Assembly for molding a lens and method thereof

Abstract

An assembly for molding a lens, comprising: an outer peripheral gasket member having a surrounding wall (112) about an axis to define a through cavity, the surrounding wall (112) having an inner peripheral ridge portion projecting inwardly toward the axis and separating the surrounding wall (112) into an upper wall portion and a lower wall portion, wherein the inner peripheral ridge portion includes a first ridge side and a second ridge side (114b); a membrane disposed at the first ridge side; an annular member disposed on the membrane to hold the membrane between the annular member and the first ridge side; a first mold part disposed such that a peripheral edge is in abutment with the upper wall portion; and a second mold part disposed opposite the first mold part and such that a peripheral edge is in abutment with the lower wall portion, wherein a molding cavity is defined between the outer peripheral gasket member, the first mold part, and the second mold part.

Description

Technical Field

[0001] This disclosure generally relates to an assembly for molding lenses and a method for molding lenses. Background Technology

[0002] The molding of polarizing lenses is typically a highly complex process, where yield and quality depend heavily on operator skill. A polarizing lens generally consists of two optical lens layers sandwiching a polarizing film. The conventional process of assembling the mold assembly for molding polarizing lenses is usually performed manually by the operator, as the placement of the polarizing film is a precise and delicate step that directly impacts the quality and success of the molding process. Typically, a conventional mold assembly includes a top mold, a bottom mold, and a gasket between them to define the molding cavity. In the conventional process, the gasket is usually expanded to allow the polarizing film to be placed within the molding cavity and held in place by grooves or recesses along the inner periphery of the gasket. However, the polarizing film is very fragile and can deform or be damaged when placed into the gasket during the conventional process. The gasket may also deform during the conventional process. Furthermore, the quality and time required to successfully place the polarizing film into the conventional gasket depend on the operator's skill.

[0003] Therefore, a more reliable, less operator-dependent, and more efficient solution for molding polarizing lenses is needed. Document US2009091825 discloses an assembly comprising a pair of lens molds, a gasket, a polarizing film located between the molds, a retaining ring, and a clamp. The gasket is formed of synthetic rubber and has a substantially cylindrical shape. It has a first step that will mate with a first lens mold and a second step that will mate with the other lens mold. Between these steps, a mounting is provided, on which the outer peripheries of the polarizing film 14 and the retaining ring 15 rest. The main challenge of this solution is ensuring the correct placement of these components and a good seal of the assembly. Summary of the Invention

[0004] According to various embodiments, an assembly for molding a lens as claimed in claim 1 is provided. The assembly includes a peripheral washer member having a surrounding wall about an axis to define a cavity extending along the axis. The surrounding wall has an inner peripheral ridge portion projecting inwardly toward the axis from inside the surrounding wall in a manner that divides the surrounding wall into an upper wall portion and a lower wall portion, the upper wall portion and the lower wall portion being located above and below the inner peripheral ridge portion, respectively, relative to the axis. The inner peripheral ridge portion includes a first ridge side surface and a second ridge side surface, the first ridge side surface pointing in a first direction corresponding to a direction extending along the axis from the inner peripheral ridge portion to the upper wall portion, and the second ridge side surface pointing in a second direction corresponding to a direction extending along the axis from the inner peripheral ridge portion to the lower wall portion. The assembly includes a membrane disposed at the first ridge side surface of the inner peripheral ridge portion of the peripheral washer member, wherein a segment of the outer peripheral boundary region of the membrane abuts against the first ridge side surface of the inner peripheral ridge portion of the peripheral washer member. The assembly includes an annular member disposed on a segment of the outer peripheral boundary region of the membrane to hold the segment between the annular member and a first ridge side of the inner circumferential ridge portion of the outer peripheral gasket member. The assembly includes a first mold member configured such that its circumferential edge abuts against an upper wall portion of the outer peripheral gasket member. The assembly includes a second mold member disposed opposite to the first mold member, with its circumferential edge abutting against a lower wall portion of the outer peripheral gasket member. A molding cavity is defined between the outer peripheral gasket member, the first mold member, and the second mold member.

[0005] According to various embodiments, a method for molding a lens as claimed in claim 10 is provided. The method includes providing a peripheral washer member comprising a surrounding wall about an axis to define a cavity extending along the axis. The surrounding wall has an inner peripheral ridge portion projecting inwardly toward the axis from inside the surrounding wall in a manner that divides the surrounding wall into an upper wall portion and a lower wall portion, the upper wall portion and the lower wall portion being located above and below the inner peripheral ridge portion, respectively, relative to the axis. The inner peripheral ridge portion includes a first ridge side surface and a second ridge side surface, the first ridge side surface pointing in a first direction corresponding to a direction extending along the axis from the inner peripheral ridge portion to the upper wall portion, and the second ridge side surface pointing in a second direction corresponding to a direction extending along the axis from the inner peripheral ridge portion to the lower wall portion. The method includes disposing a film at the first ridge side surface of the inner peripheral ridge portion of the peripheral washer member, wherein a segment of the outer peripheral boundary region of the film abuts against the first ridge side surface of the inner peripheral ridge portion of the peripheral washer member. The method includes positioning an annular member in a manner that secures the segment of the outer peripheral boundary region of the membrane between the annular member and a first ridge side of an inner circumferential ridge portion of an outer peripheral washer member. The method includes positioning a first mold member such that its circumferential edge abuts against an upper wall portion of the outer peripheral washer member. The method includes positioning a second mold member opposite to the first mold member, with its circumferential edge abutting against a lower wall portion of the outer peripheral washer member. The method includes filling a molding cavity defined by the outer peripheral washer member, the first mold member, and the second mold member with a liquid molding material to mold a lens. Attached Figure Description

[0006] To gain a more complete understanding of the descriptions and advantages provided herein, reference will now be made to the following brief description in conjunction with the accompanying drawings and detailed description, wherein the same reference numerals denote the same parts.

[0007] Figure 1A A schematic cross-sectional view of the outer peripheral gasket member of a molded assembly according to various embodiments is depicted.

[0008] Figure 1B Depicting various embodiments Figure 1A A schematic top view of the outer peripheral washer component.

[0009] Figure 1C Depicting various embodiments Figure 1A A schematic enlarged cross-sectional view of the left portion of the outer peripheral washer component.

[0010] Figure 2A Membranes and according to various embodiments are depicted. Figure 1A A schematic cross-sectional view of the outer peripheral washer component.

[0011] Figure 2B Depicting various embodiments Figure 2A A schematic top view.

[0012] Figure 3A An annular component according to various embodiments is described. Figure 2A membrane and Figure 1A A schematic cross-sectional view of the outer peripheral washer component.

[0013] Figure 3B Depicting various embodiments Figure 3A A schematic top view.

[0014] Figure 4A A schematic cross-sectional view of a molding assembly for molding lenses according to various embodiments is depicted.

[0015] Figure 4B Depicting various embodiments Figure 4A A schematic top view of the molded components.

[0016] Figure 5 A molded assembly filled with liquid molding material is depicted according to various embodiments. Detailed Implementation

[0017] In the following description, the drawings are not necessarily drawn to scale, and some features may be shown in a broad or schematic form for clarity and conciseness or for informational purposes. Furthermore, although various embodiments of manufacture and use are discussed in detail below, it should be understood that many inventive concepts that can be practiced in a variety of contexts are provided as described herein. The embodiments discussed herein are merely representative and do not limit the scope of the invention. It will also be apparent to those skilled in the art that all technical features defined with respect to the method can be transposed individually or in combination to the apparatus, and conversely, all technical features with respect to the apparatus can be transposed individually or in combination to the method.

[0018] Furthermore, it should be understood that the embodiments described below can be combined; for example, a portion of one embodiment can be combined with a portion of another embodiment.

[0019] It should be understood that the terms “up,” “above,” “top,” “bottom,” “lower,” “side,” “back,” “left,” “right,” “front,” “rear,” “lateral,” “side,” “upward,” “downward,” “vertical,” “horizontal,” etc., when used in the following description, are for convenience and to aid in understanding relative position or orientation, and are not intended to limit the orientation of any device or structure or any part of any device or structure. Furthermore, unless the context clearly indicates otherwise, the singular forms of the terms “a,” “an,” and “the” include the plural referents. Similarly, unless the context clearly indicates otherwise, the word “or” is intended to include “and.”

[0020] Various embodiments generally relate to components for molding lenses and methods for molding lenses. The lens may be a polarizing lens. Further, the lens may have an ultra-high refractive index (UHI), high refractive index (HI), medium refractive index (MI), or low refractive index (LI). Various embodiments can eliminate the difficulties of polarizing film insertion in conventional processes. Further, various embodiments may eliminate the need for the step of expanding the gasket to insert the polarizing film. Therefore, various embodiments can avoid or prevent gasket deformation. Furthermore, various embodiments may eliminate the need to assemble the polarizing film into the built-in groove or recess of the gasket. Therefore, various embodiments can eliminate the need for precise manipulation and assembly of the polarizing film. Various embodiments may also potentially eliminate the need for a skilled operator to insert the polarizing film into the gasket, or may potentially automate the insertion of the polarizing film into the gasket.

[0021] According to various embodiments, a method for molding a lens may include assembling a bottom mold (or a second mold component) with a washer (or an outer peripheral washer component); laying a film on the inner peripheral ridge of the washer; placing an annular component (e.g., a gasket) on the film; assembling a top mold (or a first mold component) to the washer; and filling the molding cavity with a liquid molding material. Accordingly, in this way, the film can be held between the inner peripheral ridge of the washer and the annular component. Therefore, the manipulation of the film and / or washer in the manner of conventional polarizing film insertion steps can be eliminated. Thus, the difficulties and problems associated with conventional polarizing film insertion steps can be avoided.

[0022] Figure 1A , Figure 2A , Figure 3A and Figure 4A A sequence of methods for assembling a molding assembly 100 (or component) for molding lenses according to various embodiments is described. Figure 1A , Figure 2A , Figure 3A , Figure 4A and Figure 5A sequence of methods for molding lenses according to various embodiments is described. According to various embodiments, the method for molding lenses may include assembling a molding assembly 100 for molding lenses, and subsequently filling the molding cavity 102 of the molding assembly 100 with liquid molding material 105 to mold the lens. Figure 5 A molding assembly 100 filled with liquid molding material 105 according to various embodiments is depicted.

[0023] Figure 4A A schematic cross-sectional view of a molding assembly 100 for molding lenses according to various embodiments is depicted. Figure 4B Depicting various embodiments Figure 4A A schematic top view of the molded component 100. Figure 1A Depicting various embodiments Figure 4A A schematic cross-sectional view of the outer peripheral washer member 110 of the molded component 100. Figure 1B Depicting various embodiments Figure 1A A schematic top view of the outer peripheral washer component 110. Figure 1C Depicting various embodiments Figure 1A A schematic enlarged cross-sectional view of the left portion of the outer peripheral washer component 110.

[0024] According to various embodiments, the molding assembly 100 may include a peripheral washer member 110. The peripheral washer member 110 may have a structure including a surrounding wall 112 that defines a cavity 113 extending along axis 111. According to various embodiments, axis 111 may be the centerline of the cavity 113 defined by the surrounding wall 112 of the peripheral washer member 110. Therefore, the centerline of the cavity 113 may coincide with axis 111. Further, the central axis of the surrounding wall 112 of the peripheral washer member 100 may coincide with axis 111. As an example, according to various embodiments, the surrounding wall 112 of the peripheral washer member 110 may be in the form of a ring-shaped structure or an annular wall structure. Accordingly, axis 111 may pass through the center of the ring-shaped structure or annular wall structure.

[0025] According to various embodiments, the surrounding wall 112 of the outer peripheral washer member 110 may include an inner peripheral ridge portion 114. The inner peripheral ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 may project inwardly toward the axis 111 from the inner side 115 of the surrounding wall 112. The inner side 115 of the surrounding wall 112 may be the inward-facing side of the surrounding wall 112. For example, when the surrounding wall 112 is in the form of a ring structure or annular wall structure, the inner side 115 of the surrounding wall 112 may be the inner circumference or inner circumferential surface of the surrounding wall 112. The inner peripheral ridge portion 114 may be a protrusion along the inner side 115 of the surrounding wall 112, which may surround the axis 111. Therefore, the inner peripheral ridge portion 114 may form a continuous annular frame structure projecting inwardly from the inner side 115 of the surrounding wall 112. Accordingly, the inner circumferential ridge portion 114 can be used as a narrowing portion of the cavity 113 along the outer circumferential washer member 110.

[0026] According to various embodiments, the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 can divide the surrounding wall 112 into an upper wall portion 116 and a lower wall portion 118, which are located above and below the inner circumferential ridge portion 114 relative to the axis 111, respectively. Accordingly, the inner circumferential ridge portion 114 can be located at the middle of the inner side 115 of the surrounding wall 112 relative to the axis 111. Further, the upper wall portion 116 and the lower wall portion 118 can be on opposite sides of the inner circumferential ridge portion 114. Therefore, by taking a reference point along the axis 111 corresponding to the position of the inner circumferential ridge portion 114, the positions of the upper wall portion 116 and the lower wall portion 118 can respectively correspond to points above and below the reference point along the axis 111.

[0027] According to various embodiments, the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer circumferential washer member 110 may include a first ridge side surface 114a. The first ridge side surface 114a of the inner circumferential ridge portion 114 may point in a first direction 111a, which corresponds to the direction along the axis 111 extending from the inner circumferential ridge portion 114 to the upper wall portion 116. Accordingly, the first ridge side surface 114a of the inner circumferential ridge portion 114 may face or point toward the end opening of the cavity 113 of the outer circumferential washer member 110 near the upper wall portion 116.

[0028] According to various embodiments, the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer circumferential washer member 110 may include a second ridge side surface 114b. The second ridge side surface 114b of the inner circumferential ridge portion 114 may point in a second direction 111b, which corresponds to the direction along the axis 111 extending from the inner circumferential ridge portion 114 to the lower wall portion 118. Accordingly, the second ridge side surface 114b of the inner circumferential ridge portion 114 may face or point toward the end opening of the cavity 113 of the outer circumferential washer member 110 near the lower wall portion 118.

[0029] Figure 2A A schematic cross-sectional view of the membrane 130 and the outer peripheral gasket member 110 according to various embodiments is depicted. Figure 2B Depicting various embodiments Figure 2A A schematic top view. According to various embodiments, the molding assembly 100 may include a film 130. The film 130 may be a polarizing film to be embedded or sandwiched within a lens to be molded. According to various embodiments, the film 130 may be disposed at a first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the peripheral washer member 110. The film 130 may be configured such that a segment of the outer peripheral boundary region 132 of the film 130 abuts against the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the peripheral washer member 110. Accordingly, the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the peripheral washer member 110 may support the film 130, wherein the segment of the outer peripheral boundary region 132 of the film 130 rests on the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the peripheral washer member 110. Therefore, the membrane 130 can be suspended on the cavity 113 of the peripheral washer member 110, wherein a section of the peripheral boundary region 132 of the membrane 130 is supported by the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the peripheral washer member 110.

[0030] Figure 3A A schematic cross-sectional view of the annular member 140, the membrane 130, and the outer peripheral washer member 110 according to various embodiments is depicted. Figure 3B Depicting various embodiments Figure 3AA schematic top view. According to various embodiments, the molding assembly 100 may include an annular member 140. The annular member 140 may be disposed on a segment of the outer peripheral boundary region 132 of the membrane 130. The annular member 140 may be disposed in such a way that it holds the segment of the outer peripheral boundary region 132 of the membrane 130 between the annular member 140 and a first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. Accordingly, when the membrane 130 rests or is supported on the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110, the annular member 140 may be placed or stacked on the membrane 130 such that the membrane 130 is between the annular member 140 and the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. Therefore, the membrane 130 can be held in place by the annular member 140 and the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110, wherein a segment of the outer peripheral boundary region 132 of the membrane 130 is located between the annular member 140 and the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. In this way, the membrane 130 can be fitted to the outer peripheral washer member 110 in a simple and efficient manner, thereby eliminating or minimizing the risk of deformation or damage to the membrane 130 and / or the outer peripheral washer member 110. Furthermore, fitting the membrane 130 to the outer peripheral washer member 110 may not require a highly skilled operator or may be automated. According to various embodiments, the segment of the outer peripheral boundary region 132 of the membrane 130 may be loosely held between the annular member 140 and the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110.

[0031] refer to Figure 4A and 4B The molding assembly 100 may include a first mold component 150 (or a top mold or a cavity mold) and a second mold component 160 (or a bottom mold or a punch mold). The first mold component 150 and the second mold component 160 may be assembled to the outer peripheral washer component 110 from two opposite end openings of the cavity 113, respectively. Accordingly, the first mold component 150 and the second mold component 160 may respectively cover the two opposite end openings of the cavity 113 of the outer peripheral washer component 110.

[0032] According to various embodiments, the first mold component 150 may be configured such that its circumferential edge 152 abuts against the upper wall portion 116 of the outer peripheral washer component 110. Accordingly, the first mold component 150 may be fitted to the outer peripheral washer component 110 in such a manner that the circumferential edge 152 of the first mold component 150 can contact or abut against the upper wall portion 116 of the outer peripheral washer component 110. According to various embodiments, the circumferential edge 152 of the first mold component 150 may completely or entirely abut against the upper wall portion 116 of the outer peripheral washer component 110, such that there is no gap around the first mold component 150 between the circumferential edge 152 of the first mold component 150 and the upper wall portion 116 of the outer peripheral washer component 110. Furthermore, according to various embodiments, the circumferential edge 152 of the first mold component 150 can be sealed to the upper wall portion 116 of the outer peripheral gasket component 110 in such a way that the first mold component 150 and the outer peripheral gasket component 110 can be airtightly sealed together in a leak-proof manner.

[0033] According to various embodiments, the second mold component 160 may be disposed opposite to the first mold component 150. Accordingly, the first mold component 150 and the second mold component 160 may be opposite each other. According to various embodiments, the second mold component 160 may be disposed such that its circumferential edge 162 abuts against the lower wall portion 118 of the outer peripheral washer component 110. Accordingly, the second mold component 160 may be fitted to the outer peripheral washer component 110 in such a manner that the circumferential edge 162 of the second mold component 160 may contact or abut against the lower wall portion 118 of the outer peripheral washer component 110. According to various embodiments, the circumferential edge 162 of the second mold component 160 may completely or entirely abut against the lower wall portion 118 of the outer peripheral washer component 110, such that there is no gap around the second mold component 160 between the circumferential edge 162 of the second mold component 160 and the lower wall portion 118 of the outer peripheral washer component 110. Furthermore, according to various embodiments, the circumferential edge 162 of the second mold component 160 can be sealed to the lower wall portion 118 of the outer peripheral gasket component 110 in such a way that the second mold component 160 and the outer peripheral gasket component 110 can be airtightly sealed together in a leak-proof manner.

[0034] According to various embodiments, a molding cavity 102 may be defined between the outer peripheral washer member 110, the first mold member 150, and the second mold member 160. Accordingly, the space surrounded by the outer peripheral washer member 110, the first mold member 150, and the second mold member 160 can be used as the molding cavity 102. Thus, the molding cavity 102 may be defined at the top by the first mold member 150, at the bottom by the second mold member 160, and around the periphery by the outer peripheral washer member 110.

[0035] According to various embodiments, the first mold component 150 may further abut against the annular member 140. Accordingly, the first mold component 150 may be fitted to the outer peripheral washer member 110 in such a way that the first mold component 150 can contact or abut against the annular member 140. According to various embodiments, the annular member 140 may fully or completely abut against the first mold component 150, such that there is no gap between the annular member 140 and the first mold component 150. Further, according to various embodiments, the annular member 140 may be sealingly engaged with the first mold component 150 in such a way that the annular member 140 and the first mold component 150 are airtightly sealed together in a leak-proof manner.

[0036] According to various embodiments, the second mold component 160 may abut against the second ridge side 114b of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer component 110. Accordingly, the second mold component 160 may be fitted to the outer peripheral washer component 110 in such a way that the second mold component 160 can contact or abut against the second ridge side 114b of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer component 110. According to various embodiments, the second mold component 160 and the second ridge side 114b of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer component 110 may abut against each other in such a way that there is no gap between the second mold component 160 and the second ridge side 114b of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer component 110. Furthermore, according to various embodiments, the second mold component 160 can be sealed to the second ridge side 114b of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral gasket component 110 in such a way that the second mold component 160 and the outer peripheral gasket component 110 can be airtightly sealed together in a leak-proof manner.

[0037] refer to Figure 1A and Figure 1C According to various embodiments, the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 may include a concentric stepped profile 120. The concentric stepped profile 120 may be radially oriented relative to the axis 111. Accordingly, the axis 111 may serve as a common center of the concentric stepped profile 120, wherein the steps of the concentric stepped profile 120 may be arranged radially from the axis 111. According to various embodiments, the concentric stepped profile 120 may include an outer step 122 and an inner step 124. The inner step 124 may be radially closer to the axis 111 than the outer step 122. As such Figure 1A and Figure 1CAs shown in the example, the concentric stepped profile 120 may include two steps, namely an outer step 122 and an inner step 124. It should be understood that the concentric stepped profile 120 may include at least two (or two or more) steps and is not limited to the illustrated embodiment.

[0038] According to various embodiments, a segment of the outer peripheral boundary region 132 of the membrane 130 may abut against the inner step 124 of the first ridge side 114a of the inner peripheral ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 (e.g., see...). Figure 2A Therefore, the segment of the outer peripheral boundary region 132 of the membrane 130 and the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 can contact or abut each other. Accordingly, the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 can support the membrane 130, wherein the segment of the outer peripheral boundary region 132 of the membrane 130 rests on the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. In this way, the membrane 130 can be suspended on the cavity 113 of the peripheral washer member 110, wherein a section of the peripheral boundary region 132 of the membrane 130 is supported by the inner step 124 of the inner ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the peripheral washer member 110.

[0039] According to various embodiments, the annular member 140 may be configured such that the outer boundary region 142 of the annular member 140 covers the outer step 122 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110, and the inner boundary region 144 of the annular member 140 overlaps with a segment of the outer peripheral boundary region 132 of the membrane 130 (e.g., see...). Figure 3A Since the section of the outer peripheral boundary region 132 of the membrane 130 is supported on the inner step 124 of the first ridge side 114a of the inner peripheral ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110, the annular member 140 may have a width sufficient to cover the inner step 124 and the outer step 122 of the first ridge side 114a of the inner peripheral ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110.

[0040] According to various embodiments, the outer boundary region 142 of the annular member 140 may abut against the outer step 122 of the first ridge side surface 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. Accordingly, the outer boundary region 142 of the annular member 140 and the outer step 122 of the first ridge side surface 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 may contact or abut against each other. According to various embodiments, there may be no gap between the outer boundary region 142 of the annular member 140 and the outer step 122 of the first ridge side surface 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. According to various embodiments, the outer boundary region 142 of the annular member 140 may be sealingly engaged with the outer step 122 of the first ridge side surface 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110, thereby achieving an airtight seal in a leak-proof manner.

[0041] According to various embodiments, a segment of the outer peripheral boundary region 132 of the membrane 130 may be located between the inner boundary region 144 of the annular member 140 and the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. According to various embodiments, when a segment of the outer peripheral boundary region 132 of the membrane 130 abuts against the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110, the annular member 140 may be disposed on the segment of the outer peripheral boundary region 132 of the membrane 130, wherein the inner boundary region 144 of the annular member 140 is on the segment of the outer peripheral boundary region 132 of the membrane 130. Therefore, the inner boundary region 144 of the annular member 140 can be placed over a segment of the outer peripheral boundary region 132 of the membrane 130, such that the segment of the outer peripheral boundary region 132 of the membrane 130 can be held or maintained between the inner boundary region 144 of the annular member 140 and the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. Accordingly, the membrane 130 can be held in place by the inner boundary region 144 of the annular member 140 and the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110, which together hold the segment of the outer peripheral boundary region 132 of the membrane 130.

[0042] According to various embodiments, the outer boundary region 142 of the annular member 140 can be sandwiched between the first mold member 150 and the outer step 122 of the first ridge side surface 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. Accordingly, when the outer boundary region 142 of the annular member 140 abuts against the outer step 122 of the first ridge side surface 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110, the first mold member 150 can be placed or stacked on the annular member 140 such that the annular member 140 can be sandwiched between the first mold member 150 and the outer step 122 of the first ridge side surface 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110.

[0043] According to various embodiments, since the annular member 140 is fastened or fixed by the outer step 122 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the first mold component 150 and the outer step 122 of the outer step 122 of the inner step 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer circumferential washer component 110 (which clamps the outer boundary region 142 of the annular member 140), the inner boundary region 144 of the annular member 140 and the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer circumferential washer component 110 can form a groove or recess, and a section of the outer boundary region 132 of the membrane 130 can be loosely fixed in the groove or recess. Accordingly, with a section of the outer peripheral boundary region 132 of the membrane 130 loosely held between the inner boundary region 144 of the annular member 140 and the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110, the membrane 130 can have some leeway or degree of freedom of displacement or movement. Such leeway and degree of freedom allow the membrane 130 to shift back and forth as the liquid molding material 105 fills the molding cavity 102, thereby minimizing, reducing, or avoiding any accumulation of tension on the membrane 130 when the liquid molding material 105 presses against it. Therefore, torsion, deformation, and / or damage to the membrane 130 can also be minimized, reduced, or avoided.

[0044] refer to Figure 1CAccording to various embodiments, the outer step 122 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 may have a vertical surface 122b and a threaded surface 122a. The vertical surface 122b of the outer step 122 may be oriented parallel to the axis 111. The threaded surface 122a of the outer step 122 may be inclined to form an acute angle with the vertical surface 122b of the outer step 122. Therefore, the vertical surface 122b of the outer step 122 may be a vertical surface parallel to the axis 111, and the threaded surface 122a of the outer step 122 may be an inclined surface that converges and intersects with the vertical surface. Accordingly, the outer step 122 may have a serrated or notched cross-sectional profile.

[0045] According to various embodiments, the inner step 124 of the first ridge side 114a of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 may have a threaded surface 124a parallel to the threaded surface 122a of the outer step 122. Accordingly, the threaded surface 124a of the inner step 124 may be an inclined surface corresponding to the threaded surface 122a of the outer step 122.

[0046] According to various embodiments, the inner step 124 may be adjacent to the outer step 122. Correspondingly, the outer step 122 may be adjacent to the inner step 124. Therefore, the vertical surface 122b of the outer step 122 may be located between the threaded surface 122a of the outer step 122 and the threaded surface 124a of the inner step 124. Thus, in the radially outward direction relative to the axis 111, the threaded surface 124a of the inner step 124 may be followed by the vertical surface 122b of the outer step 122, and then by the threaded surface 122a of the outer step 122.

[0047] According to various embodiments, the second ridge side 114b of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110 may include a protruding free edge 126 extending in a second direction 111b. Accordingly, the protruding free edge 126 may extend from the second ridge side 114b of the inner circumferential ridge portion 114 in a direction opposite to the first ridge side 114a of the inner circumferential ridge portion 114. According to various embodiments, the protruding free edge 126 may be tapered, pointed, or rounded. According to various embodiments, the second mold member 160 may abut against the protruding free edge 126 of the second ridge side 114b of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. Accordingly, the second mold member 160 may contact or abut against the protruding free edge 126 of the second ridge side 114b of the inner circumferential ridge portion 114 of the surrounding wall 112 of the outer peripheral washer member 110. According to various embodiments, the protruding free edge 126 may form a continuous annular loop. Accordingly, the protruding free edge 126 can fully or completely abut against the second mold component 160.

[0048] According to various embodiments, the annular member 140 may be made of the same material as the outer peripheral washer member 110. For example, each of the annular member 140 and the outer peripheral washer member 110 may be made of or coated with polytetrafluoroethylene (PTFE, also known as Teflon) or an elastomer.

[0049] According to various embodiments, membrane 130 may include notch 134 (e.g., see...). Figure 2B The notch 134 or cut (e.g., a circular segment cut) can facilitate the flow of liquid molding material 105 through the membrane 130 to fill the molding cavity 102 in such a way that liquid molding material 105 is present on both sides of the membrane 130. Accordingly, the liquid molding material 105 can be hardened to form a lens in which the membrane 130 is embedded.

[0050] According to various embodiments, the surrounding wall 112 of the peripheral gasket member 110 may include a filling channel 170 for filling the molding cavity 102 with liquid molding material 105. The filling channel 170 may be embedded within the peripheral gasket member 110. Further, the filling channel 170 may include an inlet port exposed externally to the peripheral gasket member 110 for connection to a source of liquid molding material 105. The filling channel 170 may also include an outlet port leading to a cavity 113 of the peripheral gasket member 110 for allowing liquid molding material 105 to flow into the molding cavity during assembly of the molding assembly 100.

[0051] refer to Figure 1A , Figure 2A , Figure 3A and Figure 4A According to various embodiments, a method of assembling the molded assembly 100 may include: providing a peripheral washer member 110; disposing a membrane 130 at a first ridge side 114a of the inner circumferential ridge portion 114 of the peripheral washer member 110, wherein a segment of the peripheral boundary region 132 of the membrane 130 abuts against the first ridge side 114a of the inner circumferential ridge portion 114 of the peripheral washer member 110; and disposing an annular member 140 in a manner on a segment of the peripheral boundary region 132 of the membrane 130 to secure the outer peripheral boundary region of the membrane 130. The section of domain 132 is held between the annular member 140 and the first ridge side 114a of the inner circumferential ridge portion 114 of the outer circumferential washer member 110; the first mold member 150 is configured such that its circumferential edge 152 abuts against the upper wall portion 116 of the outer circumferential washer member 110; and the second mold member 160 is configured opposite to the first mold member 150, and its circumferential edge 162 abuts against the lower wall portion 118 of the outer circumferential washer member 110. (See reference) Figure 1A , Figure 2A, Figure 3A , Figure 4A and Figure 5 According to various embodiments, the method of molding a lens may include a method of assembling a molding assembly 100, and additionally includes filling a molding cavity 102 defined by an outer peripheral gasket member 110, a first mold member 150, and a second mold member 160 with a liquid molding material 105 to mold the lens.

[0052] According to various embodiments, the method of assembling the molding assembly 100 and / or the method of molding the lens may further include setting the first mold component 150 to abut against the annular member 140 and setting the second mold component 160 to abut against the second ridge side 114b of the inner circumferential ridge portion 114 of the outer peripheral washer member 110.

[0053] According to various embodiments, the method of assembling the molded component 100 and / or the method of molding the lens may further include setting a first mold component 150 to sandwich the outer boundary region 142 of the annular member 140 between the first mold component 160 and the outer step 122 of the first ridge side 114a of the inner circumferential ridge portion 114 of the outer peripheral washer member 110.

[0054] According to various embodiments, the method of molding a lens may further include: curing a liquid molding material 105 within the molding assembly 100; removing a first mold component 150 from the peripheral gasket component 110; removing a second mold component 160 from the peripheral gasket component 110; removing an annular component 140 from the peripheral gasket component 140; and removing a lens from the peripheral gasket component 110, wherein the film 130 is embedded in the lens.

[0055] Various embodiments have provided simple, reliable, less operator-dependent, and more efficient solutions for molding lenses (e.g., polarizing lenses). According to these embodiments, the complexity and difficulty associated with inserting the film into the gasket in conventional methods have been avoided or eliminated. Furthermore, in these embodiments, the film can now be easily placed without causing deformation and / or damage. The film placement process no longer requires a highly skilled operator. Furthermore, the methods of these embodiments can also be automated.

[0056] Although representative methods and articles have been described in detail herein, those skilled in the art will recognize that various alternatives and modifications can be made without departing from the scope described and defined by the appended claims.

Claims

1. An assembly for molding lenses, comprising: An outer peripheral washer component (110) includes a surrounding wall (112) around an axis to define a cavity extending along the axis, the surrounding wall (112) having an inner peripheral ridge portion (114) that projects inwardly toward the axis from inside the surrounding wall (112) in a manner that divides the surrounding wall (112) into an upper wall portion and a lower wall portion, the upper wall portion and the lower wall portion being located above and below the inner peripheral ridge portion (114) respectively relative to the axis. The inner circumferential ridge portion (114) includes: A first ridge side surface (114a) pointing in a first direction, the first direction corresponding to a direction extending along the axis from the inner periphery toward the ridge portion (114) toward the upper wall portion, and The second ridge side (114b) points in a second direction, which corresponds to the direction along the axis extending from the inner periphery toward the ridge portion (114) toward the lower wall portion; A membrane (130) is disposed on the first ridge side (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member, wherein a section of the outer peripheral boundary region of the membrane (130) abuts against the first ridge side (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member; an annular member (140) is disposed on the section of the outer peripheral boundary region of the membrane (130) to hold the section of the outer peripheral boundary region of the membrane (130) between the annular member (140) and the first ridge side (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110); A first mold component (150), the first mold component being configured such that the circumferential edge of the first mold component (150) abuts against the upper wall portion of the outer peripheral washer member (110); and A second mold component (160) is disposed opposite to the first mold component (150), and the circumferential edge of the second mold component (160) abuts against the lower wall portion of the outer peripheral washer member (110). A molding cavity is defined between the outer peripheral washer component (110), the first mold component (150), and the second mold component (160). Its features are: - The first ridge side of the inner circumferential ridge portion (114) of the outer peripheral washer member (110) includes a concentric stepped profile in the radial direction relative to the axis, the concentric stepped profile including an outer step and an inner step, wherein the inner step is radially closer to the axis than the outer step. - A section of the outer peripheral boundary region of the membrane (130) abuts against the inner step of the first ridge side (114a) of the inner peripheral ridge portion (114) of the outer peripheral washer member (110). - The annular member (140) is configured such that the outer boundary region of the annular member (140) covers the outer step of the first ridge side surface (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110), and the inner boundary region of the annular member (140) overlaps with a segment of the outer peripheral boundary region of the membrane (130) in such a way that the segment of the outer peripheral boundary region of the membrane (130) is held between the inner boundary region of the annular member (140) and the inner step of the first ridge side surface (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110).

2. The component as claimed in claim 1, wherein, The first mold component (150) abuts against the annular member (140), and the second mold component (160) abuts against the second ridge side (114b) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110).

3. The component as claimed in claim 2, wherein, The outer boundary region of the annular member (140) is sandwiched between the outer step of the first ridge side (114a) of the inner circumferential ridge portion (114) of the first mold component (150) and the outer step of the outer circumferential washer component (110).

4. The component as claimed in claim 1, wherein, The outer step has a vertical surface and a threaded surface, the vertical surface being oriented parallel to the axis, and the threaded surface being inclined to form an acute angle with the vertical surface of the outer step.

5. The component as claimed in claim 4, wherein, The inner step has a threaded surface parallel to the threaded surface of the outer step, and wherein the inner step is adjacent to the outer step such that the vertical surface of the outer step is located between the threaded surface of the outer step and the threaded surface of the inner step.

6. The component of claim 1, wherein, The second ridge side surface (114b) includes a protruding free edge extending in the second direction, and wherein the second mold component (160) abuts against the protruding free edge of the second ridge side surface (114b).

7. The component of claim 1, wherein, The annular member (140) is made of the same material as the outer peripheral washer member (110).

8. The component of claim 1, wherein, The membrane (130) includes notches or circular segment cuts.

9. The component of claim 1, wherein, The surrounding wall (112) of the outer peripheral washer member (110) includes a filling channel for filling the molding cavity with liquid molding material.

10. A method for molding a lens, comprising: A peripheral washer member (110) is provided, the peripheral washer member including a surrounding wall (112) around an axis to define a through cavity extending along the axis, the surrounding wall (112) having an inner peripheral ridge portion (114) that projects inwardly toward the axis from inside the surrounding wall (112) in such a way as to divide the surrounding wall (112) into an upper wall portion and a lower wall portion, the upper wall portion and the lower wall portion being located above and below the inner peripheral ridge portion (114) respectively relative to the axis. The inner circumferential ridge portion (114) includes: A first ridge side surface (114a) pointing in a first direction, the first direction corresponding to a direction extending along the axis from the inner periphery toward the ridge portion (114) toward the upper wall portion, and The second ridge side (114b) points in a second direction, which corresponds to the direction along the axis extending from the inner periphery toward the ridge portion (114) toward the lower wall portion; The membrane (130) is disposed at the first ridge side (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110), wherein a section of the outer peripheral boundary region of the membrane (130) abuts against the first ridge side (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110). The annular member (140) is disposed on a section of the outer peripheral boundary region of the membrane (130) in such a way that the section of the outer peripheral boundary region of the membrane (130) is held between the annular member (140) and the first ridge side (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110). The first mold component (150) is configured such that the circumferential edge of the first mold component (150) abuts against the upper wall portion of the outer peripheral washer component (110); The second mold component (160) is arranged opposite to the first mold component (150), and the circumferential edge of the second mold component (160) abuts against the lower wall portion of the outer peripheral washer member (110); and A lens is molded by filling a molding cavity defined by the outer peripheral washer member (110), the first mold member (150), and the second mold member (160) with a liquid molding material, characterized in that: - The first ridge side of the inner circumferential ridge portion (114) of the outer peripheral washer member (110) includes a concentric stepped profile in the radial direction relative to the axis, the concentric stepped profile including an outer step and an inner step, wherein the inner step is radially closer to the axis than the outer step. - The membrane (130) is further configured such that a section of the outer peripheral boundary region of the membrane (130) is configured as an inner step abutting against the first ridge side surface (114a) of the inner peripheral ridge portion (114) of the outer peripheral washer member (110). - The arrangement of the annular member (140) further includes arranging the annular member (140) such that the outer boundary region of the annular member (140) covers the outer step of the first ridge side surface (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110), and the inner boundary region of the annular member (140) overlaps with a segment of the outer peripheral boundary region of the membrane (130) such that the segment of the outer peripheral boundary region of the membrane (130) is held between the inner boundary region of the annular member (140) and the inner step of the first ridge side surface (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110).

11. The method of claim 10, wherein, Setting the first mold component (150) further includes setting the first mold component (150) to abut against the annular member (140), and wherein setting the second mold component (160) further includes setting the second mold component (160) to abut against the second ridge side (114b) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110).

12. The method of claim 11, wherein, Setting the first mold component (150) to abut against the annular member (140) includes setting the first mold component (150) to sandwich the outer boundary region of the annular member (140) between the first mold component (150) and the outer step of the first ridge side surface (114a) of the inner circumferential ridge portion (114) of the outer peripheral washer member (110).

13. The method of claim 10, further comprising: The liquid molding material is cured; Remove the first mold component (150) from the outer peripheral washer component (110); Remove the second mold component (160) from the outer peripheral washer component (110); Remove the annular member (140) from the outer peripheral washer member (110); as well as The lens is removed from the peripheral gasket member (110), wherein the film (130) is embedded in the lens.

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