglass lens information as
needed. The client computer system may also optionally transmit a
response back to the server, which may then be accessed by the
receiver computer. A client computer system may also transmit the
response information to one or more additional client computer
systems. In all of these embodiments, security measures may be
employed to protect the identity of the users, as well as the
privacy and integrity of the information. Such security measures
may include secure login, encryption, private communication lines,
and other security measures.
[0457] In one embodiment, a server may be a web server operable to
maintain a web site. When a client computer system accesses the web
site of the web server, the web server may provide various data and
information to a client browser on a client computer system,
possibly including a graphical user interface (GUI) that displays
the information, descriptions of the information, and/or other
information that might be useful to the users of the system.
[0458] In some embodiments, the receiver computer may include an
electronic controller, as described herein. The electronic
controller may allow the receiver computer to be operated by a
client computer system that is coupled to the electronic
controller. The client computer system may include software that
provides the user information regarding the operation of the
receiver computer. The software may allow the user of the client
computer to issue commands that allow operation of the receiver
computer from the electronic controller. The issued commands may be
converted to control signals. The control signals may be received
by the electronic controller. The electronic controller may operate
components of the receiver computer in response to the received
control signals.
[0459] The client computer system may be coupled directly to the
receiver computer. Alternatively, the client computer system may be
coupled to the receiver computer via a computer network. In this
embodiment, an operator may be in a different location than the
location of the receiver system. By sending control signals over
the computer network, the operator may remotely control the
operation of the receiver system. The receiver system may also be
configured to transmit the obtained eyeglass lens information back
to the client computer system via the computer network.
[0460] As illustrated in FIG. 43, an embodiment of a
computer-implemented method for forming an eyeglass lens may
include receiving an eyeglass lens order with a receiver computer
as shown in step 2100. The eyeglass lens order may include eyeglass
lens information as described above. A receiver computer may be
configured as described in any of the above embodiments. Receiving
an eyeglass lens order may include receiving an eyeglass lens order
from a user. For example, a user may enter an eyeglass lens order
by using a user input device such as a keyboard coupled to a
receiver computer. Alternatively, receiving an eyeglass lens order
may include receiving an eyeglass lens order from a client such as
a doctor, an optician, an optometrist, an ophthalmologist, a
retailer of eyeglass lenses, an optical lab, or a wholesaler of
eyeglass lenses, a franchise of a national or local retail chain,
or another enterprise which supplies eyeglass lenses. Therefore,
receiving an eyeglass lens order may include receiving the eyeglass
lens order with a computer system located remotely at a client site
and sending the eyeglass lens order to the receiver computer.
[0461] A computer system located remotely at a client site may be
coupled to a receiver computer via a server as described above. The
client computer system may be configured to receive and/or transmit
information to the receiver computer. In one embodiment, the
receiver computer may be configured to receive control signals from
the client computer system via the server. The operation of the
receiver system and subsequently the controller computer and the
lens forming apparatus may, therefore, be controlled via a client
computer through a server. As discussed before, the receiver
computer may also transmit eyeglass lens information back to the
client computer system via the server. The eyeglass lens
information may be encrypted as described in above embodiments.
[0462] The method may also include storing the received eyeglass
lens order in a database. The database may be stored by a receiver
computer as described in above embodiments. Alternatively, the
database may be stored by the controller computer as described
above. The database may include a plurality of eyeglass lens
orders. Each eyeglass lens order may include eyeglass lens
information as described above. The method may also include sorting
the plurality of eyeglass lens orders such that the database may
include a sorted list of the plurality of eyeglass lens orders.
[0463] The method may also include generating a job ticket in
response to the received eyeglass lens information as shown in step
2102. A job ticket may include a barcode representative of the
received eyeglass lens information as described in above
embodiments. The barcode may be generated by a receiver computer or
a controller computer. The method may also include storing the
barcode in the database as a field associated with the received
eyeglass lens information. In this manner, the database may include
a look-up-table that may be searched by barcode or by any of the
eyeglass lens information as described above. In addition, the
method may include printing the generated job ticket. A printed job
ticket may be attached to a mold assembly holder by a user. The
mold assembly holder may be configured as described in any of the
above embodiments.
[0464] As shown in step 2104, the method may include scanning a
barcode printed on a job ticket. The method may also include
sending information resulting from scanning the barcode to a
controller computer over a serial line connection. The controller
computer may be configured as described in any of the above
embodiments. The method may further include sending the information
representative of the barcode to a receiver computer.
[0465] In addition, the method may include determining information
associated with an eyeglass lens order associated with the scanned
bar code. For example, the method may include searching a database
of eyeglass lens orders using the information representative of the
barcode. Alternatively, the method may include processing the
information representative of the barcode to determine information
representative of an eyeglass lens order. For example, the method
may include searching a first database with the barcode to
determine information representative of an eyeglass lens order
associated with the barcode. In addition, the method may include
searching a second database with the determined information
representative of an eyeglass order. Furthermore, the method may
include sending results of searching the database from a receiver
computer to a controller computer over a computer network. Results
of searching the database may include any of the information
representative of an eyeglass lens order as described above and a
barcode associated with the eyeglass lens order.
[0466] The method may also include determining a front mold member
identity and a back mold member identity from the information
representative of the eyeglass lens order, as shown in step 2106.
In addition, the method may include sending the determined front
mold member identity and the determined back mold member identity
to a controller computer. The method may further include sending
the determined front mold member identity and the determined back
mold member identity to a mold member storage array. A mold member
storage array may be configured as described in any of the above
embodiments. In addition, the method may include generating a
signal to indicate locations of mold members having the determined
mold member identities. The method may also include displaying the
generated signal to a user. For example, the generated signal may
be displayed as a visual and/or audible signal suitable for
detection by a user. Furthermore, the method may include generating
and/or displaying the signal sequentially to indicate a location of
a first mold member and a location of a second mold member. As
such; a generated signal may indicate a location of an appropriate
mold member to a user. The user may remove the appropriate mold
member from the mold member storage array and may assemble an
eyeglass lens mold containing a lens forming composition in a mold
assembly holder as described above. The lens forming composition
may include any of the lens forming compositions as described in
above embodiments.
[0467] The method may further include scanning a bar code on a job
ticket subsequent to placing a mold assembly holder including an
assembled eyeglass lens mold in a first curing unit of a lens
forming apparatus, as shown in step 2108. Scanning the bar code may
include scanning the barcode with a second barcode reader, which
may be configured as described in above embodiments. For example,
the second barcode reader may be disposed within a first curing
unit proximate to a location at which the mold assembly holder may
be placed into the first curing unit by a user. The second barcode
reader, however, may also be disposed within the first curing unit
proximate to a location at which the mold assembly holder may be
removed from the first curing unit or throughout the first curing
unit. As such, step 2108 may include scanning a barcode of job
ticket on a mold assembly holder containing an assembled eyeglass
lens mold prior to, during, or subsequent to curing at least a
portion of a lens forming composition disposed within the assembled
eyeglass lens mold. In addition, the method may include sending
information representative of the barcode to a controller computer
over a serial line connection.
[0468] As shown in step 2110, the method may include determining
parameters of an instrument of the first curing unit from
information representative of the barcode. The parameters of the
instrument of the first curing unit may define operating conditions
for at least partial curing of a lens forming composition. In
addition, the method may include altering a parameter of an
instrument coupled to a first curing unit in response to the
determined parameters. For example, altering a parameter of an
instrument may include altering a duration of a light pulse
generated by the first curing unit. In this manner, the duration of
the light pulse, which may be provided to an assembled eyeglass
lens mold by a first curing unit, may vary depending on the
eyeglass lens being formed.
[0469] Subsequent to treatment in a first curing unit, a user may
remove the mold assembly holder and the assembled eyeglass lens
mold contained within the mold assembly holder from a conveyor
system. Furthermore, the user may place the mold assembly holder
into a second curing unit of a lens forming apparatus.
[0470] In addition, the method may include scanning a barcode on a
job ticket with a third barcode reader subsequent to placing a mold
assembly holder in a second curing unit, as shown in step 2112. The
job ticket may be attached to a mold assembly holder as described
in above embodiments. The second curing unit and a third barcode
reader may be configured as described in any of the above
embodiments. In addition, the third barcode reader may be disposed
within the second curing unit proximate to a location at which the
mold assembly holder may be placed into, moved through, or removed
from the second curing unit by a user. As such, the method may
include scanning a barcode on a job ticket attached to a mold
assembly holder containing an at least partially cured lens forming
composition prior to, during, or subsequent to curing of a lens
forming composition. In addition, the method may include sending
information representative of the barcode such as detected light to
a controller computer over a serial line connection.
[0471] In addition, the method may include determining an eyeglass
lens order and/or eyeglass lens information from the information
received from the third barcode reader with a controller computer.
In addition, the method may include sending the information
received from the third barcode reader to a receiver computer over
a computer network. The method may include determining an eyeglass
lens order and/or eyeglass lens information from the information
received from the third barcode reader with a receiver computer. As
such, the method may include sending the determined eyeglass lens
order and/or the determined eyeglass lens information from the
receiver computer to a controller computer.
[0472] In addition, the method may include determining a parameter
of an instrument coupled to a second curing unit in response to the
determined eyeglass lens order and/or the determined eyeglass lens
information, as shown in step 2114. For example, the method may
include determining parameters of an instrument coupled to a second
curing unit, which may define operating conditions for post curing
of a lens forming composition. In addition, the method may include
altering a parameter of an instrument coupled to a second curing
unit in response to the determined eyeglass lens order and/or the
determined eyeglass lens information. For example, altering a
parameter of an instrument coupled to a second curing unit may
include altering a temperature of heat generated by the second
curing unit. As such, the temperature of heat, which may be
provided to an at least partially cured lens forming composition,
by a second curing unit may vary depending on the eyeglass lens
being formed.
[0473] A user may disassemble the eyeglass lens mold and may remove
the at least partially cured lens forming composition. In addition,
the user may place the at least partially cured lens forming
composition into the mold assembly holder from which the at least
partially cured lens forming composition was removed. The user may
also place the at least partially cured lens forming composition
disposed within the mold assembly holder into an anneal unit. At
least one barcode reader may also be coupled to the anneal unit as
described in any of the above embodiments. In addition, at least
the one barcode reader may be configured as described in any of the
above embodiments. Furthermore, a controller computer may be
coupled to at least the one barcode reader coupled to the anneal
unit. The controller computer may be configured as described in any
of the above embodiments.
[0474] The method may also include scanning a mold member as shown
in step 2116. The mold member may include a mold member, which may
have been disassembled by a user subsequent to removing the
eyeglass lens mold from the second curing unit as described above.
In addition, the method may include scanning a front mold member
and a back mold member of a disassembled eyeglass lens mold. For
example, a mold member may be scanned with a mold reader.
[0475] In an alternative embodiment, the method may also include
determining a mold member identity with the mold reader. The method
may also include sending information representative of a mold
member identity from a mold reader to a controller computer over a
serial line connection. In addition, the method may include
determining an identity of the front mold member and the back mold
member with the controller computer. Alternatively, the method may
include sending information representative of a mold member
identity from a controller computer to a receiver computer over a
computer network. In this manner, the method may include
determining an identity of the front mold member and the back mold
member with the receiver computer and sending the determined
identities from the receiver computer to a controller computer over
a computer network. The method may also include determining an
identity of a front mold member and an identity of a back mold
member.
[0476] In addition, the method may include sending the determined
front mold member identity and the determined back mold member
identity to a mold member storage array. A controller computer may
be coupled to a mold member storage array as described above. A
mold member storage array may be configured as described in any of
the above embodiments. For example, the mold member storage array
may include a plurality of drawers or locations configured to hold
a mold member. In addition, the method may include determining an
appropriate location for a mold member in a mold member storage
array, as shown in step 2118. The method may further include
generating a signal to indicate the determined location. In
addition, the method may include displaying the generated signal to
a user. The signal may be visual and/or audible such that the
signal may be detected by a user. The method may also include
generating multiple signals sequentially as described in above
embodiments. As such, a generated signal may indicate, to a user,
an appropriate location for an eyeglass mold member having the
determined identity. In this manner, a user may place a mold member
into an appropriate location in a mold member storage array until
an eyeglass lens order is received which requires use of the mold
member.
[0477] FIG. 44 shows an embodiment of graphical user interface
("GUI") 2200 which may display eyeglass lens forming-related
information on a front panel of controller computer 2002. GUI 2200,
as illustrated in FIG. 44, may also be displayed on a front panel
of receiver computer 2006. The controller computer and the receiver
computer may be configured as described in any of the above
embodiments. The controller computer and/or the receiver computer
may include an output device and at least one input device. A
variety of input devices may be used. Some input devices include
pressure sensitive devices (e.g., buttons or screens), movable data
entry devices (e.g., rotatable knobs, a mouse, a trackball, or
moving switches), voice data entry devices (e.g., a microphone),
light pens, or a computer coupled to the controller computer and/or
the receiver computer. The GUI preferably displays controller
and/or receiver computer data requests and responses. The output
device may be a monitor cathode ray tube, an LCD panel, a plasma
display screen, or a touch-sensitive screen.
[0478] GUI 2200 may include a main menu and may be displayed by a
controller computer or a receiver computer when initially powered.
If the main menu is not displayed, a user may access the main menu
by clicking a button, which may be labeled Main Menu, on a
displayed GUI with a mouse. In response to activating the Main Menu
button, the controller and/or receiver computer may cause the main
menu screen to be displayed. As depicted in FIG. 44, a GUI may
offer a number of initial options on the main menu. The options may
include Job Entry 2202, Job Viewer 2204, Alarm Log 2206, Start
2208, Stop 2210, and Exit 2212. Selection of some of the options
such as Job Entry 2202, Job Viewer 2204 and Alarm Log 2206 may
cause the display screen to change to a different GUI. Selection of
other options such as Start 2008 and Stop 2210 may alter an
operation of the lens forming apparatus. For example, selecting
Start 2208 may cause the lens forming apparatus to begin a process
such as curing a lens forming composition. The main menu may also
offer other options which allow the user to access machine status
information and instrument setup menus such as Maintenance 2214,
Machine Setup 2216, and Configuration 2218. Any one of the options
may be selected by a user by clicking an appropriate button with a
mouse.
[0479] GUI 2200 may also display machine status-related information
on the main menu. For example, GUI 2200 may include a graphical
icon or a display listing properties of a lens forming apparatus in
graphic and/or alphanumeric format. A graphical icon or a display
may appear or may be altered on GUI 2200 in response to a change in
status of lens forming apparatus 2000. For example, as shown in
FIG. 45, icon 2220 representative of a mold assembly holder, as
described in above embodiments, may appear on GUI 2200 when a mold
assembly holder is placed in a first curing unit or a second curing
unit of lens forming apparatus 2000. A position of icon 2220 on the
GUI may also indicate a unit within which the mold assembly holder
is disposed and a position of the mold assembly holder within the
unit. For example, a position of the mold assembly holder within
the unit may be determined from a time of initial detection and a
speed of the conveyor system. In this manner, the position of icon
2220 on the GUI may correspond to the determined position of the
mold assembly holder within the unit.
[0480] In addition, an icon may be altered in color to indicate a
change in status of a lens forming apparatus. For example, an icon,
which may represent a signal tower of a lens forming apparatus, may
include series of icons 2222 of different colors. Upon a change in
status of the apparatus or in an alarm coupled to the apparatus, a
color of one of series of icons 2222 may be altered on GUI 2200.
For example, in FIG. 44, a color intensity of two of series of
icons 2222 of signal tower may be altered to indicate 1) that an
alarm may be present and 2) that the machine may be running.
Alternatively, as shown in FIG. 45, a color of only one of series
of icons 2222 may be altered to indicate only 2) that the machine
may be running. In addition, alphanumeric characters 2224 may
appear on GUI 2200 proximate one of the series of icons
representing the signal tower to indicate a change in status of the
machine corresponding to a change in color of one of the series of
icons.
[0481] As shown in FIG. 44, upon activation of an alarm, display
2226 of GUI 2200 may display machine-status information in
alphanumeric format. Display 2226 of GUI 2200 may include a list of
properties to indicate that, for example, "Lower Left Init Filter
Not In Place" and "Job Not Found in Database" in addition to any
other status-related information. GUI 2200 may also include an
option such as Acknowledge 2228 arranged proximate text block 2226.
A user may select Acknowledge 2228 to access and/or remove
machine-status information from text block 2226.
[0482] FIG. 46 shows an alternate embodiment of graphical user
interface ("GUI") 2228 which may display eyeglass lens
forming-related information on a front panel of controller computer
2002. GUI 2228, as illustrated in FIG. 46, may also be displayed on
a front panel of receiver computer 2006 or on a front panel of
client computer system 2008. The controller computer, the receiver
computer, and the client computer system may be configured as
described in above embodiments. GUI 2228 may display controller
and/or receiver computer data requests and responses. GUI 2228 may
include a main menu and may be displayed by a controller computer
or a receiver computer when initially powered. GUI 2228 may also be
displayed by a client computer system upon request from a user.
[0483] As depicted in FIG. 46, GUI 2228 may offer a subset of the
initial options displayed on GUI 2200. For example, GUI 2228 may be
displayed to a user who may have limited access to information
and/or control of lens forming apparatus 2200. A user may be
required to obtain a user id to access the system. Access granted
to a user may vary depending on the user. For example, access
granted to a user may be determined from information provided by a
user upon request for a user id. For example, an operator or an
engineer, who may operate and/or maintain a lens forming apparatus,
may be granted more access to information and control of the
apparatus than a client. Therefore, the options, which may be,
displayed either on GUI 2200 or GUI 2228 may be determined by a
user id provided by a user during a login routine. A login routine
may also require a user to enter a password. In this manner, access
to the system through either GUI 2200 or GUI 2228 may be controlled
and/or monitored to protect the identity of the users, as well as
the privacy and integrity of the information. A user may also be
required to enter a password upon selecting Exit 2212 from either
GUI 2200 or GUI 2228 for privacy and integrity purposes.
[0484] For example, upon login by an operator, GUI 2200 may be
displayed on a controller computer or on a receiver computer. Upon
login by a client, however, GUI 2228 may be displayed on a client
computer system to provide a limited number of options such as Job
Entry 2202, View Jobs 2204, Configure 2218, and Exit 2212. As
described above, any one of the options may be selected by a user
by clicking an appropriate button with a mouse. In addition,
selection of a similar option from either GUI 2200 or GUI 2228 may
cause the display screen to change to substantially the same GUI.
Therefore, regardless of whether Job Entry or View Jobs is selected
from GUI 2200 or GUI 2228, respectively, the display screen may be
changed to a prescription input menu.
[0485] Selection of Job Entry 2202 may cause the display screen to
change to prescription input GUI 2230, an embodiment of which is
shown in FIG. 47. GUI 2230 may be displayed on a controller
computer, a receiver computer, and/or a client computer system. The
controller computer, the receiver computer, and the client computer
system may be configured as described in any of the above
embodiments. Prescription input GUI 2230 may preferably allow a
user to enter data pertaining to a new lens order. The prescription
input menu may include a number of menu items, which may be
configured to collect information from a user. For example, the
prescription input menu may include a number of input windows 2232
which may be configured to receive alphanumeric input from a user.
In addition, the system may be configured to generate and display a
signal to the user upon an invalid entry in an input window.
[0486] In addition, the prescription input menu may include a
number of selection menus, which may include radio buttons 2234,
and/or pull-down menus 2236. A radio button may be an item that may
be selected or deselected, and which displays its state to a user.
In addition, in a menu of radio buttons, typically only one radio
button may be selected at a time. For example, upon selection of
one radio button in a menu, each of the other radio buttons in the
menu may be shaded to indicate that these selections are
unavailable. Furthermore, additional menu items displayed on a GUI
may be altered upon selection of a radio button. For example, if a
user selects a radio button to indicate that a new lens order
includes a right lens and a left lens, then pull down menus may
appear on the GUI to accept prescription information for both the
right and the left lens. A pull down menu may include a number of
options, which may be viewed by selecting the pull down menu. In
addition, a user may select one of the number of options from the
pull down menu. A selected option may appear in a text box of the
pull-down menu subsequent to selection by a user. Additional pull
down menus may be altered upon a selection from a pull down menu.
For example, upon selection of zero cylindrical power, a pull down
menu for a cylinder axis power may be removed from GUI 2230 or may
be shaded to indicate that the pull down menu is currently inactive
(i.e., the menu may not accept input from a user).
[0487] Each of the menu items allows entry of a portion of the lens
prescription. The lens prescription information may include, but is
not limited to, job number, patient name, mold assembly holder
number, priority, bin location, lens location (i.e., left lens or
right lens), lens type, monomer type and/or tint, spherical power,
cylindrical power, axis, and add power. The monomer selection may
include choices for example, either clear or photochromic lenses.
The lens type item may allow selection between spheric single
vision, aspheric single vision lenses, flattop bifocal lenses, and
asymmetrical progressive lenses. The sphere item allows the sphere
power of the lens to be entered. The cylinder item allows the
cylinder power to be entered. The axis item allows the cylinder
axis to be entered. The add item allows the add power for
multifocal prescriptions to be added. Since the sphere power,
cylinder power, cylinder axis, and add power may differ for each
eye, and since the molds and gaskets may be specific for the
location of the lens (i.e., right lens or left lens), the GUI
preferably allows separate entries for right and left lenses.
[0488] A user may cancel a new lens order at any time by selecting
an option such as Cancel Entry 2238 which may be displayed on
prescription input GUI 2230. In addition, a user may submit a new
lens order by selecting an option such as Create Job 2240 which may
also be displayed on prescription input GUI 2230. Upon selection of
Create Job 2240, the new lens order submitted by the user may be
sent to a receiver computer or a controller computer. In addition,
the new lens order may be stored in a database of eyeglass lens
orders as described in above embodiments. Furthermore, each entry
of the new lens order may be compared to valid entries for an
eyeglass lens order. If any of the entries do not match valid
entries, GUI 2230 may display an error message to the user. For
example, a new lens order submitted by a user may not be filled by
a lens forming apparatus if the lens forming apparatus does not
include appropriate molds to form the ordered lens. In this manner,
GUI 2230 may display an error message to the user such as
"Prescription Not Available." In addition, an entry may be
determined to be invalid if the entry may have been left blank by a
user. An appearance of an invalid entry may be altered on GUI 2230
to indicate the invalid entry to a user. For example, if a mold is
not available for the left lens, pull down menus for prescription
information for this lens may be highlighted, may be indicated with
a graphical icon, or may be indicated by alphanumeric characters.
GUI 2230 may also be configured to allow a user to alter the
invalid entry and to provide a user with additional options such as
Cancel Entry 2238 and Create Job 2240.
[0489] After the data relating to the prescription has been added,
the controller computer, the receiver computer, or the client
computer system may prompt the user to enter a job number to save
the prescription type. The job number preferably allows the user to
recall a prescription type without having to reenter the
prescription data. The job number may also be used by the
controller computer to control the curing conditions for the lens.
The curing conditions typically vary depending on the type and
prescription of the lens. By allowing the controller computer
access to the prescription and type of lens being formed, the
controller computer may automatically set up the curing conditions
without further input from the user.
[0490] Selection of Job Viewer or View Jobs 2204 may cause the
display screen to change to an embodiment of prescription viewer
GUI 2242, an embodiment of which is shown in FIG. 48. GUI 2242 may
be displayed on a controller computer, a receiver computer, and/or
a client computer system. The controller computer, the receiver
computer, and the client computer system may be configured as
described in any of the above embodiments. Prescription viewer GUI
2242 may preferably allow a user to select an eyeglass lens order
and to view data pertaining to the selected eyeglass lens order.
For example, GUI 2242 may include input windows, radio buttons,
and/or pull down menus as described in above embodiments to allow a
user to enter information which may be associated with an eyeglass
lens order. For example, GUI 2242 may include pull down menu 2244.
The pull down menu may include a list of job numbers, which may be
viewed by selecting the pull down menu. In addition, a user may
select one of the job numbers from the pull down menu. A selected
job number may appear in a text box of the pull-down menu
subsequent to selection by a user. In addition, GUI 2242 may
include input window 2246 which may be configured to receive
alphanumeric characters representative of an eyeglass lens order.
For example, a user may enter a patient's name into an input window
on GUI 2242. GUI 2242 may also be configured such that additional
information related to an eyeglass lens order may be entered by a
user.
[0491] The information entered by the user may be used to determine
additional information related to the eyeglass lens order. The
additional information may be determined by a client computer
system, a receiver computer, or a controller computer, all of which
may be configured as described in above embodiments. For example,
the additional information may be determined by processing the
input from the user and searching a database of information stored
on the client computer system, the receiver computer, or the
controller computer. The additional information may be displayed on
GUI 2242 such that a user may view the additional information. In
addition, GUI 2242 may include a number of options, which may be
available to the user. For example, GUI 2242 may include options
such as Re-Print 2248 and Close 2250. In this manner, the user may
select to print the information displayed in GUI 2242 or to close
GUI 2242 and return to the previous menu displayed on the user's
computer.
[0492] Selection of Alarm Log 2206 may cause the display screen to
change to an embodiment of alarm viewer GUI 2252, an embodiment of
which is shown in FIG. 49. GUI 2252 may be displayed on a
controller computer and/or a receiver computer. The controller
computer and the receiver computer may be configured as described
in any of the above embodiments. Alarm viewer GUI 2252 may
preferably allow a user to view information related to alarms,
which may have occurred during operation of a lens curing
apparatus. Information related to alarms may be presented in
tabular format and may include several columns. For example, as
shown in FIG. 49, GUI 2252 may include column 2254, which may
include alphanumeric characters representative of a date and a time
at which an alarm occurred. In addition, GUI 2252 may include
column 2256 which may include alphanumeric characters
representative of a description of an alarm. GUI 2252 may also
include additional columns, which may include additional
information related to an alarm such as a classification and a
priority of the alarm.
[0493] A user may also select one of the alarms displayed in GUI
2252. Selection of one of the displayed alarms may cause the GUI to
display additional information related to the alarm or to display
additional options related to the alarm and/or operation of the
lens forming apparatus. For example, upon selection of a displayed
alarm, a user may further select to delete the selected alarm or to
restart the lens forming apparatus. GUI 2252 may also include a
number of options, which may be available to the user. For example,
GUI 2252 may include options such as Purge Log 2258 and Close 2260.
In this manner, the user may select to delete all of the
information displayed in GUI 2252 or to close GUI 2252 and return
to the previous menu displayed on the user's computer.
[0494] Selection of Maintenance 2214 may cause the display screen
to change to an embodiment of maintenance viewer GUI 2262, an
embodiment of which is shown in FIG. 50. GUI 2262 may be displayed
on a controller computer and/or a receiver computer. The controller
computer and the receiver computer may be configured as described
in any of the above embodiments. Maintenance viewer GUI 2262 may
preferably allow a user to view information related to operational
status of a lens curing apparatus. Operational status of a lens
curing apparatus may be determined by parameters of a number of
instruments coupled to the lens curing apparatus. For example,
instruments coupled to the lens curing apparatus may include, but
are not limited to, thermocouples, timing devices, light detection
devices such as photodiodes, and electrical measurement devices.
Therefore, parameters of an instrument may include, for example,
output of a thermocouple, a timing device, a light detection
device, or an electrical measurement device. In this manner,
information related to operational status of lens curing apparatus
may include, but may not be limited to, temperatures of a post-cure
chamber, time, light intensity, and electrical currents being drawn
by lamps coupled to the lens curing apparatus. As such,
information, which may be displayed, on the maintenance viewer may
include lamp current draws, current upper and lower limits for the
current draw, and lamp life remaining.
[0495] Information related to operational status of a lens curing
apparatus may be displayed in alphanumeric and graphical format.
For example, as shown in FIG. 49, GUII 2262 may include output
windows 2264 which may include alphanumeric characters
representative of information related to operational status of a
lens curing apparatus as described above. In addition, GUI 2262 may
include a plurality of digital inputs 2266 which may include
alphanumeric characters describing an operational status of a lens
curing apparatus and a corresponding graphical icon. For example,
alphanumeric characters may be used to describe an operation or a
process, which may be performed by a lens forming apparatus. A
graphical icon corresponding to the alphanumeric characters may
indicate if the operation or process is currently being performed
by the lens forming apparatus or if the operation or process is
being performed satisfactorily. For example, if the air pressure
within a lens forming apparatus is within operational limits, a
graphical icon corresponding to alphanumeric characters such as
"Air Pressure OK" may appear as a solid shape such as a circle.
Alternatively, if the air pressure within a lens forming apparatus
is outside of operational limits, a graphical icon corresponding to
alphanumeric characters such as "Air Pressure OK" may appear as an
outlined shape such as a circle. The graphical icons may also be
altered depending if various equipment of the lens forming
apparatus is on or off. In an additional example, the maintenance
viewer may also include digital inputs, which may indicate if a
lamp current draw is too high or too low and if an alarm is
currently activated for the lamp current draw, thereby indicating
lamp failure. As such, the maintenance viewer may provide
comprehensive information related to the current operational status
and setpoints for equipment of a lens forming apparatus.
[0496] GUI 2262 may also include a number of options, which may be
available to the user. For example, GUI 2262 may include options
such as More . . . 2268 and Close 2270. In this manner, the user
may select to view more digital inputs as described above by
selecting More . . . 2268 or to close GUI 2262 and return to the
previous menu displayed on the user's computer by selecting Close
2270.
[0497] Selection of Machine Setup 2216 may cause the display screen
to change to an embodiment of machine setup menu GUI 2272, an
embodiment of which is shown in FIG. 51. GUI 2272 may be displayed
on a controller computer and/or a receiver computer. The controller
computer and the receiver computer may be configured as described
in any of the above embodiments. Machine Setup GUI 2272 may
preferably allow a user to view information related to setpoints
and upper and lower limits for parameters of a number of
instruments coupled to the lens curing apparatus. As described
above, instruments coupled to the lens curing apparatus may
include, but are not limited to, thermocouples, timing devices,
light detection devices such as photodiodes, and electrical
measurement devices. A thermocouple may be configured to measure a
temperature of a curing unit or an anneal unit. For example, a
thermocouple may be disposed in an air intake vent of a curing unit
or an anneal unit. Therefore, parameters of an instrument may
include, for example, output of a thermocouple, a timing device, a
light detection device, and an electrical measurement device. In
this manner, information related to setpoints and limits for
parameters of a number of instruments coupled to the lens curing
apparatus may include, but may not be limited to, a temperature of
a cure unit, a temperature of an anneal unit, time, light
intensity, and electrical currents being drawn by lamps coupled to
the lens curing apparatus. For example, a user may use the machine
setup menu to enter a setpoint and upper and lower alarm limits for
lamp current draws. A temperature of a curing unit may have upper
and lower alarm limits of, for example, approximately 225.degree.
F. and approximately 200.degree. F., respectively. A temperature of
an anneal unit may have upper and lower alarm limits of, for
example, approximately 250.degree. F. and approximately 200.degree.
F., respectively.
[0498] The machine setup menu may include a number of menu items,
which may be configured to collect information from a user. For
example, the machine setup menu may include a number of input
windows 2274 which may be configured to receive alphanumeric input
from a user. In addition, the system may be configured to generate
and display a signal to the user upon an invalid entry in an input
window. As such, a user may view and alter setpoints and upper and
lower limits for a number of instruments coupled to the lens curing
apparatus.
[0499] In addition, the machine setup menu may include a number of
input boxes 2276, which may selected by the user. Upon selection of
an input box, a "check" may appear in the input box to indicate to
a user that the input box has been selected. The input boxes may
include a number of maintenance operations, which may be performed
by an operator. In this manner, after performing a maintenance
operation such as replacing top initialization lamps, replacing
bottom initialization lamps, and/or replacing post-cure lamps, a
user may access the machine setup menu and may select an
appropriate input box. In addition, the system may be configured to
store a date and a time at which an input box is selected and the
maintenance operation corresponding to the selected input box in a
memory. The stored information may also be stored in a database
such as a maintenance log, which may also be viewed by a user
through an appropriate GUI.
[0500] GUI 2272 may also include a number of options, which may be
available to the user. For example, GUI 2272 may include options
such as Save Changes 2278 and Cancel Changes 2280. A user may
submit changes to setpoints and upper and lower limits by selecting
an option such as Save Changes 2278. Upon selection of Save Changes
2278, the changes to the setpoints and upper and lower limits may
be sent to a receiver computer or a controller computer. In
addition, the changes to the setpoints and upper and lower limits
may be stored in a database as described in above embodiments.
Furthermore, each change to a setpoint or an upper and lower limit
may be compared to valid entries for the setpoint or the upper and
lower limit. If any of the entries do not match valid entries, GUI
2272 may display an error message to the user. In this manner, GUI
2272 may display an error message to the user such as "Setpoint Out
Of Range". In addition, an appearance of an invalid entry may be
altered on GUI 2272 to indicate the invalid entry to a user. For
example, if a temperature setpoint for an anneal conveyor is out of
range, an appearance of an input window for this information may be
altered, may be indicated with a graphical icon, or may be
indicated with alphanumeric characters. GUI 2272 may also be
configured to allow a user to alter the invalid entry and to
provide a user with additional options such as Cancel Changes 2280
and Save Changes 2278. A user may cancel changes to setpoints and
upper and lower limits at any time by selecting the Cancel Changes
option.
[0501] Selection of Configuration or Configure 2218 may cause the
display screen to change to an embodiment of configuration setup
menu GUI 2282, an embodiment of which is shown in FIG. 52. GUI 2282
may be displayed on a controller computer and/or a receiver
computer. The controller computer and the receiver computer may be
configured as described in any of the above embodiments.
Configuration GUI 2282 may preferably allow a user to view
information related to filepath names of various databases and/or
directories of information. For example, the GUI may include
various windows, which may include filepath names of Recipe DB
(database) 2284, Job DB (database) 2286, and Ticket Dir (directory)
2288. Each of the filepath names may be used by a computer system,
such as a controller computer or a receiver computer, to find,
open, and/or use a database or a directory. The Recipe DB may
include a plurality of program instructions, which may be
computer-executable to implement a method for forming an eyeglass
lens. The Job DB may include information related to lens forming
processes, which may have been performed, by a lens forming
apparatus. In addition, the Ticket Dir may include information
related to job tickets, which may have been entered by a plurality
of users. In addition, the GUI may include an option such as Browse
. . . 2290, which a user may select to search for additional
available files, which may be used for each database or directory.
For example, a user may browse through a memory medium coupled to a
computer to search for an alternate file that may be used as a
database or directory. Alternatively, a user may enter a filepath
name into an input window.
[0502] The GUI may also include additional windows, which may
include a numeric characters, which may define a Ticket Poll Rate
2292, a Ticket Print Scale 2294, and a frequency for archiving
jobs. Ticket Poll Rate 2292 may serve to define a frequency at
which a system may be checked for new files such as job tickets.
Ticket Print Scale 2294 may serve to define a size of a printed job
ticket. In this manner, a size of a printed job ticket may be
defined as a percentage of a page on which the job ticket may be
printed.
[0503] As depicted in FIG. 53, GUI 2296 may offer a subset of the
initial options displayed on GUI 2282. For example, GUI 2296 may be
displayed to a user who may have limited access to information
and/or control of lens forming apparatus 2200. As defined above, a
user may be required to obtain a user id to access the system.
Access granted to a user may vary depending on the user. For
example, access granted to a user may be determined from
information provided by a user upon request for a user id. For
example, an operator or an engineer, who may operate and/or
maintain a lens forming apparatus, may be granted more access to
information and control of the apparatus than a client. Therefore,
the options, which may be, displayed either on GUI 2282 or GUI 2296
may be determined by a user id provided by a user during a login
routine. For example, upon login by an operator, GUI 2282 may be
displayed on a controller computer or on a receiver computer. Upon
login by a client, however, GUI 2296 may be displayed on a client
computer system to provide a limited number of options such as Job
DB (database) 2286, and Ticket Dir (directory) 2288. GUI 2296,
however, may also be displayed on a controller computer and/or a
receiver computer depending on the user id entered by a user. In
addition, GUI 2296 may include an option such as Browse . . . 2290,
which a user may select to search for additional available
files.
Antireflective Coatings for Plastic Eyeglass Lenses
[0504] For plastic eyeglass lenses, formed from the materials
described above, a portion of the light incident upon the lenses
may be reflected from the eyeglass lens rather than transmitted
through the eyeglass lens. For plastic eyeglass lenses up to about
15% of the incident light may be reflected off the eyeglass lens
surfaces. To reduce the reflection of light from a plastic eyeglass
lens, a thin film may be applied to the lens. Such films may be
referred to as "antireflective coating" films. Antireflective
coatings may reduce the reflectance of light from a surface (i.e.,
increase light transmittance through the film/substrate
interface).
[0505] While numerous approaches to reducing the reflective losses
for glass materials have been developed, few techniques are
available for producing antireflective coatings on plastics. Vapor
deposition techniques have been used commercially to form
antireflective coatings on plastic materials, however these
techniques suffer from a number of drawbacks. Some of the
disadvantages of using vapor deposition include relatively large
capital expenditure for deposition equipment, significant space
requirements, and relatively long cycle times.
[0506] Reactive liquid compositions for forming antireflective
coatings on lenses have been previously studied. Many of the
previously disclosed solutions require heating of the
antireflective film to a high temperature after its application to
a substrate. In some instances, the temperature to cure such
solutions may be greater than about 200.degree. C. Such
temperatures may be suitable for the coating of glass substrates,
but are higher than most plastic lens substrates are capable of
withstanding.
[0507] U.S. Pat. No. 4,929,278 to Ashley et al. and U.S. Pat. No.
4,966,812 to Ashley et al. described a process for depositing
antireflective films on a plastic substrate by first synthesizing
an ethanol gel in a SiO.sub.2--B.sub.2O.sub.3--Al.sub.2O.sub.3--BaO
system followed by reliquifying the gel. This material may be
applied to a plastic substrate and thermally dried to form a porous
film having a low refractive index. Such films, however, may
exhibit poor abrasion resistance and can take weeks to form.
[0508] U.S. Pat. No. 5,580,819 to Li et al. and U.S. Pat. No.
5,744,243 to Li et al. disclose a composition for producing
coatings and a process for preparing single-layer broad band
antireflective coatings on a solid substrate, such as glass,
ceramics, metals and organic polymeric materials. The process
involves applying an acid-catalyzed sol-gel coating composition and
a water soluble metal salt to the surface of a solid substrate and
curing the applied coating with an aqueous electrolyte solution for
a time sufficient to produce a coating. The two step preparation of
the coating composition, however, may be time consuming since the
treatment with the aqueous electrolyte may take several days.
[0509] The use of ultraviolet light curable liquid compositions for
forming antireflective coatings on substrates offers a number of
advantages over the deposition techniques described above. In
particular, the equipment cost tends to be minimal and the
application techniques tend to minimize alterations to the shape or
clarity of the plastic item being coated. Additionally, the liquid
compositions of embodiments presented herein, may be cured in a
time of less than about 10 minutes. Finally, the liquid
compositions, of the present invention, may be applied to a variety
of visible light transmitting substrates. Such substrates may be
composed of glass or plastic. It should be understood that the
liquid compositions for forming an antireflective coating described
herein may be applied to a number of visible light transmitting
substrates including windows and the outer glass surface of
television screens and computer monitors. The liquid composition
may be used to form an antireflective coating on a lens, preferably
on plastic lenses, and more preferably on plastic eyeglass
lenses.
[0510] In an embodiment, a single layer coating may be formed on a
plastic lens by coating the substrate with an ultraviolet light
curable liquid composition and curing the composition. While the
below described procedures refer to the coating of plastic lenses,
it should be understood that the procedures may be adapted to coat
any of the above described substrates. The cured composition may
form a thin layer (e.g., less than about 500 nm) on the substrate.
The cured composition layer may have antireflective properties if
the thin layer has an index of refraction that is less than the
index of refraction of the substrate. This may be sufficient for
many applications where a limited increase in visible light
transmission is acceptable. Single layer antireflective coatings,
however, may exhibit poor adhesion to the plastic lens. Attempts to
increase the adhesion to the plastic lens by altering the
composition may cause the index of refraction of the single layer
antireflective coating to increase and reduce the effectiveness of
such layers.
[0511] Better antireflective properties and adhesion may be
achieved by use of multi-layer antireflective coatings. In one
embodiment, a two-layer stack of coating layers may be used as an
anti-reflective coating. A first coating layer may be formed on the
surface of a plastic lens. The first coating layer may be formed by
dispensing a first composition on the surface of the lens and
subsequently curing the first composition. The first coating layer
may be formed from a material that has an index of refraction that
is greater than the index of refraction of the plastic lens. A
second coating layer may be formed upon the first coating layer.
The second coating layer may be formed by dispensing a second
composition onto the first coating layer and curing the second
composition. The second coating layer may be formed from a material
that has an index of refraction that is less than the index of
refraction of the first coating layer. Together the first coating
layer and the second coating layer form a stack that may act as an
antireflective coating. The first and second coating layers,
together, may form a stack having a thickness of less than about
500 nm.
[0512] In one embodiment, the first coating layer may be formed
from a coating composition that includes a metal alkoxide or a
mixture of metal alkoxides. Metal alkoxides have the general
formula M (Y).sub.p wherein M is titanium, aluminum, zirconium,
boron, tin, indium, antimony, or zinc, Y is a C.sub.1-C.sub.10
alkoxy or acetylacetonate, and p is an integer equivalent to the
valence of M. In some embodiments, M is titanium, aluminum, boron,
or zirconium, and Y is C.sub.1-C.sub.5 alkoxy (e.g., methoxy or
ethoxy). Examples of metal alkoxides include, but are not limited
to aluminum tri-sec-butoxide, titanium (IV) isopropoxide, titanium
(IV) butoxide, zirconium (IV) propoxide, titanium allylacetoacetate
triisopropoxide, and trimethyl borate. The first coating layer may
be formed by using a sol-gel (i.e., solution-gelation) process.
Metal alkoxides, when reacted with water or an alcohol, undergo
hydrolysis and condensation reactions to form a polymer network. As
the polymer network is formed the solvent may be expelled. The
polymer network will continue to grow until a gel is formed. Upon
heating or the application of ultraviolet light, the metal alkoxide
gel densifies to become a hardened coating on the plastic lens.
[0513] The hardened first coating layer, when formed from a sol-gel
reaction of a metal alkoxide may have an index of refraction that
is greater than the plastic lens. For example, most plastic lenses
have an index of refraction from about 1.5 to about 1.7. The first
coating layer may have an index of refraction that is greater than
1.7 when formed from a metal alkoxide. The use of metal alkoxides
has the advantage of allowing a high index of refraction coating on
the surface of the lens. Another advantage attained from the use of
metal alkoxides is increased adhesion to the underlying substrate.
A general problem for many antireflective coatings is poor adhesion
to the underlying substrate. This is particularly true for coatings
formed on plastic substrates, although adhesion may also be a
problem for glass substrates. The use of metal alkoxides increases
the adhesion of the coating material to both plastic and glass
substrates. The use of metal alkoxides, therefore, increases the
durability of the antireflective coating.
[0514] The metal alkoxide may be dissolved or suspended in an
organic solvent and subsequently applied to a plastic lens. The
coating composition may include a metal alkoxide dissolved or
suspended in an organic solvent. The coating composition may
include up to about 10% by weight of a metal alkoxide with the
remainder of the composition being composed of the organic solvent
and other additive compounds described below. In one embodiment,
suitable organic solvents are capable of mixing with water and are
substantially unreactive toward the metal alkoxide. Examples of
such solvents include, but are not limited to ethyl acetate, ethers
(e.g., tetrahydrofuran and dioxane), C.sub.1-C.sub.6 alkanol (e.g.,
methanol, ethanol, 1-propanol, and 2-propanol), alkoxyalcohols
(e.g., 2-ethoxyethanol-2-(2-methoxyethoxy) ethanol,
2-methoxyethanol, 2-(2-ethoxymethoxy) ethanol, and
1-methoxy-2-propanol), ketones (e.g., acetone, methyl ethyl ketone,
and methyl isobutyl ketones, or mixtures of any of these
compounds.
[0515] In another embodiment, the first composition may include a
silane monomer. Silane monomers have the general structure
R.sub.mSiX.sub.4-m, where R may be C.sub.1-C.sub.20 alkyl,
C.sub.1-C.sub.20 haloalkyl, C.sub.2-C.sub.20 alkenyl,
C.sub.2-C.sub.20 haloalkenyl, phenyl,
phenyl(C.sub.1-C.sub.20)alkyl, C.sub.1-C.sub.20 alkylphenyl, phenyl
(C.sub.2-C.sub.20)alkenyl, C.sub.2-C.sub.20 alkenylphenyl,
glycidoxy (C.sub.1-C.sub.20) alkyl,
epoxycyclohexyl(C.sub.1-C.sub.20)alkyl, morpholino,
amino(C.sub.1-C.sub.20)alkyl, amino(C.sub.2-C.sub.20)alkenyl,
mercapto(C.sub.1-C.sub.20)alkyl, mercapto(C.sub.2-C.sub.20)alkenyl,
cyano(C.sub.1-C.sub.20) alkyl, cyano(C.sub.2-C.sub.20)alkenyl,
acryloxy, methacryloxy, or halogen. The halo or halogen
substituents may be bromo, chloro, or fluoro. Preferably, R.sup.1
is a C.sub.1-C.sub.10 alkyl, C.sub.1-C.sub.10 haloalkyl,
C.sub.2-C.sub.10 alkenyl, phenyl, phenyl(C.sub.1-C.sub.10)alkyl,
C.sub.1-C.sub.10 alkylphenyl, glycidoxy(C.sub.1-C.sub.10)alkyl,
epoxycyclohexyl(C.sub.1-C.sub.10)alkyl, morpholino,
amino(C.sub.1-C.sub.10) alkyl, amino(C.sub.2-C.sub.10) alkenyl,
mercapto(C.sub.1-C.sub.10)alkyl, mercapto(C.sub.2-C.sub.10)
alkenyl, cyano(C.sub.1-C.sub.10) alkyl,
cyano(C.sub.2-C.sub.10)alkenyl, or halogen and the halo or halogen
is chloro or fluoro. X may be hydrogen, halogen, hydroxy,
C.sub.1-C.sub.5 alkoxy,
(C.sub.1-C.sub.5)alkoxy(C.sub.1-C.sub.5)alkoxy, C.sub.1-C.sub.4
acyloxy, phenoxy, C.sub.1-C.sub.3 alkylphenoxy, or C.sub.1-C.sub.3
alkoxyphenoxy, said halo or halogen being bromo, chloro or fluoro;
m is an integer from 0 to 3. The first coating composition may
include up to about 5% by weight of a silane monomer.
[0516] Examples of silane monomers include, but are not limited to
glycidoxymethyltriethoxysilane,
.alpha.-glycidoxyethyltrimethoxysilane,
.alpha.-glycidoxyethyltriethoxysilane,
.beta.-glycidoxyethyltrimethoxysilane,
.beta.-glycidoxyethyltriethoxysilane,
.alpha.-glycidoxypropyltrimethoxysilane,
.alpha.-glycidoxypropyltriethoxysilane,
.beta.-glycidoxypropyltrimethoxysilane,
.beta.-glycidoxypropyltriethoxysilane,
.gamma.-glycidoxypropyltrimethoxysilane,
.gamma.-glycidoxypropylmethyldimethoxysilane,
.gamma.-glycidoxypropyldimethylethoxysilane,
methyltrimethoxysilane, methyltriethoxysilane,
methyltrimethoxyethoxysilane, methyltriacetoxysilane,
methyltripropoxysilane, methyltributoxysilane,
ethyltrimethoxysilane, ethyltriethoxysilane,
.gamma.-methacryloxypropyltrimethoxysilane,
.gamma.-aminopropyltrimethoxysilane,
.gamma.-aminopropyltriethoxysilane,
.gamma.-mercaptopropyltrimethoxysilane,
chloromethyltrimethoxysilane, chloromethytriethoxysilane,
dimethyldiethoxysilane, .gamma.-chloropropylmethyldimethoxysilane,
.gamma.-chloropropyl methyldiethoxysilane,
tetramethylorthosilicate, tetraethylorthosilicate, hydrolyzates of
such silane monomers, and mixtures of such silane monomers and
hydrolyzates thereof.
[0517] Silane monomers, along with colloidal silica, may form low
index of refraction silicon-based coatings. In some instances,
silane monomers and colloidal silica may be used to form a single
layer low index of refraction coating layer on a lens. The use of
silicon monomers and colloidal silica, however, tends to produce
silicon-based coatings that have poor adhesion to the underlying
substrate. The addition of a metal alkoxide to a composition that
also contains a silane monomer or colloidal silica may improve the
adhesion of the layer. In another embodiment, the adhesion of a
silicon-based coating may be improved by the formation of a
multi-layer stack. The stack may include a first coating layer,
which is formed from a metal alkoxide. A second layer may be formed
upon the first layer, the second layer being formed from a silane
monomer or colloidal silicon. The metal alkoxide based first layer
acts as an adhesion layer that helps keep the stack bound to the
underlying lens.
[0518] In addition, the silane monomers and colloidal silica may be
mixed with metal alkoxides to alter the index of refraction of the
coating composition. Typically, a mixture of a silane monomer with
a metal alkoxide when cured onto a lens, will have a lower index of
refraction than a coating formed from a metal alkoxide.
[0519] In some embodiments, one or more ethylenically substituted
monomers may be added to the first composition. The ethylenically
substituted group of monomers include, but are not limited to,
C.sub.1-C.sub.20 alkyl acrylates, C.sub.1-C.sub.20 alkyl
methacrylates, C.sub.2-C.sub.20 alkenyl acrylates, C.sub.2-C.sub.20
alkenyl methacrylates, C.sub.5-C.sub.8 cycloalkyl acrylates,
C.sub.5-C.sub.8 cycloalkyl methacrylates, phenyl acrylates, phenyl
methacrylates, phenyl(C.sub.1-C.sub.9)alkyl acrylates,
phenyl(C.sub.1-C.sub.9)alkyl methacrylates, substituted phenyl
(C.sub.1-C.sub.9)alkyl acrylates, substituted
phenyl(C.sub.1-C.sub.9)alkyl methacrylates,
phenoxy(C.sub.1-C.sub.9)alkyl acrylates,
phenoxy(C.sub.1-C.sub.9)alkyl methacrylates, substituted
phenoxy(C.sub.1-C.sub.9)alkyl acrylates, substituted
phenoxy(C.sub.1-C.sub.9)alkyl methacrylates, C.sub.1-C.sub.4
alkoxy(C.sub.2-C.sub.4)alkyl acrylates, C.sub.1-C.sub.4 alkoxy
(C.sub.2-C.sub.4)alkyl methacrylates, C.sub.1-C.sub.4
alkoxy(C.sub.1-C.sub.4)alkoxy(C.sub.2-C.sub.4)alkyl acrylates,
C.sub.1-C.sub.4 alkoxy(C.sub.1-C.sub.4)alkoxy(C.sub.2-C.sub.4)alkyl
methacrylates, C.sub.2-C.sub.4 oxiranyl acrylates, C.sub.2-C.sub.4
oxiranyl methacrylates, copolymerizable di-, tri- or tetra-acrylate
monomers, copolymerizable di-, tri-, or tetra-methacrylate
monomers. The first composition may include up to about 5% by
weight of an ethylenically substituted monomer.
[0520] Examples of such monomers include methyl methacrylate, ethyl
methacrylate, propyl methacrylate, isopropyl methacrylate, butyl
methacrylate, isobutyl methacrylate, hexyl methacrylate,
2-ethylhexyl methacrylate, nonyl methacrylate, lauryl methacrylate,
stearyl methacrylate, isodecyl methacrylate, ethyl acrylate, methyl
acrylate, propyl acrylate, isopropyl acrylate, butyl acrylate,
isobutyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, nonyl
acrylate, lauryl acrylate, stearyl acrylate, isodecyl acrylate,
ethylene methacrylate, propylene methacrylate, isopropylene
methacrylate, butane methacrylate, isobutylene methacrylate, hexene
methacrylate, 2-ethylhexene methacrylate, nonene methacrylate,
isodecene methacrylate, ethylene acrylate, propylene acrylate,
isopropylene, hexene acrylate, 2-ethylhexene acrylate, nonene
acrylate, isodecene acrylate, cyclopentyl methacrylate, 4-methyl
cyclohexyl acrylate, benzyl methacrylate, o-bromobenzyl
methacrylate, phenyl methacrylate, nonylphenyl methacrylate, benzyl
acrylate, o-bromobenzyl phenyl acrylate, nonylphenyl acrylate,
phenethyl methacrylate, phenoxy methacrylate, phenylpropyl
methacrylate, nonylphenylethyl methacrylate, phenethyl acrylate,
phenoxy acrylate, phenylpropyl acrylate, nonylphenylethyl acrylate,
2-ethoxyethoxymethyl acrylate, ethoxyethoxyethyl methacrylate,
2-ethoxyethoxymethyl acrylate, ethoxyethoxyethyl acrylate, glycidyl
methacrylate, glycidyl acrylate, 2,3-epoxybutyl methacrylate,
2,3-epoxybutyl acrylate, 3,4-epoxybutyl acrylate, 3,4-epoxybutyl
methacrylate, 2,3-epoxypropyl methacrylate, 2,3-epoxypropyl
acrylate 2-methoxyethyl methacrylate, 2-ethoxyethyl methacrylate,
2-butoxyethyl methacrylate, 2-methoxyethyl acrylate, 2-ethoxyethyl
acrylate, 2-butoxyethyl acrylate, tetrahydrofurfuryl acrylate,
tetrahydrofurfuryl methacrylate, ethoxylated
bisphenol-A-dimethacrylate, ethylene glycol diacrylate, 1,2-propane
diol diacrylate, 1,3-propane diol diacrylate, 1,2-propane diol
dimethacrylate, 1,3-propane diol dimethacrylate, 1,4-butane diol
diacrylate, 1,3-butane diol dimethacrylate, 1,4-butane diol
dimethacrylate, 1,5-pentane diol diacrylate,
2,5-dimethyl-1,6-hexane diol dimethacrylate, diethylene glycol
diacrylate, diethylene glycol dimethacrylate, trimethylolpropane
trimethacrylate, tetraethylene glycol diacrylate, tetraethylene
glycol dimethacrylate, dipropylene glycol dimethacrylate,
trimethylolpropane triacrylate, glycerol triacrylate, glycerol
trimethacrylate, pentaerythritol triacrylate, pentaerythritol
dimethacrylate, pentaerythritol tetracrylate, pentaerythritol
tetramethacrylate.
[0521] The first composition may also include amines. Examples of
amines suitable for incorporation into an antireflective coating
composition include tertiary amines and acrylated amines. The
presence of an amine tends to stabilize the antireflective coating
composition. The antireflective coating composition may be prepared
and stored prior to using. In some embodiments, the antireflective
coating composition may slowly gel due to the interaction of the
various components in the composition. The addition of amines tends
to slow down the rate of gelation without significantly affecting
the antireflective properties of subsequently formed coatings. The
first composition may include up to about 5% by weight of
amines.
[0522] The first composition may also include colloidal silica.
Colloidal silica is a suspension of silica particles in a solvent.
The silica particles may have a particle size of about 1 nanometer
to about 100 nanometers in diameter. Amorphous silica particles may
be dispersed in water, a polar solvent, or combinations of water
and a polar solvent. Some polar solvents that may be used include,
but are not limited to methanol, ethanol, isopropanol, butanol,
ethylene glycol, and mixtures of these solvents. One example of
colloidal silica is commercially available from Nissan Chemical
Houston Corp., Houston, Tex., and sold under the trade name
Snowtex. The first composition may include up to about 5% by weight
of colloidal silica.
[0523] The first composition may also include a photoinitiator
and/or a co-initiator. Examples of photoinitiators and
co-initiators have been previously described. Up to about 1% by
weight of the first coating composition may include a
photoinitiator or a combination of a photoinitiator and a
co-initiator.
[0524] The first composition may also include a fluorinated
ethylenically substituted monomer. Fluorinated ethylenically
substituted monomers have the general structure:
CH.sub.2.dbd.CR.sup.1CO--O--(CH.sub.2).sub.p--C.sub.nF.sub.2n+1
Where R.sup.1 is H or --CH.sub.3; p is 1 or 2; and n is an integer
from 1 to 40. Examples of fluorinated ethylenically substituted
monomer include, but are not limited to, trihydroperfluoroheptyl
acrylate and trihydroperfluoroheptyl acrylate. The addition of a
fluorinated ethylenically substituted monomer to a composition to
be applied to a plastic lens may increase the hydrophobicity of the
coating. Hydrophobicity refers to the ability of a substrate to
repel water. The addition of a fluorinated ethylenically
substituted monomer to the composition may increase the ability of
the coated substrate to resist degradation due to exposure to
water.
[0525] The first composition may be applied to one or both surfaces
of a plastic lens. The antireflective coating composition may be
applied using a coating unit such as the one described previously.
The antireflective coating composition may be applied to the
eyeglass lens as the lens is rotated within the coating unit. The
plastic lens may be rotated at speeds up to about 2000 rpm as the
first composition is added to the plastic lens. Less than 1 mL of
the antireflective coating composition may be applied to the
eyeglass lens. More than 1 ml may also be applied, however, this
amount may be excessive and much of the antireflective coating
composition may be flung from the surface of the lens.
[0526] The thickness of the applied antireflective coating
composition may also depend on the speed of rotation of the
eyeglass lens, the viscosity of the antireflective coating
composition, the amount of composition added to the eyeglass lens,
and the volatility of the solvent used to dissolve the components
of the composition. As an antireflective coating composition is
added to a rotating eyeglass lens, the antireflective coating is
spread evenly across the surface of the eyeglass lens. The solvent
used to dissolve the components of the antireflective coating
composition may evaporate as the composition is applied to the
eyeglass lens surface, leaving a thin film of the antireflective
coating components. As additional antireflective coating material
is added, the thickness of the antireflective coating layer will
gradually be increased. The rate at which the thickness increases
is related to the speed of rotation of the eyeglass lens, the
viscosity of the antireflective coating composition, and the
volatility of the solvent used to form the composition.
[0527] When the composition is applied to a surface of the lens by
a human operator, the thickness of the first coating composition
may vary due to the operator's inability to consistently add the
composition to the lens at the same rate each time. To overcome
this variability, the composition may be added to the plastic lens
with an automated dispensing system. The automated dispensing
system may include a syringe for holding the composition and a
controller drive system for automatically moving the plunger of the
syringe. Such systems are commercially available as syringe pumps.
A syringe pump may be coupled to a syringe that includes the
composition to be added to the lens. The syringe pump may be
configured to dispense the composition at a preselected rate. In
this manner the rate at which the composition is added to the
surface may be accurately controlled. In another embodiment, the
dispenser system may include a conveyor for drawing the syringe and
syringe pump across the surface of the lens. As the composition is
dispensed by the syringe, the conveyor system may draw the syringe
across the surface of the lens. In this manner, the rate of
application and the distribution path of the composition may be
performed in a consistent manner.
[0528] Assuming a constant speed of rotation of the eyeglass and a
constant dispensing rate, as the viscosity of the antireflective
coating composition is increased, the rate at which the thickness
of the applied antireflective coating composition increases may
increase. Alternatively, the rate at which the thickness of the
antireflective coating composition increases may be altered by
adjusting the rotation speed of the eyeglass lens. Assuming a
constant viscosity of the antireflective coating composition, as
the rotational speed of the eyeglass lens is increased, less of the
antireflective coating composition will remain on the eyeglass lens
as the composition is applied. By slowing down the rotational speed
of the eyeglass lens, the thickness of the antireflective coating
layer may be increased.
[0529] Alternatively, the viscosity of the first composition may be
changed by altering the amount of metal alkoxide and other
components present in the first composition. For example, a first
composition that includes a metal alkoxide at a concentration of
about 5% by weight, will have a greater viscosity than a
composition that has a metal alkoxide concentration of about 2.5%.
The more viscous composition will leave a thicker film on the
surface of the lens than the less viscous composition. When the
composition is cured, a thicker first coating layer may be
obtained. The viscosity may also be altered by changing the organic
solvent that the metal alkoxide is dissolved or suspended in. Each
solvent may have an inherent viscosity that may effect the overall
viscosity of the first composition. By changing the solvent this
inherent viscosity may be altered, thus altering the viscosity of
the overall composition.
[0530] As an antireflective coating composition is added to a
rotating eyeglass lens, the antireflective coating is spread evenly
across the surface of the eyeglass lens. If a solvent used to
dissolve the components of the antireflective coating composition
has a relatively low boiling point (e.g., below about 80.degree.
C.), the solvent will evaporate and allow the more viscous
components of the antireflective coating composition (e.g., the
silane, organic monomers, metal alkoxide, etc.) to form a coating
on the lens. As more composition is added to the eyeglass lens, the
thickness of the antireflective coating may increase. By changing
solvent used in the antireflective coating composition to a more
volatile solvent, the rate at which the thickness of the
antireflective coating grows may increase. Generally, a low boiling
point solvent will give a thicker coating layer than a higher
boiling point solvent.
[0531] In general, the ability to control the thickness of the
applied first composition may be important for achieving
antireflective properties. In some embodiments, a low viscosity
and/or low concentration composition may be used to form the first
coating layer. Such compositions may form relatively thin films on
the surface of the plastic lens. In some embodiments, the thickness
of the formed film may be too thin for the desired application. In
an alternate procedure, the first coating layer may be formed by
repeatedly applying the first composition to the plastic lens and
curing the deposited composition. Each iteration of this process
will create a thicker first coating layer. When the first coating
layer reaches a preselected thickness the procedure may be stopped
and the second coating layer may be formed.
[0532] After applying the first composition to the plastic lens,
the first composition may be cured to form the first coating layer.
Curing of the first composition may be accomplished by a variety of
methods. In one embodiment, the first composition may be cured by
spinning the lens until the composition forms a gel. Alternatively,
the composition may be allowed to sit at room temperature for a
time sufficient to allow the composition to gel. The gelled
composition has a higher index of refraction than the underlying
plastic lens, and may therefore serve as the first coating layer.
Additionally, at least a portion of the gelled composition may be
sufficiently adhered to the plastic lens such that a portion of the
gelled composition may remain on the lens during the application of
the second composition, thus providing antireflective properties to
the lens subsequent to formation of the second coating layer.
[0533] Alternatively, the first composition may be cured by the
application of heat to the composition. After the first composition
is deposited on the lens and spin dried, the first composition may
be in a gelled state. The gelled composition may be heated for a
period of about 1-10 minutes at a temperature in the range from
about 40.degree. C. to about 120.degree. C., preferably about
100.degree. C. Heating of the gelled composition in this matter may
cause the composition to be converted from a gelled state to a
hardened state. The heat cured first coating layer may exhibit good
adhesion to the underlying lens. In some cases, however, the flow
characteristics of the second composition when applied to a heat
cured first composition may exhibit a non-uniform distribution
across the surface of the cured first composition. Furthermore, the
first coating layer may have an index of refraction that is greater
than the index of refraction of the plastic lens.
[0534] In another embodiment, the first composition may be cured by
the application of ultraviolet light. As described above, the first
composition is applied to the lens and dried to form a gelled
composition. The gelled composition may be treated with ultraviolet
light for a time sufficient to convert the gelled composition to a
hardened state. In some embodiments, the gelled composition is
treated with ultraviolet light for a time of about 60 seconds or
less. In one embodiment, the ultraviolet light source may be a
germicidal lamp, as described above in the spin coating unit (See
FIGS. 2 and 3). It should be noted that germicidal lamps produce no
significant heat energy. Thus, it is believed that the accelerated
curing of the first composition is due to the presence of the
ultraviolet light, rather than from any heat produced by the lamps.
Advantageously, it has been found that the use of ultraviolet light
to cure the first composition may provide a surface that allows a
uniform distribution of a subsequently applied composition. In
comparison, the use of heating to cure the first composition may
provide a surface that causes a subsequently applied composition to
be unevenly dispersed. Thus, the use of ultraviolet light may offer
an advantage over heat curing with regard to forming multilayer
antireflective coatings.
[0535] It is believed that the ultraviolet light accelerates the
condensation reaction of the metal alkoxide. The ultraviolet light
may interact with the metal alkoxide and excite the electrons of
the metal alkoxide, which in turn may accelerate the polymerization
of the metal alkoxide. It is believed that most metal alkoxides
have a strong absorbance in the ultraviolet region, specifically at
wavelengths below about 300 nm. For example, titanium isopropoxide
has a maximum absorbance at 254 nm. In some embodiments, the
application of ultraviolet light to the metal alkoxide may be
directed toward the coated surface rather than through the
substrate. Many visible light transmitting media e.g., borosilicate
glasses and plastics, may not allow sufficient amounts of light to
pass through to the coating composition at the appropriate
wavelength.
[0536] After the first coating layer has been applied and cured, a
second coating layer may be formed upon the first coating layer.
The second coating layer may be formed by applying a second
composition to the exposed surface of the first coating layer. In
some embodiments, the second coating layer, after curing, is
composed of a material that has an index of refraction that is
substantially less than the first coating layer.
[0537] The second composition, in an embodiment, may be composed of
an initiator and an ethylenically substituted monomer. The
ethylenically substituted monomers that may be used have been
described previously. The initiator may be a photoinitiator, such
as was described earlier. Alternatively, the initiator may be a
metal alkoxide. It is believed that both photoinitiators and metal
alkoxides interact with ultraviolet light and this interaction
causes the initiation of polymerization of the ethylenically
substituted monomer. The second composition may be applied to the
first coating layer in a manner similar to those described earlier.
The second composition may include other monomers such as silane
monomers, colloidal silica, coinitiators, and fluorinated
ethylenically substituted monomer.
[0538] The combination of a second low index of refraction coating
layer formed upon a first high index of refraction coating material
may provide improved light transmission through the underlying
substrate. The use of metal alkoxides in one or both layers tends
to improve the adhesion of the coating material to the underlying
substrate.
[0539] Antireflective coatings are thin films that are formed upon
the surface of the eyeglass lens. Such films have an optical
thickness that is herein defined as the index of refraction of the
film times the mechanical thickness of the film. The most effective
films typically have an optical thickness that is a fraction of a
wavelength of incident light. Typically, the optical thickness is
one-quarter to one-half the wavelength. Thus for visible light
(having a wavelength approximately between 400 nm and 700 nm) an
ideal antireflective coating layer should have a thickness between
about 100 and 200 nm. Thicknesses that are less than 100 nm or
greater than 200 nm may also be used, although such thickness may
not provide an optimal transmittance. In the embodiments cited
herein, the combined optical thickness of the coating material may
be up to about 1000 nm, more particularly up to about 500 nm.
[0540] The ideal thickness of an antireflective coating should be
about one-quarter the wavelength of the incident light. For light
entering the film at normal incidence, the wave reflected from the
second surface of the film will be exactly one-half wavelength out
of phase with the light reflected from the first surface, resulting
in destructive interference. If the amount of light reflected from
each surface is the same, a complete cancellation will occur and no
light will be reflected. This is the basis of the "quarter-wave"
low-reflectance coatings, which are used to increase transmission
of optical components. Such coatings also tend to eliminate ghost
images as well as the stray reflected light.
[0541] Because visible light includes a range of wavelengths from
about 400 nm to about 700 nm, a quarter-wave coating will only be
optimized for one wavelength of light. For the other wavelengths of
light, the antireflective coating may be either too thick or too
thin. Thus, more of the light having these wavelengths may be
reflected. For example, an antireflective coating that is designed
for interior lights (e.g., yellow light) will have a minimum
reflectance for yellow light, while the reflectance for blue or red
light will be significantly higher. This is believed to be the
cause of the characteristic purple color of single layer
low-reflectance coatings for many camera and video lenses. In one
embodiment, the thickness of the antireflective coating layers of
an eyeglass lens may be varied or the indices of refraction may be
altered to produce lenses, which have different visible light
reflective characteristics. Both of these variations will alter the
optical thickness of the coating layers and change the optimal
effective wavelength of light that is transmitted. As the optical
thickness of the coating layers is altered, the reflected color of
the lens will also be altered. In an iterative manner, the optimal
reflected color of the eyeglass lens may be controlled by the
manufacturer.
[0542] While two layer antireflective coatings have been described,
it should be understood that multi-layer systems that include more
than two layers may also be used. In a two-layer system, a
substrate is coated with a high index of refraction layer. The high
index of refraction layer is then coated with a low index of
refraction layer. In an embodiment, a third high index of
refraction (e.g., at least higher than the underlying second
coating layer) may be formed on the second coating layer. A fourth
low index of refraction layer (e.g., at least lower than the index
of refraction of the third coating layer) may also be formed. The
four layer stack may exhibit antireflective properties. The four
layer stack may have an optical thickness of less than about 1000
nm, and more particularly less than about 500 nm. Additional layers
may be formed upon the stack in a similar manner with the layers
alternating between high and low index of refraction materials.
[0543] In another embodiment, the second coating layer may be
formed as a combination of two chemically distinct compositions.
The second coating layer may be formed by forming a silicon layer
upon the first coating layer. The silicon layer may be formed from
colloidal silica or a silane monomer. The silicon layer is applied
to the first coating layer and at least partially cured. The
silicon layer may be cured by drying, heating, or the application
of ultraviolet light.
[0544] To complete formation of the second coating layer, a second
composition is deposited onto the silicon layer. The second
composition may include an ethylenically substituted monomer and an
initiator. The ethylenically substituted monomers that may be used
have been described previously. The initiator may be a
photoinitiator, such as was described earlier. Alternatively, the
initiator may be a metal alkoxide. The second composition may be
applied to the silicon layer in a manner similar to those described
earlier. The second composition may include other monomers such as
silane monomers, colloidal silica, coinitiators, and fluorinated
ethylenically substituted monomers. The second composition may be
cured by the application of ultraviolet light.
[0545] The silicon layer, when partially cured or fully cured,
tends to exhibit a porous structure. It is believed that the
addition of the second composition to a substantially porous
silicon layer may allow better chemical interaction between the
second composition and the silicon layer. In general, good
antireflective properties are seen when a silicon layer is placed
upon a first coating layer, when the first coating layer includes a
metal alkoxide. The silicon layer, however, may exhibit poor
adhesion to a metal alkoxide containing underlying layer. The
adhesion of the silicon layer may be improved by the addition of a
metal alkoxide to the composition used to form the silicon layer.
Silicon containing compositions, such as compositions that include
colloidal silica or silane monomers, tend to be unstable in the
presence of a metal alkoxide. Generally, it was observed that the
mixture of silicon containing compounds with metal alkoxides
produces a cloudy composition, and in some cases gelation, prior to
the application of the composition to the first coating layer. Such
gelation tends to increase the haze observed in the coated lens.
The reactivity of metal alkoxides with silicon containing
compositions tends to reduce the shelf life of such compositions,
making it difficult to store the composition for extended periods
of time.
[0546] By separating the metal alkoxide from the silicon containing
compositions and applying the compositions in a sequential manner,
many of the above-described problems may be reduced. It is believed
that the addition of a metal alkoxide containing composition to an
at least partially cured silicon layer, causes the second
composition to interact with the underlying silicon composition
such that a composite layer is formed. This composite layer may
exhibit properties that are similar to the properties found for
single layers formed from compositions that include silicon
compounds and metal alkoxides. Since the silicon containing
composition and metal alkoxide containing compounds are applied at
different times, the compositions may be stored separately,
effectively overcoming the shelf life problems.
[0547] In one embodiment, a hardcoat composition may be applied to
the plastic lens prior to the application of the antireflective
coating stack. Curing of the hardcoat composition may create a
protective layer on the outer surface of the plastic lens.
Typically, hardcoat compositions are formed from acrylate polymers
that, when cured, may be resistant to abrasive forces and also may
provide additional adhesion for the antireflective coating material
to the plastic lens.
[0548] In another embodiment, a hydrophobic coating may be placed
onto the antireflective coating. Hydrophobic coatings may include
fluorinated ethylenically substituted monomers. Curing of the
hydrophobic coating may create a water protective layer on the
outer surface of the antireflective coating. The hydrophobic layer
may help prevent degradation of the lens due to the interaction of
atmospheric water with the lens.
[0549] In the above described procedures, the antireflective
coating may be formed onto a preformed lens. Such a method may be
referred to as an out-of-mold process. An alternative to this
out-of-mold process is an in-mold process for forming
antireflective coatings. The "in-mold" process involves forming an
antireflective coating over an eyeglass lens by placing a liquid
lens forming composition in a coated mold and subsequently curing
the lens forming composition. The in-mold method is advantageous to
"out-of-mold" methods since the in-mold method exhibits less
occurrences of coating defects manifested as irregularities on the
anterior surface of the coating. Using the in-mold method produces
an antireflective coating that replicates the topography and
smoothness of the mold casting face.
[0550] The application of an antireflective coating to a plastic
lens requires that the first and second coating layers (or more if
a multi layer stack is used) be formed onto the mold. In
particular, the second coating layer is placed onto the mold prior
to forming the first coating layer. In this manner, the stack is
built backwards. The top of the stack on the casting surface of the
mold may be the first coating layer, which is to contact the
underlying lens in the in-mold process.
[0551] In an embodiment, a second coating layer may be formed by
applying a second composition upon a casting surface of a mold and
curing the second composition. The second composition, in an
embodiment, includes a photoinitiator and an ethylenically
substituted monomer. The ethylenically substituted monomers that
may be used have been described previously. The initiator may be a
photoinitiator, such as was described earlier. The second
composition may include other additives such as coinitiators and
fluorinated ethylenically substituted monomer. The second
composition may, in some embodiments, be substantially free of
metal alkoxides. It is believed that metal alkoxides disposed
within a composition may interact with the glass and inhibit the
removal of the lens from the molds. The second monomers and other
additives of the second composition may be dissolved or suspended
in an organic solvent. The organic solvent may be used to aid in
the application of the monomer to the mold surface.
[0552] To apply the second composition to the mold member, the mold
member may be spun so that the second composition becomes
distributed over the casting face. The mold member is preferably
rotated about a substantially vertical axis at a speed up to about
2000 revolutions per minute, preferably at about 850 revolutions
per minute. Further, a dispensing device may be used to direct the
composition onto the casting face while the mold member is
spinning. The dispensing device may move from the center of the
mold member to an edge of the mold member.
[0553] After applying the second composition to the mold member,
ultraviolet light may be directed at the mold member to cure at
least a portion of the second composition. The ultraviolet light
may be directed toward either surface (i.e., the casting or
non-casting faces) of the mold to cure the second composition.
[0554] After the second composition is at least partially cured, a
first coating layer may be formed on the second composition by
applying a first composition to the second composition. The first
composition may include a metal alkoxide. The first composition may
also include other additives such as photoinitiators, coinitiators,
silane monomers, colloidal silica, ethylenically substituted
monomers, and fluorinated ethylenically substituted monomers. The
metal alkoxide and other additives may be dissolved in an organic
solvent. All of these compounds have been described previously.
[0555] The first composition may be cured by a variety of methods.
In one embodiment, the first composition may be cured by spinning
the mold member until the composition forms a gel. Alternatively,
the composition may be allowed to sit at room temperature for a
time sufficient to allow the composition to gel. In another
embodiment, the first composition may be cured by the application
of heat to the composition. After the first composition is
deposited on the mold member and spin dried, the first composition
may be in a gelled state. The gelled composition may be heated for
a period of about 1-10 minutes at a temperature in the range from
about 40.degree. C. to about 120.degree. C. Heating of the gelled
composition in this matter may cause the composition to be
converted from a gelled state to a hardened state. In another
embodiment, the first composition may be cured by the application
of ultraviolet light. As described above, the first composition is
applied to the mold member and dried to form a gelled composition.
The gelled composition may be treated with ultraviolet light for a
time sufficient to convert the gelled composition to a hardened
state. In some embodiments, the gelled composition is treated with
ultraviolet light for a time of about 60 seconds or less. In one
embodiment, the ultraviolet light source may be a germicidal
lamp.
[0556] After the formation of the first and second coating layers
on the casting surface of the mold member, the mold member may be
assembled with a second mold member by positioning a gasket between
the members to seal them. The second mold member may also include
an antireflective coating on the second molds casting surface. The
antireflective coating on the second mold may have an identical
composition as the antireflective coating on the first mold.
Alternatively, the antireflective coatings may have different
compositions. The combination of the two molds and gasket form a
mold assembly having a cavity defined by the two mold members. The
casting surfaces, and therefore the antireflective coatings, may be
disposed on the surface of the formed mold cavity.
[0557] After the mold assembly has been constructed, a lens forming
composition may be disposed within the mold assembly. An edge of
the gasket may be displaced to insert the lens forming composition
into the mold cavity. Alternatively, the gasket may include a fill
port that will allow the introduction of the lens forming
composition without having to displace the gasket. This lens
forming composition includes a photoinitiator and a monomer that
may be cured using ultraviolet light. Examples of lens forming
compositions that may be used include, but are not limited to,
OMB-99 and PhasesII monomers, as described above. When disposed
within the mold cavity, the lens forming composition, in some
embodiments, is in contact with the antireflective coating formed
on the casting surfaces of the molds.
[0558] In some embodiments, an adhesion coating layer may be formed
on the partially cured first composition. The coating adhesion
layer may be formed from an adhesion composition that is applied to
the first coating layer and cured. The adhesion composition may
include an ethylenically substituted monomer and a photoinitiator.
It is believed that curing of the first composition may reduce the
adhesion of the first coating layer to a subsequently formed
plastic lens. The adhesion coating layer may therefore improve the
adhesion between the first coating composition and the subsequently
formed lens. The adhesion layer composition, in some embodiments,
includes monomers similar to the monomers included in the lens
forming composition. This may improve the adhesion between the
adhesion layer and a lens formed from the lens forming composition.
The adhesion layer may have an index of refraction that is similar,
or less than, the index of refraction of the formed lens. Thus, the
adhesion layer may have little, if any, affect on the
antireflective properties of the first and second coating
layers.
[0559] While two layer antireflective coatings have been described
for an in-mold process, it should be understood that multi-layer
systems that include more than two layers may also be used. In a
two layer system, a mold is coated with a low index of refraction
layer. The low index of refraction layer is then coated with a high
index of refraction layer. In an embodiment, a third low index of
refraction layer (e.g., at least lower than the underlying first
coating layer) may be formed on the first coating layer. A fourth
high index of refraction layer (e.g., at least higher than the
index of refraction of the third coating layer) may also be formed.
The four layer stack may exhibit antireflective properties. The
four layer stack may have an optical thickness of less than about
1000 nm, and more particularly less than about 500 nm. Additional
layers may be formed upon the stack in a similar manner with the
layers alternating between high and low index of refraction
materials.
[0560] In another embodiment, the second coating layer may be
formed as a combination of two chemically distinct compositions.
The second coating layer may be formed by forming an organic
containing layer upon the casting surface of the mold. The organic
containing layer includes an ethylenically substituted monomer and
an initiator. The ethylenically substituted monomers that may be
used have been described previously. The initiator may be a
photoinitiator, such as was described earlier. Alternatively, the
initiator may be a metal alkoxide. The organic containing layer may
be applied to the casting surface in a manner similar to those
described earlier. The organic containing layer may include other
monomers such as silane monomers, colloidal silica, coinitiators,
and fluorinated ethylenically substituted monomers. The organic
containing layer may be cured by the application of ultraviolet
light.
[0561] The second coating layer may be completed by applying a
silicon layer upon the organic containing layer. The silicon layer
may be formed from colloidal silica or a silane monomer. The
silicon layer is applied to the organic containing layer and at
least partially cured. The silicon layer may be cured by drying,
heating, or the application of ultraviolet light.
[0562] Additional coating materials may be placed onto the
antireflective coating. In one embodiment, a hardcoat composition
may be applied to the antireflective coating formed on the casting
surface of a mold. Curing of the hardcoat composition may create a
protective layer on the outer surface of a subsequently formed
plastic eyeglass lens. Typically hardcoat compositions are formed
from acrylate polymers that, when cured, are resistant to abrasive
forces. The subsequently formed hardcoat layer may help to prevent
abrasions to the plastic lens. Other coatings that may be formed
include hydrophobic coatings and tinted coatings. Such coatings may
be formed on the casting surface of the mold, prior to the
formation of the antireflective coatings. These coatings, in some
embodiments, may allow the formed lens to be removed more easily
from the mold assembly. As discussed above, the antireflective
coatings may adhere to the molds, making removal of the lens from
the mold assembly difficult. The use of hydrophobic coatings may
reduce the adhesion between the mold assemblies and the
antireflective coating layer.
EXAMPLES
[0563] A plastic eyeglass lens was made according to the process
described above from the OMB-99 monomer solution. The lens was then
coated with two antireflective coating compositions. In all of the
examples, the following abbreviations are used:
[0564] "AC" is acetone, commercially available from Aldrich;
[0565] "AA" is an acrylic amine commercially available as CN384
from Sartomer;
[0566] "AI" is aluminum tri-sec-butoxide (98%) commercially
available from Avocado;
[0567] "AS" is 3-aminopropyltrimethoxysilane (97%) commercially
available from Aldrich;
[0568] "BDK", "BDM", and "BDMK" are Photomer 51 and
2,2-dimethoxy-2-phenylacetophenone commercially available from
Henkel;
[0569] "BYK300" is a solution of polyether modified
dimethylpolysiloxane copolymer commercially available from BYK
Chemie;
[0570] "CD1012" is diaryl iodonium hexafluoroantimonate
commercially available from Sartomer;
[0571] "CD540" is ethoxylated bisphenol A dimethacrylate
commercially available from Sartomer;
[0572] "CN124" is epoxy acrylate commercially available from
Sartomer;
[0573] "Cynox 1790" is
tris(4-t-butyl-3-hydroxy-2,6-dimethylbenzyl)-s-triazine-2,4,6-(1H,3H,5H)--
trione commercially available from Sartomer;
[0574] "D1173" is 2-hydroxy-2-methyl-1-phenyl-propan-1-one (HMPP)
commercially available from Ciba;
[0575] "DC193" is a surfactant commercially available from Dow
Corning;
[0576] "ECHMCHC" is 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexane
carboxylate;
[0577] "Eosin" is the dye Eosin Y commercially available from
Aldrich;
[0578] "EtOH" is ethanol, commercially available from Fisher;
[0579] "FC40" and "FC430" are surfactants commercially available
from 3M;
[0580] "FC-171" is a fluorochemical surfactant commercially
available from 3M;
[0581] "FC-725" also known as FLUORAD, a fluorochemical surfactant
commercially available from 3M;
[0582] "GPTMS" is 3-glycidoxypropyltrimethoxysilane commercially
available from Aldrich;
[0583] "HC-8" is a hard coat forming composition commercially
available from Fastcast Co. and includes a mixture of SR399, SR601,
Irg184, and MP;
[0584] "HC8558" is commercially available from GE;
[0585] "HC-900" is commercially available from Coburn Optical
Industries;
[0586] "HEMA" is hydroxyethyl methacrylate commercially available
from Coburn Optical Industries;
[0587] "HR-200" is a hydrophobic coating commercially available
from Group Couget;
[0588] "IPA" is isopropyl alcohol commercially available from
Fisher;
[0589] "Irg 184" is Irgacure 184 or 1-Hydroxycyclohexyl phenyl
ketone commercially available from Ciba;
[0590] "Irg 261" is Irgacure 261 or iron
(.eta.5-2,4-cyclopentadien-1-yl)[1,2,3,4,5,6-.eta.)-(1-methylethyl)benzen-
e]-hexafluorophosphate) commercially available from Ciba;
[0591] "Irg 819" is Irgacure 819 or Phosphine oxide,
phenylbis(2,4,6-trimethyl benzoyl) commercially available from
Ciba;
[0592] "MP" is 1-methoxy-2-propanol commercially available from
Arcos;
[0593] "Nalco Si2326" is a colloidal silica commercially available
from Nalco Chemical Company;
[0594] "NNDMEA" is N,N-dimethylethanolamine commercially available
from Aldrich;
[0595] "PerenolS-5" is a modified polysiloxane commercially
available from Henkel;
[0596] "PFOA" is 1H,1H-perfluorooctyl acrylate commercially
available from Lancaster;
[0597] "PFOFCS" is 1H,1H,2H.2H-perfluorooctyltrichlorosilane
commercially available from Lancaster;
[0598] "PFOMA" is perfluorooctyl methacrylate commercially
available from Lancaster;
[0599] "Q4DC" is an organic functional silicone fluid commercially
available from Dow Corning;
[0600] "Si" is MA-ST-S (30% colloidal silica in 70% methanol)
commercially available from Nissan Chemical;
[0601] "SR123" is an acrylate monomer commercially available from
Sartomer;
[0602] "SR306" is tripropylene glycol diacrylate commercially
available from Sartomer;
[0603] "SR313" is lauryl methacrylate commercially available from
Sartomer;
[0604] "SR368" is tris(2-hydroxy ethyl) isocyanurate triacrylate
commercially available from Sartomer;
[0605] "SR399" is dipentacrythritol tetraacrylate commercially
available from Sartomer;
[0606] "SR423" is isobornyl methacrylate commercially available
from Sartomer;
[0607] "SR444" is Pentaerythritol triacrylate commercially
available from Sartomer;
[0608] "SR640" is tetrabromo bisphenol A diacrylate commercially
available from Sartomer;
[0609] "SR9003" is propoxylated neopentyl glycol diacrylate
commercially available from Sartomer;
[0610] "T770" is bis(2,2,6,6-tetramethyl-4-piperidinyl sebacate
commercially available from Ciba;
[0611] "TEA" is triethylamine commercially available from
Aldrich;
[0612] "TFEMA" is trifluoroethyl methacrylate commercially
available from Cornelius Chemical;
[0613] "Ti" is titanium (IV) isoproxide commercially available from
Aldrich;
[0614] "Ti-Bu" is titanium (IV) butoxide commercially available
from Aldrich;
[0615] "TMSPMA" is 3-(trimethoxysilyl)propyl methacrylate
commercially available from Aldrich;
[0616] "TPB" is thermoplast blue 684;
[0617] "TPR" is thermoplast red 454;
[0618] "TX-100" is a surfactant commercially available from
Aldrich;
[0619] "ZelecUN" is a lubricant commercially available from Stepan;
and
[0620] "Zr" is zirconium (IV) propoxide commercially available from
Aldrich.
[0621] In Table 11, Layer 1 refers to the first antireflective
coating layer, Layer 2 refers to the second antireflective coating
layer. Solutions of each of the components were prepared and used
to form the antireflective coatings. For all of the compositions
listed in Table 11, the remainder of the composition is made up of
1-methoxy-2-propanol. For example, a listing of 5% Ti, should be
understood to mean 5% by weight of Ti and 95% by weight of
1-methoxy-2-propanol.
[0622] The plastic eyeglass lens was coated using two different
coating compositions. The "Layer 1" composition was added to a
surface of the eyeglass lens and the eyeglass lens was rotated on a
lens spin-coating apparatus. After the L1 composition was spread
onto the eyeglass lens surface, the solvent was allowed to
substantially evaporate and the remaining composition was subjected
to ultraviolet light from the germicidal lamp from the previously
described coating unit for about 60 seconds. In some instances,
more or less UV light was applied. Alternate times are noted in
parenthesis. The "Layer 2" composition was added to the eyeglass
lens after the Layer 1 composition was cured. The eyeglass lens was
spun on a lens spin-coating apparatus until the solvent was
substantially evaporated. Layer 2 was then cured by the application
of ultraviolet light from the germicidal lamp from the previously
described coating unit. Curing time of the second layer is 60
seconds, unless otherwise noted. The % transmittance refers to the
amount of light transmitted through the lens after the Layer 2
composition was cured. The transmittance was measured in a BYK
Gardner Haze Guard Plus Meter, available from BYK Gardner, Silver
Springs, Md. Transmission readings were taken of an uncoated lens
to use as a control standard. The visible light transmittance of an
uncoated lens measured with the convex face of the lens positioned
against the haze port of the BYK Gardner Haze Guard Plus Meter is
about 92%. Color refers to the color of the light reflected from
the coated lens. TABLE-US-00013 TABLE 11 Visible Light Transmit-
Ex. # Layer 1 Layer 2 tance % Color 1 5% Ti 5.1% Si 99.0% RED 1.04%
Ti 1.04% GPTMS 0.144% HC-900 (Heat 20 Min.) 2 5% Ti 4.25% Si 99.0%
0.87% GPTMS 0.17HC-900 (Heat 20 Min.) 3 5% Ti 4.5% Si 96.0% PURPLE
1.8% Ti 1.8% GPTMS 0.17% HC-900 (Heat 20 Min.) 4 5% Ti 4.25% Si
99.0% 1.04% Ti 0.87% GPTMS 0.17% HC-900 (Heat 20 Min.) 5 5% Ti 4.5%
Si 97.4% BLUE 1.8% Ti 1.8% GPTMS 0.17% HC-900 6 3% Ti 4.5% Si 97.0%
PURPLE 1.8% Ti 1.8% GPTMS 0.17% HC-900 7 3% Ti 3% Si 93.0% 1.2% Ti
1.2% GPTMS 0.11% HC-900 8 3% Ti 5.4% Si 97.7% RED 1.17% Ti 1.17%
GPTMS 0.107% HC-900 9 5% Ti 5.4% Si 99.0% PURPLE 1.17% Ti 1.17%
GPTMS 0.107% HC-900 10 5.2% Ti 5.4% Si 96.0% 1.33% Si 1.17% Ti
1.33% GPTMS 1.17% GPTMS 0.107% HC-900 11 4.13% Ti 5.4% Si >97%
0.66% Si 1.17% Ti 0.66% GPTMS 1.17% GPTMS 0.107% HC-900 (Heat 5
Min.) 12 5.4% Ti 5.4% Si 98.0% 0.32% Si 1.17% Ti 0.32% GPTMS 1.17%
GPTMS 0.053% HC- 0.107% HC-900 900 (UV 90 s) 13 3% Ti 0.45% Al
97.0% 0.445% Ti 3.5% GPTMS 3.5% TMSPMA 14 3% Ti 0.3% Al 97.7% 0.36%
Ti 2% GPTMS 2% TMSPMA 0.01% TBPO 0.08% FC-430 15 3% Ti 0.62% Al
>97% 0.17% Ti 1.2% GPTMS 1.2% TMSPMA 3.87% HC-8 16 2.8% Ti 0.62%
Al >96% 0.49% Al 0.17% Ti 2.79% HC-8 1.2% GPTMS 1.2% TMSPMA
3.87% HC-8 17 3% Ti 0.54% Al 94.4% 0.5% Ti 0.82% GPTMS 0.9% TMSPMA
1.27% HC-8 18 3% Ti 0.9% Al 97.3% 0.46% Ti 0.75% GPTMS 0.83% TMSPMA
3.43% HC-8 19 3% Ti 0.8% Al 97.0% 0.1% Ti 0.42% GPTMS 0.42% TMSPMA
6% HC-8 20 3% Ti 0.62% Al 97.0% 0.17% Ti 1.2% GPTMS 1.2% TMSPMA
3.9% HC-8 21 10% Ti 0.19% Ti >97% 0.05% AA 0.19% GPTMS 22.7% MP
0.19% TMSPMA 67.25% IPA 1.9% HC-8 3.9% Si 22 10% Ti 0.46% Ti 96.2%
0.05% AA 0.9% Al 22.7% MP 0.8% GPTMS 67.25% IPA .75% TMSPMA 3.4%
HC-8 23 2% Ti 0.3% Al 92.5% 100 ppmAA 18.5% HC-8 25.2% MP (UV 60 s)
72.8% IPA (UV 60 s) 24 2% Ti 0.11% Al 92.8% 100 ppmAA 3.35% SR368
25.2% MP (UV 200 s) 72.8% IPA (UV 60 s) 25 1.54% Ti 0.24% Ti 96.3%
77 ppmAA 0.048% Al 42.3% MP 1.94% SR368 56.2% IPA 1.47% TMSPMA (UV
86 s) 96.3% MP (UV 180 s) 26 1.54% Ti 0.186% Ti 97.2% 77 ppmAA
0.036% Al 42.3% MP 1.48% SR368 56.2% IPA 1.13% TMSPMA (UV 40 s)
0.02% DC193 97.17% MP (UV 180 s) 27 1.54% Ti 0.36% Ti 96.8% 77
ppmAA 0.033% Al 42.3% MP 1.39% SR368 56.2% IPA 1.06% TMSPMA (UV 40
s) 0.0187% DC193 97.16% MP (UV 10 s) 28 2.8% Ti 2% SR399 96.8% 2.8%
Irg184 (UV 20 s) 29 2.99% Ti 1.86% SR399 95.7% 0.294% Irg184 0.31%
Ti (UV 20 s) (UV 30 s) 30 2.99% Ti 2% SR399 95.7% GOLD 0.28% Irg184
0.349% Ti (UV 40 s) (UV 30 s) 31 2.99% Ti 0.34Ti 95.7% DEEP BLUE
0.28% Irg184 0.5% SR306 2% SR399 (UV 120 s) 32 2.99% Ti 2% SR399
95.8% 0.28% Irg184 0.5% SR306 (UV 40 s) 0.349% Ti (UV 100 s) 33 2%
Ti 2% SR399 95.2% GOLD 0.2Irg184 0.4% Ti (UV 30 s) 0.04% Irg184 (UV
30 s) 34 2% Ti 2% SR399 97.1% 0.2% Irg184 0.4% Ti (X3) 0.04% Irg184
(UV 20 s each) (UV 60 s) 35 2% Ti 2% SR399 95.6% 0.2Irg184 0.4% Ti
(UV 30 s) 0.04% Irg184 0.1% BYK300 (UV 30 s) 36 3.25% Ti 2% SR399
97.2% GOLD 0.1% Irg184 0.4% Ti (UV 30 s) 0.04% Irg184 0.1% BYK300
(UV 30 s) 37 3.25% Ti 2% SR399 97.9% 0.1% Irg184 0.4% Ti (350 rpm)
0.04% Irg184 0.1% BYK300 (UV 30 s) 38 3.25% Ti 2% SR399 97.5% GOLD
0.1% Irg184 0.4% Ti (UV 60 s) 0.04% Irg184 0.1% BYK300 (UV 60 s) 39
2% Ti 2% SR399 96.0% 0.2% Irg184 0.4% Ti (UV 60 s) 0.04% Irg184
0.12% Zelecun (UV 60 s) 40 2% Ti 2% SR399 96.0% 0.2% Irg184 0.4% Ti
(UV 60 s) 0.04% Irg184 0.1% Q4DC 41 3.25% Ti 2% SR399 97.4% 0.1%
Irg184 0.4% Ti (UV 70 s) 0.04% Irg184 0.1% Q4DC (UV 70 s) 42 3.25%
Ti 2% SR399 97.4% 0.1% Irg819 0.4% Ti (UV 60 s) 0.04% Irg184 0.1%
Q4DC (UV 70 s) 43 3.03% Ti 2% SR399 96.9% 0.4% Irg819 0.4% Ti (UV
60 s) 0.04% Irg184 0.1% Q4DC (UV 70 s) 44 2.5% Ti 2% SR399 96.5%
0.16% Irg184 0.4% Ti (UV 60 s) 0.04% Irg184 0.13% FC430 (UV 60 s)
45 3.5% Ti 2% SR399 97.5% 0.08% Irg184 0.4% Ti (UV 60 s) 0.04%
Irg184 (UV 60 s) 46 3.5% Ti 2% SR399 98.1% 0.08% Irg184 0.4% Ti (UV
60 s) 0.04% Irg184 0.1% FC430 0.1% BYK300 (UV 60 s) 47 3.5% Ti 2%
SR399 98.3% 0.08% Irg184 0.4% Ti
(UV 20 s) 0.04% Irg184 0.13% FC430 0.1% BYK300 (UV 60 s) 48 2.5% Ti
0.2% Ti 95.2% 0.2% Irg184 0.2% SR239 44.8% AC 0.8% SR399 52.5% MP
49 2.46% Ti 0.5% Ti 97.5% 0.197Irg184 0.1% Irg184 0.157% SR313
0.55% SR313 44.3% AC 1.75% SR399 (UV 60 s) 50 3.47% Ti 0.5% Ti
96.9% 0.294% Irg184 0.1% Irg184 (UV 30 s) 0.55% SR313 1.75% SR399
51 2.5% Ti 0.5% Ti 97.5% 0.2% Irg184 0.1% Irg184 45% AC 0.55% SR313
52.3% MP 1.75% SR399 (UV 60 s) 52 2.47% Ti 0.53% Ti 97.0% 0.197%
Irg184 0.1% Irg184 0.12% SR313 0.85% SR313 44.47% AC 1.38% SR399
(UV 60 s) (UV 60 s) 53 2.47% Ti 0.57% Ti 95.0% 0.197% Irg184 0.087%
Irg184 0.12% SR313 1.74% CN124 44.47% AC (UV 60 s) (UV 60 s) 54
2.47% Ti 0.5% Ti 96.8% 0.197% Irg184 0.19% Irg184 0.12% SR313 0.6%
CN124 44.47% AC 0.4% SR313 1.07% SR399 (UV 60 s) 55 2.47% Ti 0.167%
Ti 96.7% 0.197% Irg184 0.083% Irg184 0.12% SR313 0.167% Al 44.47%
AC 1.555% SR399 56 2.47% Ti 0.35% Ti 97.1% 0.197% Irg184 0.076%
Irg184 0.12% SR313 0.15% Al 44.47% AC 1.43% SR399 0.414% SR313 57
5% Ti 2% CD540 97.6% 0.5% Ti 3.4 ppmTPB 0.2 ppmTPR 12 ppmCynox-1790
58 5% Ti 0.21% Irg184 97.4% 1.93% CD540 0.48% Ti 3.3 ppmTPB 0.19
ppmTPR 11.6 ppmCynox-1790 59 5% Ti 0.084% Irg 184 98.5% 0.77% CD540
0.192% Ti 1.3 ppmTPB 0.075 ppmTPR 4.6 ppm-Cynox-1790 60 5% Ti 2%
ECHMCHC 97.6% (UV 60 s) 0.5% Ti 61 5% Ti 0.12% CD1012 98.1% (UV 40
s) 1.88% ECHMCHC 0.47% Ti (UV 90 s) 62 5% Ti 0.22% CD1012 95.0% (UV
30 s) 2% ECHMCHC 0.43% Ti (UV 90 s) 63 5% Ti 0.22% CD1012 94.0% (UV
60 s) 2% ECHMCHC 0.43% Ti (UV 90 s) 64 5% Ti 0.356Ti 98.4%
0.073CD1012 0.67% ECHMCHC 1.33% SR399 65 5% Ti 0.14% Irg184 98.3%
(UV 50 s) 0.348% Ti 0.07% CD1012 0.65% ECHMCHC 1.3% SR399 (Heat) 66
5% Ti 0.133% Irg184 96.4% (UV 45 s) 0.33% Ti 0.066% CD1012 0.62%
ECHMCHC 1.24% SR399 0.1% PerenolS-5 (Heat) 67 3% Ti 2.6% SR399
96.7% (UV 60 s) 0.3% Ti (UV 60 s) 68 5% Ti 2.6% SR399 94.4% (UV 60
s) 0.3% Ti (UV 60 s) 69 3% Ti 2.6% SR399 96.2% (UV 60 s) 0.3% Ti
(UV 60 s) 70 3% Ti 2.0% SR399 97.2% (UV 60 s) 0.3% Ti (UV 60 s) 71
2.5% Ti 2% SR399 96.2% 2.5% HEMA 0.06% Irg184 72 1.5% Ti 2% SR399
95.3% 1.5% HEMA 0.06% Irg184 73 1.5% Ti 2% SR399 97.0% 1.5% HEMA
0.06% Irg184 9.3 ppmAA 13.3% IPA 74 3% Ti 0.0525% PFOFCS 95.6% (UV
60 s) 0.144% CD1012 1.955% ECHMCHC (UV 60 s) 75 3% Ti 0.0256%
PFOFCS 97.0% (UV 60 s) 0.145% CD1012 1.978% ECHMCHC (UV 60 s) 76 3%
Ti 0.0232% PFOFCS 96.8% (UV 60 s) 0.476% Ti 0.131% CD1012 1.79%
ECHMCHC (UV 60 s) 77 3% Ti 0.051% PFOFCS 97.3% (UV 60 s) 0.139%
CD1012 1.89% ECHMCHC 0.49% HEMA (UV 60 s) 78 3% Ti 0.0477% PFOFCS
96.9% (UV 60 s) 0.13% CD1012 1.767% ECHMCHC 0.78% HEMA 0.32% Ti (UV
60 s) 79 3% Ti 0.0457% PFOFCS 97.5% (UV 60 s) 0.124% CD1012 0.26%
Irg184 1.685% ECHMCHC 0.746% HEMA 0.306% Ti (UV 60 s) 80 3% Ti
0.11% Irg184 97.1% (UV 60 s) 0.44% Ti 2% SR399 (UV 60 s) 81 5% Si
0.05% Irg184 93.8% (UV 60 s) 5% Ti 0.19% SR399 (UV 60 s) 82 5% Si
0.08% Irg184 92.6% 0.32% Ti 1.44% SR399 0.005% PFOTCS (UV 60 s) 83
3.1% Ti-Bu 2% SR399 96.3% 1.1% HEMA 0.08% Irg 184 13.3% IPA 84 3.1%
Ti-Bu 2% SR399 96.3% 1.1% HEMA 0.08% Irg 184 13.3% IPA 85 4% Ti 2%
SR399 97.7% 0.08% Irg184 0.32% Ti-Bu
[0623] In Table 12, Layer 1 refers to the first antireflective
coating layer, Layer 2 refers to the second antireflective coating
layer. HR-200 refers to a hydrophobic coating layer formed upon
Layer 2. Solutions of each of the components were prepared and used
to form the antireflective coatings. For all of the compositions
listed in Table 12, the remainder of the composition is made up of
1-methoxy-2-propanol. For example, a listing of 5% Ti, should be
understood to mean 5% by weight of Ti and 95% by weight of
1-methoxy-2-propanol.
[0624] The application of the compositions to the lenses, and the
measurement of the transmittance was performed in substantially the
same manner as recited above for Table 11. Curing times are 60
seconds, unless otherwise noted. TABLE-US-00014 TABLE 12 Visible
Light Transmittance Ex. # Layer 1 Layer 2 Layer 3 % Color 86 3% Ti
4.65% Si HR-200 >98% 0.7% Ti 0.05% HC-900 87 1.5% Ti 0.46% Ti
HR-200 97.3% 454 ppmAA 0.75% GPTMS 300 ppmAS 0.83% TMSPMA 92.8% MP
3.4% HC-8 5.6% IPA 0.9% Al (UV 40 s) 88 0.75% Ti 0.46% Ti HR-200
96.0% 38 ppmAA 0.75% GPTMS 14.2% MP 0.83% TMSPMA 85% IPA 3.4% HC-8
0.9% Al 89 2% Ti 0.24% Al HR-200 94.7% 100 ppmAA 9.8% HC-8 25.2% MP
(UV 60 s) 72.8% IPA (UV 60 s) 90 2% Ti 0.09% Al HR-200 93.5% 100
ppmAA 2.8% SR368 25.2% MP 0.32% Ti 72.8% IPA 16 ppmAA (UV 60 s)
11.7% IPA (UV 90 s) 91 2% Ti 0.41% Ti HR-200 94.6% 100 ppmAA 0.045%
Al 25.2% MP 1.4% SR368 72.8% IPA 0.88% SR123 0.78% TFEMA 8 ppmAA
5.8% IPA (UV 90 s) 92 1% Ti 0.13% Ti HR-200 94.8% 50 ppmAA 0.031%
Al 12.6% MP 1.52% SR368 86.4% IPA 0.467% SR123 (UV 30 s) 0.417%
TFEMA (UV 60 s) 93 1% Ti 0.21% Ti HR-200 96.7% 50 ppmAA 0.35% Al
12.6% MP 2.4% SR368 86.4% IPA 0.74% SR123 (UV 40 s) 0.66% TFEMA (UV
60 s) 94 1.54% Ti 0.19% Ti HR-200 96.9% 77 ppmAA 0.037% Al 42.3% MP
1.5% SR368 56.2% IPA 1.14% TMSPMA (UV 30 s) 97.16% MP (UV 180
s)
[0625] In Table 13, multiple coating layers are formed on the
plastic lens. For all of the compositions listed in Table 13, the
remainder of the composition is made up of 1-methoxy-2-propanol.
For example, a listing of 5% Ti, should be understood to mean 5% by
weight of Ti and 95% by weight of 1-methoxy-2-propanol.
[0626] The application of the compositions to the lenses, and the
measurement of the transmittance was performed in substantially the
same manner as recited above for Table 11. Curing times are 60
seconds, unless otherwise noted. TABLE-US-00015 TABLE 13 Visible
Light Ex. # Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 Layer 6 Layer 7
Transmittance % Color 95 2.5% Ti 10% Ti 0.7% Ti HR200 96.8% BLUE
2.5% Si 4.6% Si 0.05% HC900 96 2% Ti 0.368% Al 26.8% HC-8 HR200
96.0% 57 ppmNNDMEA (UV 40 s) 73.2% IPA (UV 30 s) 97 3% Ti 0.055%
Irg184 3% Si 0.055% Irg184 97.2% (UV 70 s) 0.22% Ti (UV 20 s) 0.22%
Ti 1% SR399 1% SR399 0.0125PFOMA (UV 20 s) 0.0125% PFOMA (UV 70 s)
98 3% Ti (UV 70 s) 0.055% Irg184 3.7% Natco Si 0.055% Irg184 97.9%
0.22% Ti (UV 20 s) 0.22% Ti 1% SR399 1% SR399 0.0125PFOMA (UV 20 s)
0.0125% PFOMA 99 3% Ti (UV 60 s) 0.54% SR399 0.54% SR399 0.54%
SR399 97.5% 0.12% Ti 0.12% Ti 0.12% Ti 0.03% Irg184 0.03% Irg184
0.03% Irg184 0.07% PFOMA 0.07% PFOMA 0.07% PFOMA 45.4% AC 45.4% AC
45.4% AC (UV 20 s) (UV 20 s) (UV 20 s) 100 3% Ti 0.527% SR399
0.527% SR399 0.54% SR399 96.1% 0.235% Ti 0.235% Ti 0.12% Ti 0.029%
Irg184 0.029% Irg184 0.03% Irg184 0.066% PFOMA 0.066% PFOMA 0.07%
PFOMA 44.3% AC 44.3% AC 45.4% AC (UV 20 s) (UV 60 s) 101 1.5% Ti
0.525% SR399 3% Si 0.527% SR399 97.0% 0.235% Ti 0.23% Ti 0.029%
Irg184 0.024% Irg184 0.066% PFOMA 0.066% PFOMA 102 3.5% Ti--Bu
0.033% BDKK 0.086% BDKK 0.026% BDKK 97.5% 0.095% Ti--Bu 0.173%
Ti--Bu 0.3% SR399 0.375% SR399 1% SR399 0.0037% PFOTCS 2.5% Si
0.0037% FC430 0.0037% BYK300 103 5% Ti--Bu 0.086% BDKK 0.086% BDKK
0.026% BDKK 98.1% (UV 60 s) 0.17% Ti--Bu 0.17% Ti--Bu 0.3% SR399 1%
SR399 1% SR399 0.0037% PFOTCS (UV 40 s) (UV 50 s) 0.0037% FC430
0.0037% BYK300 (UV 60 s) 104 5% Ti--Bu 0.033% BDKK 0.086% BDKK
0.026% BDKK 97.9% (UV 60 s) 0.095% Ti--Bu 0.17% Ti--Bu 0.3% SR399
0.375% SR399 1% SR399 0.0037% PFOTCS 2.5% Si (UV 50 s) 0.0037%
FC430 (UV 40 s) 0.0037% BYK300 (UV 60 s) 105 5% Ti--Bu 0.033% BDKK
0.033% BDKK 0.026% BDKK 98.2% (UV 60 s) 0.095% Ti--Bu 0.095% Ti--Bu
0.3% SR399 0.375% SR399 0.375% SR399 0.0037% PFOTCS 2.5% Si 2.5% Si
0.0037% FC430 (UV 40 s) (UV 50 s) 0.0037% BYK300 (UV 60 s) 106 5%
Ti--Bu 0.086% BDKK 0.033% BDKK 0.026% BDKK 97.9% (UV 60 s) 0.17%
Ti--Bu 0.095% Ti--Bu 0.3% SR399 1% SR399 0.375% SR399 0.0037%
PFOTCS (UV 50 s) 2.5% Si 0.0037% FC430 (UV 60 s) 0.0037% BYK300 107
2% Ti 5% Si 5% Ti 5% Si 1% SR399 97.5% (UV 50 s) 0.4% SR399 0.4% Ti
0.17% Ti 0.067% Ti 0.06% Irg184 0.0416% Irg184 108 2% Ti 5% Si 5%
Ti 2% Si 0.2% SR399 97.7% (UV 50 s) 0.4% SR399 0.0346% Ti 0.067% Ti
0.2% SR399 0.0346% Ti 0.0085% Irg184 109 2% Ti 1% SR399 2% Ti 2% Ti
0.1% SR399 96.8% (UV 50 s) 0.17% Ti (UV 30 s) (UV 40 s) 0.0416%
Irg184 (UV 50 s) 110 1.5% Ti 2% SR399 2.75% Ti 1% SR399 1% Si 1.4%
SR399 96.4% (UV 60 s) 0.5% Si 0.05% Irg184 0.062% Irg184 0.1%
Irg184 0.3% Ti 0.3% Ti 0.3% Ti (UV 60 s) (UV 60 s) 111 1.5% Ti 1%
SR399 2.75% Ti 1% SR399 1% Si 1% SR399 95.1% (UV 60 s) 1% Si 0.05%
Irg184 0.05% Irg184 0.05% Irg184 0.3% Ti 0.21% Ti 0.3% Ti (UV 60 s)
(UV 60 s) 112 1.5% Ti 2% SR399 2.75% Ti 1% SR399 1% Si 1% SR399
0.4% SR399 96.1% (UV 60 s) 0.5% Si 0.05% Irg184 0.05% Irg184 0.017%
Irg184 0.1% Irg184 0.3% Ti 0.21% Ti 0.085% Ti 0.3% Ti (UV 60 s) 113
1.5% Ti 0.33% SR399 2.75% Ti 1% SR399 1% Si 1% SR399 0.4% SR399
94.7% (UV 60 s) 3% Si 0.05% Irg184 0.05% Irg184 0.017% Irg184
0.017% Irg184 0.3% Ti 0.21% Ti 0.085% Ti 0.3% Ti 114 1.5% Ti 0.33%
SR399 2.75% Ti 1% SR399 1% Si 0.8% SR399 97.5% 3% Si 0.05% Irg184
0.035% Irg184 0.017% Irg184 0.3% Ti 0.17% Ti 0.3% Ti 115 1.5% Ti
0.33% SR399 2.75% Ti 0.33% SR399 0.8% SR399 97.5% 3% Si 3% Si
0.035% Irg184 0.017% Irg184 0.017% Irg184 0.17% Ti 0.3% Ti 0.3% Ti
116 2.75% Ti 0.596% SR399 2.75% Ti 2.75% Ti 0.596% SR399 1.3% SR399
95.6% (UV 50 s) 0.03% Irg184 (UV 50 s) 0.03% Irg184 0.065% Irg184
0.3% Ti 0.3% Ti 0.245% Ti 2.2% Si (UV 50 s) 2.2% Si 0.58% Si 117
2.75% Ti 1.3% SR399 2.75% Ti 2.75% Ti 0.596% SR399 1.3% SR399 95.4%
(UV 50 s) 0.065% Irg184 (UV 50 s) 0.03% Irg184 0.065% Irg184 0.245%
Ti 0.3% Ti 0.245% Ti 0.58% Si (UV 50 s) 2.2% Si 0.58% Si 118 1.5%
Ti 0.596% SR399 2.75% Ti 1.5% Ti 1.3% SR399 0.596% SR399 96.7%
0.03% Irg184 0.065% Irg184 0.03% Irg184 0.3% Ti 0.245% Ti 0.3% Ti
2.2% Si 0.58% Si 2.2% Si 119 1.5% Ti 0.596% SR399 2.75% Ti 1.5% Ti
1.4% SR399 0.596% SR399 97.2% 0.03% Irg184 0.062% Irg184 0.03%
Irg184 0.3% Ti 0.3% Ti 0.3% Ti 2.2% Si 2.2% Si 120 1.5% Ti 0.8%
SR399 4% Ti 0.596% SR399 1.4% SR399 97.6% (UV 50 s) 0.035% Irg184
(UV 50 s) 0.03% Irg184 0.062% Irg184 0.17% Ti 0.3% Ti 0.3% Ti (UV
50 s) 2.2% Si (UV 50 s) 121 1.5% Ti 1% SR399 4% Ti 0.596% SR399
1.4% SR399 97.2% (UV 50 s) 0.05% Irg184 (UV 50 s) 0.03% Irg184
0.062% Irg184 0.21% Ti 0.3% Ti 0.3% Ti (UV 50 s) 2.2% Si (UV 50 s)
122 1.5% Ti 1.4% SR399 4% Ti 0.596% SR399 1.4% SR399 0.4% SR399
96.9% 0.062% Irg184 0.03% Irg184 0.062% Irg184 0.017% Irg184 0.3%
Ti 0.3% Ti 0.3% Ti 0.085% Ti 2.2% Si (UV 70 s) 123 1.5% Ti 0.4%
SR399 4% Ti 0.596% SR399 1.4% SR399 98.2% 0.017% Irg184 0.03%
Irg184 0.062% Irg184 0.085% Ti 0.3% Ti 0.3% Ti 2.2% Si (UV 70 s)
124 2% Ti 1.4% SR399 4% Ti 0.596% SR399 0.596% SR399 1.4% SR399
96.4% (UV 60 s) 0.062% Irg184 0.03% Irg184 0.03% Irg184 0.062%
Irg184 0.3% Ti 0.3% Ti 0.3% Ti 0.3% Ti (UV 60 s) 2.2% Si 2.2% Si
125 2% Ti 1% SR399 4% Ti 0.596% SR399 0.596% SR399 1.4% SR399 96.5%
(UV 60 s) 0.05% Irg184 0.03% Irg184 0.03% Irg184 0.062% Irg184
0.21% Ti 0.3% Ti 0.3% Ti 0.3% Ti (UV 60 s) 2.2% Si 2.2% Si 126 2%
Ti 0.596% SR399 4% Ti 0.596% SR399 0.596% SR399 1.4% SR399 95.3%
0.03% Irg184 0.03% Irg184 0.03% Irg184 0.062% Irg184 0.3% Ti 0.3%
Ti 0.3% Ti 0.3% Ti 2.2% Si 2.2% Si 2.2% Si (UV 60 s) 127 2% Ti
0.596% SR399 4% Ti 0.596% SR399 0.596% SR399 0.4% SR399 96.1% 0.03%
Irg184 0.03% Irg184 0.03% Irg184 0.017% Irg184 0.3% Ti 0.3% Ti 0.3%
Ti 0.085% Ti 2.2% Si 2.2% Si 2.2% Si (UV 60 s) (UV 60 s) 128 2.75%
Ti 0.6% SR399 4% Ti 0.6% SR399 1.3% SR399 1% SR399 0.1% Ti 97.0%
RED 0.03% Irg184 0.03% Irg184 0.065% Irg184 0.05% Irg184 0.21% Ti
0.1% PFOTCS 0.3% Ti 0.3% Ti 0.245% Ti EtOH 4.4% Si 4.4% Si 0.58% Si
(UV 60 s) 129 2.75% Ti 1.4% SR399 5% Ti 0.4% SR399 0.6% SR399 1.4%
SR399 0.1% Ti 96.9% BLUE 0.062% Irg184 0.017% Irg184 0.03% Irg184
0.062% Irg184 0.1% PFOTCS 0.31% Ti 0.085% Ti 0.3% Ti 0.31% Ti EtOH
4.4% Si 130 1.75% Ti 0.9% SR399 4% Ti 0.6% SR399 0.9% SR399 0.01%
PFOA 96.6% BLUE (UV 60 s) 0.042% Irg184 (UV 60 s) 0.03% Irg184
0.042% Irg184 0.01% PFOMA 0.19% Ti 0.3% Ti 0.19% Ti 0.005% PFOTCS
(UV 60 s) 3.3% Si (UV 60 s) 0.1% Ti (UV 60 s) 0.007% TBPO 4% MP
95.9% IPA (UV 50 s) 131 1.75% Ti 0.6% SR399 4% Ti 0.6% SR399 0.9%
SR399 0.01% PFOA 96.9% YELLOW-RED (UV 60 s) 0.03% Irg184 (UV 60 s)
0.03% Irg184 0.042% Irg184 0.01% PFOMA 0.3% Ti 0.3% Ti 0.19% Ti
0.005% PFOTCS 3.3% Si 3.3% Si (UV 60 s) 0.1% Ti (UV 60 s) (UV 60 s)
0.007% TBPO 4% MP 95.9% IPA (UV 50 s) 132 1.75% Ti 0.9% SR399 1.75%
Ti 1.75% Ti 0.6% SR399 0.9% SR399 96.1% 0.042% Irg184 (UV 60 s) (UV
60 s) 0.03% Irg184 0.042% Irg184 0.19% Ti 0.3% Ti 0.19% Ti 3.3% Si
(UV 60 s) (UV 30 s) 133 1.75% Ti 0.9% SR399 1.75% Ti 1.75% Ti 0.6%
SR399 0.9% SR399 96.5% 0.042% Irg184 (UV 60 s) (UV 60 s) 0.03%
Irg184 0.042% Irg184 0.19% Ti 0.3% Ti 0.19% Ti 3.3% Si (UV 60 s)
(UV 30 s) 134 1.75% Ti 1.4% SR399 5% Ti 0.6% SR399 1.4% SR399 97.6%
0.3% Ti 0.03% Irg184 0.3% Ti 0.3% Ti (UV 60 s) 3.3% Si 135 1.75% Ti
1.4% SR399 5% Ti 0.6% SR399 0.9% SR399 96.8% 0.3% Ti 0.03% Irg184
0.042% Irg184 0.3% Ti 0.19% Ti 3.3% Si (UV 60 s) 136 1.15% Ti--Bu
1.15% Ti--Bu 3.85% Ti--Bu 1.5% SR399 95.4% 0.84% Ti 0.84% Ti 0.25%
SR399 0.1% Irg184 0.55% SR399 0.55% SR399 0.017% Irg184 50
ppmBYK300 0.068% Irg184 0.068% Irg184 8 ppmBYK300 50 ppmPFOMA 18.5
ppmBYK300 18.5 ppmBYK300 8 ppmPFOMA 18.5 ppmPFOMA 18.5 ppmPFOMA 137
1.15% Ti--Bu 2.5% Si 1.15% Ti--Bu 3.85% Ti--Bu 1.5% SR399 0.085%
Ti--Bu 96.4% RED-GREEN 0.84% Ti (UV 60 s) 0.84% Ti 0.25% SR399 0.1%
Irg184 0.4% SR399 0.55% SR399 0.55% SR399 0.017% Irg184 50
ppmBYK300 0.017% Irg184 0.068% Irg184 0.068% Irg184 8 ppmBYK300 50
ppmPFOMA 18.5 ppmBYK300 18.5 ppmBYK300 8 ppmPFOMA 18.5 ppmPFOMA
18.5 ppmPFOMA
[0627] In Table 14, three coating layers are formed on the plastic
lens. For all of the compositions listed in Table 14, the remainder
of the composition is made up of 1-methoxy-2-propanol. For example,
a listing of 5% Ti, should be understood to mean 5% by weight of Ti
and 95% by weight of 1-methoxy-2-propanol.
[0628] The application of the compositions to the plastic lens, and
the measurement of the transmittance was performed in substantially
the same manner as recited above for Table 11. Curing times are 60
seconds, unless otherwise noted. TABLE-US-00016 TABLE 14 Visible
Light Ex. # Layer 1 Layer 2 Layer 3 Transmittance % Color 138 2% Ti
0.186% Al 26.8% HC-8 94.0% 0.02% NNDMEA (UV 40 s) 73.2% IPA (UV 30
s) 139 1.54% Ti 0.24% Ti 0.3% Al 93.0% 77 ppmAA 0.048% Al (UV 50 s)
42.3% MP 1.94% SR368 56.2% IPA 1.47% TMSPMA 96.3% MP (UV 180 s) 140
2.99% Ti 2.99% Ti 2% SR399 97.3% 0.28% Irg184 0.28% Irg184 0.349%
Ti (UV 20 s) (UV 20 s) (UV 30 s) 141 0.3% Al 2.99% Ti 2% SR399
95.5% (UV 20 s) 0.28% Irg184 0.5% SR306 (UV 40 s) 0.349% Ti (UV 100
s) 142 2.97% Ti 2.99% Ti 2% SR399 93.6% 0.29% Irg184 0.28% Irg184
0.5% SR306 1% SR368 0.349% Ti (UV 30 s) 143 1.69% Ti 2.99% Ti 2%
SR399 94.5% 0.168% Irg184 0.28% Irg184 0.5% SR306 0.58% SR368
0.349% Ti 144 3.25% Ti 3.25% Ti 2% SR399 93.0% GREENISH 0.1% Irg184
0.1% Irg184 0.4% Ti BLUE (UV 30 s, 350 rpm) (UV 30 + 60 s) 0.04%
Irg184 0.1% BYK300 (UV 60 s) 145 0.5% Ti 2.46% Ti 0.53% Ti 97.3%
0.25% Irg184 0.5% Al 0.197% Irg184 0.1% Irg184 4.67% SR399 0.157%
SR313 0.85% SR313 44.3% AC 1.38% SR399 146 3% Ti 3% HEMA 0.06%
Irg184 97.4% (UV 60 s) 0.25% Ti 0.32% Ti 0.33% TEA 2% SR399 0.02%
Eiosin (UV 60 s) (UV 60 s) 147 3% HEMA 0.25% Ti 3% Ti 0.06% Irg184
97.5% 0.33% TEA (UV 60 s) 0.32% Ti 0.02% Eiosin 2% SR399 (UV 60 s)
(UV 60 s) 148 3% Ti 2.5% HEMA 0.06% Irg184 97.4% (UV 60 s) 0.25%
T770 0.32% Ti 0.5% Ti 2% SR399 (UV 60 s) 149 3% Ti 2.5% HEMA 0.06%
Irg184 97.8% (UV 60 s) 0.25% T770 0.32% Ti 0.5% Ti 2% SR399 (UV 60
s) 150 3% Ti 0.037% PFOFCS 2% SR399 94.4% 0.1% CD1012 0.32% Ti
0.21% Irg184 0.06% Irg184 1.35% ECHMCHC (UV 60 s) 0.6% HEMA 0.246%
Ti 1% SR399 151 1.3% HEMA 0.05% BDKK 0.164% HEMA 98.5% 0.96% SR640
0.57% SR399 0.05% PFOTCS 3.576% Ti--Bu 0.43% HEMA 97.86% IPA 5.66%
Si 1.93% MP 152 3.5% Ti--Bu 0.087% BDKK 0.035% BDKK 97.0% 0.095%
Ti--Bu 0.4% SR399 1% SR399 0.005% PFOTCS 2.9% Si 0.005% FC430
0.005% BYK300 153 3.5% Ti--Bu 0.043% BDKK 0.174% BDKK 94.0% BLUE
0.047% Ti--Bu 0.173% Ti--Bu 0.5% SR399 2% SR399 1.45% Si 154 5%
Ti--Bu/5% Ti--Bu 0.033% BDKK 0.026% BDKK 97.2% 0.095% Ti--Bu 0.3%
SR399 0.375% SR399 0.0037% PFOTCS 2.5% Si 0.0037% FC430 0.0037%
BYK300 155 1.15% Ti--Bu 1.15% Ti--Bu 1.5% SR399 95.7% YELLOW 0.84%
Ti 0.84% Ti 0.1% Irg184 0.55% SR399 0.55% SR399 50 ppmBYK300 0.068%
Irg184 0.068% Irg184 50 ppmPFOMA 18.5 ppmBYK300 18.5 ppmBYK300 18.5
ppmPFOMA 18.5 ppmPFOMA
[0629] In Table 15, Layer 1 refers to the first antireflective
coating layer, Layer 2 refers to an intermediate silicon layer, and
Layer 3 refers to the second antireflective coating layer.
Solutions of each of the components were prepared and used to form
the antireflective coatings. For all of the compositions listed in
Table 15, the remainder of the composition is made up of
1-methoxy-2-propanol. For example, a listing of 5% Ti, should be
understood to mean 5% by weight of Ti and 95% by weight of
1-methoxy-2-propanol.
[0630] The plastic eyeglass lens was coated using different coating
compositions. The "Layer 1" composition was added to a surface of
the eyeglass lens and the eyeglass lens was rotated on a lens
spin-coating apparatus. After the Layer 1 composition was spread
onto the eyeglass lens surface the solvent was allowed to
substantially evaporate and the remaining composition was subjected
to ultraviolet light from the germicidal lamp from the previously
described coating unit for about 60 seconds, unless otherwise
noted. Layer 2 (the silicon layer) was added to the eyeglass lens
after the Layer 1 composition was cured. Curing time of the second
layer is 60 seconds, unless otherwise noted. The Layer 2
composition was spread onto the eyeglass lens surface and the
eyeglass lens was spun until the solvent was substantially
evaporated. The Layer 3 composition was added to the eyeglass lens
after the Layer 2 composition was dried. The eyeglass lens was spun
on a lens spin-coating apparatus until the solvent was
substantially evaporated. Layer 3 was then cured by the application
of ultraviolet light from the germicidal lamp from the previously
described coating unit. Curing time for the third layer is 60
seconds, unless otherwise noted. From one to four additional layers
were added to the top of the antireflective stack. The %
transmittance refers to the amount of light transmitted through the
lens after the final layer was cured. The transmittance was
measured as described above. TABLE-US-00017 TABLE 15 Visible Light
Ex. # Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 Layer 6 Layer 7
Transmittance % Color 156 1.5% Ti 1.5% Si 0.257% Ti HR200 96.0%
BROWN 454 ppmAA 98.5% IPA 0.257% GPTMS GOLD 300 ppmAS (UV 40 s)
2.85% HC-8 92.8% MP 0.5% Al 5.6% IPA 0.26% TMSPMA (UV 40 s) (UV 120
s) 157 1.5% Ti 1.5% Si 0.46% Ti HR200 94.4% 76 ppmAA 98.5% IPA
0.75% GPTMS 28.4% MP (UV 40 s) 0.83% TMSPMA 70.1% IPA 3.4% HC-8 (UV
60 s) 0.9% Al (UV 120 s) 158 3% Ti 1.5% Si 0.055% Irg184 0.055%
Irg184 97.4% (UV 70 s) 0.22% Ti 0.22% Ti 1% SR399 1% SR399 0.0125%
PFOMA 0.0125% PFOMA (UV 70 s) (UV 60 s) 159 3% Ti 1.5% Si 0.025%
Irg184 1.5% Si 0.025% Irg184 94.5% YELLOW (UV 60 s) (UV 20 s) 0.14%
Ti 0.14% Ti 0.96% SR399 0.96% SR399 (UV 20 s) (UV 60 s) 160 3% Ti
1.5% Si 1.5% Si 0.08% Irg184 97.4 RED (UV 60 s) 0.32% Ti 1.44%
SR399 0.005% PFOTCS (UV 60 s) 161 3% Ti 1.5% Si 1.5% Si 0.08%
Irg184 97.3 (UV 60 s) (UV 60 s) 0.32% Ti 1.44% SR399 0.005% PFOTCS
(UV 60 s) 162 3% Ti 1.5% Si 1.5% Si 0.11% Irg184 93 (UV 60 s) (UV
60 s) 0.44% Ti 2% SR399 0.005% PFOTCS (UV 60 s) 163 3% Ti 1.5% Si
1.5% Si 0.055% Irg184 95.3% 0.22% Ti 1% SR399 0.0125% PFOTCS 164 3%
Ti 1.5% Si 1.5% Si 0.055% Irg184 0.055% Irg184 94.6% 0.22% Ti 0.22%
Ti 1% SR399 1% SR399 0.0125% PFOTCS 0.0125% PFOTCS 165 3% Ti 2.4%
Si 2.4% Si 0.08% Irg184 97.6% 0.53% SR640 0.97% SR640 0.97% SR640
0.32% Ti 70 ppmFC430 70 ppmFC430 70 ppmFC430 1.44% SR399 (UV 60 s)
0.005% PFOTCS 166 3% Ti 5% Si 0.33% SR399 0.527% SR399 97.3% 0.07%
Ti 0.23% Ti 0.018% Irg184 0.029% Irg184 0.07% PFOMA 0.066% PFOMA
167 3.85% Ti--Bu 1% SR399 1% SR399 1.15% Ti--BU 1.739% SR399 96.7%
0.25% SR399 2.4% Si 2.4% Si 0.84% Ti 0.12% Irg184 0.017% Irg184
0.55% SR399 60 ppmBYK300 8 ppmBYK300 0.068% Irg184 60 ppmPFOMA 8
ppmPFOMA 18.5 ppmBYK300 18.5 ppmPFOMA (UV 60 s)
[0631] In Table 16, Layer 1 refers to the first antireflective
coating layer, Layer 2 refers to an intermediate silicon layer, and
Layer 3 refers to the second antireflective coating layer.
Solutions of each of the components were prepared and used to form
the antireflective coatings. For all of the compositions listed in
Table 16, the remainder of the composition is made up of
1-methoxy-2-propanol. For example, a listing of 5% Ti, should be
understood to mean 5% by weight of Ti and 95% by weight of
1-methoxy-2-propanol.
[0632] The plastic eyeglass lens was coated using different coating
compositions. The "Layer 1" composition was added to a surface of
the eyeglass lens and the eyeglass lens was rotated on a lens
spin-coating apparatus. The first coating layer was formed by a two
step procedure. In the first step, a solution of Ti was added to
the plastic lens and allowed to dry. In the second step, an
additional solution of Ti was added to the plastic lens and allowed
to dry. The % of Ti used for the first and second steps are
respectively listed in the "Layer 1" column. The Layer 1
composition was allowed to substantially evaporate and the
remaining composition was subjected to ultraviolet light from the
germicidal lamp from the previously described coating unit for
about 60 seconds, unless otherwise noted. Layer 2 (the silicon
layer) was added to the eyeglass lens after the Layer 1 composition
was cured. The Layer 2 composition was spread onto the eyeglass
lens surface and the eyeglass lens was spun until the solvent was
substantially evaporated. The Layer 3 composition was added to the
eyeglass lens after the Layer 2 composition was dried. The eyeglass
lens was spun on a lens spin-coating apparatus until the solvent
was substantially evaporated. Layer 3 was then cured by the
application of ultraviolet light from the germicidal lamp from the
previously described coating unit. Curing time was 60 seconds,
unless otherwise noted. From one to four additional layers were
added to the top of the antireflective stack. The % transmittance
refers to the amount of light transmitted through the lens after
the final layer was cured. The transmittance was measured as
described above. TABLE-US-00018 TABLE 16 Visible Light Trans- Ex. #
Layer 1 Layer 2 Layer 3 mittance % Color 168 1.5% Ti/3% Ti 3% Si
0.08% Irg184 97.6% BLUE (UV 40 s/40 s) 0.32% Ti 1.45% SR399 (UV 60
s) 169 3% Ti/1.5% Ti 3% Si 0.08% Irg184 98.3% PUR- (UV 40 s/40 s)
0.32% Ti PLE 1.45% SR399 (UV 60 s) 170 5% Ti/3% Ti 3% Si 0.08%
Irg184 92.2% (UV 40 s/40 s) 0.32% Ti 1.45% SR399 (UV 90 s) 171 3%
Ti/5% Ti 3% Si 0.08% Irg184 94.1% (UV 40 s/40 s) 0.32% Ti 1.45%
SR399 (UV 90 s) 172 1.5% Ti/1.5% 3% Si 0.08% Irg184 97.6% Ti (UV 60
0.32% Ti s/60 s) 1.45% SR399 173 3% Ti/3% Ti 3% Si 0.08% Irg184
97.6% (UV 60 s/60 s) (UV 0.32% Ti 30 s) 1.45% SR399
[0633] In Table 17, Layer 1 refers to the first antireflective
coating layer, Layer 2 refers to an intermediate silicon layer, and
Layer 3 refers to the second antireflective coating layer.
Solutions of each of the components were prepared and used to form
the antireflective coatings. For all of the compositions listed in
Table 17, the remainder of the compostion is made up of
1-methoxy-2-propanol. For example, a listing of 5% Ti, should be
understood to mean 5% by weight of Ti and 95% by weight of
1-methoxy-2-propanol.
[0634] The application of the compositions to the plastic lens, and
the measurement of the transmittance was performed in substantially
the same manner as recited above for Table 11. Curing time was 60
seconds, unless otherwise noted. TABLE-US-00019 TABLE 17 Visible
Light Ex. # Layer 1 Layer 2 Layer 3 Transmittance % Color 174 3% Ti
6% Si 0.8% Ti 96.0% 0.8% GPTMS 0.8% TMSPMA 175 5.2% Ti 5% Si 0.75%
Ti 96.6% 0.97% HC8558 0.75% HC8558 176 3.75% Ti 3% Si 0.257% Ti
98.3% RED 0.019% AA 97% IPA 0.257% GPTMS 71% MP 2.85% HC-8 25.25%
IPA 0.5% Al 177 3.75% Ti 1.5% Si 0.257% Ti 95.6% RED 0.019% AA
98.5% IPA 0.257% GPTMS 71% MP 2.85% HC-8 25.25% IPA 0.5% Al 178
7.5% Ti 1.5% Si 0.257% Ti 96.0% RED 0.038AA 98.5% IPA 0.257% GPTMS
45.3% MP 2.85% HC-8 47.2% IPA 0.5% Al 179 3% Ti 5% Si 0.16% Ti
98.1% 1% SR399 50 ppmPFOFCS 180 3% Ti 6.94% Nalco Si 0.16% Ti 95.7%
1% SR399 50 ppmPFOFCS 181 3% Ti 6.94% Nalco Si 0.317% Ti 93.0% 2%
SR399 0.08% Irg184 0.06% PFOFCS 182 3% Ti 3% Si 0.11% Irg184 93.0%
BLUE 0.44% Ti 2% SR399 183 3% Ti 3% Si 0.05% Irg184 94.3% GOLD
0.02% Ti 0.9% SR399 184 3% Ti 4% Si 0.05% Irg184 96.4% 0.2% Ti 0.9%
SR399 185 3% Ti 5% Si 0.05% Irg184 97.9% 0.2% Ti 0.9% SR399 186 3%
Ti 4% Si 0.079% Irg184 97.0% 0.322% Ti 1.45% SR399 187 3% Ti 4% Si
0.079% Irg184 96.8% 0.322% Ti 1.45% SR399 188 3% Ti 3% Si 0.079%
Irg184 97.3% 0.322% Ti 1.45% SR399 189 3% Ti 3% Si 0.08% Irg184
97.7% 0.32% Ti 1.44% SR399 0.005% PFOA 190 3% Ti 3% Si 0.08% Irg184
97.6% 0.32% Ti 1.44% SR399 0.047% PFOMA 191 3% Ti 3% Si 0.08%
Irg184 97.8% 0.32% Ti 1.44% SR399 0.005% PFOTCS 192 3% Ti 5% Si
0.08% Irg184 95.7% 0.32% Ti 1.44% SR399 0.005% PFOTCS 193 1.5% Ti
5% Si 0.08% Irg184 94.6% 0.32% Ti 1.45% SR399 194 1.5% Ti 3% Si
0.08% Irg184 95.1% 0.32% Ti 1.45% SR399 195 2% Ti 3% Si 0.08%
Irg184 95.6% 0.32% Ti 1.45% SR399 196 2% Ti 3% Si 0.08% Irg184
96.0% 0.03% BYK300 0.32% Ti 1.45% SR399 197 3% Ti 1.5% Si 0.11%
Irg184 97.2% 0.44% Ti 2% SR399 0.005% PFOMA 198 3% Ti 1.5% Si 0.08%
Irg184 95.0% 0.32% Ti 1.44% SR399 0.005% PFOMA 199 3% Ti 1.5% Si
0.11% Irg184 96.7% 0.44% Ti 2% SR399 0.005% PFOMA 200 3% Ti 3% Si
0.08% Irg184 97.5% 0.53% SR640 0.32% Ti 1.44% SR399 0.005% PFOTCS
201 3% Ti 3% Si 0.08% Irg184 97.1% 0.32% Ti 1.44% SR399 0.005%
PFOTCS 202 3% Ti 3% Si 0.08% Irg184 97.8% 0.5% SR640 0.32% Ti 1.44%
SR399 0.005% PFOTCS 203 3% Ti 3% Si 0.08% Irg184 97.8% 0.53% SR640
0.53% SR640 0.32% Ti 70 ppmFC430 70 ppmFC430 1.44% SR399 0.005%
PFOTCS 204 3% Ti 5% Si 1.44% SR399 97.4% 0.32% Ti 0.08% Irg184
0.005% PFOTCS 205 3.85% Ti--Bu 5% Si 1.56% Ti--Bu 95.8% YELLOW
0.25% SR399 0.5% SR399 0.017% Irg184 0.033% Irg184 8 ppmBYK300 16
ppmBYK300 8 ppmPFOMA 16 ppmPFOMA
[0635] Table 18 refers to a series of experiments using an in-mold
curing process. In the in-mold process, the layers are built in the
opposite manner than they are built upon the plastic lens. Layer 1,
thus, refers to the second antireflective coating layer, Layer 2
refers to the first antireflective coating layer, and Layer 3
refers to an adhesion layer. Solutions of each of the components
were prepared and used to form the antireflective coatings. For all
of the compositions listed in Table 18, the remainder of the
composition is made up of 1-methoxy-2-propanol. For example, a
listing of 5% Ti, should be understood to mean 5% by weight of Ti
and 95% by weight of 1-methoxy-2-propanol.
[0636] A casting face of a mold was coated using the different
coating compositions. The "Layer 1" composition was added to a
surface of the mold and the mold was rotated on a lens spin-coating
apparatus. The Layer 1 composition was allowed to substantially
evaporate and the remaining composition was subjected to
ultraviolet light from the germicidal lamp from the previously
described coating unit for about 60 seconds, unless otherwise
noted. Layer 2 was added to the mold after the Layer 1 composition
was cured. The Layer 2 composition was spread onto the mold surface
and the mold was spun until the solvent was substantially
evaporated. Layer 2 was then cured by the application of
ultraviolet light from the germicidal lamp from the previously
described coating unit. Curing time was 60 seconds, unless
otherwise noted. Layer 3 was then added to the antireflective
stack. Layer 3 was added to the mold, spun dried and cured. Curing
time was 60 seconds, unless otherwise noted. A pair of coated molds
was then used to in a mold assembly to form a plastic lens. After
the lens was formed, the lens was removed from mold assembly and
the % transmittance of the plastic lens measured. The transmittance
was measured as described above. TABLE-US-00020 TABLE 18 Visible
Light Ex. # Layer 1 Layer 2 Layer 3 Transmittance % Color 206 1%
SR399 92.5% 0.059% Irg184 0.007% PFOMA 207 1% SR399 92.5% 0.059%
Irg184 0.007% PFOMA 0.0062% Q4DC 208 1% SR399 1.44% SR399 3% Ti
97.0% GOLD 0.059% Irg184 0.08% Irg184 0.007% PFOMA 0.32% Ti 0.0062%
Q4DC 0.005% PFOTCS 209 2.58% SR399 4% Ti--Bu 2.58% SR399 94.5%
0.147% Irg184 1.2% HEMA 0.147% Irg184 0.32% Ti--Bu 14% IPA 0.32%
Ti--Bu (UV 60 s) (UV 60 s) (UV 60 s) 210 2.2% SR399 2.2% SR399 2.2%
SR399 97.7% BLUISH RED 0.126% Irg184 0.126% Irg184 0.126% Irg184
0.003% PFOMA 0.003% PFOMA 0.003% PFOMA 211 2.2% SR399 4% Ti--Bu
97.7% 0.126% Irg184 1.2% HEMA 0.0031% PFOMA 14% IPA 212 2.2% SR399
4% Ti--Bu 97.1% 0.14% D1173 1.2% HEMA 14% IPA 213 2.2% SR399 2.022%
Ti--Bu 1% Si >95.5 0.14% D1173 2.026% HEMA 2.2% SR399 (UV 70 s)
(UV 70 s) 0.165% Ti--Bu 0.14% D1173 (UV 70 s) 214 2.06% SR399 3.62%
Ti--Bu 2.06% SR399 97.0% RED GOLD 0.136% D1173 1.5% HEMA 0.136%
D1173 0.95% HEMA (UV 90 s) 0.95% HEMA (UV 90 s) (UV 90 s) 215 2%
SR399 3.62% Ti--Bu 2.12% SR399 97.0% 0.145% D1173 1.5% HEMA 0.14%
D1173 (UV 90 s) (UV 90 s) 0.5% HEMA (UV 90 s) 216 2.2% SR399 3.6%
Ti--Bu 2.2% SR399 94.7% 0.117% BDK 1.5% HEMA 0.117% BDK (UV 90 s)
217 2.66% SR399 3.6% Ti--Bu 2.66% SR399 95.0% 0.114% BDK 1.5% HEMA
0.114% BDK (UV 90 s) 218 2.886% SR399 3.6% Ti--Bu 2.886% SR399
94.5% 0.124% BDK 1.5% HEMA 0.124% BDK 219 2.2% SR399 3.46% Ti--Bu
2.2% SR399 97.7% 0.19% BDK (UV 60 s) 0.19% BDK (UV 60 s) (UV 60 s)
220 2.2% SR399 3.7% Ti--Bu 2.2% SR399 97.6% 0.19% BDK 0.005% PFOMA
0.19% BDK (UV 60 s) 0.003% BDK (UV 60 s) 221 2.2% SR399 3.7% Ti--Bu
2.2% SR399 98.0% 0.19% BDK 0.0247% BDK 0.19% BDK 0.028% PFOTCS
0.091% HEMA 222 2.2% SR399 3.7% Ti--Bu 2.2% SR399 98.2% 0.19% BDK
0.0123% BDK 0.19% BDK (UV 60 s) 0.014% PFOTCS 0.045% HEMA 223
0.028% BDK 1.3% HEMA 0.19% BDK 95.2% 0.32% SR399 0.96% SR640 2.2%
SR399 0.24% HEMA 3.576% Ti--Bu 0.01% HEMA 3.2% Si 0.03% PFOTCS 5.9%
IPA 91.7% MP 224 1.5% SR399 3.849% Ti 1.04% Ti 94.7% 0.1% Irg184
0.25% SR399 0.5% SR399 0.005% BYK300 0.0016% Irg184 0.033% Irg184
0.005% PFOMA 8 ppmBYK300 16 ppmBYK300 8 ppmPFOMA 16 ppmPFOMA
[0637] In Table 19, multiple coating layers are formed on the
casting surface of the molds prior to use. For all of the
compositions listed in Table 19, the remainder of the composition
is made up of 1-methoxy-2-propanol. For example, a listing of 5%
Ti, should be understood to mean 5% by weight of Ti and 95% by
weight of 1-methoxy-2-propanol.
[0638] The application of the compositions to the lenses, and the
measurement of the transmittance was performed in substantially the
same manner as recited above for Table 18. Curing times were 60
seconds, unless otherwise noted. TABLE-US-00021 TABLE 19 Visible
Light Trans- Ex. # Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 Layer 6
Layer 7 mittance % Color 225 0.5% SR399 1.44% SR399 3% Ti HC-8
96.7% 0.02% Irg184 0.32% Ti 0.02% PFOMA 0.08% Irg184 0.005% PFOTCS
226 0.05% BDKK 1.3% HEMA 0.19% BDKK 0.164% HEMA 94.7% 0.57% SR399
0.96% SR640 2.2% SR399 0.05% PFOTCS 0.43% HEMA 3.576% Ti--Bu 0.01%
HEMA 97.86% IPA 5.66% Si 0.03% PFOTCS 1.93% MP 5.9% IPA 91.7% MP
227 0.01% FC725 0.0134% Irg184 0.6% SR399 0.9% SR399 4% Ti 0.01%
FC725 97.7% 40% IPA 0.033% D1173 0.03% Irg184 0.04% Irg184 40% IPA
0.015% FC171 0.527% SR399 0.3% Ti 0.19% Ti 0.015% FC171 50% AC
0.178% SR423 3.3% Si (UV 60 s) 50% AC 0.088% SR9003 0.008% CD540
0.06% ppmTPB (UV 60 s) 228 0.01% FC725 0.0134% Irg184 1.4% SR399 4%
Ti 0.6% SR399 0.0134% Irg184 97.5% 0.015% FC171 0.033% D1173 0.1%
Irg184 0.04% TX-100 0.03% Irg184 0.033% D1173 50% IPA 0.527% SR399
0.3% Ti 0.3% Ti 0.527% SR399 50% AC 0.178% SR423 3.3% Si 0.178%
SR423 0.088% SR9003 0.088% SR9003 0.008% CD540 0.008% CD540 0.06
ppmTPB 0.06 ppmTPB 229 0.01% FC725 1% SR399 0.9% SR399 4% Ti 0.9%
SR399 1% SR399 98.0% 50% IPA 0.5% SR368 0.042% Irg184 0.04% TX-100
0.042% Irg184 0.5% SR368 0.015% FC171 0.01% Irg184 0.19% Ti 0.19%
Ti 0.01% Irg184 50% AC 0.05% TPB 0.05% TPB 230 1.5% SR399 1.04% Ti
3.849% Ti 1.5% SR399 97.5% 0.1% Irg184 0.5% SR399 0.25% SR399 0.1%
Irg184 0.005% BYK300 0.033% Irg184 0.0016% Irg184 0.005% BYK300
0.005% PFOMA 16 ppmBYK300 8 ppmBYK300 0.005% PFOMA 16 ppmPFOMA 8
ppmPFOMA 231 1.5% SR399 2.5% Si/2.5% Si 1.04% Ti 1.04% Ti 3.849% Ti
1.04% Ti 95.5% 0.1% Irg184 0.5% SR399 0.5% SR399 0.25% SR399 0.5%
SR399 0.005% BYK300 0.033% Irg184 0.033% Irg184 0.0016% 0.033%
Irg184 0.005% PFOMA 16 ppmBYK300 16 ppmBYK300 Irg184 16 ppmBYK300
16 ppmPFOMA 16 ppmPFOMA 8 ppmBYK300 16 ppmPFOMA 232 1.5% SR399
1.04% Ti 3.849% Ti 0.3% Ti 8 ppmPFOMA 1.04% Ti 97.0% 0.1% Irg184
0.5% SR399 0.25% SR399 1.4% SR399 2.5% Si 0.5% SR399 0.005% BYK300
0.033% Irg184 0.0016% Irg184 0.06% Irg184 0.033% Irg184 0.005%
PFOMA 16 ppmBYK300 8 ppmBYK300 16 ppmBYK300 16 ppmPFOMA 8 ppmPFOMA
16 ppmPFOMA
Additional Improvement
[0639] Systems and methods for preparing optical lenses using
radiation curing techniques and coatings applied to eyeglass lens
molds are described in U.S. Pat. No. 3,494,326 to Upton, U.S. Pat.
No. 4,544,572 to Sandvig et al., U.S. Pat. No. 4,728,469 to
Lipscomb et al., U.S. Pat. No. 4,758,448 to Sandvig et al., U.S.
Pat. No. 4,879,318 to Lipscomb et al., U.S. Pat. No. 4,895,102 to
Kachel et al., U.S. Pat. No. 5,364,256 to Lipscomb et al., U.S.
Pat. No. 5,415,816 to Buazza et al., U.S. Pat. No. 5,514,214 to
Joel et al., U.S. Pat. No. 5,516,468 to Lipscomb, et al., U.S. Pat.
No. 5,529,728 to Buazza et al., U.S. Pat. No. 5,689,324 to Lossman
et al., U.S. Pat. No. 5,928,575 to Buazza, U.S. Pat. No. 5,976,423
to Buazza, U.S. Pat. No. 5,989,462 to Buazza et al., U.S. Pat. No.
6,022,498 to Buazza et al., U.S. Pat. No. 6,086,799 to Buazza et
al., U.S. Pat. No. 6,105,925 to Lossman et al., U.S. Pat. No.
6,201,037 to Lipscomb et al., U.S. Pat. No. 6,206,673 to Lipscomb
et al., U.S. Pat. No. 6,228,289 to Powers et al., U.S. Pat. No.
6,280,171 to Buazza, U.S. Pat. No. 6,284,159 to Lossman et al.,
U.S. Pat. No. 6,331,058 to Lipscomb et al., U.S. Pat. No. 6,328,445
to Buazza, U.S. Pat. No. 6,494,702 to Buazza et al., U.S. Pat. No.
6,730,244 to Lipscomb et al., U.S. Pat. No. 6,416,307 to Buazza et
al., U.S. Pat. No. 6,451,226 to Buazza, U.S. Pat. No. 6,478,990 to
Powers et al., U.S. Pat. No. 6,368,523 to Buazza et al., U.S. Pat.
No. 6,712,596 to Buazza et al., U.S. Pat. No. 6,367,928 to Buazza
et al., U.S. Pat. No. 6,576,167 to Buazza et al., U.S. Pat. No.
6,673,278 to Buazza et al., U.S. Pat. No. 6,464,484 to Powers et
al., U.S. Pat. No. 6,723,260 to Powers et al., U.S. Pat. No.
6,716,375 to Powers et al., U.S. Pat. No. 6,528,955 to Powers et
al., U.S. Pat. No. 6,698,708 to Powers et al., U.S. Pat. No.
6,632,535 to Buazza et al., U.S. Pat. No. 6,729,866 to Buazza et
al., U.S. Pat. No. 6,557,734 to Buazza et al., U.S. Pat. No.
6,634,879 to Buazza et al., U.S. Pat. No. 6,712,331 to Foreman et
al., U.S. Pat. No. 6,702,564 to Foreman et al., U.S. Pat. No.
6,709,257 to Foreman et al., U.S. Pat. No. 6,676,398 to Foreman,
U.S. Pat. No. 6,790,024 to Foreman, U.S. Pat. No. 6,752,613 to
Foreman, U.S. Pat. No. 6,726,463 to Foreman, U.S. Pat. No.
6,790,022 to Foreman, U.S. Pat. No. 6,676,399 to Foreman, U.S. Pat.
No. 6,840,752 to Foreman et al., U.S. Pat. No. 6,808,381 to Foreman
et al., U.S. Pat. No. 6,612,828 to Powers et al., U.S. Pat. No.
6,655,946 to Foreman et al., U.S. Pat. No. 6,758,663 to Foreman et
al., U.S. Pat. No. 6,863,518 to Powers, U.S. Pat. No. 6,579,478 to
Lossman et al.; U.S. Pat. No. 6,875,005 to Foreman et al. U.S. Pat.
No. 6,893,245 to Foreman et al.; U.S. Pat. No. 6,899,831 to Forman;
U.S. Pat. No. 6,962,669 to Foreman et al.; U.S. Pat. No. 7,025,910
to Lattis et al., U.S. Pat. No. 7,051,290 to Foreman et al.; U.S.
Pat. No. 7,011,773 to Fore man; U.S. Pat. No. 7,037,449 to Foreman;
U.S. Pat. No. 7,004,740 to Foreman; U.S. Design Pat. No. D467948 to
Powers et al. and D460468 to Powers et al.; U.S. patent application
Ser. No. 08/904,289 filed Jul. 31, 1997 now abandoned, Ser. No.
09/232,261 filed Jan. 19, 1999 now abandoned, Ser. No. 09/272,815
filed Mar. 19, 1999 now abandoned, Ser. No. 09/397,489 filed Sep.
16, 1999 now abandoned, Ser. No. 09/496,567 filed Feb. 2, 2000 now
abandoned, Ser. No. 09/539,211 filed Mar. 30, 2000; and Ser. No.
09/789,122 filed Feb. 20, 2001; and U.S. Patent Application
Publication Nos. U.S. 2001/0038890 to Buzza et al. now abandoned,
U.S. 2001/0047217 to Buazza et al., U.S. 2002/0166944 to Foreman et
al., U.S. 2002/0168439 to Foreman et al., U.S. 2002/0167098 to
Foreman et al., U.S. 2002/0167097 to Foreman et al., U.S.
2002/0167099 to Foreman, et al., U.S. 2003/0042633 to Foreman et
al., 2005-0077639 to Foreman et al., and U.S. 2003/0003176 to
Foreman et al., all of which are hereby specifically incorporated
by reference. In addition, systems and methods for generating and
reading data codes are described in U.S. Pat. No. 4,939,354 to
Priddy et al., U.S. Pat. No. 5,053,609 to Priddy et al., and U.S.
Pat. No. 5,124,536 to Priddy et al., all of which are hereby
specifically incorporated by reference.
[0640] A controller as discussed below, may be coupled to one or
more computer systems via a network. In such a case, the controller
and one or more computers on the network may exchange data and/or
instruction to implement various methods disclosed herein. In such
a case, for ease of reference herein, the controller and/or one or
more computer in communication with the controller via the network
may be collectively referred to as a "controller."
[0641] As used herein, eyeglass lens information related to a set
of eyeglass lenses prescribed to a particular patient may be
referred to as a "job." In an embodiment, certain eyeglass lens
information may be associated with a job identifier. For example, a
job may be assigned a unique identifier, generally referred to
herein as a "job number." As used herein, a "job ticket" may refer
to a label or other hardcopy printout containing information
identifying a particular job. For example, in some embodiments, a
job ticket may include a job number. In such embodiments, the job
number may be a human readable alphanumeric sequence or a
machine-readable encoded sequence (e.g., a bar code).
[0642] In an embodiment, an operator preparing one or more lens
according to a job may interact with a computer system as described
above. For example, upon initiating work on a job and/or at another
point in a lens forming process, the operator may provide input to
the controller identifying the job. For example, the operator may
scan a job ticket or manually enter a job number. The operator may
couple a job ticket to a mold assembly holder to relate a job with
the mold assembly holder and its contents. The operator may also
select one or more mold members appropriate to form at least one
lens substantially conforming to the eyeglass lens information.
[0643] In an embodiment, a system and method for the location,
storage, and identification of eyeglass mold members may be used in
the production of eyeglass lenses. As used herein, an "eyeglass
mold member storage system" refers to a device or group of devices
configured to store eyeglass lens mold members in an organized
fashion. In certain embodiments, an eyeglass mold member storage
system may include both hardware and software. For example,
hardware included in an eyeglass mold member storage system may
include but is not limited to: a series of mold member storage
locations, a controller and various input and/or output devices. In
an embodiment, a mold member storage system may be arranged as a
multi-dimensional array of mold member storage locations. For
example, a mold member storage system may be roughly cubical in
shape with mold members arranged in three dimensions. The mold
members may be organized within the storage array in a manner
convenient to the operator. For example, mold members may be
arrange so that mold members with similar properties are proximate
one another. In another example, mold members may be arranged to
allow easy access to frequently used mold members. A controller may
be coupled to the mold member storage array. Additionally, one or
more indicators may be coupled to the mold member storage array to
assist an operator in locating a desired mold member. One or more
indicators may also be coupled to the mold member storage array to
assist an operator in locating a mold member storage location
designated for storage of a particular mold.
[0644] As used herein, a "mold member storage location" refers to a
portion of an eyeglass mold member storage system configured to
retain one or more mold members in an organized fashion. In some
embodiments, the mold members may include lens molds. In such
embodiments, it may be desirable for a mold member storage location
to retain one or more lens molds in a manner that inhibits damaging
the molds. For example, lens molds may be damaged by contact with
one another. A mold member storage location may therefore include
one or more mechanisms configured to inhibit molds from touching
one another. As used herein, such mechanisms may be generally
referred to as "separating devices." Lens molds may also be damaged
by contact with various portions of an eyeglass mold member storage
system. For example, the lens molds may be scratched or chipped by
contact with hard portions of the eyeglass mold member storage
system. Thus, an eyeglass mold member storage system may be formed
primarily of relatively soft materials (e.g., wood, plastic, etc.)
in areas that may come into contact with lens molds. In an
embodiment, a mold member storage location may include a means for
urging one or more mold members disposed within the mold member
storage location toward a dispensing end of the mold member storage
location. For example, mold members may be moved toward the
dispensing end by a conveyor, by one or more elastic members and/or
by gravity.
[0645] As used herein, an "indicator" is intended to include,
without limit, any device configured to draw the attention of a
user or operator to a particular area. For example, an indicator
may draw attention by turning on a light, generating a sound and/or
moving a mechanical or electromechanical member. As used herein, an
action by an indicator intended to draw the attention of a user or
operator to a particular area may generally be referred to as a
"user detectable signal." As used herein with reference to an
indicator, a "light" may refer to any suitable light source such as
but not limited to: a fiber optic light system, a light bulb, a
fluorescent light source or a light emitting diode. In various
embodiments, an electromechanical indicator may include a device
that changes its appearance upon receipt of an electrical
activation signal. Examples may include but are not limited to a
resettable pop-out button, or a partially obscured multicolor disk
that may be rotated to expose a different color to view.
[0646] FIG. 54 depicts an embodiment of an eyeglass mold member
storage array 10101. Storage array 10101 may facilitate the storage
of a large number of mold members 10102. Storage array 10101 may
include a body 10111 housing a plurality of mold member storage
locations. Mold member storage array 10101 may be configured
vertically (e.g., such that molds within the array are vertical),
horizontally or at an angle. In an embodiment, mold members may be
arranged on a plurality of shelves 10112. In an embodiment, shelves
10112 may be tilted toward the front of array 10103. For example,
various embodiments may include shelves having any angle between
and including horizontal and vertical. In such embodiments, mold
member retaining devices and separating devices (as discussed
below) may be appropriately configured to interact with mold
members at the angle of the shelves. For example, an embodiment may
include a shelf having an angle between about 5 degrees to about 15
degrees (e.g., 7 degrees). The angle of the shelf may be selected
to enable mold members in the mold member storage location to
advance under the influence of gravity. For example, physical
dimensions of the separating devices (e.g., height, weight,
stiffness, etc) may be selected to interact with mold members at
the angle of the shelf. In an embodiment, mold member storage array
10101 may also include one or more work surfaces 10110. For
example, a work surface may include a job tray staging area and/or
a mold assembly area for assembling one or more selected mold
members to form a lens. A work surface may also include a mold
indexing area for aligning the axes of two or more selected molds
appropriately to form a desired lens.
[0647] When the mold members stored are lens molds, as shown in
FIG. 54, individual molds 10102 may be damaged if they are allowed
to contact one another. To inhibit molds 10102 from contacting each
other, separating devices 10113 may be coupled to the mold member
storage array. Separating device 10113 (more clearly illustrated in
FIG. 55) may include a variety of cams or other separating devices.
Many different types and arrangements of separating devices may be
used. FIGS. 55, 41A, 41B, 41C, and 41D depict several embodiments
of separating devices, which may be suitable for use. Reference
numerals 10202, 10203, 1861, and 1862 indicate rocking type cams.
In general, a lens mold may roll over a rocking type cam as it
advances toward the front of the mold member storage location. The
back end of the cam 10209 may be heavier than front end 10208.
Therefore, back end 10209 may normally be down. However, as a mold
member approaches front end 10208 of the rocking type cam, the
weight of the lens mold may push the front end of the cam down,
pushing the back end up. Back end 10209 may block the next lens
mold from advancing. A pivot member 10210 for a rocking type cam
may be coupled to or formed on a shelf portion of a mold member
storage location. Hinged cams (e.g., 1863 in FIG. 41C) and
reciprocating cams (e.g., 1864 in FIG. 41D) may be linked to
activating means. For example, a linking member under shelf 10112
may link the cams on a particular shelf together so that when one
cam moves they all move. Thus, when a first cam is pushed down to
allow the first lens mold on a shelf to be dispensed, all of the
cams on that shelf may move out of the way to allow the lens molds
to advance. As a mold member in a first mold member storage
location advances across or over one or more separating devices,
the position of the mold member relative to a second mold member
storage location over the first mold member storage location may
vary. To inhibit an advancing mold member from contacting the
bottom surface 10211 of the second mold member storage location,
bottom surface 10211 may be contoured. Contoured bottom surface
10211 may provide adequate clearance between the advancing mold
member and the bottom surface of a mold member storage location
above the mold member.
[0648] FIG. 55 also depicts interaction of cams 10202 and 10203
with mold members 10201 and 10205. Within the mold member storage
location, cam 10203 may prevent mold members 10201 and 10205 from
contacting one another. At dispensing end 10204, a retaining device
10206 may retain mold member 10205 within the storage location. In
some embodiments, retaining device 10206 may be coupled to cam
10203. For example, cam 10203 may have a design that includes a
flexible upturned end, which may act to retain mold member 10205.
In various embodiments, retaining device 10206 may include a
resilient member that may be bent, flexed and/or compressed to
allow mold member 10205 to be dispensed. Retaining device 10206 may
be located such that the height or width of the dispensing end of
the mold member storage location is reduced sufficiently to retain
mold member 10205. In an embodiment, retaining device 10206 may
include a sensor 10207. Sensor 10207 may detect dispensing of a
mold member from the mold member storage location. If mold 10205 is
removed for use, the separating devices 10203 may move to dispense
the mold member 10205 and mold member 10201 may advance to the
position previously occupied by mold member 10205. Similarly,
subsequent mold members may advance until all of the mold members
in the storage location are adjacent to one another. In an
embodiment, the mold members advance under the influence of
gravity. For example, the mold member storage location may be at an
angle, as depicted in FIG. 54. However, it will be obvious to one
of skill in the art that other urging means may also be used. For
example, a spring mechanics may push the molds toward front end
10103, or a series of roller mechanisms may urge the molds toward
front end 10103.
[0649] In an embodiment, a mold member storage location may include
a roll back inhibitor 10213. Roll back inhibitor 10213 may inhibit
the first mold member in a mold member storage location from moving
backward into the storage system. For example, if the mold member
is bumped while an operator is selecting an adjacent mold member,
there may be a tendency for the mold member to be pushed backward.
If the mold member were allowed to move backward into the storage
system, it might contact another mold member causing damage to one
of the mold members. Roll back inhibitor 10213 may restrict such
backward motion. In an embodiment, roll back inhibitor 10213 may
include a hinged member. The hinged member may be configured to
move to allow an advancing mold member to move forward, but to
inhibit the mold member from moving backward. In another
embodiment, roll back inhibitor 10213 may include a resilient
member. The resilient member may be configured to deform to allow
an advancing mold member to move forward, but to inhibit the mold
member from moving backward.
[0650] Once a mold member has been used and cleaned, it may be
ready for storage. A mold member may be returned to storage by
placing the mold member in a designated loading area. The loading
area may be the same as the dispensing area, or it may be
different. In an embodiment where the mold member is a lens mold,
mold member storage array 10101 may be configured to allow the user
to remove a desired mold from a first point. The array may further
be configured to allow the user to restock the array at a second
point. The second point may be on the opposite side of the array
from the first point, or it may be on a side adjacent to the side
of first point. For example, the first point may coincide with
front end 10103 of the array (as shown in FIG. 54). The second
point may coincide with back end 10104 of the array. However, in
certain embodiments, rather than being restocked from back end
10104 of the array, the array may be configured to allow restocking
from top end 10105 of the array. For example, the mold member
storage system may include a plurality of chutes that make up the
mold member storage locations. The chutes may be oriented such that
the mold members are dispensed from bottom end 10106 of the array
and restocked at top end 10105 of the array. In each of these
embodiments, separating devices 10113 may separate and secure
returned molds in place automatically.
[0651] FIG. 56 depicts an exemplary embodiment of a plurality of
mold member storage locations 10402 arranged on a panel 10401 of a
mold member storage system. Mold member storage location 10402 may
include a side wall 10406 opposite panel 10401. Side wall 10406 may
retain mold members on the side of the mold member storage location
opposite panel 10401. A plurality of panels 10401 may be housed in
a mold member storage system body to form the array of mold member
storage locations. An advantage of coupling mold member storage
locations to panels may be that panels may be easily assembled in
manufacturing and/or replaced for maintenance. Panel 10401 may be
mounted in the body of a mold member storage system on one or more
rails 10403. Panel 10401 may be attached to rail 10403 by
fasteners, inter-engaging members and/or adhesives. Rails 10403 may
include one or more support members 10404. Support members 10404
may be configured to engage portions of the body of the mold member
storage system. For example, in an embodiment, support members
10404 may engage a slot or groove of the mold member storage system
body. In an embodiment, support members 10404 may include rollers,
bearing, or other sliding devices (e.g., polyethylene glides or
TEFLON.RTM. (E.I. Du Pont De Nemours and Co., Wilimington, Del.,
U.S.A.) glides). In such an embodiment, slots may be arranged
across the top of the body of the mold member storage system.
Support members 10404 may have a T-shaped cross-section configured
to engage the slots. For example, support member 10404 may include
a fastener (e.g., a screw, a nail, a brad, a pin, a bolt, etc.)
having a head portion wider than a shaft portion and having
sufficient strength to safely support the panel when the mold
member storage locations are full. In other embodiments, panels
10401 may be coupled to the body of the mold member storage system
by other methods. For example, the panels may be directly fastened
to the body, the rails may be directly fastened to the body, the
panels may be support by hangers coupled to the body, or the panels
may rest on supporting members coupled to the body.
[0652] In certain embodiments, mold member storage locations may be
coupled to panel 10401 using one or more fasteners 10405. Fasteners
10405 may include threaded members (e.g., screws, bolts, etc.),
inter-engaging members (e.g., nails, pins, clips, snaps, tenons,
projections, etc.), deformable members (e.g., rivets, cotter pins,
etc.) chemical or physical bonds (e.g., welds, adhesives, etc.), or
combinations thereof. In an embodiment, one or more of fasteners
10405 may be formed of a material selected to minimize damage to
mold members if a mold member should happen to contact a fastener.
For example, one or more fasteners may be formed of a plastic
material. Likewise, other mold member storage system components may
be formed of materials selected to minimize damage to mold members
due to unintended contact.
[0653] In an embodiment, a mold member storage system may include
one or more end panels 10501 as depicted in FIG. 57. End panel
10501 may include openings 10503 to provide access to one or more
mold member storage locations. Additionally, in some embodiments,
indicators 10704 may be coupled to end panel 10501. In such
embodiments, indicators 10704 may face toward the outside of the
mold member storage system. For example, openings 10504 (as shown
in FIG. 58) may be provided in end panel 10501 to receive
indicators 10704. Alternately, one or more indicators 10704 may be
directed inwardly (e.g., to illuminate a portion of the interior of
an adjacent mold member storage location). One or more spacers
10502 may be coupled to end panel 10501 to align openings 10503
and/or indicators 10704 with mold member storage locations. Spacers
10502 may also maintain desired spacing between mold member storage
locations and/or panels coupled thereto. In alternate embodiments,
other methods of aligning mold member storage locations with end
panels and/or maintaining spacing between panels or mold member
storage locations may be used. For example, elongated members
extending from panels and/or mold member storage locations may
engage portions of an end panel, or visa versa. In an embodiment,
end panel 10501 may be coupled to the body of a mold member storage
array using coupling devices 10605. In other embodiments, other
coupling means may be used. For example, threaded members,
inter-engaging members, deformable members, chemical or physical
bonds, or combinations thereof, may be used.
[0654] In an embodiment, indicators 10704 may be coupled to one or
more circuit boards 10601, as depicted in FIG. 58. Circuit board
10601 may include at least one electrical and/or communications
connection 10602 for coupling circuit board 10601 to a controller
and/or power supply. In an embodiment, circuit board 10601 may
include a microprocessor 10603 and/or addressing switches 10604.
Microprocessor 10603 and addressing switches 10604 may be used to
associate each indicator on circuit board 10601 with a particular
mold member type. For example, each circuit board of a mold member
storage system may be assigned a unique address using addressing
switches 10604. Individual indicators 10704 may be assigned
addresses on the circuit board. Microprocessor 10603 may receive an
activation signal from a controller. Microprocessor 10603 may
determine based on the position of the addressing switches whether
the activation signal is addressed to the microprocessor's circuit
board. If it is, microprocessor 10603 may determine which indicator
or indicators 10704 to activate. Additionally, microprocessor 10603
may determine based on the activation signal how to activate one or
more indicators 10704. For example, in an embodiment where
indicators 10704 include lights, an indicator may be activated to
produce a steady light, a flashing light and/or a light of two or
more different colors.
[0655] FIG. 59 depicts an embodiment of an eyeglass mold member
storage system including a mold member storage array 10701 coupled
to controller 10702. In an embodiment, controller 10702 may include
a computer and/or and application specific integrated circuit.
Controller 10702 may be coupled to mold member storage array 10701
via an interface connection (e.g., a serial interface, etc.) Mold
member storage array 10701 may include a plurality of mold member
storage locations 10703. Indicators 10704 may be arranged proximate
each mold member storage location 10703. For example, in the
embodiment depicted in FIG. 59, four indicators 10704 surround each
mold member storage location 10703 with adjacent storage locations
sharing the indicators between them. Controller 10702 may be
configured to produce an activation signal to activate one or more
indicators 10704. For example, in the embodiment depicted in FIG.
59, to direct a user to select a mold member in mold member storage
location 10710, controller 10702 may activate indicators 10711.
[0656] Controller 10702, may be configured to interact with an
operator. The controller may include at least one input device
10705 and at least one output device 10706. Input device 10705 may
include a keyboard (e.g., a full computer keyboard or a modified
keyboard), a light sensitive pad, a mouse, a touch sensitive pad, a
light based code reader (e.g., a bar code scanner), a microphone,
or another appropriate input device. Output device 10706 or devices
may include a display screen, a voice synthesizer, or another
suitable output device. In an embodiment, input device 10705 and
output device 10706 may be combined in a single device. For
example, a touch-sensitive screen (also called a "touch screen")
may act as both input device 10705 and output device 10706. An
operator may interact with controller 10702 to determine a mold
member storage location associated with a desired mold member or a
mold member to be stored. For example, in an embodiment, a bar code
scanner coupled to controller 10702 may be used by the operator to
scan a job ticket on a mold assembly holder. Controller 10702 or a
computer 10712 coupled to the controller via a network 10713 may be
configured to determine one or more mold members appropriate for
use in forming one or more lenses associated with the job ticket.
Controller 10702 may also be configured to determine a mold member
storage location designated for storage of a determined mold
member. Likewise, when a mold member 10709 is ready to be placed in
storage, the operator may scan the mold member with a mold reader
10707. Controller 10702 may be configured to determine a mold
member storage location designated for storage of the mold
member.
[0657] A controller may be configured to search a database of
eyeglass lens information using job ticket information as described
above (e.g., job number, bar code, etc.). For example, the
controller may search a first database with a job number to
determine information representative of an eyeglass lens order
associated with the job. In addition, the controller may use the
determined information representative of an eyeglass order to
search a second database. Results of searching the database may
include any of the information representative of an eyeglass lens
order as described above. For example, results of searching the
database may include a job number, a patient name, a mold assembly
holder number, a priority, a bin location, a lens location (i.e.,
left lens or right lens), a lens type, a monomer type and/or tint,
a spherical power, a cylindrical power, axis, an add power, curing
conditions. In addition, the controller may be configured to at
least temporarily store the information in a memory coupled to the
controller.
[0658] Controller 10702 may be configured to send a determined
front mold member identity and a determined back mold member
identity to mold member storage array 10701. Additionally, the
location of front and back mold members may be determined by the
controller. The mold member storage system may also be configured
to display an indication of the location of a mold member to a
user. The indication may be a visual and/or audible signal suitable
for detection by a user. The mold member storage system may be
configured to generate and/or display multiple indications
sequentially (e.g., one mold at a time). As such, an indicator may
direct a user to an appropriate mold member. The user may remove
the appropriate mold member from the mold member storage system and
may assemble an eyeglass lens mold in a mold assembly holder.
Assembly of the eyeglass lens mold may also include filling a space
between two mold members with a lens forming composition.
[0659] As used herein, a "light based code reader" refers to a
device configured to detect light patterns, particularly light
patterns formed by illumination of a data code. A light based code
reader may include a light detection device and a light source. As
used herein, a "data code" generally refers to a machine-readable
mark or pattern. In various embodiments, a data code may include
but is not limited to: a bar code, a matrix data code and/or human
readable text. As used herein, a "bar code" refers to a data code
formed by a series of lines. Data in a bar code may be represented
by bars alternating with blank spaces. The bars and blank spaces
may have various widths and/or frequencies to encode the data. As
used herein, a "matrix data code" refers to a data code formed by a
series of data elements arranged in a matrix. For example, a matrix
data code may refer to a two-dimension matrix code. A matrix data
code may include one or more data elements arranged in a
substantially blank field to encode the data. Data may be encoded
in the data elements based on the size, shape and/or arrangement of
the data elements.
[0660] A mold reader 10707 may be coupled to controller 10702 to
ease inputting data pertaining to mold member 10709. In an
embodiment, mold members may be marked for identification as
described in further detail below. Identifying mark 10708 may
include, but is not limited to: a symbol, a data code, a human
readable code, or text. Mold reader 10707 may be configured to read
an identifying mark 10708 of mold member 10709.
[0661] In an embodiment, an eyeglass mold member storage system
controller may be configured to interact with an operator
identifying, selecting, inventorying and/or storing mold members in
a mold member storage system. FIG. 60A depicts an exemplary
embodiment of a mold member selection graphical display 10801.
Display 10801 may be provided to an operator by a controller as
part of a mold member selection process. In an embodiment, an
operator may identify a job, for example, by scanning a job ticket
or entering a job number. The controller may determine one or more
mold members appropriate to form one or more lenses associated with
the identified job. Display 10801 may include a graphical
representation of a mold assembly tray 10802. Mold assembly tray
representation 10802 may include fields and/or graphical
representations of mold members determined to be appropriate to
form one or more lenses associated with a job. For example, as
depicted in FIG. 60A, for hypothetical job number 1111 (10803) a
left lens may be formed using a back mold (10804) of type "PP-127,"
a front mold (10805) of type "SB-60" and a gasket (10808) of type
"G-22." Likewise, a right lens may be formed using a back mold
(10806) of type "PP-128," a front mold (10807) of type "SB-61" and
a gasket (10809) of type "G-23." Display 10801 may also include
mechanisms to allow the operator to indicate a status of one or
more mold members during the selection process. A current mold
member to be selected may be highlighted in the display (e.g., mold
10804 in FIG. 60A). The operator may search for a mold member of
the current mold member type. If a mold of the current mold member
type is available, the operator may select and inspect the mold to
determine if the mold is usable. If the mold is usable, the
operator may acknowledge the selection of the mold by using
"Acknowledge" button 10810. If the selected mold is unusable, the
operator may indicate this status using "Reject" button 10811. If
no mold of the current mold member type is available, the operator
may indicate this status using "Out of Stock" button 10812. If a
mold member selection is acknowledged, display 10801 may be altered
to reflect a new current mold member to be selected. For example,
as depicted in FIG. 60B, left front mold 10805 may be the new
current mold member. If a selected mold member is rejected, a
message may be displayed to the operator in message display area
10820 indicating that the operator should select another mold
member of the same type. If no molds of the desired type are
available, display area 10820 of display 10801 may direct the
operator to place the job on hold, as depicted in FIG. 60C. If
sometime after a job has been placed on hold it is determined that
all of the mold members needed to complete a job are now available,
display area 10820 of display 10801 may indicate the operator that
the molds are available and request that the operator process the
job, as depicted in FIG. 60D. Display 10801 may also be used to
indicate to the operator when a manual inventory of one or more
mold member types should be completed, as depicted in display area
10820 of FIG. 60E. For example, the manual inventory may be part of
a re-inventory process as discussed further below.
[0662] FIG. 61 depicts a flowchart of an exemplary embodiment of a
computer-implemented method of identifying a mold member. A mold
member storage system and plurality of mold members may be provided
as indicated by boxes 10901 and 10902, respectively. Input may be
received regarding at least one desired mold member at box 10903.
For example, the input received may include a mold member
identification, a job number, a data code of a job ticket and/or an
eyeglass lens prescription. In an embodiment, the input received
may include an identification of a job. The identified job may be
associated with eyeglass lens information. In such an embodiment, a
desired mold member may include a mold member appropriate to form
at least one lens substantially conforming to the eyeglass lens
information. At least one mold member storage location associated
with a desired mold member may be determined, as indicated at box
10904. At least one activation signal may be sent to at least one
indicator proximate at least one determined storage location at
10905. For example, in an embodiment, an activation signal may be
sent from a controller to the eyeglass mold member storage system
to activate a plurality of indicators around a mold member storage
location associated with a desired mold member. In an embodiment,
the activation signal sent may determine how one or more indicators
are activated. For example, if the indicators are lights, the
activation signal sent may determine whether the activated
indicators produce a steady light or a flashing light. Alternately,
the indicators may include lights configured to produce a plurality
of different colors of light. In such a case, the activation signal
sent may determine the color of light produced by one or more
indicators. An advantage of providing different activation signals
may be that indicators activated in different ways may mean
different things to an operator. For example, a red light produced
by an indicator may mean that the mold indicated is for use in
forming the right lens. In another example, a flashing indicator
may indicate a back mold. The operator may select a mold member
from a mold member storage location proximate an activated
indicator.
[0663] Optionally, in an embodiment, the method may also include a
mold selection confirmation process. For example, in an embodiment,
the method may include receiving input from the operator after
sending the activation signal. In an embodiment, the method may
include receiving input from the operator regarding a selected mold
member, as shown at box 10906. For example, the operator may
provide information identifying the selected mold member (e.g., a
data code). The mold selection confirmation process may include
determining if the selected mold member corresponds to a desired
mold member at box 10907. The mold selection confirmation process
may provide output to the operator confirming or rejecting the
selected mold member at box 10908 based on the determination of box
10907.
[0664] In an embodiment, the method may optionally include a mold
member inventory process. A mold member inventory process may
include receiving input from the operator regarding the status of
at least one desired mold member at box 10909. For example, as
previously discussed, the operator may acknowledge selection of a
desired mold member, reject a selected desired mold member, or
indicate that a desired mold member is not in stock. At box 10910,
the mold member inventory process may adjust a mold member
inventory based on the input received. Mold member inventory
processes are discussed further below. After selection of one or
more mold members, one or more lens may be formed using the
selected mold members.
[0665] FIG. 62 depicts an embodiment of a flow chart of a mold
inventory method. As used herein, the method depicted in FIG. 62
may be referred to as a "pick process" as shown in box 11001. Pick
process 11001 may include receiving input regarding one or more
desired mold members. For example, as depicted in box 11002, a job
ticket associated with a job may be scanned. The pick process may
include determining if mold members appropriate to form all of the
lenses associated with the job are identified, as depicted in box
11003. Mold members may not be identified because they do not exist
in the mold library in use. They may also not be identified because
of a data error. For example, the data related to one or more
desired mold members might have been incorrectly entered. If the
mold members are not identified, an error message may be sent to
the operator, at box 11004. For example, a mold member selection
graphical display, as previously discussed, may provide the error
message to the operator. If all of the mold members are identified,
the pick process may determine if all of the mold members are
available, at box 11005. For example, an expected number of mold
members in the eyeglass mold member storage system may be checked
to see if at least one mold of each desired mold member type is
expected to be available. The expected number of mold members may
be based on a physical inventory. If at least one mold member of at
least one desired mold member type is not available, the pick
process may initiate a hold job process, as depicted in box 11006.
If at least one mold member of each mold member type is determined
to be available, the pick process may initiate a mold selection
process, as depicted in box 11007.
[0666] FIG. 63 depicts an embodiment of a flow chart of a mold
inventory method. As used herein, the method depicted in FIG. 63
may be referred to as a "hold job process," as shown in box 11006.
In an embodiment, a hold job process may be initiated if one or
more mold members needed to complete a job are not available in a
mold member storage system. By placing the hold job process before
the physical selection of mold members, it is believed that
problems such as mold member stock out may be avoided.
[0667] As used herein, mold member "stock out" refers to a
condition in which one or more molds needed to complete a job are
not available in a mold member storage system because the needed
mold(s) are in a job holding area. Stock out conditions may be
particularly troublesome in high volume lens manufacturing
environments. For example, mold member stock out may occur when an
operator begins selecting mold members to complete a first job
without determining beforehand if all needed mold members are
available. The operator may, for example, select first, second, and
third mold members and place them in a mold assembly tray for
processing. The operator may then determine that a fourth mold
member needed to complete the first job is out of stock. The
operator may place the mold assembly tray into a holding area until
it is determined that the fourth mold member is available. Due to
the high volume nature of the operation, the operator may not take
time to restock the first, second and third mold members, which
have already been selected since they will have to be selected
again to complete the first job. Later, the operator may begin
selecting mold members for a second job. The second job may require
fifth, sixth, first and seventh mold members. After selecting the
fifth and sixth mold members, the operator may determine that the
first mold member is out of stock in the mold member storage
system. In fact, at least one first mold member is available for
use, but is in the holding area in the mold assembly tray for the
first job. The second job may therefore be placed on hold pending
availability of all of the required mold members. Similarly, the
operator may select mold members for other jobs only to discover
that one or more mold members are not in stock in the mold member
storage system. At least a portion of these "out of stock" mold
members may actually be associated with on hold jobs. Thus, as more
jobs are placed on hold due to unavailability of one or more mold
members, more mold members may be taken out of stock and put into
the holding area. This causes even more molds to be out of stock.
Eventually, a point may be reached where every job the operator
tries to fill requires one or more out of stock mold members,
leading to complete gridlock, or stock out.
[0668] Another advantage of a mold member inventory method may be
prioritizing jobs. For example, when work is initiated on a job, a
mold member inventory may be checked to determine if any mold
member desired to complete the job is a high-usage mold member.
Determining if a mold member is a high-usage mold member may
include checking historical usage information, checking a user
defined setting associated with the mold member type, and/or
checking a listing of outstanding jobs. For example, if historical
usage data indicates that a mold member of a desired mold member
type has been used in more than a determined percentage of jobs,
the mold member type may be considered high-usage. In another
example, if a determined number of jobs on the outstanding job list
require use of the desired mold member, it may be considered a
high-usage mold member type. If one or more of the desired mold
members is a high-usage mold member, the mold member inventory may
be checked to see if a quantity of the desired mold members is
available. For example, the current mold member inventory may be
checked against the list of outstanding jobs. If the number of
available mold members is determined to be insufficient to process
the outstanding jobs in a timely fashion, the current job may be
expedited.
[0669] In the embodiment depicted in FIG. 63, the hold process
includes assigning an on-hold job to a holding bin, as shown in box
11101. The operator may place a mold assembly tray for the on-hold
job in the appropriate holding bin. The method may include
periodically determining whether all of the mold members for an
on-hold job are available 11102. For example, the method may
include determining whether all of the mold members needed to
complete an on-hold job are available after each change in the
expected number of mold members. In an embodiment, determination of
the availability of mold members for two or more on-hold jobs may
be conducted according in order of a priority assigned to the job.
That is, on-hold jobs having a higher priority may be checked first
for availability of mold members. In an alternate embodiment,
determination of the availability of mold members for two or more
on-hold jobs may be conducted according to a first-in-first-out
order. Thus, jobs that have been on-hold longer may be checked
first for availability of mold members. If it is determined that
all of the mold members needed to complete an on-hold job are
present in the mold member storage system, the method may include
notifying the operator to process the on-hold job, as depicted in
box 11103. Optionally, processing the on-hold job may include
referring the job to a mold selection process, as depicted in box
11007.
[0670] FIG. 64 depicts an embodiment of a flow chart of a mold
inventory method. As used herein, the method depicted in FIG. 64
may be referred to as a "mold selection process," as shown in box
11007. Optionally, a mold selection process may alter a mold member
selection display to indicate to an operator which desired mold
member is being selected, as shown in box 11201. For example, the
mold member selection display may be a display as discussed with
reference to FIGS. 60A, 60B, 60C, and 60D. The method may include
indicating a mold member storage location associated with a desired
mold member type, as depicted in box 11202. For example, one or
more indicators proximate a mold member storage location associated
with mold members of the desired mold member type may be activated.
The method may receive input from an operator indicating the status
of a desired mold member, as shown in box 11203. The operator may
indicate that a desired mold member has be selected and accepted,
that a desired mold member has been selected and rejected, or that
no desired mold member is available. The operator may also elect to
cancel the mold selection process. If the operator cancels the mold
selection process, the method may return to a pick process as
previously described.
[0671] To indicate that a desired mold member has been selected and
accepted the operator may acknowledge the selection at box 11203.
If the operator acknowledges the selection of a desired mold
member, the method may include adjusting the mold member inventory,
as shown in box 11204. For example, an expected number of molds of
the desired mold member type may be reduced by one to account for
the desired mold member removed from the mold member storage
system. The method may also determine if another mold member should
be selected to complete the current job, at box 11205. If no other
mold members are needed, the process may end. If one or more other
mold members are still needed in order to finish the job, the
method may return to the start of the mold selection process 11007,
to select the next mold member.
[0672] In some instances, a desired mold member may be removed from
the mold member storage system then rejected. For example, after
the mold member is removed from the mold member storage system, it
may be inspected. Upon inspection, the operator may determine that
the selected mold member is not fit for use. For example, the
operator may determine that the selected mold member is damaged or
dirty. In another example, the operator may determine that the
selected mold member is not a mold member of the desired mold
member type. If a desired mold member is rejected at box 11203, the
method may include adjusting the mold member inventory, as shown in
box 11206. For example, an expected number of available mold
members may be reduced by one to account for the rejected mold
member. The method may determine if another mold member of the
desired mold member type is available, as shown in box 11207. If
another mold member of the desired mold member type is available,
the method may return to the beginning of the mold selection
process to select the desired mold member. If no other mold member
of the desired mold member type is available, the job may be placed
on hold.
[0673] In some instances, an expected number of available mold
members may indicate that at least one mold member of the desired
mold member type is available. However, when the operator goes to
remove one of the desired mold members from the mold member storage
system, the operator may find that the desired mold member type is
out of stock. Such an instance may occur if an expected number of
mold members in the mold member storage system does not match an
actual number of mold members available in the mold member storage
system. For example, an operator placing molds into the mold member
storage system may have incorrectly identified or incorrectly
stored a mold member in the storage system. Another instance in
which an out of stock situation might occur is if an operator
placing mold members in the mold member storage system indicated
that a mold was being placed into the mold member storage system
then failed to place the mold member in the storage system. For
example, the operator may have indicated that the mold member was
being placed in the storage system and then dropped or otherwise
damaged the mold member before placing the mold member in the
storage system. If the operator selecting a mold members of the
desired mold member types determines that no mold of the desired
mold member type is available, the operator may indicate an "out of
stock" situation at box 11203. The process may adjust the inventory
of the desired mold member type at box 11208. In an embodiment, the
expected number of mold members of the desired mold member type may
be set to zero. In some embodiments, the method may also include
adding the out of stock mold member type to a re-inventory list, at
box 11209. The re-inventory list may be used as described in
further detail below. The method may further include placing the
job on hold.
[0674] A mold member inventory may be initiated by setting an
expected number of mold members of each mold member type in the
mold member storage system equal to the actual number of mold
members of the mold member type in the mold member storage system.
For example, a hand count of each mold member type may be used to
establish the expected number of mold members. Once a mold member
inventory has been initiated, it may be updated periodically by
mold member inventory methods as described above. The mold member
inventory may also be periodically checked. FIG. 65 depicts an
exemplary embodiment of a method of updating a mold member
inventory. The method may include determining a re-inventory list,
box 11301. In an embodiment, a re-inventory list may be determined
on a periodic basis. For example, a re-inventory list may be
determined at the start of each work shift. The re-inventory list
may identify one or more mold member types to be counted to verify
or reset the expected number of mold members in the mold member
inventory. In an embodiment, a re-inventory list may be determined
such that all of the mold member types in the mold member storage
system are recounted on a periodic basis. Additionally, in some
embodiments, mold member types that have had an out of stock status
during a mold member selection process may be put on the
re-inventory list. The method may also include identifying one or
more mold member types to be counted, as shown in box 11302. One
more mold members types to be counted may be identified in a number
of ways. For example, in an embodiment, all or part of the
re-inventory list may be provided to an operator. The operator may
then find mold member storage locations associated with the
identified mold member types. In another embodiment, one or more
indicators proximate one or more storage locations associated with
a mold member type on the re-inventory list may be activated. The
method may also include receiving input from the operator regarding
the actual number of mold members of a mold member type, as shown
in box 11303. In an embodiment, the operator may count all of the
mold members of a mold member type on the re-inventory list and
enter the total number of mold members present. In another
embodiment, the operator may remove all of the mold members from
one or more mold member storage locations associated with a mold
member type on the re-inventory list. When all of the mold members
have been removed, the expected number of mold members may be set
to zero. The operator may then go through a method of storing a
mold member in an eyeglass mold member storage system as discussed
below to place the mold members back in the eyeglass mold member
storage system. The restocking process may include updating the
expected number of mold members 11303. The method may further
include determining if there are more mold member types to be
inventoried, at box 11304.
[0675] Several embodiments of a lens mold coating apparatus are
shown and described with reference to FIGS. 66A, 66B, 66C, 67A,
67B, and 68. In general, a lens mold coating apparatus be
configured to apply one or more mold coating compositions to a lens
mold. As used herein, a "mold coating composition" refers to a
polymerizable composition used to form a coating layer on a lens
mold. A lens mold coating apparatus may include a plurality of
process units and at least one transport device. Operation of the
process units and at least one transport device may be controlled
by a controller. The plurality of process units may include at
least one coating process unit and at least one curing process
unit. In addition, the process units may include one or more
cleaning process units. A transport device may include a rotation
device. The rotation device may be configured to rotate a mold
holder coupled thereto.
[0676] Turning to FIG. 66A, a perspective side view of an
embodiment of a mold coating apparatus is depicted, and generally
referenced by numeral 11401. Mold coating apparatus 11401 includes
a transport device 11405, a coating process unit 11403, and a
curing process unit 11404 (see FIG. 66C). Additionally, mold
coating apparatus 11401 may include a cleaning process unit 11402
(see FIG. 66C).
[0677] Transport device 11405 may include a body 11450 and at least
one rotation device 11451 coupled to the body. Body 11450 may
include one or more internal wire chases for routing wiring and/or
air lines to rotation device 11451 and/or mold holder 11452.
Additionally, external wire chase 11461 may provide access to the
one or more internal wire chases. Mold holder 11452 may be
directly, or indirectly, coupled to rotation device 11451. For
example, mold holder 11452 may be directly coupled to a spindle or
rotor of rotation device 11451. Alternately, mold holder 11452 may
be indirectly coupled to rotation device 11451 through a system of
gears or through a system of pulleys coupled by at least one
flexible loop member (e.g., a belt, chain, wire, cable, rope,
etc.). In an embodiment, mold holder 11452 may be configured to
adhere to a non-casting face of a lens mold and to retain the lens
mold during processing. For example, the lens mold holder may
include a suction cup or a vacuum chuck. In an embodiment where
lens mold holder 11452 includes a vacuum chuck, mold coating
apparatus 11401 may include a vacuum pump (not shown).
[0678] Rotation device 11451 may be configured to rotate a lens
mold disposed in mold holder 11452 during processing. In an
embodiment, rotation device 11451 may include an electric motor. A
sensor system associated with the rotation device may provide
feedback information to a controller coupled to the mold coating
apparatus. For example, the sensor system may include an encoder
wheel 11453 and an encoder wheel sensor 11454 (shown in FIG. 66B).
Encoder wheel sensor 11454 may be configured to sense the rotation
rate of mold holder 11452.
[0679] Referring now to FIG. 66B, transport device 11405 may also
include a lifting device 11455. Lifting device 11455 may include a
motor 11456 coupled to a threaded member 11448 (shown in FIG. 66A).
For example, threaded member 11448 may include a ball screw.
Rotation of threaded member 11448 by motor 11456 may change the
elevation of transport device 11405 with respect to the process
units. A number of guides 11457 may interact with body 11450 of the
transport device to assist lifting device 11455 in generating
substantially linear upward motion. For example, guides 11457 may
move along linear bearings disposed within body 11450 of transport
device 11405, thereby constraining motion generated by lifting
device 11455. Lifting device 11455 may be coupled to a rotary
platform 11458. Rotary platform 11458 may be directly or indirectly
coupled to a motive apparatus 11459. For example, rotary platform
11458 may be directly coupled to a spindle or rotor of motive
device 11459. Alternately, rotary platform 11458 may be coupled to
motive apparatus 11459 via a system of gears or a system of pulleys
coupled by at least one flexible loop member (e.g., a belt, chain,
wire, cable, rope, etc.). Rotary platform 11458 and motive
apparatus 11459 may together provide motion of transport device
11405. Transport device 11405 may be configured to move such that
mold holder 11452 follows a substantially circular travel path
11460 (shown in broken lines on FIG. 66C).
[0680] Referring now to FIG. 66C, in various embodiments, transport
device 11405 may be configured to acquire a lens mold at a lens
mold staging area 11483, 11484, 11485, or 11486, transport the lens
mold to a plurality of process units, and deposit the lens mold at
the lens mold staging area. In addition, the transport device may
be configured to rotate the lens mold during processing. In an
embodiment, transport device 11405 may be configured to move a lens
mold along circular travel path 11460 during one or more process
steps. Moving the mold along travel path 11460 during processing
may ensure that a coating and/or cleaning process is conducted
uniformly and includes the center of the lens mold. That is, moving
the mold may allow a fluid dispensed from a coating or cleaning
applicator to sweep over the surface of the mold. An advantage of
such a configuration may be that the apparatus may require fewer
moving parts than systems in which one or more applicators are
moved to ensure even uniform dispensing.
[0681] FIG. 66C depicts a top view of the process area of mold
coating apparatus 11401. In an embodiment, a cleaning process unit
11402 of lens mold coating apparatus 11401 may include at least one
basin 11420. Basin 11420 may include at least one cleaning fluid
applicator 11421 coupled to a clean fluid source. The cleaning
fluid source may include a water source, for example, a de-ionized
water source. Additionally, the cleaning fluid source may include a
surfactant or other cleaning agent. Basin 11420 may also include a
drain 11422 for removing used cleaning fluid from the basin. Drain
11422 may be coupled to a waste collection system or waste
collection reservoir. Cleaning process unit 11402 may be configured
to apply a drying agent to a cleaned lens mold. In various
embodiments, the drying agent may include a chemical drying agent
and/or a physical drying agent. As used herein, a "chemical drying
agent" refers to a drying agent that is selected to increase the
evaporation rate of a process fluid by chemical interaction with
the process fluid. Examples of chemical drying agents may include
certain alcohols, for example, isopropyl alcohol. In embodiments
where a chemical drying agent is used, the cleaning process unit
basin may include a drying agent applicator (not shown). As used
herein a "physical drying agent" refers to a drying agent that
increases the evaporation rate of the cleaning fluid through
physical processes such as convection or heating. Examples of
physical drying may include blowing dry air over the lens mold
and/or heating the lens mold. In an embodiment, transport device
11405 may be configured to rotate the lens mold in cleaning process
unit 11402 during application of the cleaning fluid. In additional
embodiments, transport device 11405 may be configured to rotate the
lens mold after application of the cleaning fluid. For example, the
mold may be rotated to facilitate drying and/or during application
of a drying agent. Transport device 11405 may also be configured to
move the mold in relation to a stationary cleaning applicator or
drying agent applicator during application of a cleaning fluid or
drying agent. For example, the mold may be along travel path 11460
within the cleaning process unit during application of a cleaning
fluid and/or drying agent. In another example, the mold may be in a
direction other than along travel path 11460 within the cleaning
process unit during application of a cleaning fluid and/or drying
agent. Such motion may ensure that the clean fluid and/or drying
agent stream crosses the center of the mold. The motion may also
facilitate even application of the cleaning fluid and/or drying
agent over the surface of the lens mold. Additionally, transport
device 11405 may be configured to move the mold in an oscillatory
manner in relation to a stationary cleaning applicator or drying
agent applicator. Such oscillatory motion may provide for more
thorough cleaning and/or drying of the mold.
[0682] A coating process unit 11403 of lens mold coating apparatus
11401 may include at least one coating process basin 11430. Coating
process basin 11430 may include at least one coating fluid
applicator 11431 coupled to a mold coating composition supply 11432
(shown in FIG. 66A). Additionally, in some embodiments, coating
process basin 11430 may include a drying agent applicator 11435 as
previously described. Drying agent applicator 11435 may be coupled
to a drying agent supply 11433 (shown in FIG. 66A). In an
embodiment, coating process basin 11430 may also include a drain
(not shown) for removing a coating composition and/or drying agent
from the basin. The drain may be coupled to a waste collection
system or waste collection reservoir. In some embodiments, coating
process basin 11430 may include a liner. The liner may be absorbent
and removable. A removable, absorbent liner may ease removing dried
mold coating composition from the coating process basin. Coating
process unit 11403 may also include a splash guard 11436. Splash
guard 11436 may inhibit process fluids dispensed in coating unit
11403 from splashing outside basin 11430. In some embodiments, a
shield 11437 on transport device 11405 may also inhibit splashing
of process fluids out of basins 11430 and 11420. In such
embodiments, shield 11437 may also limit the amount of activating
light that shines outside curing unit enclosure 11441.
[0683] Transport device 11405 may be configured to rotate the lens
mold in the coating process unit during application of a mold
coating composition. Additionally, in some embodiments, transport
device 11405 may be configured to rotate the lens mold after
application of the mold coating composition. Rotating the lens mold
after applying a mold coating composition may facilitate drying of
the mold coating composition. In an embodiment, a drying agent may
be applied to a mold coating composition to facilitate drying of
the mold coating composition. Drying the mold coating composition
before curing the composition may be desirable for certain coating
compositions. For example, after applying certain antireflective
coatings, as discussed in previously referenced patent
applications, it may be desirable to dry the coating compositions
before initiating curing of the compositions. Transport device
11405 may also be configured to move the mold in relation to a
stationary coating applicator or drying agent applicator during
application of a coating composition or drying agent. For example,
the mold may be along travel path 11460 within the coating process
unit during application of a mold coating composition and/or drying
agent. In another example, the mold may be in a direction other
than along travel path 11460 within the coating process unit during
application of a mold coating composition and/or drying agent. Such
motion may ensure that the mold coating composition and/or drying
agent stream crosses the center of the mold. The motion may also
facilitate even application of the mold coating composition and/or
drying agent over the surface of the lens mold.
[0684] Coating process unit 11403 may include at least one coating
applicator 11431. Coating applicators 11431 may be coupled to a
fluid delivery system. The fluid delivery system may include piping
or tubing 11434 (shown in FIG. 66A) to transport a process fluid
(e.g., a mold coating composition or drying agent). A fluid
delivery system may also include a process fluid pump. The fluid
delivery system may be coupled to a process fluid supply. In an
embodiment, a process fluid supply may include a replaceable fluid
canister, bag, bottle, tube, syringe or other fluid container. Such
embodiments may allow a process fluid supply to be refreshed by an
operator with minimal process interruption. In an embodiment, as
depicted in FIG. 66A, the process fluid supplies and process fluid
pumps may be combined in syringe pumps 11432 and 11433. In some
embodiments, each coating applicator 11431 may be coupled to a
different process fluid supply. Such embodiments may allow more
than one mold coating composition to be applied to a lens mold in
the same coating process unit. A plurality of pneumatic control
valves 11438 (as shown in FIG. 66B) may regulate dispensing of
process fluids from syringe pumps 11432 and 11433.
[0685] In an embodiment, as depicted in FIG. 66C, a curing process
unit 11404 of lens mold coating apparatus 11401 may include at
least one activating light source 11440. Activating light source
11440 may be a light source as described in previously referenced
patents and pending patent applications. Such activating light
sources may include but are not limited to: germicidal lamps,
mercury vapor lamps, halide lamps and/or strobe lamps. In an
embodiment, activating light source 11440 may include a strobe
light source. Advantages of a strobe light source may include
reduced power consumption and reduced environmental heat generation
as compared to conventional lamps (e.g., mercury vapor lamps).
Strobe lamps may also provide for an instant on and instant off
capability. This feature may allow a strobe lamp to produce less
heat between process runs. An additional advantage of including a
strobe lamp in activation light source 11440 may be that activating
light dosage may be controlled by controlling the intensity of
light applied, the frequency of activating light flashes, the
duration of activating light flashes and/or the number of
activating light flashes. Suitable strobe lamps and equipment are
available from Speedotron Corporation of Chicago, Ill. In an
embodiment, a curing process unit may also include an enclosure
11441. In an embodiment, enclosure 11441 may be configured to
shield at least a portion of the activating light from coating
process unit 11403. Additionally, enclosure 11441 may shield at
least a portion of the activating light from an operator using mold
coating apparatus 11401. In some embodiments, transport device
11405 may be configured to rotate a lens mold disposed in the
curing process unit while it is exposed to activating light.
Rotating the mold during curing may help to ensure even exposure of
the mold to the activating light. In an embodiment, where a strobic
light source or flashing lights source is used to provide
activating light, transport device 11405 may be configured to
rotate the lens mold between flashes of activating light. For
example, the lens mold may be rotated up to 180 degrees between
activating light flashes to ensure even exposure of the mold
coating composition. In an embodiment, an activating light source
of a curing unit may be electrically coupled to a remote power
source. Such a remote power source may include capacity to provide
power to more than one activating light source. A suitable remote
power supply is available from Speedotron Corporation of Chicago,
Ill. For example, in an embodiment, a Speedotron MW9Q flash lamp
might be used with a Black Line 103 lamp holder coupled to a Black
Line 1205cx and/or 2403cx power supply.
[0686] Referring back to FIG. 66A, lens mold coating apparatus
11401 may include an enclosure 11400 (as shown in FIG. 66A)
providing at least a partially controlled process environment.
Enclosure 11400 may inhibit ambient contaminants from entering a
processing area 11409 of mold coating apparatus 11401. An air
filtration system may provide purified air to the process units
within the enclosure. The air filtration system may include a high
efficiency particulate arresting (HEPA) filter 11492 and at least
one blower 11493 (shown in FIG. 66B). In an embodiment, enclosure
11400 may include a mold assembly area 11494. For example, mold
assembly area 11494 may be disposed on the inside of a door 11495.
Mold assembly area 11494 may include one or more mold indexing
guides 11496 to assist an operator with properly aligning lens
molds during assembly.
[0687] In an embodiment, mold coating apparatus 11401 may include
one or more mold staging areas 11483, 11484, 11485 and 11486. A
mold staging area may include an area configured to retain at least
one lens mold. Mold staging areas 11483, 11484, 11485, and 11486
may be arranged in a manner similar to a mold assembly tray. That
is, mold staging areas 11483 and 11486 may be configured to retain
front molds, and mold staging areas 11484 and 11485 may be
configured to retain back molds. Additionally, mold staging areas
11483 and 11484 may be designated for right lens mold members, and
mold staging areas 11485 and 11486 may be designated for left lens
mold members. In an embodiment, one or more front mold staging
areas 11483 and 11486 may be recessed into a surface in the
processing area 11409. In such embodiments, the front mold staging
areas may include one or more recesses 11480. Recesses 11480 may
aid an operator in removing a coated lens mold from a front mold
staging area. In an embodiment, one or more back mold staging areas
11484 and 11485 may include a raised member 11487. Raised member
11487 may inhibit scratching or other damage to the casting face of
a back mold disposed in a back mold staging area.
[0688] In an embodiment, mold coating apparatus 11401 may be
coupled to a controller, as previously described. One or more input
devices may be coupled to the controller. For example, touch-screen
user interface 11497 may be coupled to the controller. Touch-screen
user interface 11497 may be configured to both receive input from
an operator to the controller, and to provide output from the
controller to the operator. The controller may be configured to
independently control each process unit 11402, 11403, and 11404 and
transport device 11405. In addition, the controller may control
operation of one or more other devices, such as one or more doors
providing access to the process units and/or an air filtration
system. In an embodiment, the controller may receive eyeglass lens
information, as previously discussed, from an operator and/or a
computer coupled to the controller via a network. In another
embodiment, the controller may receive information specific to mold
coating processes from an operator and/or a computer coupled to the
controller via a network. Mold coating process information may
include cleaning, coating, curing and/or transport information
specific to the configuration of the mold coating apparatus and/or
one or more specific molds to be coated. For example, mold coating
process information may include process feedback (e.g., process
alarms, process status notifications, process warnings, etc.). Mold
coating process information may also include mold coating apparatus
configuration information, such as what process fluid is coupled to
a process fluid applicator, scheduled maintenance notifications,
etc. The mold coating process information may also include process
specific data. For example, mold coating process information
related to a fluid application process (e.g., cleaning, drying or
curing) may include, but is not limited to: fluid to apply, fluid
application time, fluid application rate, mold rotation rate and
time before fluid application, mold rotation rate and time during
fluid application, and/or mold rotation rate and time after fluid
application. In another example, mold coating process information
related to a curing process, may include, but is not limited to:
whether continuous or flashing activating light is applied,
intensity of the activating light, flash frequency and duration of
activating light, and/or mold rotation rate and time during
application of activating light. The mold coating process
information may also include information related to a specific job.
For example, mold coating process information related to a specific
job may include, but is not limited to: one or more coating
compositions to be applied to one or more lens molds, and/or one or
more processes to modify or skip for one or more lens molds.
[0689] FIGS. 67A and 67B depict another embodiment of a mold
coating apparatus, generally referenced by numeral 11501. Referring
to FIG. 67A, mold coating apparatus 11501 may include a process
area 11502 including a plurality of process units 11503, 11504 and
11505. Process area 11502 may be housed within a framework 11511.
Framework 11511 may be at least partially covered to form an
enclosure around process area 11502. An air filtration system 11585
may provide air flow to process area 11502. A load lock system,
including first door 11512 and second door 11513 may provide access
from outside the apparatus into process area 11502. A
loading/unloading area 11514 may be present between first door
11512 and second door 11513. Loading/unloading area 11514 may
include a plurality of mold staging areas 11509. Mold staging areas
11509 may retain molds awaiting application of one or more coatings
and/or molds that have completed processing in the mold coating
apparatus. First door 11512 and second door 11513 may be controlled
so that both doors are not open at the same time.
[0690] Process area 11502 may include a cleaning process unit
11503, a coating process unit 11504, a curing process unit 11505,
and a transport device 11506, as previously described. The
transport device includes at least one rotation device 11507 and at
least one mold holder 11508. In addition, at least one lifting
device 11515 may be coupled to transport device 11506. Process
units 11503, 11504, and 11505 may be disposed substantially along
the travel path of transport device 11506. Additionally,
applicators of cleaning process unit 11503 and coating process unit
11504 may also be disposed substantially along the travel path of
transport device 11506.
[0691] In some embodiments, a plurality of mold holders 11508 may
be coupled to transport device 11506. In such embodiments, the
process units may include equipment for processing a mold disposed
in each mold holder substantially independently and simultaneously.
For example, referring to FIG. 67B, parallel coating basins 11540a
and 11540b may be provided for mold holders 11508a and 11508b.
Likewise, a cleaning and/or curing process unit may include
equipment for processing the molds substantially simultaneously and
independently. For ease of reference herein, parallel components
(e.g., process units, mold holders, lifting devices, rotation
devices, etc.) may be referenced individual by including lower case
letters indicating which processing line is being referenced.
Alternately, parallel components may be referenced collectively by
omitting the lower case letter. For example, mold holder 11508a
refers to the mold holder indicated in FIG. 67A, which is
associated with process line 11575a (shown in FIG. 67B) that
includes cleaning unit 11503a, coating unit 11504a, curing unit
11505a, and coating unit 11570a. Likewise, mold holder 11508b
refers to the mold holder indicated in FIG. 67A, which is
associated with process line 11575b (shown in FIG. 67B) that
includes cleaning unit 11503b, coating unit 11504b, curing unit
11505b, and coating unit 11570b. Mold holders 11508a and 11508b may
be collectively referred to as mold holders 11508. Such embodiments
may be configured to process two or more lens molds in
parallel.
[0692] Referring to FIG. 67A, transport device 11506 includes a
body 11560 coupled to a motive apparatus. Body 11560 may interact
with one or more guides 11517. In an embodiment, the motive
apparatus may be directly coupled to body 11560 of transport device
11506. For example, the motive apparatus may include a pneumatic or
hydraulic cylinder. In another example, the motive apparatus may
include a motor coupled to body 11560 of transport device 11506. In
such an embodiment, the motor may push or pull body 11560 along one
or more guides 11517. In another embodiment, the motive apparatus
may be indirectly coupled to body 11560 of transport device 11506.
For example, a motor 11523 may be coupled to framework 11511. Motor
11523 may be couple to body 11560 by a system of gears or a system
of pulleys coupled by at least one flexible loop member (e.g., a
belt, chain, wire, cable, rope, etc.).
[0693] Turning to FIG. 67D, in an embodiment, at least one rotation
device 11507 may be coupled to the body 11560. Additionally, a mold
holder (shown in FIG. 67A) may be coupled to each rotation device
11507. Rotation device 11507 may be coupled to body 11560 via
lifting device 11515. Lifting device 11515 may be configured to
change the height of a lens mold disposed in the mold holder
relative to one or more process units. In an embodiment, lifting
device 11515 may include a motor 11516 coupled to a threaded member
11586. For example, threaded member 11586 may include a ball screw.
Rotation of threaded member 11586 by motor 11516 may change the
elevation of a mold holder with respect to the process units. A
number of guides 11587 may interact with body 11560 of the
transport device to assist lifting device 11515 in generating
substantially linear upward motion. For example, guides 11587 may
move along linear bearings, thereby constraining motion generated
by lifting device 11515.
[0694] In an embodiment, rotation device 11507 may include or be
coupled to a rotor 11588. Rotor 11588 may transfer rotary motion
from rotation device 11507 to a mold holder coupled thereto. In an
embodiment, a shield 11589 may be coupled to the transport device.
Shield 11589 may inhibit splashing of a process fluid out of a
process unit. Shield 11589 may also limit the amount of activating
light that shines outside of a curing unit enclosure.
[0695] In an embodiment, a lens mold holder may be configured to
adhere to a non-casting face of a lens mold and to retain the lens
mold during processing. In an alternate embodiment, a lens mold
holder may include a gripping mechanism configured to grasp the
edges of the lens mold. In an embodiment, the lens mold holder may
include a suction cup or vacuum chuck. As described with regard to
the embodiment depicted in FIG. 66A, a rotation device may be
configured to rotate a lens mold disposed in the mold bolder during
processing.
[0696] In an embodiment, transport device 11506 may include a
plurality of mold holders 11508a and 11508b. In such an embodiment,
controller 11510 may be configured to independently control mold
holders 11508a and 11508b, associated rotating devices 11507a and
11507b, and associated lifting devices 11515a and 11515b.
Controller 11510 may also be configured to independently control
each process unit. Such embodiments may allow two or more molds to
be coated simultaneously, even if the coatings to be applied to the
molds are different. For example, in some instances, it may be
desirable for different coatings to be applied to two or more molds
disposed in the mold holders. Independently controlling the process
units and transport device 11506 may allow the molds to be
processed simultaneously. In an embodiment, transport device 11506
may include four mold holders. In such embodiments, each mold
holder, rotation device, and lifting device may be independently
controlled by controller 11510. Such an embodiment may allow four
molds to be coated simultaneously.
[0697] In some embodiments, two or more loading/unloading areas
11514 may be provided. For example, a first loading/unloading area
may be provided primarily for loading molds to be coated, and a
second loading/unloading area may be provided primarily for
unloading coated molds. The first and second loading/unloading area
may be remote from one another. For example, the loading area may
be on a first end of mold coating apparatus 11501, and the
unloading area may be on the opposite end of the mold coating
apparatus. Such an embodiment may allow molds to be simultaneously
loaded and unloaded, thereby potentially increasing throughput of
the apparatus. Additionally, in such an embodiment, transport
device 11506 or an additional transport device may be configured to
transport a mold assembly tray associated with one or more lens
molds from the loading area to the unloading area.
[0698] In an embodiments, transport device 11506 may be configured
to acquire a lens mold at a lens mold staging area, transport the
lens mold to a plurality of process units, and deposit the lens
mold at a lens mold staging area. In addition, the transport device
may be configured to rotate the lens mold during processing. As
used herein, "lateral" motion may refer to motion along a primary
travel path of transport device 11506. For example, the movement of
a lens mold from a first process unit to a second process unit may
be described as lateral motion. As used herein, "vertical" motion
may refer to motion induced by a lifting device 11515. As used
herein, "rotational" motion may refer to motion induced by a
rotation device 11507. In some embodiments, transport device 11506
may be configured to move a lens mold laterally during one or more
process steps. Moving the mold laterally may ensure that a coating
and/or cleaning process is conducted uniformly and includes the
center of the lens mold.
[0699] In an embodiment, lens mold coating apparatus 11501 may
include an enclosure (not visible) providing at least a partially
controlled process environment. The enclosure may inhibit ambient
contaminants from entering processing area 11502 of the mold
coating apparatus. An air filtration system 11585 may provide
purified air to the process units within the enclosure. In an
embodiment, air filtration system 11585 may provide a substantially
downward airflow in process area 11502. A mold may be retained in a
mold holder with a casting face of the lens mold facing downward.
Thus, it is believed that a substantially downward airflow may
inhibit deposition of air borne contaminants on the casting face of
the lens mold. To facilitate the substantially downward flow of
air, a surface of the process area 11502 may include a plurality of
openings. The plurality of openings may allow air to flow through
the surface, so that substantially downward airflow may be
maintained. In various embodiments, a lens mold coating apparatus
enclosure may include one or more access controls to inhibit
operator contact with transport device 11506 and to maintain the
controlled process environment.
[0700] Referring to FIG. 67B, cleaning process unit 11503 may
include at least one basin 11530. Basin 11530 may include at least
one cleaning fluid applicator 11531 coupled to a clean fluid
source. The cleaning fluid source may include a water source, for
example, a de-ionized water source. Additionally, the cleaning
fluid source may include a surfactant or other cleaning agent.
Basin 11530 may also include a drain 11532, for removing used
cleaning fluid from the basin. The drain may be coupled to a waste
collection system or waste collection reservoir. Cleaning process
unit 11503 may be configured to apply a drying agent, as previously
described, to a cleaned lens mold. In an embodiment, transport
device 11506 may be configured to rotate a lens mold in cleaning
process unit 11503 during application of the cleaning fluid. In
additional embodiments, transport device 11506 may be configured to
rotate the lens mold after application of the cleaning fluid. For
example, the mold may be rotated to facilitate drying and/or during
application of a drying agent. Transport device 11506 may also be
configured to move the mold laterally within cleaning process unit
11503 during application of a cleaning fluid and/or drying agent.
Such lateral motion may ensure that the clean fluid and/or drying
agent stream crosses the center of the mold. The lateral motion may
also facilitate even application of the cleaning fluid and/or
drying agent over the surface of the lens mold.
[0701] Coating process unit 11504 may include at least one coating
process basin 11540. Coating process basin 11540 may include at
least one coating fluid applicator 11541 coupled to a mold coating
composition source. Additionally, in some embodiments, coating
process basin 11540 may include a drying agent applicator as
previously described. Coating process basin 11540 may also include
a drain (not shown) for removing a coating composition and/or
drying agent from the basin. The drain may be coupled to a waste
collection system or waste collection reservoir. In some
embodiments, the coating process basin may include a liner. The
liner may be absorbent and removable. A removable, absorbent liner
may ease removing dried mold coating composition from the coating
process basin. In certain embodiments, transport device 11506 may
be configured to rotate the lens mold in coating process unit 11504
during application of a mold coating composition. Additionally, in
some embodiments, transport device 11506 may be configured to
rotate the lens mold after application of the mold coating
composition. Rotating the lens mold after applying a mold coating
composition may facilitate drying of the mold coating composition.
Drying the mold coating composition before curing the composition
may be desirable for certain coating compositions. For example,
after applying certain antireflective coatings, as discussed in
previously referenced patent applications, it may be desirable to
dry the coating compositions before initiating curing of the
compositions. Transport device 11506 may be configured to move the
mold laterally within coating process unit 11504 during application
of a mold coating composition and/or drying agent. Such lateral
motion may ensure that the mold coating composition and/or drying
agent stream crosses the center of the mold. The lateral motion may
also facilitate even application of the mold coating composition
and/or drying agent over the surface of the lens mold.
[0702] At least one coating applicator 11541 may be coupled to a
fluid delivery system. A fluid delivery system may include piping
or tubing to transport a process fluid (e.g., a mold coating
composition or drying agent). A fluid delivery system may also
include a process fluid pump 11575 (depicted in FIG. 67C). The
fluid delivery system may be coupled to a process fluid supply. In
an embodiment, a process fluid supply may include a replaceable
fluid canister 11542, bag, bottle, tube, or other fluid container.
Such embodiments may allow a process fluid supply to be refreshed
by an operator with minimal process interruption. In some
embodiments, coating process unit 11504 may include a plurality of
coating applicators 11541. Each coating applicator may be coupled
to a different process fluid supply. Such embodiments may allow
more than one mold coating composition to be applied to a lens mold
in the same coating process unit.
[0703] Curing process unit 11505 may include at least one
activating light source 11551 and an enclosure 11550, as previously
described with reference to the embodiment of FIG. 66A.
[0704] In an embodiment, mold coating apparatus 11501 may include
one or more mold staging areas 11509. Mold staging area 11509 may
be configured to retain at least one lens mold. Mold staging area
11509 may also include one or more centering guides 11590.
Centering guides 11590 may assist an operator and/or transport
device in placing a lens mold precisely within mold staging area
11509. Precise placement of molds within the mold staging area may
assist transport device 11506 in picking up the mold with the
center of the mold substantially aligned with the axis of rotation
of mold holder 11508.
[0705] Referring back to FIG. 67A, in an embodiment, mold coating
apparatus 11501 may be coupled to a controller 11510. One or more
input devices may be coupled to controller 11510. For example, a
touch screen user interface, as previously described, may be
coupled to the controller. Controller 11510 may be configured to
independently control each process unit and the one or more
transport devices. In addition, the controller may control
operation of one or more other devices, such as doors 11512 and
11513, and/or air filtration system 11585. In an embodiment,
controller 11510 may receive eyeglass lens information, as
previously discussed, from an operator and/or a computer coupled to
the controller via a network. In another embodiment, controller
11510 may receive information specific to mold coating processes
(as previously described) from an operator and/or a computer
coupled to the controller via a network.
[0706] In certain embodiments, one or more process units of mold
coating apparatus 11501 may be modular. As used herein, a "modular"
process unit may refer to a process unit that is configured to
allow quick removal and replacement of the entire process unit. In
an embodiment, modular configuration may include slides coupled to
framework 11511 upon which the process unit may rest. In an
alternate embodiment, modular configuration may include easily
removable connectors coupling a process unit to framework 11511.
For example, easily removable connectors may be operated by hand,
without the need of tools. Modular configuration may also include
one or more self-aligning connectors for coupling a modular process
unit with mold coating apparatus 11501. For example, self-aligning
connectors may couple the process unit to a power supply,
controller 11510 and/or fluid reservoirs 11542. In an embodiment, a
process unit module may include all equipment needed to make the
process unit functional when it is connected to power and provided
with appropriate control signals. For example, a cleaning or
coating process unit module 11573 as depicted in FIG. 67C, may
include at least one basin 11574, one or more process fluid
applicators coupled to process fluid delivery lines, and one or
more process fluid delivery pumps 11575. Additionally, cleaning or
coating process unit 11573 module may include one or more fluid
reservoirs 11542. Fluid reservoirs 11542 may include process fluid
reservoirs and/or waste fluid reservoirs. In another example, a
modular curing process unit 11577 may include an activating light
source and an enclosure 11576. Modular curing process unit 11577
may also include one or more electrical connections 11578. For
example, module curing unit 11577 may include a remote power supply
electrically coupled to each of the activating light sources of the
modular curing unit.
[0707] Embodiments of a mold coating apparatus as depicted in FIG.
67A may generally provide higher throughput capacity than
embodiments as depicted in FIGS. 66A, 66B, and 66C. In some
circumstances, even higher throughput capacity may be provided by
multiplying the number of process units in a mold coating
apparatus. For example, FIG. 68 depicts a schematic perspective
side view of an embodiment of a mold coating apparatus 11601. Mold
coating apparatus 11601 may be particularly useful in circumstances
were a plurality of different of lens coating layers are expected
to be applied to a single mold. For example, if multiple hard coat
layers are desired on a lens mold or if an antireflective coating
stack is to be applied to a lens mold.
[0708] Mold coating apparatus 11601 includes a plurality of
transport devices 11602 and 11603. Each transport device may serve
a plurality of process units. For example, first transport device
11603 may serve a cleaning process unit 11604, a coating process
unit 11605 and a curing process unit 11606. Additionally, first
transport device 11603 may be configured to access a first mold
staging area 11617 and a second mold staging area 11607. First mold
staging area 11617 may be configured to receive one or more molds
into mold coating apparatus 11601. Second mold staging area 11607
may be configured to receive a mold having a first coating layer
applied by first set of process units 11608. Second transport
device 11602 may be configured to access second mold staging area
11607 to acquire a mold having a first coating layer applied by
first set of process units 11608, and to transport the mold through
one or more other sets of process units. For example, second
transport device 11602 may move the mold to a second coating
process unit 11610 and a second curing process unit 11611. After a
second coating layer is applied by second set of process units
11609, the mold may be deposited at a third mold staging area
11612. In an embodiment, mold coating apparatus 11601 may include
one set of process units for each coating layer desired to be
applied to a lens mold. For example, if mold coating apparatus
11601 is configured to apply a seven layer antireflective coating
stack and a hard coat, the apparatus may be extended to include
eight sets of process units. Additionally, in some embodiments, a
transport device may serve each set of process units. Thus, in the
previous example, eight transport devices may serve the eight sets
of process units. In such embodiments, mold staging areas may be
present between sets of process units to enable the transition from
one transport device to the next transport device.
[0709] In an embodiment, each transport device and each process
unit may be independently controlled by controller 11613. In some
embodiments, controller 11613 may also independently control each
mold holder 11616, rotation device 11615 and/or lifting device
11614. Independent control of components of a transport device may
allow different coatings to be applied to two or more molds coupled
to different mold holders of a single transport device
simultaneously. For example, in an embodiment, each transport
device of a mold coating apparatus may include four mold holders.
During use, one lens mold may be coupled to each mold holder. In
such an embodiment, the four lens molds selected to form two lenses
of a pair of eyeglasses may be processed simultaneously. In such a
case, a first coating may be desired on the front of the formed
lenses. The first coating may not be desired on the back of the
formed lenses. During application of mold coating compositions to
form the first coating, the front molds may be coated, while the
back molds are not coated. Likewise, activating light may be
applied to the front molds to cure mold coating composition
applied, while activating light may not be applied to the back
molds. Similarly, in this embodiment or other embodiments,
situations may arise where only one lens mold requires a certain
process step or where two lens molds couple to the same transport
device require processing under different process conditions.
[0710] FIG. 69 depicts a flowchart of an exemplary embodiment of a
method of coating a lens mold. The method may include coupling a
lens mold to a mold holder 11701. In an embodiment, an operator may
place a lens mold in a lens mold staging area. A transport device
of a lens coating apparatus may move to the lens mold by executing
one or more preprogrammed movements. The mold holder of the
transport device may contact the lens mold so that the lens mold is
coupled to the mold holder. The lens mold staging area and/or the
transport device may be configured such that a lens mold disposed
within the staging area may be coupled to the transport device with
the center of the lens mold substantially aligned with an axis of
rotation of the mold holder. For example, the mold staging area may
include one or more centering guides. A controller coupled to the
transport device may be configured to direct a mold holder of the
transport device to a determined position to acquire the lens mold.
In some embodiments, one or more mold centering guides may be
couple to the transport device. The mold centering guides may
interact with the lens mold in the staging area such that the lens
mold and/or mold holder are moved into the desired relationship
(e.g., aligned mold center and axis of rotation).
[0711] After a lens mold is coupled to the mold holder, the mold
may be moved to one or more process units. In an embodiment, the
mold may be move into an operational relationship with a cleaning
process unit 11702. As used herein, an "operational relationship"
refers to a spatial orientation appropriate for processing within a
process unit. For example, the lens mold may be positioned such
that the cleaning fluid applicator of the cleaning process unit is
directed toward the casting face of the lens mold. The lens mold
and/or a shield coupled to the transport device or cleaning process
unit may inhibit the cleaning fluid from spraying out of the
cleaning process unit. The desired operational relationship between
the lens mold and the cleaning process unit may include positioning
the lens mold in relation to a cleaning fluid applicator such that
cleaning fluid dispensed from the applicator strikes at or near the
center of the lens mold. The lens mold may be rotated as cleaning
fluid is applied to the lens mold 11703. Additionally, in some
embodiments, the lens mold may be moved along a travel path of the
transport device as the cleaning fluid is being applied to the lens
mold 11704. Moving the lens along the travel path while the
cleaning fluid is being applied may help to ensure that the entire
casting surface of the lens mold is cleaned. After cleaning, the
lens mold may be dried 11705. Drying the lens mold may include
rotating the lens mold. Additionally, drying the lens mold may
include applying a drying agent as previously described.
[0712] In various embodiments, a clean lens mold may be moved into
an operational relationship with a coating process unit 11706. The
lens mold may have been cleaned in a cleaning process unit of a
mold coating apparatus, as previously described, or external to the
mold coating apparatus. While in operational relationship with the
coating process unit the mold may be rotated 11707. A mold coating
composition may be applied to the rotating lens mold. In an
embodiment, the lens mold may be moved along a travel path of the
transport device as the mold coating composition is applied 11708.
Moving the lens along the travel path while the mold coating
composition is being applied may help to ensure that the entire
casting surface of the lens mold is coated evenly. In some
embodiments, it may be desirable to dry a mold coating composition
applied to a lens mold before initiating curing of the composition
11710. Drying the lens forming composition may include inducing
evaporation of one or more solvents in the lens coating
composition. After the mold coating composition is applied to the
lens mold, the mold may be moved into operation relationship with a
curing process unit 11709. In the curing process unit, activating
light may be applied to the mold coating composition to initiate
curing of the composition 11711.
[0713] In an embodiment, more than one coating layer may be formed
on the lens mold. For example, two or more layers of may be needed
to be form an antireflective coating stack. Therefore, the method
may include determining whether additional coatings are to be
applied 11712. If additional coatings are to be applied, the lens
mold may be moved into operation relationship with a coating
process unit 11706. The coating process unit may be the same
coating process unit that applied the previous coating layer, or a
different coating process unit. If no additional coating layers are
to be applied, the lens mold may be deposited at a mold staging
area 11713.
[0714] An embodiment of a demolding device is depicted in FIG. 70
and generally referenced by numeral 11801. Demolding device 11801
may be useful for separating a lens 11802 from a lens mold 11803
after casting the lens.
[0715] In an embodiment, demolding device 11801 may include two or
more clamping members 11804 and 11805, and an urging means 11806
for urging clamping members 11804 and 11805 toward one another. In
an embodiment, the clamping members may include a fixed clamping
member 11805 and a movable clamping member 11804. Urging means
11806 may include an elastic member, a lever, a compressed gas, one
or more vise screws, etc.
[0716] After curing, certain lens forming compositions may adhere
strongly to a casting face of one or more molds. Similarly, certain
mold coating compositions may form coating layers on a mold that
adhere strongly to the mold and a cast lens. This adhesion to a
casting face may make separation of a cast lens from a lens mold
very difficult. Demolding device 11801 may be used to assist in
separating a cast lens from a lens mold.
[0717] A lens 11802 and mold 11803 may be disposed between clamping
members 11804 and 11805. Urging means 11806 may be initiated or
applied to urge the clamping members toward one another. As movable
clamping member 11804 moves toward fixed clamping member 11805, a
clamping surface of each may contact an edge of lens mold 11803. By
careful sizing of clamping members 11804 and 11805, they may be
formed such that their clamping surfaces contact lens mold 11803,
but do not contact lens 11802. Force may be applied via clamping
members 11804 and 11805 substantially along a diameter of lens mold
11803. By applying force substantially along a diameter of the lens
mold, little or no lateral component of force may be generated.
Force applied via clamping members 11804 and 11805 may be
sufficient to cause elastic deformation of the lens mold. That is,
the lens mold may bend slightly, without breaking. The force may be
carefully regulated to reduce the likelihood of breaking the lens
mold. Thus, a pressure regulation device may be used to limit the
force applied. For example, a mechanical stop, or breakaway device
may prevent applying excess pressure. In an embodiment where urging
means 11806 includes a pressurized gas, a compressed gas pressure
regulator may limit the force applied. The amount of force that a
lens mold can withstand without exceeding the elastic limit (or
breaking point) of the mold may vary depending on the material of
the mold, the shape of the mold, the age of the mold, etc. For
example, the force may be limited to less than about 500 pounds of
force. In another embodiment, the force may be limited to less than
about 300 pounds of force.
[0718] The elastic deformation of lens mold 11803 may reduce the
contact area between lens 11802 and the mold. Reducing the contact
area may reduce the force required to separate the lens from the
lens mold. Additionally, elastically deforming the lens mold may
allow a prying instrument to be inserted between the lens and the
lens mold along the edge of the lens and lens mold interface. The
prying instrument may be used to assist in separating the lens from
the lens mold. Other means of separating the lens from the lens
mold may also be used. For example, a suction device may be applied
to a face of the lens opposite the lens mold, and a peeling or
pulling force may be applied via the suction device.
[0719] After a lens casting process, the lens and lens molds may be
quite warm to the touch due to the exothermic nature of the
polymerization process of the lens forming composition and/or
process conditions. The heating may increase cross-linking in the
cured lens forming composition. After processing the lens and one
or more lens molds may be cooled. For example, in an embodiment,
after casting the lens mold assembly may be placed into a fluid
bath having a temperature between processing temperature and
ambient temperature. At least one mold (e.g., the front mold), may
be readily removed after cooling in the bath. A second mold (e.g.,
the back mold) may then be removed using demolding device 11801.
After such processing, a cast lens may have a diameter slightly
smaller than the diameter of an associated lens mold. For example,
in an embodiment, a gasket as described in U.S. Pat. No. 6,228,289
to Powers, et al., which is specifically incorporated herein by
reference, is used in a lens casting process, the cast lens
diameter may be only slightly smaller than or equal to the diameter
of the lens mold after casting. It is believed that both increasing
cross-linking, and cooling the lens may tend to cause some
shrinkage of the cured lens forming composition. The smaller
diameter of the cured lens relative to the lens mold enables
clamping members 11804 and 11805 to have a height greater than that
of the edge of lens mold 11803 without contacting lens 11802 during
use.
[0720] In an embodiment, demolding device 11801 may be activated by
a switch 11807. For example, switch 11807 may be a pressure switch.
Activating switch 11807 may initiate urging means 11806. For
example, a pressurized gas from a gas source (not shown) may be
allowed into a pneumatic cylinder of urging means 11806.
[0721] In an embodiment, demolding device 11801 may be coupled to a
work surface to inhibit the demolding device from moving during
operation. Coupling members 11809 may be used to couple demolding
device 11801 to the work surface. In various embodiments, coupling
members 11809 may include threaded members (e.g., screws, bolts,
etc.), inter-engaging members (e.g., nails, pins, clips, snaps,
tenons, projections, etc.), deformable members (e.g., rivets,
cotter pins, etc.) and/or chemical or physical bonds (e.g., suction
cups, welds, adhesives, etc.), or combinations thereof.
Additionally, a cover 11810 may shield portions of demolding device
11801. Cover 11810 may reduce the risk of an operator being pinched
in the device. Additionally, cover 11810 may reduce the risk of the
operator being struck by fragments if a lens or lens mold is
accidentally broken.
[0722] To cast a wide variety of lenses, a large number of
different types of lens molds may be needed. Additionally, if high
production volumes of lenses are to be manufactured, it may be
desirable to have multiple lens molds of certain mold types. With
such large numbers of lens molds in a mold library, it may be
desirable to be able to quickly and accurately identify a
particular lens mold. However, visual identification of a lens mold
may be difficult or impossible. Thus, it may be desirable to mark
or otherwise associate a lens mold with a lens mold identification.
Each of the lens molds of a particular type may have substantially
identical lens forming properties, assuming none of the molds are
defective. Thus, a single identification may be used to describe
all molds of a particular mold type. In some embodiments, a unique
identifier may be used in addition to, or in place of a mold type
identification to describe each lens mold. Assigning a unique
identifier to each lens mold may assist in tracking or identifying
defective lens molds.
[0723] In an embodiment, an eyeglass lens mold 11901 may include a
data code 11902, as depicted in the exemplary embodiment of FIG.
71. Data code 11902 may include an encoded identification of lens
mold 11901. The encoded identification may include a mold type
identification and/or a unique identifier of mold 11901.
[0724] Data code 11902 may include one or more machine-readable
symbols. For example, data code 11902 may include a bar code, a
matrix data code and/or human readable text. U.S. Pat. No.
4,939,354 to Priddy et al., U.S. Pat. No. 5,053,609 to Priddy et
al., and U.S. Pat. No. 5,124,536 to Priddy et al. described systems
and methods of creating and reading data codes and are hereby
specifically incorporated by reference as though fully set forth
herein. For casting a lens using an activating light curing
process, data code 11902 may inhibit some activating light from
reaching the curable lens forming composition. It may therefore be
desirable for data code 11902 to be relatively small and/or located
in an area where it will not have a significant detrimental impact
on the lens curing process. For example, in an embodiment, a data
code may be less than about 0.25 inches square (e.g., about 0.20
inches square). Additionally, it may be desirable for data code
11902 to be located on a non-casting surface of mold 11903 to
prevent any surface roughness caused by the data code from causing
defects in lenses cast using the mold.
[0725] In an embodiment, data code 11902 may be formed inside lens
mold 11901, for example by a layering process. In another
embodiment, data code 11902 may be adhered to a surface of lens
mold 11901. For example, data code 11901 may be formed on a label,
which may be affixed to mold 11901. In yet another embodiment, data
code 11902 may be etched onto a surface of mold 11901. For example,
a chemical or physical etching process may be used. In still
another embodiment, data code 11902 may be applied to a surface of
mold 11901 using a laser marking process.
[0726] FIG. 72 depicts an exemplary embodiment of a flowchart of a
method of applying a data code to an eyeglass lens mold. The method
may include providing a data code 12001 and a lens mold 12002.
Providing a data code may include providing data for forming a data
code or directions for forming the data code. For example, in a
data encoding system wherein some data is encoded in spatial
relationships between two or more data elements providing a data
code is intended to include providing a description of the spatial
relationship between two or more data elements of the data code.
Thus, providing a coordinate set or vector description of the
location of a plurality of data elements may be equivalent to
providing a graphical depiction of the data code. A data code may
also be represented by a numerical or alphanumerical sequence. For
example, a data code may be represented by a numerical matrix. As
used herein, a "data element" refers to a portion of a data code
that conveys information due to its location, size, color, shape,
etc. For example, in a bar code a data element may include a line.
In a matrix data code, a data element may include a dot, or other
matrix element.
[0727] In an embodiment, a data code may represent an alphanumeric
sequence assigned to a lens mold. In such an embodiment, a standard
software application may determine a data code representative of
the alphanumeric sequence based on a translation algorithm. In such
an embodiment, the alphanumeric sequence assigned to a lens mold
may be based on properties of the lens molds, names assigned to the
lens molds, or other distinguishing criteria as appropriate for the
particular mold library.
[0728] The method may further include alternately directing a laser
toward a determine location on the lens mold 12003 and allowing the
lens mold to cool 12004. One or more of the determined locations on
the lens mold may be determined based on a predetermined protocol.
For example, a marking protocol may include placing an initial mark
or terminal mark at a particular location on the lens mold.
Additionally, one or more of the determined locations on the lens
mold may be determined based on the provided data code. Directing
the laser and allowing the lens mold to cool may continue until the
data code has been formed on a surface of the lens mold 12005. It
is believed that heat from the laser may cause formation of micro
fractures in the surface of the lens mold. However, it is
recognized that directing the laser toward the lens mold may also
cause localized hazing and/or discoloration of the lens mold. By
alternating applying heat via the laser and cooling the lens mold,
localized overheating of the lens mold may be avoided. It is
believed that localized overheating of the lens mold may cause
excessive fracturing of the lens mold. In an embodiment, the lens
may be cooled sufficiently by ceasing application of energy from
the laser for less than about 0.1 seconds, for example, about 0.03
seconds.
[0729] In an embodiment, the laser marking process described above
may be used to generate a plurality of data elements on a surface
of lens mold to form a data code. Each data element may be formed
by a single application of energy from the laser. Alternately, a
plurality of applications of the laser may be used to form a single
data element. Forming a data element using two or more applications
of the laser, as opposed to a single application of the laser, may
reduce the risk of localized overheating. Each data element may
have a shape substantially similar to the shape of the intersection
of the laser beam and the surface to which the element is applied.
For example, a laser beam having a circular cross-section may be
directed substantially normal to a non-casting surface of a front
mold. A non-casting surface of a front mold may have a convex
shape. Thus, the intersection of the circular beam and convex
surface may form a regular or slightly irregular circular shape. In
an embodiment, the laser beam path may not coincide with a normal
of the surface. In such an embodiment, an oval or oval-like shape
may form the data element. An error correction algorithm may be
used in conjunction with a code reader to mitigate any problems
caused by irregularly shaped data elements.
[0730] An advantage of a laser marking process may be that such a
process may be used to apply a data code to a tempered glass
surface. Many commercially available lens molds are shipped from
their manufacture with at least one tempered glass surface. Since a
laser marking process may be used to apply a data code to a
tempered glass surface, no special manufacturing process may be
required on the part of a lens mold manufacturer to enable
application of data codes to their lens molds.
[0731] Referring now to FIG. 73, an embodiment of a light based
code reader is depicted in a cut-away perspective side view. As
used herein, a light based code reader configured to read data
codes on lens molds may be referred to as a "mold reader." Mold
reader 12101 may include at least one light source 12102 and at
least one light detection device 12103.
[0732] Light detection device 12103 may be configured to detect
light reflected from or shined through a data code 12104 disposed
on lens mold 12105. A pattern may be formed in the light by data
elements of the data code. Light detection device 12103 may sense
the light pattern and send a signal to a controller 12106
corresponding to the light pattern. Light detection device 12103
may include an electronic photosensor array for detecting the light
pattern. For example, a charge-coupled device (CCD) photo array, or
a complimentary metal-oxide semiconductor (CMOS) photo array may be
used to detect the light pattern. The controller may determine the
content of the data code based on the light pattern signal sent by
light detection device 12103. The controller may use one or more
computer implemented methods to treat the light pattern signal
before determining the content of the data code. For example, a
filtering method may be applied to the signal to reduce the amount
of data present that does not pertain to the data code. For
example, light detection device 12103 may have a field of vision
that is larger than a data code read by the system. Having a large
field of vision may allow light detection device 12103 to have
greater detection flexibility. For example, if the field of vision
of light detection device 12103 is exactly the same size as a data
code disposed on a lens mold, then an operator attempting to read
the data code using the mold reader might have to position the data
code very precisely in order to ensure an accurate reading of the
data code. If the field of vision of light detection device 12103
is larger than the data code, positioning the mold may be
simplified. However, it may be advantageous to eliminate or
minimize information that does not correspond to the light pattern
of the data code transmitted by the light detection device.
Additionally, light detection device 12103 may be focused so that
objects in the background of the data code are substantially out of
focus. This may inhibit background objects from being detected as
high contrast images, which may confuse the data code signal. Other
computer-implemented methods applied to the light pattern signal
may include one or more error correction algorithms and/or a
translation algorithm. Machine vision software applications and
hardware including filtering methods, error correction algorithms,
translation algorithms, light detection devices and controllers are
available from Robotic Vision Systems, Inc. of Canton, Mass.
[0733] Light source 12102 may be configured to illuminate data code
12104. As used herein, "illuminating" refers to directing light
toward an object or area. In various embodiments, illuminating
light may include visible light and/or non-visible light (e.g.,
infrared light, ultraviolet light, etc.). In an embodiment, light
source 12102 may be positioned such that light reflected from mold
12105 is directed toward light detection device 12103. In such an
embodiment, the reflected light may carry the light pattern
detected by the light detection device. In an alternate embodiment,
light source 12102 may be positioned such that light from the light
source passes through at least a portion of lens mold 12105. The
light may then carry the light pattern on to light detection device
12103.
[0734] Accuracy and speed of reading a data code may be improved if
the code is illuminated evenly, as compared to reading accuracy and
speed if the code is not illuminated evenly. Evenly illuminating
data codes disposed on a variety of lens molds types may be
challenging. The curvature of the casting face and/or non-casting
face of molds of different mold types may be significantly
different. To increase evenness of the illumination, light source
12102 may include an array of individual light sources. The
individual light sources may be distributed in an area selected to
provide substantially even illumination of a data code on a
spherical lens mold. For example, an arrangement of the individual
light sources to produce even illumination may be determined by
positioning a spherical mold in the mold reader at an angle
selected to minimize reflection of light toward the light detection
device. Each individual light source may then be treated as a light
beam. The point of incidence of each light beam may be held
constant while the angle of incidence is changed until an array of
evenly spaced point is created on the mold surface. The point of
incidence, the mold reader dimensions, the angle of the lens mold,
the optical properties of the lens mold and the determined angle of
incidence may then be used to determine the arrangement of each
individual light source of light source 12102. In an embodiment,
light-emitting diodes (LEDs) may be used as individual light
sources. To help ensure even illumination a constant current source
may power the LEDs. The constant current power source may help to
minimize light intensity variations due to LED to LED variability
and power supply fluctuations.
[0735] In addition, minimizing light reflected from edges and
surfaces within the mold reader may be desirable. For example, an
edge of lens mold 12105 may reflect light toward light detection
device 12103. Light reflected toward light detection device 12103
might obscure the light pattern formed by data code 12104, thereby
reducing the accuracy and/or speed of the reading process. Careful
selection of the angle between light source 12102, data code 12104
and light detection device 12103 may minimize problems of light
reflection. Selecting this angle may be an iterative process which
depends on the particular mold library with which the reader is
intended to work. For example, the angle may depend on issues such
as but not limited to: the size of the molds, the range of lens
that can be manufactured by molds in the mold library, and the
material of construction of the molds.
[0736] In mold readers having a single light source 12102,
unintentional shadows may also have a detrimental effect on mold
reader speed and/or accuracy. For example, edge shadows of a lens
mold may disrupt the data code pattern or reduce the speed and/or
accuracy of interpreting the data code pattern. To alleviate
shadowing problems a secondary light source 12107 may be used.
Secondary light source 12107 may be positioned to inhibit formation
of unintentional shadows within the field of view of light
detection device 12103. For example, secondary light source 12107
may be positioned to shine light at an angle to light shined from
primary light source 12102.
[0737] In certain embodiments, light detection device 12103 may
also detect patterns formed by illumination of high contrast
features of the mold reader. In such embodiments, one or more light
shields 12108 and 12109 may be used to reduce problems associated
with detection of high contrast features of the mold reader. For
example, a primary light shield 12108 may reduce the field of
vision of light detection device 12103 to an area surrounding data
code 12104 of a mold 12105 disposed within mold reader 12101. By
limiting the field of vision in this manner, the amount of
extraneous data (e.g., data not related to a light pattern formed
by data code 12104) generated by light detection device 12103 may
be limited. Additionally, the lens mold entrance 12111, support
platform 12112 and mold guides 12113 may be restricted from the
field of view. This may be desirable since lighting and contrast in
these areas may be difficult to control. Additionally, light
detection device 12103 and/or controller 12106 may be configured to
ignore data from an area approximately equal to the area blocked by
light shield 12108. By ignoring data from the area blocked by light
shield 12108, the size of the data set to be analyzed by the mold
reader may be reduced. Reducing the size of the data set to be
analyzed may increase the speed of the mold reader. In an
embodiment, primary light shield 12108 may be placed close enough
to a lens of light detection device 12103 that the shield is out of
focus. In such an embodiment, primary light shield 12108 may not
generate any high contract images in light detection device 12103.
This may reduce the likelihood of dirt or other contaminants on
light shield 12108 being detected by light detection device
12103.
[0738] In an embodiment where secondary light source 12107 is
present, a secondary light shield 12109 may also be employed.
Secondary light shield 12109 may obstruct components of secondary
light source 12107 from the field of vision of light detection
device 12103. For example, in an embodiment, secondary light source
12107 may include a plurality of LEDs arranged on a circuit board.
In such an embodiment, lead lines on the circuit board may reflect
light in an undesirable manner. Likewise, circuit board components
may generate high contrast images in light detection device 12103.
Such high contrast images may disrupt identifying and/or
interpreting the light pattern formed by data code 12104.
[0739] Additionally, in some embodiment, components of mold reader
12101 may be disposed within an enclosure 12110. Enclosure 12110
may inhibit external light sources from disrupting the data code
detection process. Internal portions of enclosure 12110, as well as
certain internal components, may be black and/or non-reflective.
For example, the interior portion of enclosure 12110 may be painted
with a non-reflective black paint. In some embodiments, enclosure
12110 may also include a shield or hood 12114 adjacent to the mold
entrance to inhibit external light entering the mold reader.
[0740] To assist an operator in using mold reader 12101, a support
platform 12112 may be located adjacent to mold entrance 12111.
Support platform 12112 may support a mold disposed in the mold
reader in a desired position for reading the data code. For
example, support platform 12112 may be configured so that a data
code of a mold resting on the platform is focused on a light sensor
of light detection device 12103.
[0741] In an embodiment, mold guides 12113 may similarly assist the
operator in obtaining an accurate reading of the mold data code.
For example, one or more mold guides may assist an operator in
positioning a data code of a mold disposed in the mold reader
within a field of vision of light detection device 12103. In an
embodiment, support platform 12112 and mold guides 12113 may be
combined into a single feature. For example, a pair of converging
rails having an L-shaped cross-section may both support a lens mold
and limit how far into the mold reader the mold may be place.
[0742] A flow chart of an exemplary embodiment of a method of
determining the identification of a lens mold is depicted in FIG.
74. The method may include providing a lens mold having an
identification data code, as shown in box 12201. For example, a
data code may be applied to the lens mold as describe with
reference to FIG. 72. The data code may include but is not limited
to: a bar code, a matrix data code and/or human readable text. The
data code may include information sufficient to uniquely identify
the individual lens mold and/or data sufficient to identify the
type of the lens mold.
[0743] The method may include illuminating the data code, as shown
in box 12202. The data code may be illuminated by reflecting light
off the mold and/or by shining light through the mold. For example,
a mold reader (such as the mold reader described with reference to
FIG. 73) may be used to illuminate the data code. The mold may be
placed in the mold reader with the data code positioned within the
field of vision of the light detection device. The mold may be
illuminated in a manner that inhibits formation of shadows within
the field of vision of the light detection device. Additionally,
the mold may be illuminated in a manner that inhibits reflection of
light toward the light detection device off surfaces of the mold
and the mold reader.
[0744] While the data code is illuminated, a light pattern formed
by the illumination of the data code may be detected, as shown in
box 12203. Detecting the light pattern may include using a light
detection device. For example, the light detection device may
generate an electrical signal based on light received at a light
sensor. The light sensor may be configured to differentiate light
and dark areas on the sensor formed by focusing the light pattern
of the data code on the sensor. For example, in various
embodiments, a CCD photo array, CMOS photo array, or another type
of photovoltaic array may be used as the sensor. In an embodiment,
light may strike the sensor in areas corresponding to field areas
of the data code (e.g., areas containing no data elements).
Likewise, darker areas may be formed on the sensor in areas
corresponding to data elements of the data code. However, it is
recognized that in alternate embodiments data elements may form
lighter areas of the light pattern while darker areas are formed by
the field.
[0745] The identification of the lens mold may be determined based
on the detected light pattern, as shown in box 12204. Determining
the identification of the lens mold based on the detected light
pattern may include sending an electrical signal corresponding to
the light pattern to a controller. The controller may determine the
identity of the lens mold based on the electrical signal. For
example, the electrical signal may be translated into a
corresponding alphanumeric identification of the lens mold. In
another example, the electrical signal may be used to search a
database. The database may include a listing of lens mold
identifications and associated electrical signals formed by data
codes disposed on the lens molds.
[0746] In an embodiment, after a mold member has been used to form
a lens, the mold member may be returned to storage in a mold member
storage system. FIG. 75 depicts a flowchart of an embodiment of a
method of storing a mold member in a provided eyeglass mold member
storage system. The method may include receiving input identifying
a mold member to be stored, as shown in box 12301. For example,
input identifying a mold member to be stored may be provided via a
mold reader as previously described. One or more mold member
storage locations designated for storage of the identified mold
member may be determined based on the input at box 12302. For
example, a mold member storage location associated with a mold
member type of the mold member may be determined. As shown in box
12303, an activation signal may be sent to one or more indicators
proximate one or more determined mold member storage locations. In
some embodiments, the method may also include receiving input
regarding the status of at least one mold member to be stored, as
depicted in box 12304. For example, the input may include an
indication that the mold member has been placed into the eyeglass
mold member storage system. Alternately, the input may include an
indication that the mold member has not been placed into the
storage system. As shown in box 12305, the mold member inventory
may be adjusted according the input received. For example, if the
input indicates that a mold member was added to the eyeglass mold
member storage system, the expected number of mold members of the
mold member type may be increased by one.
[0747] Various embodiments further include receiving or storing
instructions and/or data implemented in accordance with the
foregoing description upon a carrier medium. Suitable carrier media
include memory media or storage media such as magnetic or optical
media, e.g., disk or CD-ROM, as well as signals such as electrical,
electromagnetic, or digital signals, conveyed via a communication
medium such as networks and/or a wireless link.
[0748] Further modifications and alternative embodiments of various
aspects of the invention will be apparent to those skilled in the
art in view of this description. Accordingly, this description is
to be construed as illustrative only and is for the purpose of
teaching those skilled in the art the general manner of carrying
out the invention. It is to be understood that the forms of the
invention shown and described herein are to be taken as the
presently preferred embodiments. Elements and materials may be
substituted for those illustrated and described herein, parts and
processes may be reversed, and certain features of the invention
may be utilized independently, all as would be apparent to one
skilled in the art after having the benefit of this description of
the invention. Changes may be made in the elements described herein
without departing from the spirit and scope of the invention as
described in the following claims.
* * * * *