Universal basket

Abstract

A basket assembly for holding an optical article, the basket comprising: a planar base; and a plurality of lens holders inclined with respect to a reference plane perpendicular to the planar base, each lens holder comprising: a central arm, a first oblique arm and a second oblique arm disposed on opposite sides of the central arm wherein: the first oblique arm and the second oblique arm extend from the central arm at a common angle and from a common intersection point, and the first and second oblique arms and the central arm together define an oblique plane that is oblique at an angle with respect to a reference plane. A method of loading and unloading a basket configured to hold an optical article is also presented.

Description

Technical Field

[0001] The present invention relates to a method of manufacturing a semi-finished lens with a high refractive index, the method involving the use of a universal basket. Background Art

[0002] The process of manufacturing an ophthalmic lens typically begins with an unfinished or semi-finished glass or plastic lens blank. Such lenses can be manufactured using a casting process and subsequently annealed in an oven at predetermined parameters (such as a predetermined temperature and / or duration). As the manufacturing process proceeds, the blank is edged and formed into a lens. In a typical lens manufacturing process, high refractive index semi-finished lenses (both progressive multifocal lenses or PALs and single vision lenses) are cast and then annealed in baskets (also known as lens trays or lens racks) that have different configurations to accommodate lenses with various diameters, edge thicknesses, and center thicknesses.

[0003] Several baskets are known in the art, but they have been found to be unsatisfactory for various reasons. Such lens baskets typically have a variety of lens holder configurations, with multiple receiving points located at various locations on the lens holder to receive lenses of various sizes (i.e., various diameters, center thicknesses, and edge thicknesses). The multiple receiving points of the lens holder make it almost impossible to implement any manufacturing process involving such a basket in an automated manner using tools (such as robotic arms) because there is no geometric consistency between the different lens holder parts of such a basket. The receiving points of the lens holder are uneven and unbalanced. Therefore, it is very difficult to implement an automated computerized process to allow lenses to be loaded and unloaded from the basket in a consistent, automated manner. Further, such baskets may cause adverse mechanical stresses to be applied to the lenses and may produce astigmatism in the lenses themselves, thereby compromising the optical quality and performance of the lenses. Such systematic astigmatism may be caused when the semi-finished lenses are positioned in the basket so that they are tilted at an unfavorable angle. Further, the lens holders are not configured to keep the lenses stationary and fixed in a single position. Instead, the lenses move around during the manufacturing process. Additionally, some basket configurations are limited to certain uses or products, thereby limiting the usability of such baskets for other lens products and potentially creating gaps between lenses if not all lens holders can be filled with the same type of lenses, resulting in inefficiencies and increased manufacturing costs.

[0004] Accordingly, there is a need for an improved lens basket design that is configured to receive different types of semi-finished lenses having various diameters and edge thicknesses, and that can be used in an automated process such that the optical quality of the lenses is not compromised.

[0005] A unique support lens basket is presented herein that is configured to receive a wide variety of lens geometries and can be used to automate the loading and unloading of lenses during the manufacturing process. Preferably, the lenses used with the apparatus of the disclosed invention are eyeglass lenses, more preferably high index semi-finished lenses. However, the apparatus and methods described herein can be used with other types of lenses, such as finished lenses. Summary of the invention

[0006] The present invention provides a basket assembly for holding optical products, the basket comprising: a planar base; and a plurality of lens holders, the lens holders being inclined relative to a reference plane perpendicular to the planar base, each lens holder comprising: a central arm, a first oblique arm and a second oblique arm arranged on opposite sides of the central arm, wherein: the first oblique arm and the second oblique arm extend from the central arm at a common angle and from a common intersection point, and the first oblique arm, the second oblique arm and the central arm jointly define an inclined plane, the inclined plane being inclined at a certain angle relative to the reference plane, and a first supporting member and a second supporting member respectively coupled to the first oblique arm and the second oblique arm, wherein: the first supporting member and the second supporting member are arranged on a side of the inclined plane facing away from the planar base, and the first supporting member and the second supporting member extend away from the first oblique arm and the second oblique arm along a direction perpendicular to the inclined plane.

[0007] The planar base extends between a first side and a second side of the basket assembly. The basket assembly includes at least one longitudinal support coupled to the planar base and extending between the first side and the second side of the basket assembly. The plurality of lens holders includes a row of lens holders extending along a length of the longitudinal support and spaced equidistantly apart.

[0008] The basket assembly includes a plurality of longitudinal supports spaced equidistantly from each other. The plurality of lens holders includes a row of lens holders for each longitudinal support, thereby defining a two-dimensional array of lens holders. The row of lens holders is an integral part of the longitudinal supports. Each central arm in the row of lens holders extends from the longitudinal support and terminates at a free end.

[0009] The row of lens holders includes adjacent pairs of oblique arms that merge into each other at a junction point as they extend from their respective central arms. The longitudinal support includes a tab extending to the junction point.

[0010] The planar base includes first and second side walls extending along first and second sides of the basket assembly, respectively. The longitudinal bracket is coupled to the first and second side walls.

[0011] The first oblique arm and the second oblique arm each have a receiving port arranged to pass through themselves, and each support member associated with each oblique arm has a portion arranged to pass through the receiving port. The angle of each lens holder relative to the reference plane ranges from 10° to 30°. Specifically, the angle is 20° relative to the reference plane.

[0012] Also presented herein is a method for loading and unloading a basket assembly configured to hold an optical article, the method comprising: contacting the optical article with a central arm of a lens holder, the lens holder being a portion of a plurality of lens holders of the basket, the basket comprising: a planar base, and a plurality of lens holders, the plurality of lens holders being inclined relative to a reference plane perpendicular to the planar base, each lens holder comprising: a central arm, a first oblique arm and a second oblique arm disposed on opposite sides of the central arm, wherein: the first oblique arm and the second oblique arm extend from the central arm at a common angle and extend from a common intersection, and the first oblique arm and the second oblique arm extend from the central arm at a common angle and extend from a common intersection, and the first oblique arm and the second oblique arm extend from the central arm at a common angle and extend from a common intersection. and the central arm jointly defines an inclined plane, the inclined plane being inclined at a certain angle relative to the reference plane, and a first support member and a second support member coupled to the first inclined arm and the second inclined arm, respectively, wherein: the first support member and the second support member are disposed on a side of the inclined plane facing away from the planar base, and the first support member and the second support member extend away from the first inclined arm and the second inclined arm in a direction perpendicular to the inclined plane; and the optical article is contacted with the first support member and the second support member of the lens holder, thereby loading the optical article into the basket assembly. The method further includes: tilting the optical article to be parallel to the inclined plane, thereby orienting the optical article to be parallel to the inclined plane of the lens holder.

[0013] The method further includes: displacing the optical article in a direction parallel to the inclined plane of the lens holder and away from the planar base, thereby unloading the optical article from the basket assembly. The method further includes: wherein the planar base extends between a first side and a second side; wherein the basket assembly includes a longitudinal support coupled to the planar base and extending between the first side and the second side; and wherein the plurality of lens holders includes a row of lens holders extending along the length of the at least one longitudinal support and being equally spaced apart.

[0014] The basket assembly includes a plurality of longitudinal supports spaced equidistantly from one another; and wherein the plurality of lens holders includes a row of lens holders for each longitudinal support, thereby defining a two-dimensional array of lens holders. The row of lens holders is an integral part of the longitudinal support. Each central arm in the row of lens holders extends from the longitudinal support and terminates at a free end. The row of lens holders includes adjacent pairs of oblique arms that merge with each other at a joint point when extending from their respective central arms; and wherein the longitudinal support includes a tab extending to the joint point. The method further includes: wherein the planar base includes a first side wall and a second side wall extending along the first side and the second side, respectively; and wherein the longitudinal support is coupled to the first side wall and the second side wall. The method further includes: the first oblique arm and the second oblique arm each have a receiving port configured to pass through themselves, and each support member associated with each oblique arm has a portion configured to pass through the receiving port. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] For a more complete understanding of the description provided herein and the advantages thereof, reference is now made to the following brief description taken in conjunction with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

[0016] Figure 1 is a front view of a lens holder that may be used herein to hold a lens.

[0017] Figure 2 is a front view of a single panel of multiple lens holders that are connected (releasably or permanently) so that they can be used as a unit with a basket or tray assembly.

[0018] Figure 3 is a side view of a plurality of lens holders positioned within a tray of a basket assembly, together forming a lens holder assembly.

[0019] Figure 4 is a perspective view of a plurality of lens holders assembled into a tray of a basket assembly to form a lens holder assembly.

[0020] Figure 5 is a graph showing the amount of astigmatism for various lenses due to using different lens basket assemblies during the manufacturing process. DETAILED DESCRIPTION

[0021] In the following description, the drawings are not necessarily drawn to scale, and certain features may be shown in generalized or schematic form for the purpose of clarity and simplicity or for information purposes. In addition, although the manufacture and use of various embodiments are discussed in detail below, it should be understood that many inventive concepts that can be implemented 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 is also obvious to those skilled in the art that all technical features defined relative to the method can be transposed to the device alone or in combination, and conversely, all technical features relative to the device can be transposed to the method alone or in combination. In order to avoid unnecessary details for practicing the present invention, this specification may omit certain information known to those skilled in the art.

[0022] "High refractive index" means having a refractive index higher than 1.55.

[0023] "Lens blank" is defined herein as a block of material, such as clear plastic or glass, to be machined to obtain an optical lens. As used herein, the term "lens" refers to an optical grade product. The term includes plano lenses as well as lenses with focal length. Lens blanks can be made of synthetic materials. Each lens has a convex surface and a concave surface. These lenses are used in spectacles (eyeglasses). Lenses can be finished (cut or uncut) or unfinished (e.g., semi-finished).

[0024] "Ophthalmic lenses" refer to intraocular lenses, spectacle lenses, etc. "Ophthalmic lenses" can be selected from afocal lenses, single vision lenses, semi-finished lenses, sunglass lenses, plano lenses, single-focus lenses, multifocal lenses, bifocal straight-top lenses, trifocal lenses, trifocal straight-top lenses, PAL or progressive lenses. Ophthalmic lenses are made in various focal powers.

[0025] A "semi-finished lens blank" (or semi-finished blank) refers to a lens having two surfaces, one of which is a finished surface (usually the front surface) and the other surface (usually the back surface) is unfinished. The semi-finished blank is intended to be machined, typically by surface treatment and polishing, so that both surfaces are finished, thereby producing a finished lens. Methods for obtaining semi-finished blanks are known in the art and may generally include a casting step or a surface machining step.

[0026] Optical lenses are usually manufactured from provided optical lens blanks (such as semi-finished lens blanks). As known in the art, the blanks can be obtained by cutting them from a plate (e.g., by stamping), or by cutting a rod. Further, instead of simply cutting from a plate and thus having parallel plane faces, the initial lens blank can be preformed. The lens blank can be obtained in standard diameters, such as 76 mm in diameter and 9 mm in thickness, but as described herein, other sizes can certainly be envisioned.

[0027] The lens blank typically has a circular peripheral profile. The semi-finished lens blank generally has two opposite surfaces: a first blank convex surface and a second blank concave surface opposite to the convex surface, at least one of which is unfinished. The lens blank further comprises a peripheral blank surface connecting the first blank surface to the second blank surface. The unfinished surface of the lens blank is machined according to the wearer's prescription to provide the desired surface of the optical lens. According to a further manufacturing process, an optical lens can be obtained by machining both surfaces of the optical lens blank. An optical lens having a finished front surface and a rear surface is generally referred to as an uncut optical lens. The lens blank is edged along a line in accordance with the shape of the spectacle frame of the optical lens to obtain an edged or cut optical lens. The preferred lens type produced using the invention described herein is a high refractive index semi-finished lens.

[0028] For the process described herein, ophthalmic lenses are manufactured using a casting process followed by an annealing process. Patent application WO 2015 / 097245 (incorporated herein by reference) discloses a machine and method for molding ophthalmic lenses by casting, specifically by automatically filling a mold assembly formed by two mold shells and an annular closure member, the annular closure member being configured to connect these shells to define a mold cavity. These shells can be made of transparent material. The two mold elements can be sealed with gaskets or other sealing mechanisms (such as tape). The sealing mechanism can be used as an annular closure member. The mold cavity is formed by keeping the two mold elements separated from each other by the sealing mechanism. The cavity of the mold is filled with a molding material, such as a monomer. The mold cavity is filled by allowing the molding material to flow into the mold cavity through a filling hole provided on the sealing mechanism. The filling hole is located at the periphery of the mold shell so as not to interfere with the optical surface of the formed ophthalmic lens. The molding material is preferably a polymerizable synthetic material, such as a UHI monomer or MR7 or MR8. Thus, the filling of the mold cavity can be performed automatically and in a controlled manner by means of filling means, acquisition means and control means known in the art. Alternatively, the filling of the mold cavity can be performed manually, rather than automatically. After filling, the mold is polymerized using a polymerization device, which includes, for example, a lighting and heating source, such as a UV source. To this end, the mold is placed in an oven to thermally cure the monomer for several hours. The resulting lens is then demoulded from the mold.

[0029] After the lenses have gone through the casting process, they are assembled and placed into baskets or trays for further processing in an oven for annealing. A robotic arm or gripper (not shown) configured to be programmably controlled by a user, such as is known in the art, is used to retrieve and place the individual lenses to be annealed into the lens baskets ( Figure 3 and Figure 4 ). For the invention described herein, there are various devices or machines and modules incorporating these machines necessary to implement the processes herein. These machines are preferably positioned relative to each other to allow continuous, uninterrupted movement of lenses throughout the manufacturing process. The lenses are moved between stations, or between machines throughout the automated process by any convenient transport means, including but not limited to lens baskets as described herein, at least one conveyor belt, robotic devices, etc. and combinations thereof.

[0030] Preferably, the lens carrier, tray or basket 52 as described herein is used in conjunction with a plurality of transport devices as described above to transport the lenses without deforming or otherwise damaging the lenses. The basket 52 can be configured to carry at least one lens, or more preferably, a plurality of lenses. Although Figure 1 A single lens holder 10 is shown that can be used in the processes described herein, but multiple lens holders ( Figures 2 to 4 ). The lenses may be manipulated at the station or machine using conveyors, robotic devices, indexing stations, grippers, and the like, and combinations thereof, as are known in the art. A robot having a mechanical pivoting arm having a gripper attached thereto comprising at least one finger-shaped member may be used. Preferably, the gripper is at least double-sided (not shown) and is capable of grasping at least one lens at a time. In some embodiments, the gripper may be capable of gripping two or more lenses at a time. A separate transfer device may be connected to the pivot arm via a mounting (not shown). An opening device, such as a pneumatic cylinder, may be used to open and close the gripper by displacing the fingers relative to each other around the lens on a reference plane.

[0031] like Figure 1As shown, each lens holder 10 is configured to receive a lens. A robotic device (such as the above-mentioned robotic arm) is used to place each lens into a single lens holder 10 of the basket assembly 91. At least one side of each lens positioned in the lens holder is in contact with the lens holder 10. In one aspect, the convex surface can be in contact with at least a portion of the lens holder 10. In another aspect, the concave surface can be in contact with at least a portion of the lens holder 10. The lens holder 10 can be made of stainless steel, but it is also conceivable that it can be made of other heat-resistant materials, such as but not limited to other types of metals or heat-resistant plastics. Stainless steel is preferred for cost purposes and is the most common or desired material for lens holders. Other materials that can be used can be heat-resistant polyetheretherketone ("PEEK"). Other materials can include but are not limited to rubber, glass, ceramics, alloys, etc. or any combination thereof.

[0032] The lens holder 10 includes a central arm 71 and a plurality of lens holders, wherein the central arm extends upward away from at least one longitudinal bracket 63 through the center of the lens holder 10, and the plurality of lens holders are inclined relative to a reference plane perpendicular to the planar base 93, and each lens holder includes: a central arm 71, a first oblique arm and a second oblique arm 15, 17 arranged on opposite sides of the central arm 71, wherein: the first oblique arm and the second oblique arm 15, 17 extend from the central arm 71 at a common angle and extend from a common intersection point, and the first oblique arm and the second oblique arm 15, 17 and the central arm 71 jointly define an inclined plane, which is inclined at a certain angle relative to the reference plane, and a first support member and a second support member 57, 85 respectively coupled to the first oblique arm and the second oblique arm 17, 15, wherein: the first support member and the second support member 57, 85 are arranged on a side of the inclined plane facing away from the planar base 93, and the first support member and the second support member 57, 85 extend away from the first oblique arm and the second oblique arm 15, 17 in a direction perpendicular to the inclined plane.

[0033] The central arm 71 is continuously coupled to each of the first and second oblique arms 15, 17 and the longitudinal bracket 63. In one embodiment, the longitudinal bracket 63 can be removably coupled to at least a portion of the basket 52. The angle α formed between the central arm 71 and the first oblique arm 15 is between about 130 degrees and about 140 degrees. More particularly, the angle α formed between the central arm 71 and each of the first and second oblique arms 15, 17 is about 137 degrees. However, other angles are contemplated. The longitudinal bracket 63 is continuously coupled to the first and second oblique arms 15, 17. The diameter of the longitudinal bracket 63 is between about 70 mm and 80 mm, more preferably about 77 mm, but other sizes are also contemplated. The angle λ between the longitudinal bracket 63 and the central arm 71 is about 90 degrees. The internal angle β between the central arm 71 and the first oblique arm 15 is between about 40 degrees and about 50 degrees. More particularly, the internal angle β between the central arm 71 and the first oblique arm is about 45 degrees. Likewise, the interior angle between the central arm 71 and the second oblique arm 17 is between about 40 and 50 degrees. More particularly, the interior angle between the central arm 71 and the second oblique arm 17 is about 45 degrees. However, other angles between the central arm 71 and the first and second oblique arms 15, 17 are contemplated.

[0034] The lens holder 10 is configured such that it includes two substantially triangular sections that are positioned adjacent to each other and opposite each side of the central arm 71 of the lens holder 10. Each of the substantially triangular sections is defined by a substantially 90 degree corner defined by at least a portion of the longitudinal support 63 and the central arm 71. The three sides of the first substantially triangular section are defined by at least a portion of the central arm 71, at least a portion of the longitudinal support 63, and at least a portion of the first oblique arm 15 and the opening 21. The second substantially triangular section is defined by at least a portion of the central arm 71, at least a portion of the longitudinal support 63, and at least a portion of the second oblique arm 17, respectively, and a second opening 39 located on the opposite side of the central arm 71, the second opening being located in the center of the second section of the triangle. Thus, the central arm 71, the first oblique arm 15, the second oblique arm 17, and the longitudinal support 63 together define a continuously connected, uniform lens holder 10 that is perforated by the substantially triangular openings 21 and 39 on both sides of the central arm 71, as shown in FIG. Figure 1 As shown, the substantially triangular openings are mirror images of each other. The lens holder 10 is cut and formed from a single piece of stainless steel material. Thus, all segments are continuously joined to form a single lens holder unit 10.

[0035] The first oblique arm 15 and the second oblique arm 17 each include a receiving port 9 and a port 7 arranged to pass through themselves, respectively, so as to receive the first support member 85 and the second support member 57, respectively. Each support member 85, 57 associated with the oblique arms 15, 17 has a portion arranged to pass through the receiving ports 9, 7, respectively. When placed in the lens holder 10, each lens having a substantially circular shape is positioned so that the lens is retained between the central arm 71, the first oblique arm 15, the second oblique arm 17, and the first support member 85 on one side of the peripheral surface of the lens and the second support member 57 on the opposite side of the peripheral surface of the lens. The various support points of the lens holder 10 are configured to receive lenses with many different diameters and thicknesses. In one aspect, the lens holder is configured to receive lenses with a diameter range of about 65 mm to about 81 mm. However, the lens holder 10 can accommodate diameters much larger than this. In one aspect, the lens holder 10 can accommodate lenses with a thickness range of about 4 mm to about 22 mm.

[0036] The lens holder 10 is designed to be positioned at an angle between about 10 and 30 degrees relative to a reference plane, or between about 15 and 25 degrees relative to a reference plane, or between about 20 and 30 degrees relative to a reference plane, more preferably at an angle of about 20 degrees relative to a reference plane. The reference plane referred to herein is defined by the horizontal bottom surface or planar surface 93 of the lens tray 52. ​​In one aspect, the lens holder 10 is configured to be stationary once it is secured to the basket 52. In other embodiments, the lens holder 10 can be configured to be movable from a position of about 20 degrees relative to the reference plane to up to 90 degrees or more relative to the reference plane. The angle at which the lens can be moved can vary depending on the desired positioning of the lens. The lens holder shown here has an inclined support of about 20 degrees with at least three mechanical support points. The spatial arrangement of this support allows the semi-finished lens to be freely loaded onto and unloaded from the lens holder by an automatic gripper. Each lens holder 10 is capable of holding at least one lens. Each basket assembly 91 is capable of holding multiple lenses. More preferably, each basket assembly 91 is capable of holding up to 20 lenses at a time. However, if desired, each basket assembly is capable of holding up to 50 lenses.

[0037] like Figure 2 and Figure 3As shown, the lens holders can be removably attached to each other along the longitudinal frame 63. In yet another embodiment, the lens holder 10 can include a single unit 47 that is configured to be inserted into the basket 52. The plurality of lens holders can include a row or unit 47 of lens holders that extend along the length of the longitudinal frame and are equally spaced. Thus, "lens holders" can refer to the lens holders that are connected together to a single frame 47 ( Figure 2 ) or at least one lens holder or multiple lens holders that can be detached from each other.

[0038] The planar base 93 extends between the first side 5 and the second side 3 of the basket 52. The basket 52 includes a longitudinal support 63 that is coupled to the planar base 93 and extends between the first side 5 and the second side 3 of the basket 52. More specifically, the basket 52 includes a plurality of longitudinal supports 63 that are equally spaced from one another; and wherein the plurality of lens holders 47 include a row of lens holders for each longitudinal support 63, thereby defining a two-dimensional array of lens holders 47. The row of lens holders 47 is an integral part of the longitudinal supports 63. Each central arm 71 in the row 47 of lens holders extends from the longitudinal supports 63 and terminates at a free end. The row 47 of lens supports includes adjacent pairs of oblique arms 15, 17 that merge into one another at a junction point as they extend from their respective central arms; and the longitudinal supports 63 include tabs extending to the junction point.

[0039] The planar base 93 includes first and second side walls 5 , 3 extending along the first and second sides 5 , 3 , respectively, and the longitudinal bracket 63 is coupled to the first and second side walls 5 , 3 .

[0040] The invention described herein also relates to a method of loading and unloading a basket configured to hold an optical article. In one aspect, the optical article can be a lens body. More specifically, the optical article can be an ophthalmic lens. The method involves contacting the optical article with a central arm 71 of a lens holder 10 that is part of a plurality of lens holders of a lens basket 52. The lens basket includes a planar base 63, and a plurality of lens holders 10, which are inclined relative to a reference plane perpendicular to the planar base 93, each lens holder 10 including: a central arm 71, a first oblique arm and a second oblique arm 15, 17 arranged on opposite sides of the central arm 71, wherein: the first oblique arm and the second oblique arm 15, 17 extend from the central arm 71 at a common angle and extend from a common intersection, and the first oblique arm and the second oblique arm 15, 17 and the central arm 71 jointly define an inclined plane, which is inclined at a certain angle relative to the reference plane, and a first supporting member and a second supporting member respectively coupled to the first oblique arm and the second oblique arm 15, 17, wherein: the first supporting member and the second supporting member are arranged on a side of the inclined plane facing away from the planar base 93, and the first supporting member and the second supporting member extend away from the first oblique arm and the second oblique arm in a direction perpendicular to the inclined plane; then the method involves bringing the optical product into contact with the first supporting member and the second supporting member of the lens holder, thereby loading the optical product into the basket 52. The method further includes tilting the optical article to be parallel to the inclined plane, thereby orienting the optical article to be parallel to the inclined plane of the lens holder.

[0041] The method further involves unloading the optical articles from the basket 52 by displacing the optical articles in a direction parallel to the inclined plane of the lens holder and away from the planar base.

[0042] After the individual lenses are placed in the basket 52 by the robotic arm, the basket 52 with the lenses is positioned in an oven (not shown) for annealing. There may be several sections with different heating and / or cooling zones within the oven. The annealing process described herein may be used for semi-finished (SF) Rx lenses. Although not shown, the oven into which the basket 52 is positioned may be a tunnel oven having a loading area at its entrance end and an unloading area at its exit end. Between these entrance and exit areas is a cavity into which the at least one lens blank is positioned so that the at least one lens blank is positioned in a non-contact relationship with the inner surface of the cavity. The oven is configured to be completely sealed using a door (not shown) once the lens blank is positioned inside the cavity. In one embodiment, the oven may include additional separate heating and / or cooling zones inside the cavity of the oven, wherein the temperature in the various heating zones of the cavity may be appropriately adjusted throughout the process as needed. The temperature may be manually adjusted or may be adjustable via a programmable feature. In another embodiment, a programmable oven may be used instead of a tunnel oven to perform the forming and annealing steps of the process. Preferably, the lenses are positioned so that they are not in contact with any portion of the interior surface of the oven or with each other. Individual lens holders 10 may be used to prevent the lenses from contacting each other. In one embodiment, the oven is accurate to + / -1°C. Once the oven door is closed, it cannot be opened again until the process is complete. This is then required to prevent overcompensation of heat losses when the lenses are exposed to ambient air temperatures.

[0043] In one embodiment, the oven further comprises a conveyor (not shown) for transferring the basket assembly 91 from the inlet end of the oven to the outlet end thereof. The linear speed of the conveyor may be 8 cm / min, but other speeds are contemplated. During the annealing process described herein, the conveyor is stationary. In one embodiment, the temperature in the cavity may be adjusted to a value that exceeds the glass state or glass transition temperature of the synthetic material from which the lens is made. During the annealing process, the temperature in the cavity may be independently adjusted and monitored and / or programmably controlled by a preprogrammed computer.

[0044] The lens blank used herein may have a lens geometry defined by concentric curves (i.e., 6.75 diopters = 86.800 mm concavity and 86.800 mm convexity) so that the thickness of the entire lens is substantially equal. In addition to the annealing process, this geometric profile is beneficial to prevent uneven stress from being formed on the entire lens during the manufacturing process. The concentric curvature of the lens and the annealing of the lens allow for better downstream assembly of the finished ophthalmic lens product, including surface treatment and bonding processes that occur after casting and annealing. The key process steps and parameter combinations described herein also enable the bonding process to occur more smoothly, thereby enabling a higher lens yield. The minimized residual stress of the lens produced herein can also have better chemical resistance to any adhesive used during the bonding step of the process. In turn, this allows a wider range of adhesive options to be used in future bonding processes of the lens.

[0045] The annealing process involves providing at least one lens blank; providing a heating device, wherein the heating device includes a cavity defined by an inner surface, wherein the cavity has a first temperature; positioning the at least one lens blank within the interior of the heating device; substantially completely sealing the heating device; and annealing the at least one lens blank in the heating device during a predetermined time period and at a predetermined temperature.

[0046] The step of providing the at least one lens blank further comprises providing at least one lens blank, and the step of providing the at least one lens blank further comprises providing a lens blank, wherein the lens blank has a substantially equal thickness substantially throughout the lens blank.

[0047] For the methods described herein, the optical article is selected from the group consisting of an ophthalmic device, an ophthalmic lens, a finished lens, a semi-finished (SF) lens, and an optical display.

[0048] In one aspect, after the annealing step, the process further comprises at least one of: finishing the lens, applying a hard coating to at least a portion of the at least one lens blank, and edging the optical article. Thus, the methods described herein include optical articles manufactured according to the above process.

[0049] After annealing, the at least one lens blank is released from the oven manually. However, in another embodiment, the at least one lens can also be released via an automated programmable mechanism. The released blank constitutes a semi-finished lens. The annealing method described herein can also be used to produce finished lenses. After the lenses are annealed, the above-mentioned mechanical gripper is used to remove the lenses one by one from the basket assembly 91.

[0050] After casting, annealing and releasing the at least one lens blank, the lens may be surface treated and bonded at a later stage. For the produced lens blank, once the prescription has been determined for the wearer, the prescriber finishes the rear face of the lens by standard surface treatment steps, which include grinding and polishing the rear face to the desired curvature. No further machining is required on the front face of the lens, as the molding process produces an optical quality lens for this surface. Once the lens is finished to the desired power and optical quality, it can be edged and placed into the frame selected by the user.

[0051] The invention disclosed herein is advantageous because it allows the use of automated tools, as described above. This allows for a reduction in manpower by allowing for automatic loading and unloading of semi-finished lenses during disassembly and unloading prior to packaging. Due to the present invention, manpower is no longer required to perform such manual operations as loading lenses into trays, inserting trays into ovens for annealing, and unloading trays. This frees up manpower used elsewhere in the manufacturing process and eliminates the need for manual process steps, thereby resulting in a more efficient and cost-effective process. In particular, the present invention is very useful for high refractive index semi-finished product manufacturing during the annealing step. The present invention allows for improved optical performance of the manufactured semi-finished lenses. The present invention also allows for better traceability of the semi-finished lenses throughout the annealing process. The lens holder described herein allows for improved traceability through various identification ("ID") tools, which allows tracking of lenses in individual batches, thereby improving efficiency and quality, reducing costs and streamlining the manufacturing process.

[0052] While representative methods and apparatus have been described in detail herein, those skilled in the art will recognize that various substitutions and modifications may be made without departing from the scope described and defined by the appended claims.

Claims

1. A basket assembly for holding optical products, the basket assembly comprising: Flat base; as well as a plurality of lens holders, the lens holders being inclined relative to a reference plane perpendicular to the planar base, each lens holder comprising: Central arm, A first oblique arm and a second oblique arm are provided on opposite sides of the central arm, wherein: The first and second oblique arms extend from the central arm at a common angle and from a common intersection point, and The first oblique arm, the second oblique arm and the central arm together define an inclined plane, and the inclined plane is inclined at a certain angle relative to the reference plane, and A first support member and a second support member coupled to the first oblique arm and the second oblique arm, respectively, wherein: The first supporting member and the second supporting member are arranged on a side of the inclined plane facing away from the planar base, and The first and second support members extend away from the first and second oblique arms in a direction perpendicular to the inclined plane.

2. The basket assembly of claim 1, in, The planar base extends between a first side and a second side; wherein the basket assembly includes a longitudinal support coupled to the planar base and extending between the first side and the second side; and Wherein, the plurality of lens holders include a row of lens holders extending along the length of the longitudinal support and spaced equidistantly apart.

3. The basket assembly of claim 2, in, The basket assembly includes a plurality of longitudinal supports spaced equidistantly from one another; and Wherein the plurality of lens holders comprises a row of lens holders for each longitudinal support, thereby defining a two-dimensional array of lens holders.

4. The basket assembly of claim 2, wherein: The row of lens holders is an integral part of the longitudinal support.

5. The basket assembly of claim 3, wherein: Each central arm in the row of lens holders extends from the longitudinal support and terminates at a free end.

6. The basket assembly of claim 3, in, The row of lens holders includes adjacent pairs of oblique arms that merge into one another at a joining point as they extend from their respective central arms; and Wherein, the longitudinal support includes a tab extending to the joint point.

7. The basket assembly of claim 2, in, The planar base includes a first side wall and a second side wall extending along the first side and the second side, respectively; and Wherein, the longitudinal support is coupled to the first side wall and the second side wall.

8. The basket assembly of claim 1, wherein: The first and second slanted arms each have a receiving port disposed therethrough, and a support pin associated with the slanted arm has a portion disposed therethrough.

9. The basket assembly of claim 1, wherein: The angle ranges from 10° to 30°.

10. The basket assembly of claim 9, wherein: The angle is 20°.

11. A method of loading and unloading a basket assembly configured to hold optical articles, the method comprising: contacting the optical article to a central arm of a lens holder that is part of a plurality of lens holders of a basket assembly, the basket assembly comprising: A flat base, and The plurality of lens holders are tilted relative to a reference plane perpendicular to the planar base, each lens holder comprising: Central arm, A first oblique arm and a second oblique arm are provided on opposite sides of the central arm, wherein: The first and second oblique arms extend from the central arm at a common angle and from a common intersection point, and The first oblique arm, the second oblique arm and the central arm together define an inclined plane, and the inclined plane is inclined at a certain angle relative to the reference plane, and A first support member and a second support member coupled to the first oblique arm and the second oblique arm, respectively, wherein: The first supporting member and the second supporting member are arranged on a side of the inclined plane facing away from the planar base, and the first support member and the second support member extend away from the first oblique arm and the second oblique arm in a direction perpendicular to the inclined plane; and The optical article is loaded into the basket by contacting the optical article with the first and second support members of the lens holder.

12. The method of claim 11, comprising: The optical article is tilted to be parallel to the inclined plane, thereby orienting the optical article parallel to the inclined plane of the lens holder.

13. The method of claim 11, comprising: The optical article is displaced in a direction parallel to the inclined plane of the lens holder and away from the planar base, thereby unloading the optical article from the basket assembly.

14. The method according to claim 11, in, The planar base extends between a first side and a second side; wherein the basket assembly includes a longitudinal support coupled to the planar base and extending between the first side and the second side; and Wherein, the plurality of lens holders include a row of lens holders extending along the length of the longitudinal support and spaced equidistantly apart.

15. The method of claim 14, in, The basket assembly includes a plurality of longitudinal supports spaced equidistantly from one another; and Wherein the plurality of lens holders comprises a row of lens holders for each longitudinal support, thereby defining a two-dimensional array of lens holders.

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