Manufacture of optical articles

Abstract

A method and system for manufacturing an ophthalmic lens blank, the method comprising: introducing a radiation-curable composition into a mold, the mold surrounding a cavity having a diameter of at least 50 mm, a bottom wall portion of the mold being shaped for forming a first surface of the ophthalmic lens thereon; rotating the mold about its center of rotation at a speed of at least 30 rpm and no more than 120 rpm to displace a portion of the radiation-curable composition so as to change a profile of an upper surface of the curable composition to a concave parabolic shape; and subjecting the curable composition to curing radiation to solidify the composition.

Description

Cross-references with other published sources

[0001] This application claims priority to UK Patent Application No. GB2401153.8 filed on 29 January 2024, UK Patent Application No. GB2406129.3 filed on 1 May 2024 and UK Patent Application No. GB2409917.8 filed on 8 July 2024, the teachings of all of which are incorporated herein by reference in their entirety. Technical Field

[0002] This invention relates to methods, apparatus and systems for manufacturing optical articles, and particularly to optical articles formed from radiation-polymerizable compositions. Background Technology

[0003] Spectrum lenses are currently manufactured using a variety of different processes. A common method used in optical laboratories to produce spectrum lenses involves first selecting clear lens blanks, which are commercially available for various diopters. These blanks are often outsourced to large manufacturers that produce them using molding and / or machining. Even small laboratories must track and maintain a vast inventory of lens blanks of different diopters. The number of different blanks increases further when tinting and other coatings are involved. The laboratory work may involve measuring or scanning selected spectrum frames and trimming or edging the lens blanks to fit the frames. Some methods involve selecting semi-finished or finished lens blanks with a given base curvature (i.e., the curvature of the first surface) and then machining them to produce lenses with the final diopter.

[0004] Currently, there is no known practical method that allows optical laboratories to gain greater control over lens production (e.g., the production of lens blanks themselves). A practical method is needed that reduces the need to manage large inventories of expensive, diopter-specific lens blanks and allows optical laboratories to control all or most of lens production, while producing precision lenses in a more convenient and cost-effective manner.

[0005] Another common method for producing spectacle lenses or lens blanks involves casting the lens or lens blank into a two-piece mold, and then curing the lens using photochemical radiation and / or heat. This method is characterized by curing times of up to 24 hours, and further by requiring a different mold for each different ophthalmic prescription. Compared to current casting and curing methods, this less costly and time-consuming method offers significant commercial and operational benefits. Summary of the Invention

[0006] According to an embodiment, a method for manufacturing an optical article is disclosed, the optical article including a first main surface and a second main surface, the first main surface and the second main surface being characterized at least in part by a first curvature and a second curvature, respectively. The method includes: (a) introducing a quantity of a radiation-polymerizable composition into a mold, a bottom wall portion of the mold being shaped to form a surface thereon, the surface being characterized at least in part by the first curvature; (b) rotating the mold to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape, the concave parabolic shape being characterized at least in part by the second curvature; and (c) subjecting the polymerizable composition to polymerization radiation to solidify the composition.

[0007] According to an embodiment, an apparatus for manufacturing an optical article from a radiation-polymerizable composition includes: (a) a power-driven rotatable mold shaped to receive a quantity of the radiation-polymerizable composition, the mold including: a bottom wall portion disposed thereon for forming a first surface of the optical article thereon; and a peripheral wall portion having a minimum height at least 1 mm higher than the highest point of the bottom wall portion; and (b) a source of polymerization radiation disposed thereon for irradiating at least a portion of the polymerizable composition with the polymerization radiation to solidify the polymerizable composition, wherein, in a first operating mode of the apparatus, when the mold rotates at a speed between 10 and 200 revolutions per minute with a radiation-polymerizable composition having a viscosity between 20 and 2000 cP at room temperature residing therein, the rotation effectively alters the profile of a second surface of the polymerizable composition to form a concave parabolic shape.

[0008] According to an embodiment, a method for manufacturing an optical article is disclosed. The method includes: (a) introducing a radiation-curable composition into a mold, the bottom wall portion of the mold being shaped to form a first surface of the optical article thereon; (b) rotating the mold about its rotation center to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape; and (c) subjecting the curable composition to curing radiation to solidify the composition.

[0009] According to an embodiment, a system for manufacturing optical articles includes: (a) a molding assembly comprising: (i) a rotatable mold adapted to produce the optical article from a radiation-polymerizable composition therein, wherein the production includes forming a parabolic shape on a surface of the radiation-polymerizable composition by rotating the mold; and (ii) a source of polymerization radiation arranged to solidify at least a portion of the polymerizable composition by irradiating the at least a portion thereof; and (b) electronic circuitry configured to adjust the operation of the molding assembly in response to input received via a user interface, the input defining one or more shape and / or compositional parameters of the optical article.

[0010] According to an embodiment, an apparatus for manufacturing an optical article from a radiation-polymerizable composition includes: (a) a mold shaped to receive a quantity of the radiation-polymerizable composition, the mold including a bottom wall portion arranged for forming a first surface of the optical article thereon, and configured, upon electrical activation, to rotate at a selectable speed to generate a centrifugal force, which, in combination with gravity, alters the profile of a second surface of the polymerizable composition received in the mold to a concave parabolic shape; and (b) a source of polymerization radiation aligned with the mold to irradiate at least a portion of the polymerizable composition upon activation, causing the portion to solidify.

[0011] According to one embodiment, an optical article includes: a first main surface characterized at least partially by zero curvature; and a second main surface characterized at least partially by a concave parabolic curvature. According to another embodiment, an optical article includes: a first main surface characterized at least partially by a plurality of different curvatures; and a second main surface characterized at least partially by a concave parabolic curvature. According to yet another embodiment, an optical article includes: a first main surface characterized at least partially by a concave spherical curvature; and a second main surface characterized at least partially by a concave parabolic curvature.

[0012] According to an embodiment, a method for manufacturing spectacle lens blanks is disclosed. The method includes: (a) introducing a radiation-curable composition into a mold surrounding a cavity with a diameter of at least 50 mm, the bottom wall portion of the mold being shaped to form a first surface of the spectacle lens thereon; (b) rotating the mold about its rotation center at a speed of at least 30 rpm and not exceeding 120 rpm to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape; and (c) subjecting the curable composition to curing radiation to solidify the composition.

[0013] According to an embodiment, a system for manufacturing spectacle lens preforms from a radiation-polymerizable composition includes: (a) a rotatable mold surrounding a cavity with a diameter of at least 50 mm, the mold including: a bottom wall portion disposed thereon for forming a first surface of the spectacle lens preform; and a peripheral wall portion having a minimum height at least 1 mm higher than the highest point of the bottom wall portion; (b) an electric motor operable to rotate the mold at a constant speed between 30 and 120 revolutions per minute; and (c) a source of polymerization radiation disposed to irradiate at least a portion of the polymerizable composition with the polymerization radiation, wherein in a first operating mode of the system, when the mold rotates at a speed between 30 and 120 revolutions per minute while the radiation-polymerizable composition with a viscosity between 20 and 2000 cP at room temperature resides in the cavity, the rotation effectively alters the profile of the upper surface of the polymerizable composition to form a concave parabolic shape, the radiation-polymerizable composition having a cavity area of ​​0.25 to 0.35 cm². The volume between cc.

[0014] According to an embodiment, an optical article includes: a spectacle lens, the maximum size of which is between 30 mm and 85 mm; or a spectacle lens blank, the diameter of which is between 40 mm and 100 mm. The optical article includes: a first surface characterized at least partially of a convex spherical shape; and a second surface characterized at least partially of a concave parabolic shape. According to an embodiment, an optical article includes: a spectacle lens, the maximum size of which is between 30 mm and 85 mm; or a spectacle lens blank, the diameter of which is between 40 mm and 100 mm. The optical article includes: a first surface characterized at least partially of a convex spherical shape; and a second surface characterized at least partially of a concave parabolic shape. Attached Figure Description

[0015] The invention will now be further described by way of example with reference to the accompanying drawings, in which the dimensions of the parts and features shown are chosen for ease of and clarity of presentation and are not necessarily drawn to scale. In the drawings: Figure 1 This is a schematic perspective view illustrating a power-driven rotatable mold according to an embodiment of the present invention.

[0016] Figure 2 The embodiment according to the invention is illustrated schematically. Figure 1 The cross-section of the mold.

[0017] Figure 3A A perspective view of an exemplary optical article according to an embodiment of the present invention is shown.

[0018] Figure 3B An embodiment according to the present invention is shown. Figure 3A A schematic cross-sectional profile of an optical product.

[0019] Figure 4A and Figure 4B A corresponding perspective view of an exemplary bottom wall portion of a mold according to an embodiment of the present invention is shown.

[0020] Figure 5A , Figure 5B , Figure 5C , Figure 5D , Figure 5E and Figure 5F A schematic cross-sectional profile of the bottom wall portion of a mold according to an embodiment of the present invention is shown.

[0021] Figure 6 This is a schematic diagram of a removable element constraining the peripheral contour of an optical article according to an embodiment of the present invention.

[0022] Figure 7A According to an embodiment of the present invention, wherein an assembly is installed Figure 6 A schematic diagram of a mold for removable components.

[0023] Figure 7B It shows Figure 7A The details of the cross-section.

[0024] Figure 8 A block diagram of some components of an apparatus for manufacturing optical articles from radiation-polymerizable compositions according to an embodiment of the present invention is shown.

[0025] Figure 9 This is a schematic diagram of using a source of curing radiation to irradiate the upper surface of a curable composition in a mold according to an embodiment of the present invention.

[0026] Figure 10AThis is a schematic diagram of using a source of curing radiation to irradiate at least the lower surface of a curable composition in a mold according to an embodiment of the present invention.

[0027] Figure 10B This is a schematic diagram of a mold cavity according to an embodiment of the present invention, which has a reflective surface below the bottom wall of a transparent mold.

[0028] Figure 11A and Figure 11B This is a schematic diagram of curable radiation that is shielded from the upper surface of the curable composition in the mold according to an embodiment of the present invention.

[0029] Figure 12 This is a schematic diagram of the use of directional radiation to irradiate the upper surface of a curable composition in a mold according to an embodiment of the present invention.

[0030] Figure 13 This is a schematic diagram of a fluid delivery device for delivering a curable composition from a storage container to a mold according to an embodiment of the present invention.

[0031] Figure 14 A block diagram of some components of a system for manufacturing optical articles from radiation-polymerizable compositions according to an embodiment of the present invention is shown.

[0032] Figure 15 An embodiment according to the present invention is shown. Figure 14 A block diagram of some components of the system's control system.

[0033] Figure 16A , Figure 16B and Figure 16C An embodiment according to the present invention is shown. Figure 14 A corresponding example of the system's user interface.

[0034] Figure 17 This is a schematic diagram of a desktop implementation of a system for manufacturing optical articles from radiation-polymerizable compositions according to an embodiment of the present invention.

[0035] Figure 18A , Figure 18B , Figure 18C , Figure 18D , Figure 18E , Figure 18F , Figure 18G , Figure 18H , Figure 18I , Figure 18J , Figure 18K , Figure 18L and Figure 19 A flowchart illustrating a method and method steps for manufacturing an optical article according to an embodiment of the present invention is shown.

[0036] Figure 20A and Figure 20B These are schematic cross-sectional views of the bottom wall of a mold and the optical articles produced thereon, respectively, according to an embodiment of the present invention.

[0037] Figure 21A and Figure 21B This is a schematic cross-sectional view of the bottom wall of a mold according to an embodiment of the invention, which is tilted or eccentrically rotated for producing optical articles shaped thereon for prism correction.

[0038] Figure 21C According to an embodiment of the present invention Figure 21A and Figure 21B A schematic cross-sectional view of an optical product manufactured on one of the bottom walls of a mold. Detailed Implementation

[0039] This invention is described herein by way of example only with reference to the accompanying drawings. Referring now to the drawings in detail, it should be emphasized that the details shown are by way of example only and for the purpose of illustrative discussion of preferred embodiments of the invention, and are presented to provide the most useful and readily understood description of the principles and concepts of the invention. In this respect, no attempt is made to show the structural details of the invention in more detail than is necessary for a basic understanding of the invention; the description taken in conjunction with the drawings will make it clear to those skilled in the art how various forms of the invention can be embodied in practice. In all the drawings, similar reference numerals are generally used to denote similar elements.

[0040] Embodiments of the present invention relate to the manufacture of optical articles in a rotary mold. These embodiments include methods and systems for manufacturing such articles, and the manufactured optical articles themselves. In some implementations, the optical articles comprise spectacle lens blanks. In various implementations, the optical articles may include lenses, including but not limited to corrective lenses such as spectacle lenses, including tinted or photochromic lenses for eyeglasses and sunglasses. In other implementations, the optical articles may include elements of optical instruments, such as, and not exhaustively, telescopes, microscopes, binoculars, laser emitters, optical sights for weapons, and flashlights. As used herein, the term 'spectacle lens blank' includes any type of spectacle lens blank, such as finished, semi-finished, or unfinished products, and single-vision or multifocal (or progressive multifocal) spectacle lens blanks, unless otherwise specified. As used herein, the distinction between a spectacle lens blank and a spectacle lens lies at least in that a spectacle lens is formed or has been formed, cut, or trimmed into the shape of a spectacle lens, including, in some implementations, formed from a spectacle lens blank. In contrast, spectacle lens blanks are generally not shaped like the final spectacle lenses, but are circular or any other suitable convex shape, and large enough to be trimmed or cut from them. Spectacle lens blanks can have any necessary diameter, such as 50 mm, 65 mm, 80 mm, or any other diameter, to accommodate spectacle lenses of different sizes and profiles. In some embodiments, the diameter of the spectacle lens blank is at least 40 mm, and / or at most 100 mm. Conversely, according to some embodiments, the maximum dimension of the spectacle lens (e.g., the diagonal from one rounded corner to another) is at least 30 mm, and / or at most 85 mm.

[0041] All scopes set forth in this disclosure and the appended claims include the endpoints.

[0042] In embodiments, the optical article is formed at least partially in the cavity of a rotating mold from a radiation-polymerizable composition, which may be in a liquid phase, or alternatively a semi-liquid or semi-solid phase. In some embodiments, the composition is radiation-curable but not necessarily polymerizable; nevertheless, these terms are used interchangeably in this disclosure and the appended claims, and both can be understood to mean radiation polymerization or otherwise radiation curing. In exemplary examples, polymer dispersions (such as aqueous polyurethane dispersions) may be radiation-cured but do not undergo further polymerization. Examples of suitable radiation-polymerizable compositions include, but are not limited to: Vitralit® 1505, 1527, 1528, 1605, 1702, 3385, 4451, and 6128, all of which are commercially available from Panacol-Elosol GmbH, Frankfurt am Main, Germany; and PARLITE® 4123, 4127, and 4116, all of which are commercially available from ParsonsAdhesives, Rochester, Michigan, USA.

[0043] In embodiments, a suitable polymerizable composition may have one or more of the following exemplary properties. In an example, the static viscosity of a suitable polymerizable composition does not exceed 2000 cP. In an example, the surface tension of a suitable polymerizable composition does not exceed 35 N / m. In an example, a suitable polymerizable composition can be stored at room temperature or at a temperature of at least 15°C, and / or at a temperature of up to 28°C for up to 18 months. In another example, the precursor material of a suitable radiation-polymerizable composition can be stored within the aforementioned temperature range for up to 24 months. Various methods and processes associated with polymerizing the compositions are disclosed herein, such as by irradiating the composition, for example using photochemical radiation, such as, and not exhaustively, UV, IR, microwave, and / or visible light.

[0044] In the example, a suitable polymerizable composition can cure to 80% of its final hardness (e.g., Rockwell hardness value) within no more than 2 minutes. In some embodiments, curing (e.g., polymerization) can be carried out when the upper surface of the composition is exposed to a low-oxygen environment during the curing process, and optionally, curing can be accelerated. This environment can be achieved, for example and without limitation, by injecting and / or flowing an inert gas (e.g., additional nitrogen) into the chamber where the process takes place, and / or by reducing the gas pressure to a partial or substantially complete vacuum.

[0045] In one example, for a suitable polymerizable composition, a material layer with a thickness of at least 1 mm can be cured as a single layer. In another example, a material layer with a thickness of at least 2 mm can be cured as a single layer. In yet another example, a material layer with a thickness of at least 3 mm can be cured as a single layer.

[0046] In the example, a suitable polymerizable composition experiences no more than 2% linear shrinkage during the curing process, for example, 1% to 2% linear shrinkage. In the example, a suitable polymerizable composition experiences no more than 5% volume shrinkage during the curing process, for example, 2% to 5% linear shrinkage.

[0047] In the examples, for suitable polymerizable compositions, the radiation-curable polymer may contain a photoinitiator or its reaction product. Examples of suitable photoinitiators include radical-curing photoinitiators and cationic-curing photoinitiators. Radical-curing photoinitiators involve the generation of free radicals that initiate the polymerization of acrylates and other unsaturated compounds. Examples of suitable radical-curing photoinitiators include: type I (cleavage-type) photoinitiators that undergo bond cleavage upon UV exposure to directly generate free radicals, such as, and not exhaustively, benzoin derivatives (e.g., benzoin ether), phosphine oxides (e.g., TPO, BAPO), α-hydroxy ketones (e.g., Irgacure 184, Darocur 1173), and α-amino ketones (e.g., Irgacure...). 369); Type II (H-abstracting) photoinitiators, which generate free radicals by abstracting hydrogen from a co-initiator (amine or alcohol), such as, but not exhaustively, benzophenone, thioxanthone (e.g., isopropylthioxanthone, ITX), camphorquinone (CQ), and anthraquinone; hybrid photoinitiators, which include combinations of Type I and Type II mechanisms for achieving improved curing efficiency, such as, but not exhaustively, blends of acylphosphine oxide and thioxanthone; and polymeric photoinitiators, which are macromolecular photoinitiators designed to minimize migration in the cured coating, such as, but not exhaustively, polymeric α-hydroxy ketones or phosphine oxides. Cationic curing involves generating cations to initiate the polymerization of epoxides, vinyl ethers, or oxetanes. Examples of suitable cationic curing photoinitiators include, but are not exhaustive, onionium salts that decompose upon UV exposure to generate strong acids that initiate cationic polymerization, such as, but not exhaustively, iodonium salts (e.g., diphenyliodonium hexafluorophosphate) and sulfonium salts (e.g., triarylsulfonium hexafluoroantimonate); ferrocene derivatives, which are metallocene-based photoinitiators for specific formulations, such as, but not exhaustively, cyclopentadienyl-iron aromatic complexes; and non-onionium salt acid-generating agents that generate acids without relying on onionium chemistry mechanisms, typically used for special applications, such as, but not exhaustively, diazonium salts and sulfonyl chloride derivatives.

[0048] The curable composition can be introduced into the cavity of a mold via a suitable conveying device, which in some embodiments includes some form of measurement or metering of the composition. In some implementations, a precise (minimum tolerance) predetermined amount of composition is introduced into the mold, and in some implementations, excess material is removed through an outlet in the mold or in a downstream process. The mold may be part of an apparatus that also includes a source of polymerization radiation capable of solidifying a particular composition. As used herein, 'solidification' may mean complete solidification, or alternatively, solidification to a degree in which the solidified composition retains its shape upon removal from the mold. Examples of solidification to such a degree include solidification to at least 70%, or at least 80%, or at least 90% of the Rockwell hardness value of the final (i.e., fully cured / polymerized and 100% solidified) optical article. Examples of polymerization or curing radiation include electromagnetic radiation in the ultraviolet spectrum, and especially electromagnetic radiation in the high end of the EV-A range, such as 390-400 nm, or 395-405 nm, or 395-400 nm. In some implementations, the polymerization wavelength or wavelength range depends on the formulation of the specific radiation-polymerizable composition. In some implementations, the wavelength can be selected by the user or software based on the specific composition used, and in some implementations, different UV radiation emitters (e.g., different lamps) are used in combination with different compositions that require different wavelengths.

[0049] The curable composition is rotated at a selected rotational speed, which effectively creates a profile forming a concave parabolic shape on the upper surface of the composition. The term 'parabolic' is used herein to mean a three-dimensional shape having two or more non-parallel two-dimensional parabolic sections; the shape can be a solid, such as a solid or a rotating non-solid, and / or the surface of a solid or rotating non-solid solid. The terms 'parabola' and 'parabolic' are also used herein with the same meaning as 'parabolic', and no distinction is made between the two terms because in everyday language, the term parabola is often applied to parabolic shapes. The parabolic shape referred to herein can be a circular parabola, an elliptical parabola, or any other parabolic shape satisfying the above definition. In some embodiments, the rotational speed is selected at least in part based on the desired parabolic shape of the finished product and / or the desired total optical power (diopter). The rotational speed may also be selected at least in part based on any one or more of the following (and not exhaustively): material composition, quantity, refractive index, and / or viscosity.

[0050] In some implementations, the profile having a parabolic (or parabolic) shape extends to the entire upper surface of the composition. In other implementations, the parabolic profile extends only to a portion of the upper surface.

[0051] In some embodiments, curing can result in slight shrinkage of the composition and / or distortion of the pre-cured concave parabolic shape. For example, the height of the cured composition above the bottom wall of the mold can be reduced by up to 1%, or up to 2%, or up to 3%, or up to 4%, or up to 5%, or up to 10% or even more. In another example, the final refractive power of the cured composition can vary by up to 0.05 diopters, or up to 0.1 diopters, or up to 0.15 diopters, or up to 0.2 diopters, or up to 0.25 diopters, or up to 0.3 diopters, or up to 0.35 diopters, or up to 0.4 diopters, or up to 0.45 diopters, or up to 0.5 diopters or even more, or less if limited by industry standards. In some embodiments, for a given material, amount of material, and rotational speed, shrinkage or distortion is predictable and repeatable, allowing the final article to still be produced with high precision. In some embodiments, slight deviations in material composition and / or amount, rotational speed and / or duration, or any other factor or combination of factors can cause the parabolic profile to deviate from a 'perfect' parabolic shape. For example, the height of the cured composition above the bottom wall of the mold can increase or decrease (or both at different locations) by up to 1%, or up to 2%, or up to 3%, or up to 4%, or up to 5%, or up to 10%. Any of the foregoing shrinkage, distortion, or deviation is not material, and any resulting profile can still be considered a 'parabola' according to any embodiment disclosed herein.

[0052] In some embodiments, curing the composition in spin mode may result in certain detectable artifacts of the manufacturing process in the final product. An example of such a detectable artifact is that the surface roughness (e.g., average surface roughness) of the second surface (the exposed parabolic upper surface) is greater than the surface roughness of the first surface (the bottom surface formed on the mold bottom wall). In one example, the average roughness (Ra) of the parabolic surface is at least twice the average roughness Ra of the lower surface produced by the mold. In other examples, the average roughness of the parabolic surface may be at least 3 times, at least 5 times, at least 10 times, at least 30 times, or at least 100 times the average roughness Ra of the lower surface produced by the mold. In some examples, the ratio of the average roughness Ra of the parabolic upper surface to the average roughness Ra of the lower surface produced by the mold may be in any of the following ranges: 2 to 500, 2 to 100, 2 to 50, 2 to 10, 5 to 500, 5 to 100, 5 to 50, or 8 to 100. Another example of such a detectable artifact is traceable internal material flow during polymerization within the spin mold.

[0053] According to embodiments, the methods and systems disclosed herein are capable of producing optical articles comprising spectacle lenses with a maximum size between 30 mm and 85 mm. According to embodiments, the methods and systems disclosed herein are capable of producing optical articles comprising spectacle lens blanks with a diameter between 40 mm and 100 mm. The optical article may have: a first primary surface characterized at least partially by a convex spherical curvature; and a second primary surface characterized at least partially by a concave parabolic shape. In some embodiments, an optical article having non-zero refractive power through its optical axis is characterized in that the refractive power of at least half an area of ​​the optical article is close to the non-zero refractive power through the optical axis (e.g., differing from the non-zero refractive power by ±0.25 diopters or ±0.125 diopters, or differing from the non-zero refractive power by at most ±5%, or at most ±3%, or at most ±2%, or at most ±1%, or at most ±0.5%). In other words, for the central portion of the optical article, the parabolic curve is sufficiently close to a similar spherical curve such that the total optical power (in diopters) is consistent throughout the central portion. In some embodiments, the annular region between the 'central portion' of the optical article and the outer periphery is characterized in that its local and / or average refractive power deviates from the non-zero refractive power through the optical axis greater than the value indicated above for the corresponding central portion, because the parabolic curve's analogue to the spherical curve decreases with increasing radial distance from the optical axis. The 'central portion' can be absolutely defined, for example, 15 mm from the optical axis, or 17.5 mm from the optical axis, or 20 mm from the optical axis. Alternatively or additionally, the 'central portion' can be defined as having a given percentage of the total area of ​​the optical article. Such a central portion can occupy 10% to 80% of the total area of ​​the optical article. In some embodiments, the size of the central region and / or the degree of deviation of the refractive power in the outer annular region from the non-zero refractive power at the optical axis can be adjusted by selecting the operating parameters of the process for forming and curing the optical article as embodied in the various methods and systems disclosed herein.

[0054] The bottom wall of the mold has a shape chosen to define one of the two main surfaces of the optical article. For example, if the bottom wall of the mold is planar, the optical article will be manufactured with a planar main surface. If the bottom wall of the mold, or at least a portion thereof, has a concave spherical curvature, the optical article will be manufactured with a corresponding convex spherical curvature. In some embodiments, among others, the bottom wall portion may be shaped to accommodate a wide variety of corrective lenses, including not only monofocal lenses but also progressive lenses, multifocal lenses, bifocal lenses, and not only spherical lenses but also aspherical lenses.

[0055] In some embodiments, the optical article has a main surface characterized at least partially by a convex spherical shape formed on a mold bottom wall that is at least partially concave spherical. In some embodiments, slight deviations in material composition and / or amount, rotational speed and / or duration, or any other factor or combination of factors can cause the spherical profile to deviate from a 'perfect' spherical shape. For example, the spherical profile may be distorted by up to 1%, or up to 2%, or up to 3%, or up to 4%, or up to 5%, or up to 10%. Any of the foregoing shrinkage, distortion, or deviation is not substantial, and any resulting profile can still be considered 'spherical' according to any embodiment disclosed herein.

[0056] In one embodiment, the convex spherical profile of the first principal surface is combined with the concave parabolic profile of the second principal surface to form an ophthalmic lens or lens blank. The optical power (e.g., refractive power) of each surface is selected such that the combination achieves the target refractive power not only at the point on the optical axis (the straight line connecting the two centers of curvature of the two principal surfaces) but also over a large portion of the optical article. For example, the refractive power of at least one-quarter of the area of ​​the optical article (e.g., the area surrounding the optical axis) differs from the refractive power through the optical axis by ±0.125 diopters or ±0.25 diopters. In another example, the refractive power of at least half of the area of ​​the optical article (e.g., the area surrounding the optical axis) differs from the refractive power through the optical axis by ±0.125 diopters or ±0.25 diopters. In some examples, the refractive power of the area around or near the optical article (rather than the area around the optical axis) (e.g., up to 20% of the area of ​​the optical article) may differ from the refractive power through the optical axis by more than ±0.25 diopters.

[0057] The mold is designed to rotate, for example, by a low-speed electric motor. In this context, 'low speed' means below 200 revolutions per minute (rpm), such as 10-200 rpm, or 50-120 rpm, or 50-100 rpm, or 70-100 rpm, or 70-120 rpm, or any other suitable range below 200 rpm, as will be discussed further below. Depending on the embodiment, lower speeds (e.g., below 50 rpm or below 30 rpm, below 20 rpm, below 15 rpm, or below 10 rpm) may produce unsatisfactory optical results. Alternatively, a higher-speed motor (i.e., above 200 rpm) may be used in conjunction with a drive that maintains the mold's rotational speed between 10 and 200 rpm, including but not limited to maintaining it within any of the ranges mentioned above. In some embodiments, a higher-speed motor may be employed to provide higher rotational speeds during pre-production stages (which include, for example, mixing or sonication of polymerizable compositions) and / or post-production stages (which may include, for example, spin coating). In some designs, higher-speed motors enable sufficiently precise low-speed operation without reduction gears, while in others, gear drives are used to provide low speeds suitable for forming optical articles in molds. Alternatively, other means of rotation (such as magnetic induction) can be employed to achieve rotation across a wider range of selectable speeds.

[0058] The rotation of the mold and the radiation-polymerizable composition within it, when performed at an appropriate rotational speed, effectively causes the upper surface of the composition to take on a concave parabolic shape. After the composition, for example, has solidified by polymerization, the parabolic shape formed by rotation characterizes at least a portion of the second primary surface of the two primary surfaces of the optical article.

[0059] The rotational speed can be selected based on one or more parameters, such as the amount of material in the mold and the desired parabolic curvature. Other parameters that directly or indirectly affect the selection of the rotational speed may include the prescription (e.g., diopter) and the refractive index of the radiopolymerizable composition. In the case of an optical lens, the total power, or diopter, is derived from the combined curvature of the two principal surfaces. Therefore, for a given final diopter, the shape of the parabola formed on the upper surface in the mold is selected to take into account the shape of the bottom wall of the mold. The base arc curvature selected for the bottom wall of the mold is another parameter that can affect the selection of the rotational speed. In various designs, the bottom wall of the mold may be removable and replaceable, for example, non-destructively removable and reusable or repeatedly reusable. In other designs, the bottom wall of the mold may be permanently mounted in the mold as a permanent component or formed integrally with the mold. In some designs, the user selects a particular mold for forming a specific optical article because its base wall portion matches the desired base curve curvature, and in other designs, the user only needs to select a removable / reusable base wall element (e.g., a non-destructive separable base wall element) for use, also based on matching the desired base curve curvature.

[0060] The rotation of the mold can begin before, during, or after the composition is introduced into the mold. Determining when to introduce the composition into the mold can depend on factors such as the size of the mold, the viscosity of the composition, the rotational speed, the throughput of the equipment, etc. Once the parabolic shape formed on the upper surface reaches a stable state (e.g., at a constant rotational speed), curing can begin by exposing the composition, or at least a portion thereof, to curing radiation. The duration of rotation prior to initiating the curing step can be calculated in advance or based on empirical history, such as for similar composition amounts, similar compositions, and / or similar desired curvatures. Alternatively or concurrently, the shape can be observed using optical or other sensors, triggering the initiation of irradiation.

[0061] In some implementations, the production of the optical article requires preliminary process steps, including, but not limited to, mixing multiple components of a polymerizable composition and / or ultrasonic treatment for mixing and / or degassing (i.e., bubble removal). In some implementations, the manufacture of the final optical article requires further processing, including, for example, but not exhaustively, machining, edging, cutting, stamping, polishing, grinding, and / or buffing one of the two main surfaces and / or the edge of the article. In some implementations, the optical article leaves the mold in a finished state, such that manufacturing (excluding optional coating or printing, etc.) is completed within the mold. In such implementations, it may be desirable to use a mold whose shape corresponds to the desired contour of the finished optical article. Therefore, the mold can be selected for use based on the matching of the mold contour with the contour of the final article to be formed. In some embodiments, the mold is designed to form a spectacle lens blank therein. In some embodiments, a removable mold insert corresponding to the contour of the article is used, such that the same mold can be used for different products, such as different spectacle lenses. The removable mold insert can be stored in stock until needed and optionally returned to stock after use. Alternatively or concurrently, removable mold inserts can be manufactured as a preliminary process step in the overall process of manufacturing optical products. For example, a 3D printer can be used to produce removable mold inserts, which are then inserted into a mold to manufacture the optical product.

[0062] The system for producing optical articles according to the embodiments can be modular or scalable to include multiple molds and / or multiple sources of cohesive radiation, for example, multiple devices as used herein. For example, a device in a retail location may include a pair of molds to allow the parallel production of two lenses for a pair of eyeglasses, or the parallel production of two different eyeglass lens blanks for the production of the final eyeglass lens. In another implementation, a large array of molds may be arranged for supplier-scale production of lenses or other optical articles. Other components, including, for example, radiation sources, fluid delivery devices, and storage containers, may be provided in any quantity appropriate to the throughput of the molds. The device according to the embodiments may be part of a system that includes additional components related to the manufacture of optical articles, such as coating and printing stations, and a control system, among others, including a user interface. The user interface may include one or more interface elements, such as, and not exhaustively, a screen with a graphical user interface, a microphone, a barcode scanner, or other visual sensors (e.g., for determining the power of existing lenses and / or the exact lens volume of selected eyeglass frames). The control system can be programmed to calculate process parameters based on user input and other inputs, and to regulate the operation of any system components, such that any manufacturing system disclosed herein can be mechanized, semi-automated, or fully automated. Any system disclosed herein for producing optical products can be designed to operate in a 'batch production' mode, where multiple optical products, optionally including those with different optical properties, are produced serially and / or in parallel. Production rates can be significantly faster than those known from prior art casting systems, for example, using conventional double-sided molds and having extended curing times (e.g., up to 24 hours). Those skilled in the art should understand that the illustrations of single-mold equipment and overly simplified curing and material handling systems in the accompanying drawings are provided only to facilitate an understanding of the types of processes and equipment involved, and not to comprehensively illustrate the scope of systems designed for commercial operation.

[0063] Now refer to the attached diagram and especially to... Figure 1 and Figure 2 An apparatus 200 for manufacturing an optical article 100 from a radiation-curable composition 15 includes a rotatable mold 120. The mold 120 surrounds and / or includes a cavity 121 having a suitable diameter, for example (but not exhaustively) 50 mm, 65 mm, or 80 mm.

[0064] Rotation of the mold is necessary and effective for forming the desired concave parabolic shape on the upper surface of the radiation-curable composition 15 within the mold 120. According to an embodiment, the mold 120 is configured, upon electroactivation, to rotate at a selected or optional speed to generate a centrifugal force that, in combination with gravity, alters the profile of the second surface of the polymerizable composition 15 received within the mold 120 to a concave parabolic shape. In an example, in a first operating mode of the device, when the mold 120 rotates at a speed between 10 and 200 revolutions per minute while a radiation-polymerizable composition with a viscosity between 20 and 500 cP or between 20 and 2000 cP at room temperature resides therein, rotation effectively alters the profile of the second surface of the polymerizable composition 15 to form a concave parabolic shape.

[0065] Among other things, the expressions 'rotatable' and 'arranged to rotate' mean that mold 120 is mechanically connected, directly or indirectly (e.g., via gear transmission), to motor 110 (not shown), which is configured for rotation, for example designed for rotation and capable of rotation, and, according to embodiments, the rotation of motor 110 causes mold 120 to rotate at a suitable rotational speed. The term 'motor' is used herein to include any means of converting electrical energy into rotational kinetic energy, including, for illustrative purposes, magnetic induction. In some embodiments, mold 120 includes or is mechanically connected to a rotor element such that mold 120 is part of an integral motor-mold assembly, and in other embodiments, motor 110 is a separate element of device 200. Mold 120 may include a power connection 215 for supplying power to motor 110 (not shown), or may include built-in wiring.

[0066] The mold 120 is arranged to rotate at a selected speed suitable for the process of producing optical elements 100 with a desired set of physical and optical parameters. In an embodiment, a suitable rotational speed is less than 200 revolutions per minute (rpm). Examples of suitable rotational speed ranges include (and are not exhaustive): between 10 and 200 rpm, or between 10 and 150 rpm, or between 10 and 100 rpm, between 20 and 200 rpm, or between 20 and 150 rpm, or between 20 and 100 rpm, or between 30 and 200 rpm, or between 30 and 120 rpm, or between 30 and 100 rpm, or between 50 and 200 rpm, or between 50 and 150 rpm, or between 50 and 130 rpm, or between 50 and 120 rpm, or between 50 and 100 rpm, or between 70 and 200 rpm, or between 70 and 150 rpm, or between 70 and 130 rpm, or between 70 and 120 rpm, or between 70 and 100 rpm, or any other range below 200 rpm.

[0067] In the implementation, among other things, the internal volume of the mold 120 (i.e., cavity 121) is defined by the shape of the bottom wall 130 and the height of the surrounding edges or walls 124.

[0068] During the production of the optical article 100, the shape of the upward-facing surface of the bottom wall 130 is imparted to the lower surface of the optical article 100, for example... Figure 3B Surface 82. Therefore, the curvature of the bottom wall portion 130 of the mold defines the corresponding curvature of one of the two main surfaces of the optical article 100. For example, if the upward-facing surface of the bottom wall portion 130 is concave, then the corresponding main surface of the optical article 100 is convex. Figure 2 The cross-sectional view shows a non-limiting example of the bottom wall portion 130 with concave spherical curvature. Using... Figure 2The exemplary bottom wall portion 130 forms an optical article 100 characterized by a main surface with a convex spherical curvature. In some embodiments, the bottom wall portion is removable from the mold, i.e., non-destructive removal, and optionally reusable with or without further processing. This type of bottom wall portion 130 allows for selection of an appropriate bottom wall portion 130 based on the design of a particular optical article. In some embodiments, the bottom wall portion 130 is permanently attached to the mold, i.e., not removable without damaging the bottom wall portion or the mold, and in some embodiments, the bottom wall portion is an integral element of the mold, or even formed integrally with the mold, for example, formed together with the peripheral wall 124 of the mold 120. The latter two types of bottom wall portions allow for selection of an appropriate mold 120 based on the design of a particular optical article 100. Figure 1 and Figure 2 In a non-limiting example, the bottom wall portion 130 is fastened within the mold 120 by a mechanical means to illustrate a particular design among many possible designs for holding and / or fixing the bottom wall portion 130 in the mold 120 according to the embodiment.

[0069] In some embodiments, the bottom wall portion 130 or at least its upper surface is treated to enable efficient removal of the optical article 100 from the mold 120. The treatment can be a pre-production treatment and / or a permanent treatment, such as by providing an optical-grade hard coating to the upper surface of the bottom wall portion 130. Alternatively or additionally, the treatment can be performed before each use, such as before introducing the polymerizable composition into the mold, and the treatment may include a material with lubricating or non-stick properties. The bottom wall portion 130 may be made, for example, of glass or plastic; a transparent bottom wall portion may be desirable in implementations where irradiation of the polymerizable composition through the bottom wall 130 (e.g., from below) becomes part of the curing process.

[0070] According to the embodiments, the mold wall 124 can serve multiple functions, including but not limited to: retaining the curable composition 15 within the mold, especially during rotation; and forming an edge around the periphery of the optical article 100 according to a designed or desired profile. In the embodiments, a suitable selection of the amount of composition 15 is one option to avoid undesirable edge effects, such as the formation of a circumferential ring in the optical article 100, which must be removed after curing. A suitable selection of the material of the mold wall 124 is one option to facilitate the efficient removal of the optical article 100 after curing. An exemplary and non-limiting example of a suitable material for the mold wall 124 is polyurethane coated with polytetrafluoroethylene.

[0071] like Figure 1 As shown, the mold 120 is arranged around the center of rotation. 128 Rotation. In many implementations, that is, for many types and forms of optical articles 100, the center of rotation...128 Corresponding to the optical axis of optical product 100. Rotation center. 128 It need not be located at the center of the mold; in the embodiment, the optical article 100 with an eccentric optical axis is formed by rotating the mold 120 around an eccentric rotation center. 128 Asymmetrical rotation, not necessarily around its own center, as shown in the following reference. Figure 21A and Figure 21B The discussion.

[0072] Figure 3A This illustrates the application of a radiation-curable composition 15 in a mold 120 (such as...). Figure 1 and Figure 2 A perspective view of an exemplary optical article 100 produced in a mold, and Figure 3B The cross-sectional profile of the same optical article 100 is shown. Figure 3A and Figure 3B In a non-limiting example, optical article 100 is a single-focus positive meniscus lens blank, whose first primary surface 82 ( Figure 3B The lower surface of the mold 120 is characterized by a spherical curvature, and the second primary surface 81 (upper surface) is characterized by a parabolic curvature. According to an embodiment, rotation of the mold 120 and the curable composition 15 residing therein causes a portion of the curable composition 15 to be displaced, for example, due to a so-called centrifugal force. This displacement of the portion of the composition 15 includes moving away from the center of rotation. 128 The component is radially displaced outward toward the outer periphery. After a period of rotation, such as at a constant speed, at least a portion of the upper surface of the composition 15 takes on a concave parabolic shape. At a constant rotational speed, the parabolic shape reaches a stable state, such that the in-situ solidification of the composition 15 during the continuous rotation of the mold 120 effectively retains the parabolic profile in the fully or partially solidified composition 15 forming the optical article 100.

[0073] Figure 4A and Figure 4B Two exemplary bottom wall portions 130 for mold 120 are illustrated, and in particular, they can be used for production. Figure 3A and Figure 3BThe optical article 100 has a bottom wall portion 130. The upper surface 131 of the bottom wall portion 130 is precisely shaped to form the spherical curvature of the bottom surface 81 of the optical article 100 thereon. The spherical curvature can be used, for example, to produce negative meniscus lenses and / or positive meniscus lenses. The material composition, thickness, and bottom profile of the bottom wall portion 130 can be selected depending on the specific implementation. In some implementations, a thicker bottom wall portion is chosen to improve heat distribution and / or heat transfer properties during curing, for example, to control or reduce shrinkage, or to prevent or reduce the degree of distortion and / or other optical defects. As will be discussed below, in some embodiments, it may be desirable that the bottom wall portion is transparent to the wavelength of the photochemical radiation of the composition used to cure the lens, or at least 90% transparent to that wavelength, or at least 80% transparent to that wavelength, or at least 70% transparent to that wavelength.

[0074] Figures 5A to 5E An additional example of the bottom wall portion 130 used for producing the corresponding optical article 100 is shown in cross-section. Figure 5A The bottom wall portion 130 includes an upper surface 131 having a planar shape (i.e., zero curvature) for use in the production of optical articles 100, such as, for example, plano-concave lenses. Figure 5B A bottom wall portion 130 including a concave upper surface 131 is shown, which is used for manufacturing optical articles 100, such as, for example, biconcave lenses (or biconcave mirrors). Figure 5C A bottom wall portion 130 is shown, comprising an upper surface 131 characterized by an aspherical curvature, which is used for the production of optical articles 100, such as, for example, aspherical lenses. Figure 5D and Figure 5E An example is illustrated of a bottom wall portion 130 comprising a corresponding upper surface 131 having multiple curvatures or facets, the bottom wall portion being used for the production of optical articles 100, such as, for example, bifocal lenses. In other examples (not shown), the bottom wall portion includes an upper surface characterized by multiple curvatures, thereby allowing the production of multifocal lenses and progressive lenses.

[0075] Figure 5F This is an exemplary example of the base portion 130, in which ophthalmic features (e.g., Figure 5F The bifocal feature shown is added to the bottom wall portion 130 to produce an optical article 100 with a 'negative' ophthalmic feature formed in the surface, which is, for example... Figure 5D The bottom wall portion 130, which creates a 'positive' feature on the surface of the optical article, forms a contrast. In some embodiments, the ophthalmic feature is added to the bottom wall 130 of the mold via additive manufacturing, and this can be done on order during the production of the optical article. Other multifocal lenses and progressive lenses can also be manufactured in this manner.

[0076] Figure 1 and Figure 2 The internal volume of mold 120 is shown to be circular. Sometimes it may be desirable to produce optical articles with different peripheral profiles. For example, spectacle lenses typically have non-circular shapes. According to embodiments, non-circular optical lenses can be manufactured using the rotational molding and curing techniques disclosed herein in any of the following (and not exhaustively) ways: shaping the optical article into a desired profile; after curing, edge-grinding, cutting, or trimming the optical article into the desired profile; and selectively irradiating the polymerizable composition.

[0077] Figure 6 A non-limiting example of a mold profile insert 140 is shown, which is shaped to constrain the peripheral profile of an optical article 100. The profile insert 140 includes a wall 144 surrounding a volume (defined from below by the upper surface 131 of the bottom wall portion 130) in which the optical article 100 is formed by rotation of the mold 120 and exposed to polymer radiation. Similar to the wall 124 of the mold 120, the selection of a suitable material for the insert wall 144 (such as, for example, polyurethane coated with polytetrafluoroethylene) allows for efficient removal of the optical article 100 after curing. Furthermore, although the respective walls 124, 144 of the mold 120 and the profile insert 140 appear as straight vertical walls in the figures, this is an illusion created for the purposes of the figures, and the walls 124, 144 can be profiled (i.e., laterally profiled) to form the desired edge profile of the final optical lens without further processing. In some embodiments, the height of either the pattern wall 124 or the profile insert wall 144 is at least 2 mm, or at least 3 mm, or at least 4 mm, or at least 5 mm, or at least 6 mm, or at least 7 mm, or at least 8 mm, or at least 9 mm, or at least 10 mm, or even higher.

[0078] Figure 7A and Figure 7B The mold 120 according to the embodiment is shown. Figure 6 The outline insert 140. (As from...) Figure 7B As can be seen in the cross-sectional view, it may be desirable for the lower surface of the contour insert 140 to conform to the contour of the upper surface 131 of the bottom wall portion 130. In some designs, the gap between the contour insert 140 and the upper surface 131 of the bottom wall portion 130 is eliminated by using a properly shaped washer (not shown).

[0079] In some embodiments, the contour insert 140 is selected by a user or software based on user input establishing various parameters of the optical article 100. In some embodiments, the contour insert 140 is produced as part of a manufacturing process, such as using additive manufacturing (3D printing), and then inserted into the mold 120. In some embodiments, the contour insert 140 is integrally formed with the mold 120, or the mold 120 is formed to have the shape of the contour insert, thereby eliminating the need for the contour insert; in such embodiments, the final mold 120 (combined with…) Figure 6 and Figure 7A The shape associated with it (including the shape of the molded volume surrounded by contour inserts) can be produced as part of a manufacturing process, such as using 3D printing.

[0080] Now we refer to Figure 8 The block diagram illustrates components of an apparatus 200 for manufacturing an optical article 100 from a radiation-polymerizable composition 15, according to an embodiment. Figure 8 (and Figure 14 Solid lines in the diagram represent elements or components that are present in every implementation of the scheme, while dashed lines represent elements or components that may not be present in some implementations but are present in others.

[0081] As previously referenced Figure 1 and Figure 2The discussed device 200 includes a power-driven (e.g., electric) rotatable mold 120, which is shaped to have a volume appropriately sized and shaped to receive a quantity of the radiation-polymerizable composition 15. In one embodiment, the mold 120 includes a bottom wall portion 130, which, during operation, is inserted into or mounted therein. This bottom wall portion is shaped to impart curvature to a first primary surface of the optical article 100 formed on the bottom wall portion 130 (e.g., a shaped bottom surface 82). In one embodiment, the bottom wall portion 130 may be removable without damage, non-removable, or permanently attached to the mold 120, or may be integrally formed with the mold 120, for example, together with the wall 124 of the mold 120. In some embodiments, the amount of the polymerizable composition 15 is selected based on the physical parameters of the particular optical article 100 being formed in the mold 120, such as volume, weight, specific gravity, or any other parameter required to set the amount of material. In some embodiments, the amount is selected based on the optical properties of the particular optical article 100 being formed in the mold 120, such as the refractive power and / or refractive index of the optical article 100, and / or the base arc curvature of the bottom wall portion 130 transferred to the first surface of the optical article 100. In some embodiments, the amount of polymerizable composition 15 supplied to the mold 120 is greater than the amount required for the particular optical article 100, and the excess is discharged from the mold and / or trimmed off from the cured optical article 100. In either of these cases, the mold 120 is large enough to receive the delivered amount. In some embodiments, the device 200 includes a contour insert 140, such as... Figure 6 and Figure 7A The contour insert 140 is shown; in some embodiments, the molding volume of the contour insert 140 is integrated into the design. In some embodiments, the contour insert 140 and / or mold 120 can be produced locally using a 3D printer.

[0082] In some embodiments, device 200 includes motor 110. The motor may be positioned, for example... Figure 1 The mold 120 is housed in the housing 115 shown. In some embodiments, other rotational means are used to rotate the mold 120, such as, for example, magnetic induction. The motor 110 or alternative rotational means (such as magnetic induction) is configured or can be configured to rotate the mold 120 at a constant speed of less than 200 revolutions per minute within any speed range disclosed herein. In some embodiments, the rotational speed of the motor can be selected by the user or software in increments not exceeding 10 revolutions per minute.

[0083] like Figure 8 As shown in the block diagram, device 200 further includes a source 250 for polymerizing radiation 25. Now refer to... Figure 9The radiation source 250 is graphically represented by a UV flashlight, but according to embodiments, the radiation source 250 may take any form suitable for emitting polymerizable radiation 25 and may include more than one emitter. For operability, the radiation source 250 is configured to generate radiation 25 of at least one wavelength that effectively solidifies a particular radiation-polymerizable composition 15. In some embodiments, the wavelength may be selected by the user and / or control system software. Figure 9 As shown in the non-limiting example, radiation source 250 is arranged to irradiate at least a portion of the upper surface of the polymerizable composition 15 in mold 120 with polymeric radiation 25. Additionally or alternatively, radiation source 250 may include more than one radiation source, such as in... Figure 10A In a non-limiting example, the emitter 250 is located below and / or on each side of the mold 120, as shown in the figure. Figure 9 Details of the cross-section of mold 120. In some embodiments, irradiating the curable composition 15 from more than one angle can shorten the time required for the composition 15 to solidify. A bottom wall portion 130 that is transparent to at least the polymerization wavelength of emitter 250 (including for this purpose) may be desirable. Alternatively or alternatively, such as Figure 10B As shown in the cross-section, the mold may include a reflective surface 126, which is positioned to reflect photocuring radiation transmitted through the transparent bottom wall portion 130 onto the lower surface of the composition 15.

[0084] In some embodiments, irradiating the polymerizable composition 15 may include selectively exposing a first portion of the upper surface of the composition to polymerization radiation 25 while excluding a second portion of the upper surface from polymerization radiation. In a first example of selective irradiation, the radiation source 250 is shielded to limit the radiation to the portion of the composition that ultimately becomes the optical article 100. The shielding at least partially prevents polymerization radiation from reaching the portion of the composition 15 that is not intended to appear in the final optical article 15. This approach involves edge-grinding or trimming the cured composition, or employing an alternative or reinforcement of the contour insert 140. Figure 11A The use of a spectacle lens shape mask 255 is illustrated schematically. This spectacle lens shape mask is placed at or near the radiation source 250 so that only the spectacle lens shape portion of the composition 15 in the mold 120 is cured. Figure 11A In a non-limiting example, the radiation source 250 is arranged to rotate together with the mold 120 so as to irradiate the same portion of the composition 15 throughout the duration of the curing process. Figure 11BThe use of a spectacle lens shape mask 255 is schematically illustrated, which is placed at or near (or even within) the cavity of mold 120 to cure only the spectacle lens shape portion of composition 15 within mold 120. In other examples, spectacle lens shape mask 255 may be located anywhere between radiation source 250 and the upper surface of mold 120. Alternatively, mask 255 may be placed on or above mold 120, or anywhere between radiation source 250 and the top of mold 120 (or the top surface of composition 15 within mold 120). In a second example of selective irradiation, a directional radiation emitter 250 is employed to irradiate a desired portion, such as irradiating only the desired portion or substantially only the desired portion. Figure 12 As schematically shown, a laser emitter 270 tuned to emit light at a focused wavelength is a suitable directional radiating emitter. Other suitable directional radiating emitters include tunable arrays of small emitters or emitters with electronically or mechanically narrowed beams.

[0085] In some embodiments, the device 200 further includes a container 21 for storing a supply of the radiation-curable composition 15, such as Figure 8 As shown in the block diagram. Container 21 is arranged, for example, appropriately sized and configured to achieve switchable fluid communication with mold 120, so that composition 15 can be delivered to mold 120 in a timely manner, for example, via a fluid delivery device 35 arranged to mediate between container 21 and mold 120. Container 21 and fluid delivery device 35 are in... Figure 13 In a non-limiting example, the equipment component is graphically represented as a simple container with a tap. In other examples, the container 21 and the fluid delivery device 35 may be more sophisticated and / or more industrialized, while performing the same functions as... Figure 13 The illustrated example serves the same function. In yet another example, container 21 may be a simple bottle, and the corresponding fluid delivery device 37 may be a simple nozzle. In some embodiments, fluid delivery device 35 includes a metering or measuring device 37 for metering or measuring the amount of composition 15 delivered to mold 120 for each optical article 100. In some embodiments, fluid delivery device 35 may be designed, constructed, and / or adjusted to supply a desired amount without metering, for example, but not limited to, by adjusting the duration of supply or by adjusting electrical parameters associated with the supply. The size and quantity of container 21, the type and size of fluid delivery device 35, and the type of metering device 37 may be configured according to the specific implementation to meet the requirements of the equipment.

[0086] We refer to it again Figure 8In some embodiments, two or more components of the polymerizable composition 15 are mixed outside the mold 120 before the composition 15 is introduced into the mold 120. In a non-limiting example, one of the components is a colorant. In such embodiments, the external mixer 111 may include, but is not limited to, a static mixer, a mixing tube, or a mixing container, and may be provided as part of the apparatus 200. In some embodiments, pre-manufacturing mixing is performed within the mold 120. In some embodiments, regardless of whether or where mixing is performed, an ultrasonic probe 112 or an equivalent degassing device is provided as part of the apparatus 200 for degassing the composition 15, i.e., removing air bubbles. In some embodiments, regardless of where mixing is performed, a heater 113 is provided as part of the apparatus 200 for heating the mixer 111 or the mold 120, for example, to reduce the viscosity of the composition 15 for more efficient or effective mixing. In some embodiments, the heater 113 includes an infrared radiation source, such as, for example, an IR lamp.

[0087] In some embodiments, the apparatus 200 includes means (not shown) for flowing an inert gas (e.g., N2) to reduce oxygen exposure of the composition 15. In some embodiments, rotation and / or curing are performed in an atmosphere at least partially depleted of oxygen. In some embodiments, rotation and / or curing are performed in a partial vacuum or substantially a complete vacuum, i.e., at gas pressures below 1 atmosphere, or below 0.9 atmospheres, or below 0.7 atmospheres, or below 0.5 atmospheres, or below 0.3 atmospheres, or below 0.1 atmospheres.

[0088] Now we refer to Figure 14 The figure shows a block diagram of a system 500 for manufacturing an optical article 100. System 500 includes at least a molding assembly 220 and electronic circuitry 150. The molding assembly includes a mold, for example... Figure 1 and Figure 2A rotatable mold 120 surrounds a cavity 121 having a minimum diameter of 50 mm for producing an optical article 100 from a radiation-polymerizable composition 15. Producing the optical article in the mold 120 involves forming a parabolic shape on the surface of the radiation-polymerizable composition 15 by rotating the mold 120, for example, at a constant speed of less than 200 rpm. A molding assembly 220 further includes an emitter 250 for polymerizing radiation 25. The emitter 250 is arranged to solidify at least a portion of the polymerizable composition 15 by irradiation. In some embodiments, the system includes: a material supply assembly 230 comprising one or more containers 21 storing the radiation-polymerizable composition 15; and a conveying device 35 mediating between the containers 21 and the mold 120 for supplying the radiation-polymerizable composition 15 to the mold 120.

[0089] In some embodiments, electronic circuitry 150 includes: a control system 60 configured (e.g., programmed) to regulate the operation of molding assembly 220 in response to inputs; and a user interface 60. In some embodiments, regulation includes the operation of material supply assembly 230. Some or all of the inputs are received via user interface 60. Each input defines one or more parameters relating to the shape and / or composition of optical article 100 and / or the operation of molding assembly 220 or material supply assembly 230. Figure 15 As shown in the block diagram, the exemplary control system 50 includes computing devices and auxiliary devices configured to monitor, control, regulate, and / or actuate one or more components or subsystems of system 500. Depending on location customization, the control system may include any or all of the following (and not exhaustively): one or more computer processors 55, computer-readable storage media 58, 59, and communication module 57. The computer-readable program storage media 58, 59 may include transient and / or transient storage, and may include one or more storage units, all selected according to desired functionality and design. Some or all of the computer-readable program storage media 58, 59 may be cloud-based. In embodiments, program storage 58 may be used to store program instructions in firmware and / or software for execution by one or more processors 55; operational data and / or maintenance data relating to any or more of the components of system 500 and / or the manufactured optical articles 100, their subsystems, and their components may be stored in data storage module 59. The communication module 57 can be configured to establish a communication link with an external computer, for example, for software and firmware updates, database access, etc., and to interact with the user via the user interface 60. In some embodiments, not all exemplified components of the control system 50 are provided. In some embodiments, not all communication arrangements are provided.

[0090] In some embodiments, electronic circuitry 150 includes a user interface 60 configured to receive user input and provide (e.g., display and / or store) information about the manufacture of optical articles 100 using system 500. As discussed above, user interface 60 may include a screen, such as a touchscreen. In some embodiments, user interface 60, or at least a screen portion of user interface 60, is implemented in a computer program or an app on a mobile device. In some embodiments, user interface 60 includes a communication-enabled handheld device designed to run interface software or pre-loaded software.

[0091] Figure 16A , Figure 16B and Figure 16C The diagram schematically illustrates a sample screenshot of an exemplary user interface 60. The three illustrations are non-limiting examples of the types of information exchanged through the user interface. In other examples, more technical and detailed data is input, displayed, and / or adjusted; while in still other examples, fewer options are offered to the user, and more decisions can be made by the software of the control system 50, for example, using machine learning and artificial intelligence.

[0092] Figure 16A A screen is shown displaying buttons that allow data entry of input parameters and / or receiving image scans, barcode scans, and other primary inputs. Figure 16B Another screen shows a display button that allows the user to check and / or adjust process parameters, including those based on... Figure 16A The screen shown displays the input parameters received. Figure 16C A panel with a status indicator is shown, which displays the progress of the manufacturing process of the optical article 100.

[0093] Refer again Figure 14The block diagram illustrates that, according to some embodiments, system 500 may include one or more additional components. A first example of an additional component is a 3D printer 205 for manufacturing, for example, a contour insert 140 or a mold 120 having a forming volume, which is shaped to form the final optical article 100, such as mold 120 including an integral contour insert 140. A second example of an additional component is a fluid bath 208 for cleaning the optical article 100 formed in mold 120, for example, by chemical cleaning or ultrasonic cleaning. Fluid bath 208 may be equipped with a drying station (not shown). A third example of an additional component is a spin coater 209 for coating the optical article 100 formed in mold 120. The optical article 100 may be coated with one or more coatings, including, for example (and not exhaustively), functional coatings including colorants, protective hard coatings, anti-reflective or anti-glare coatings, and / or superhydrophobic or anti-fog coatings. A fourth example of an additional component is a printer 210 for adding, for example, a dyeing layer or a photochromic layer to the main surface of the optical article 100. Printer 210 is adapted to deposit a colorant directly or indirectly onto the surface of the optical article after the optical article 100 has been formed in the mold 120, using any suitable technique. A fifth example of an additional component is a quality control (QC) station 206 for final measurement and adjustment (if required), such as grinding or polishing. A sixth example of an additional component is a scanner (not shown) for measuring the shape or internal space of an eyeglass frame, or a focimeter for evaluating existing lenses, wherein either or both are deployed to communicate with the control system 50 to transmit information required for manufacturing new lenses.

[0094] refer to Figure 17 This image is a photorealistic rendering of a non-limiting example of a single-mold system 500 designed for desktop operation. In some other examples, the desktop system 500 is configured differently with fewer or more optional components, and / or more than one mold, and / or higher or lower levels of mechanization or automation. In some other examples, the system 500 may be wall-mounted or assembled on the floor. In some other examples, the system 500 can be scaled up to include multiple molds and components, reaching an industrial scale. In other examples, the components of the system 500 may be physically separate from each other in a production facility.

[0095] Figure 17 The exemplary system 500 includes at least the following elements (clockwise from the lower left): - A power-driven rotatable mold 120 powered directly by a motor 110; - A multi-purpose arm 45 that combines the following functions: a polymerizable radiation emitter 250; a portion of a fluid delivery device 35 that supplies a polymerizable composition 15 (not shown) to a mold 120; a metering device 37 for metering a defined amount of composition 15 for each optical article 100 to be formed in the mold 120; and a robotic or remote-controlled suction gripper for handling and moving the formed cured optical articles 100. - Printer 210, which is used to deposit colorant onto the surface of optical article 100; - User interface screen 60, which communicates electronically with control system 50 (not shown); - QC Station 206; - A cartridge 21 for storing multiple polymerizable compositions 15; and a cartridge 22 for storing multiple colorants for premixing in the compositions 15 and / or for printing on optical articles 100; and - Fluid bath 208, used for post-curing cleaning or treatment of optical articles 100 after curing in mold 120. An optional dryer is not shown.

[0096] Discussion of the first method Now for reference Figure 18A A method for manufacturing an optical article 100 is disclosed. According to the method, the optical article 100 includes a first main surface 82 and a second main surface 81, characterized at least partially by a first curvature and a second curvature, respectively. In some embodiments, the optical article 100 includes a spectacle lens blank. In some embodiments, the lens blank is a single-vision lens blank (with or without cylindrical correction for astigmatism). In some embodiments, the lens blank is a finished lens blank. In some embodiments, the optical article 100 includes a corrective spectacle lens. Figure 18A As illustrated in the flowchart, the method includes at least three steps S101, S102, and S103.

[0097] Step S101 includes: introducing a certain amount of radiation-polymerizable composition 15 into mold 120, such as, for example... Figure 1 , Figure 2 , Figure 7A or Figure 9 Any mold 120 shown. The bottom wall portion 130 of mold 120 is shaped to form a surface 82 thereon, the surface being characterized at least in part by a first curvature. Mold 120 surrounds a cavity 121 with a diameter of at least 50 mm. In some embodiments, the minimum amount of composition 15 is 6 cc. In some embodiments, the amount of composition 15 is per cm 2The cavity area is between 0.25 and 0.35 cc of the composition.

[0098] Step S102 includes: causing the mold 120 to rotate around the center of rotation. 128 Rotation to displace a portion of the polymerizable composition 15, for example, at least from the center of rotation. 128 Radial outward displacement. This displacement effectively alters the profile of the upper surface of the polymerizable composition 15 to a concave parabolic shape characterized at least in part by a second curvature. In embodiments, the rotation is at a speed between 10 and 200 rpm. In some embodiments, the rotation is within any of the narrower ranges discussed above.

[0099] Step S103 includes exposing the polymerizable composition 15 to polymerization radiation 25 to solidify the composition 15. In some embodiments, exposing the polymerizable composition 15 to polymerization radiation 25 includes exposing substantially all of the upper surface to polymerization radiation 25. "Substantially" as used herein means at least 80%, or at least 85%, or at least 90%, or at least 95%, or at least 99%. In some embodiments, exposing the polymerizable composition 15 to polymerization radiation 25 includes selectively exposing a first portion of the upper surface to polymerization radiation 25 while excluding a second portion of the upper surface from polymerization radiation 25. In some embodiments, "selectively exposing" includes masking the polymerization radiation 25 to prevent it from reaching the second portion, for example, by installing a mask 255 to block the second portion of the radiation 25. In some embodiments, "selectively exposing" includes using a directional radiation source (e.g., a laser emitter 270) to emit polymerization radiation 25 so as to irradiate only the first portion. In some embodiments, exposing the polymerizable composition 15 to polymerization radiation 25 includes directly exposing at least a portion of the lower surface of the polymerizable composition 15 to polymerization radiation 25. In some embodiments, exposing the polymerizable composition 15 to polymerization radiation 25 includes indirectly exposing at least a portion of the lower surface of the polymerizable composition 15 to polymerization radiation 25, for example, by reflecting the polymerization radiation using a reflective surface 126 disposed below the transparent bottom wall portion 130, the reflective surface 126 including, for example, a polished metal surface or a metal-coated surface. In some embodiments, at least a portion of exposing the polymerizable composition 15 to polymerization radiation 25 is performed during rotation. In some embodiments, all of the exposing the polymerizable composition 15 to polymerization radiation 25 is performed during rotation.

[0100] In some embodiments, the minimum thickness of the solidified composition 15 is at least 1 mm. In some embodiments, the average thickness of the solidified composition 15 is at least 2 mm.

[0101] In some implementations, the method may additionally include step S104, by Figure 18B The flowchart in the example is shown.

[0102] Step S104 includes selecting the base portion 130 based on parameters of the optical article 100. These parameters may include, but are not limited to: lens type, such as, for example, a bifocal or multifocal lens; desired refractive power; shape, such as spherical or aspherical; or material. The base portion 130 may be selected for (and not exhaustively) its shape, its material, and / or its transparency to photochemical radiation at a selected wavelength.

[0103] In some implementations, the method may additionally include step S105, by Figure 18C The flowchart in the example is shown.

[0104] Step S105 includes selecting a mold 120 based on the shape of its base wall portion 130. This selection is based on parameters of the optical article 100, such as, but not limited to: lens type, such as, for example, a bifocal or multifocal lens; desired refractive power; shape, such as spherical or aspherical; or material. The mold 120 may be selected for (and not exhaustively) the shape, material, and / or the transparency of its base wall portion 130 to photochemical radiation at a selected wavelength. In step S105, compared to step S104, the entire mold 120 may be selected based on the base wall portion 130, rather than just the base wall portion 130; therefore, step S1015 is more likely to be performed as part of the method in implementations where the base wall portion 130 is constructed in the mold 120, permanently fixed to the mold, or integrally formed with the mold.

[0105] In some implementations, the method may additionally include step S106, such as by Figure 18D The flowchart in the example is shown.

[0106] Step S106 includes: installing a non-destructive removable element, namely a contour insert 140, in the mold 120, which constrains the peripheral contour of the optical article 100.

[0107] In some embodiments that perform step S106, the method may additionally include step S107, by... Figure 18E The flowchart in the example is shown.

[0108] Step S107 includes selecting a removable element 140 that constrains the peripheral contour of the optical article 100 based on parameters of the optical article 100. These parameters may include, but are not limited to, the shape, thickness, or material of the optical article 100, or the model of the lens eyeglass frame.

[0109] In some embodiments that perform step S106, the method may additionally include step S108, by... Figure 18F The flowchart in the example is shown.

[0110] Step S108 includes, for example, manufacturing a removable element 140 that constrains the peripheral contour of the optical article 100 using a 3D printer 205.

[0111] In some implementations, the method may additionally include step S109, by Figure 18G The flowchart in the example is shown.

[0112] Step S109 includes performing at least one of the following: machining, grinding, stamping, polishing, and buffing the edges of the solidified composition 15. In some embodiments, performing step S109 completes the manufacture of the optical article 100.

[0113] In some implementations, the method may additionally include step S110, by Figure 18H The flowchart in the example is shown.

[0114] Step S110 includes performing at least one of the following: machining, grinding, polishing, and buffing the main surfaces 82, 81 of the solidified composition 15. In some embodiments, performing step S110 completes the manufacture of the optical article 100.

[0115] In some implementations, the method may additionally include step S111, by... Figure 18I The flowchart in the example is shown.

[0116] Step S111 includes performing at least one of the following: coating, printing, and depositing on at least one of the first main surface 82 and the second main surface 81. Printing or depositing can be performed using, for example, a printer 210.

[0117] In some implementations, the method may additionally include step S112, by Figure 18J The flowchart in the example is shown.

[0118] Step S112 includes curing the solidified composition 15. In some embodiments, performing step S112 completes the manufacture of the optical article 100. Coating can be performed using, for example, a spin coater 209. Further curing can be performed, for example, by using an additional polymeric radiation emitter arranged remotely from the mold 120. In another example, further curing in step S112 includes thermal curing or a hybrid thermal-radiation curing.

[0119] In some embodiments, the manufacture of the optical article 100 is completed by performing step S03 (specifically, subjecting the polymerizable composition 15 to polymerization radiation 25), in which case steps S109, S110, S111, and S112 are not performed.

[0120] In some implementations, the method may additionally include step S113, by Figure 18KThe flowchart in the example is shown.

[0121] Step S113 includes: installing the optical article 100 into the eyeglass frame.

[0122] In some implementations, the method may additionally include step S114, by Figure 18L The flowchart in the example is shown.

[0123] Step S114 includes adding a colorant to the radiation-polymerizable composition 15. In some embodiments, the colorant is added to and / or mixed with the composition in the mold 120. In some embodiments, the colorant is added and / or mixed during rotation. In some embodiments, the composition contains the colorant when the composition 15 is introduced into the mold 120 in step S01. The colorant may be added to the composition before performing step S01, for example, using a mixer 111. In some embodiments, the colorant in step S113 comprises a photochromic dye.

[0124] In some implementations, the automated manufacturing system 500 includes a power-driven rotatable mold 120, a source 250 for polymer radiation 25, and a control system 50 programmed to execute steps S101, S102, and S103.

[0125] Discussion of the second method Now for reference Figure 19 A method for manufacturing an optical article 100 is disclosed. In some embodiments, the optical article 100 includes corrective spectacle lenses. In some embodiments, the optical article 100 includes progressive lenses. In some embodiments, the optical article 100 includes multifocal lenses. In some embodiments, the optical article 100 includes bifocal lenses. In some embodiments, the optical article 100 includes a coloring agent. Figure 19 As illustrated in the flowchart, the method includes at least three steps S201, S202, and S203.

[0126] Step S201 includes introducing a radiation-curable composition 15 into a mold 120, the mold surrounding a cavity 121 with a diameter of at least 50 mm. According to this method, a bottom wall portion 130 of the mold 120 is shaped to form a first surface 82 of the optical article 100 thereon. In some embodiments, the first surface 82 is characterized at least partially by a spherical curvature. In some embodiments, the first surface 82 is characterized at least partially by an aspherical curvature. In some embodiments, the first surface 82 is characterized at least partially by zero curvature. In some embodiments, the first surface 82 is characterized by a plurality of different curvatures. In some embodiments, the first surface 82 is characterized by including one or more facets.

[0127] Step S202 includes: moving the mold 120 around the center of rotation. 128 Rotation is performed to displace a portion of the radiation-curable composition 15, thereby altering the profile of the upper surface of the curable composition 15 to a concave parabolic shape. In some embodiments, the second surface 81 of the optical article 100 is characterized by a concave parabolic curvature.

[0128] Step S203 includes subjecting the curable composition 15 to curing radiation 25 to allow the composition 15 to solidify. In some embodiments, solidifying the composition 15 effectively preserves the concave parabolic shape.

[0129] Any method and / or method steps disclosed herein (including, but not limited to, the steps of the first and second methods discussed above) may be performed in any combination and in any order that may be considered useful for the manufacture of the optical article 100, including substitutions and combinations of features and / or limitations.

[0130] In some embodiments, the manufacturing system 500 is configured to perform any combination of the methods and / or method steps and / or features and / or limitations disclosed herein to manufacture optical articles 100. The system includes: a power-driven rotatable mold 120 surrounding a cavity 121 with a diameter of at least 50 mm; and a source 250 for polymerizing radiation 25.

[0131] As is known in the ophthalmology industry, it may be desirable to manufacture optical products (such as spectacle lenses or spectacle lens blanks) that have prism correction (i.e., correction that changes the direction of the optical axis of the optical product). The optical axis is a straight line connecting the respective centers of curvature of the anterior and posterior surfaces. The optical axis is shifted by causing a shift in one of the centers of curvature, such that, for example, the optical axis is not perpendicular to the tangent of the anterior (convex) surface.

[0132] Figure 20A A schematic cross-section of the mold bottom wall 130 is shown, the bottom wall having features such as Figure 4B The spherical profile shown. Rotation axis. 128 Similar to the center of the bottom wall 130 of the mold, in this non-limiting example, the center is located exactly at the center of curvature of the spherical profile. Figure 20B A cross-section of an optical article 100 (in this case, a spectacle lens blank) is shown, which is manufactured by applying any of the methods disclosed herein for manufacturing optical articles in a mold. Figure 20A Manufactured on the bottom wall of the mold at 130mm. Optical axis 700 At point A The curvature center of the front (convex) surface 82 passes through the point, and at the point... B The curvature center passes through the rear (concave) surface 81. Figure 20B Optical products 100 do not provide prism correction.

[0133] Figure 21A and Figure 21B Three exemplary methods are used to illustrate the manufacture of an optical article 100 with prism correction. Figure 21A In the middle, the bottom wall of the mold is inclined at 130 degrees, as shown by the arrow. 720 As instructed, and in Figure 21B In order to avoid passing through the center of curvature of the spherical bottom wall mold 130, the rotation axis 128 It is offset laterally. In either of these cases, the center of curvature of the parabolic profile formed by the rotation of the curable composition in the mold will be located at the axis of rotation 128, rather than as... Figure 20A and Figure 20B In the case of the spherical bottom wall mold 130, it is located above the center of curvature. Figure 21C The exemplary results are illustrated schematically. Although the center of curvature of the convex spherical profile of the front surface 82... A There was no movement, but the center of curvature of the concave parabolic shape of the rear surface 81 remained unchanged. B An offset has occurred. Furthermore, depending on the specific curved surface, the resulting optical article 100 is no longer symmetrical, but is shaped for prism correction. This is achieved by tilting the mold bottom wall 130 and adjusting the axis of rotation around which the parabolic profile is formed. 128 Besides lateral offset, a third method (not illustrated) involves both tilting the bottom wall of the mold 130° and adjusting the axis of rotation. 128 It shifts laterally.

[0134] According to an embodiment, a method for manufacturing an optical article is disclosed, the optical article including a first main surface and a second main surface, the first main surface and the second main surface being characterized at least in part by a first curvature and a second curvature, respectively. The method includes: (a) introducing a quantity of a radiation-polymerizable composition into a mold, a bottom wall portion of the mold being shaped to form a surface thereon, the surface being characterized at least in part by the first curvature; (b) rotating the mold to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape, the concave parabolic shape being characterized at least in part by the second curvature; and (c) subjecting the polymerizable composition to polymerization radiation to solidify the composition.

[0135] According to an embodiment, an apparatus for manufacturing optical articles from a radiation-polymerizable composition includes: (a) a power-driven rotatable mold shaped to receive a quantity of the radiation-polymerizable composition, the mold including: a bottom wall portion disposed thereon for forming a first surface of the optical article thereon; and a peripheral wall portion having a minimum height at least 1 mm higher than the maximum point of the bottom wall portion; and (b) a source of polymerization radiation disposed thereon to irradiate at least a portion of the polymerizable composition to cause the polymerizable composition to solidify. In a first operating mode of the apparatus, when the mold rotates at a speed between 10 and 200 revolutions per minute while a radiation-polymerizable composition with a viscosity between 20 and 2000 cP at room temperature resides therein, the rotation effectively alters the profile of a second surface of the polymerizable composition to form a concave parabolic shape.

[0136] According to an embodiment, an apparatus for manufacturing an optical article from a radiation-polymerizable composition includes: (a) a mold shaped to receive a quantity of the radiation-polymerizable composition, the mold including a bottom wall portion arranged for forming a first surface of the optical article thereon, and configured, upon electrical activation, to rotate at a selectable speed to generate a centrifugal force, which, in combination with gravity, alters the profile of a second surface of the polymerizable composition received in the mold to a concave parabolic shape; and (b) a source of polymerization radiation aligned with the mold to irradiate at least a portion of the polymerizable composition upon activation, causing the portion to solidify.

[0137] According to an embodiment, a method for manufacturing an optical article is disclosed. The method includes: (a) introducing a radiation-curable composition into a mold, the bottom wall portion of the mold being shaped to form a first surface of the optical article thereon; (b) rotating the mold about a rotation center to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape; and (c) subjecting the curable composition to curing radiation to solidify the composition.

[0138] According to an embodiment, a system for manufacturing an optical article includes: (a) a molding assembly comprising: (i) a rotatable mold adapted to produce the optical article from a radiation-polymerizable composition therein, wherein the production includes forming a parabolic shape on a surface of the radiation-polymerizable composition by rotating the mold; and (ii) a source of polymerization radiation arranged to solidify at least a portion of the polymerizable composition by irradiating the at least a portion thereof; (b) a material supply assembly including one or more containers for storing the radiation-polymerizable composition; and a conveying device for supplying a quantity of the radiation-polymerizable composition to the rotatable mold via the conveying device; and (c) electronic circuitry configured to regulate the operation of the molding assembly and the material supply assembly in response to input received via a user interface, the input defining one or more shape and / or compositional parameters of the optical article.

[0139] According to an embodiment, a method for manufacturing spectacle lens blanks is disclosed. The method includes: (a) introducing a radiation-curable composition into a mold surrounding a cavity with a diameter of at least 40 mm and at most 100 mm, the bottom wall portion of the mold being shaped to form a first surface of the optical article thereon; (b) rotating the mold about its rotation center at a speed of at least 50 rpm and not exceeding 120 rpm to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape; and (c) subjecting the curable composition to curing radiation to solidify the composition.

[0140] According to an embodiment, a system for manufacturing spectacle lens preforms from a radiation-polymerizable composition includes: (a) a rotatable mold surrounding a cavity with a diameter of at least 50 mm, the mold including: a bottom wall portion disposed thereon for forming a first surface of the spectacle lens preform; and a peripheral wall portion having a minimum height at least 1 mm higher than the highest point of the bottom wall portion; (b) an electric motor operable to rotate the mold at a constant speed between 50 and 120 revolutions per minute; and (c) a source of polymerization radiation disposed to irradiate at least a portion of the polymerizable composition with the polymerization radiation, wherein in a first operating mode of the system, when the mold rotates at a speed between 50 and 120 revolutions per minute while the radiation-polymerizable composition with a viscosity between 20 and 2000 cP at room temperature resides in the cavity, the rotation effectively alters the profile of the upper surface of the polymerizable composition to form a concave parabolic shape, the radiation-polymerizable composition having a per cm²...2 The cavity area is between 0.25 and 0.35 cc.

[0141] According to an embodiment, a method for manufacturing spectacle lens blanks is disclosed. The method includes: (a) introducing a radiation-curable composition into a mold surrounding a cavity with a diameter of at least 50 mm, the bottom wall portion of the mold being shaped to form a first surface of the optical article thereon; (b) rotating the mold about its rotation center at a speed of at least 30 rpm or at least 50 rpm and not exceeding 120 rpm to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape; and (c) subjecting the curable composition to curing radiation to solidify the composition.

[0142] According to an embodiment, a system for manufacturing spectacle lens preforms from a radiation-polymerizable composition includes: (a) a rotatable mold surrounding a cavity with a diameter of at least 50 mm, the mold including: a bottom wall portion disposed thereon for forming a first surface of the spectacle lens preform; and a peripheral wall portion having a minimum height at least 1 mm higher than the highest point of the bottom wall portion; (b) an electric motor operable to rotate the mold at a constant speed between 50 and 120 revolutions per minute; and (c) a source of polymerization radiation disposed to irradiate at least a portion of the polymerizable composition with the polymerization radiation, wherein in a first operating mode of the system, when the mold rotates at a speed between 50 and 120 revolutions per minute while the radiation-polymerizable composition with a viscosity between 20 and 500 cP at room temperature resides in the cavity, the rotation effectively alters the profile of the upper surface of the polymerizable composition to form a concave parabolic shape, the radiation-polymerizable composition having a per cm²... 2 The cavity area is between 0.25 and 0.35 cc.

[0143] Inventive concept Among other things, this disclosure includes inventive concepts numbered 1-204, which are set forth below for convenience of reference. Some of the concepts disclosed above may not be outlined in this section, but their absence should not be construed as indicating a lack of inventiveness or that they are outside the scope of the embodiments. For the sake of brevity, some of the inventive concepts are introduced for the first time below.

[0144] Inventive Concept 1: A method for manufacturing an optical article comprising a first primary surface and a second primary surface, the first primary surface and the second primary surface being characterized at least in part by a first curvature and a second curvature, the method comprising: (a) introducing a quantity of a radiation-polymerizable composition into a mold, a bottom wall portion of the mold being shaped to form a surface thereon, the surface being characterized at least in part by the first curvature; (b) rotating the mold to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave paraboloid shape, the concave paraboloid shape being characterized at least in part by the second curvature; and (c) subjecting the polymerizable composition to polymerization radiation to solidify the composition.

[0145] Inventive Concept 2: The method as described in Inventive Concept 1, wherein the solidification effectively maintains the concave parabolic shape.

[0146] Inventive Concept 3: The method as described in any one of Inventive Concepts 1 or 2, wherein the optical article includes a lens.

[0147] Inventive concept 3a: The method as described in any one of inventive concepts 1 or 2, wherein the optical article comprises spectacle lens blank.

[0148] Inventive Concept 4: The method of any one of Inventive Concepts 1 to 3, wherein the optical article includes corrective spectacle lenses.

[0149] Inventive Concept 5: The method as described in any one of Inventive Concepts 1 to 4, the method further comprising: selecting the bottom wall portion based on parameters of the optical article.

[0150] Inventive Concept 6: The method of any one of Inventive Concepts 1 to 4, the method further comprising: selecting a mold based on the shape of the bottom wall portion, the selection being based on parameters of the optical article.

[0151] Inventive Concept 7: The method of any one of Inventive Concepts 1 to 6, wherein subjecting the polymerizable composition to the polymerization radiation comprises subjecting substantially all of the upper surface to the polymerization radiation.

[0152] Inventive Concept 8: The method of any one of Inventive Concepts 1 to 6, wherein subjecting the polymerizable composition to the polymerization radiation comprises selectively subjecting a first portion of the upper surface to the polymerization radiation while not subjecting a second portion of the upper surface to the polymerization radiation.

[0153] Inventive Concept 9: The method as described in Inventive Concept 8, wherein the selective exposure includes shielding the polymeric radiation so that it cannot reach the second portion.

[0154] Inventive Concept 10: The method as described in Inventive Concept 8, wherein the selective exposure includes using a directional radiation source to emit the aggregated radiation.

[0155] Inventive Concept 11: The method as described in any of the foregoing inventive concepts, wherein subjecting the polymerizable composition to the polymerization radiation comprises subjecting at least a portion of the lower surface of the polymerizable composition to the polymerization radiation.

[0156] Inventive Concept 11A: The method of Inventive Concept 11, wherein subjecting at least a portion of the lower surface to the polymerization radiation includes reflecting the polymerization radiation through a mold bottom wall that is at least 90% transparent to the polymerization radiation.

[0157] Inventive Concept 12: The method as described in any of the foregoing inventive concepts, the method further comprising: mounting in the mold a non-destructive removable element that constrains the peripheral contour of the optical article.

[0158] Inventive Concept 13: The method as described in Inventive Concept 12, the method further comprising: selecting the removable element constraining the peripheral contour of the optical article based on parameters of the optical article.

[0159] Inventive Concept 14: The method of Inventive Concept 12, the method further comprising: manufacturing the removable element constraining the peripheral contour of the optical article.

[0160] Inventive Concept 15: The method as described in any of the foregoing inventive concepts, the method further comprising performing at least one of the following: machining, grinding, stamping, polishing and buffing the edges of the solidified composition.

[0161] Inventive Concept 16: The method as described in any of the foregoing inventive concepts, the method further comprising performing at least one of the following: machining, grinding, polishing and buffing the main surface of the solidified composition.

[0162] Inventive Concept 17: The method as described in any of the foregoing inventive concepts, the method further comprising performing at least one of the following: coating, printing, or depositing on at least one of the first main surface and the second main surface.

[0163] Inventive Concept 18: The method as described in any of the foregoing inventive concepts, the method further comprising: further curing the solidified composition.

[0164] Inventive Concept 19: The method as described in any of the foregoing inventive concepts, wherein the manufacture of the optical article is completed by subjecting the polymerizable composition to the polymerization radiation.

[0165] Inventive Concept 20: The method as described in any of the foregoing inventive concepts, the method further comprising: mounting the optical article in an eyeglass frame.

[0166] Inventive Concept 21: The method as described in any of the foregoing inventive concepts, wherein the rotation is at a speed of up to 200 RPM.

[0167] Inventive Concept 21A: The method as described in Inventive Concept 21, wherein the speed is at most 180 RPM.

[0168] Inventive Concept 21B: The method as described in Inventive Concept 21, wherein the speed is at most 160 RPM.

[0169] Inventive Concept 21C: The method as described in Inventive Concept 21, wherein the speed is at most 150 RPM.

[0170] Inventive Concept 21D: The method as described in Inventive Concept 21, wherein the speed is at most 140 RPM.

[0171] Inventive Concept 21E: The method as described in Inventive Concept 21, wherein the speed is at most 130 RPM.

[0172] Inventive Concept 21F: The method as described in Inventive Concept 21, wherein the speed is at most 120 RPM.

[0173] Inventive Concept 21G: The method as described in Inventive Concept 21, wherein the speed is at most 110 RPM.

[0174] Inventive Concept 21H: The method as described in any one of Inventive Concepts 21 to 21G, wherein the speed is at least 10 RPM.

[0175] Inventive Concept 21I: The method as described in Inventive Concept 21H, wherein the speed is at least 20 RPM.

[0176] Inventive Concept 21J: The method as described in Inventive Concept 21H, wherein the speed is at least 25 RPM.

[0177] Inventive Concept 21K: The method as described in Inventive Concept 21H, wherein the speed is at least 30 RPM.

[0178] Inventive Concept 21L: The method as described in Inventive Concept 21H, wherein the speed is at least 40 RPM.

[0179] Inventive Concept 21M: The method as described in Inventive Concept 21H, wherein the speed is at least 50 RPM.

[0180] Inventive Concept 21N: The method as described in Inventive Concept 21H, wherein the speed is at least 60 RPM.

[0181] Inventive Concept 21O: The method as described in Inventive Concept 21H, wherein the speed is at least 70 RPM.

[0182] Inventive Concept 22: The method as described in any of the foregoing inventive concepts, wherein the rotation is at a speed between 10 and 200 revolutions per minute.

[0183] Inventive Concept 23: The method as described in any of the foregoing inventive concepts, wherein the rotation is at a speed between 30 and 120 revolutions per minute.

[0184] Inventive Concept 23A: The method as described in any of the foregoing inventive concepts, wherein the rotation is at a speed between 40 and 100 revolutions per minute.

[0185] Inventive Concept 24: The method as described in any of the foregoing inventive concepts, the method further comprising: adding a colorant to the radiation-polymerizable composition.

[0186] Inventive Concept 25: The method as described in Inventive Concept 24, wherein the colorant is added to the mold.

[0187] Inventive Concept 26: The method as described in Inventive Concept 24, wherein the colorant is added during the rotation.

[0188] Inventive Concept 27: The method of any one of Inventive Concepts 1 to 23, wherein the composition comprises a colorant.

[0189] Inventive Concept 28: The method of any one of Inventive Concepts 24 to 27, wherein the colorant comprises a photochromic dye.

[0190] Inventive Concept 29: The method as described in any of the foregoing inventive concepts, wherein at least a portion of subjecting the polymerizable composition to the polymerization radiation is performed during the rotation.

[0191] Inventive Concept 30: The method as described in any of the foregoing inventive concepts, wherein the second surface of the optical article is characterized by a concave parabolic curvature.

[0192] Inventive Concept 31: The method as described in any of the foregoing inventive concepts, wherein the optical article includes a progressive lens.

[0193] Inventive Concept 32: The method as described in any of the foregoing inventive concepts, wherein the optical article includes a multifocal lens.

[0194] Inventive Concept 33: The method as described in any of the foregoing inventive concepts, wherein the optical article comprises a bifocal lens.

[0195] Inventive Concept 34: The method as described in any of the foregoing inventive concepts, wherein the first surface is characterized at least in part by spherical curvature.

[0196] Inventive Concept 35: The method as described in any of the foregoing inventive concepts, wherein the first surface is characterized at least in part by aspherical curvature.

[0197] Inventive Concept 35A: The method as described in Inventive Concept 35, wherein at least a portion of the aspherical curvature of the first surface is aligned with at least a portion of the concave parabolic curvature of the second surface such that a straight line parallel to the optical axis of the optical article passes through both portions.

[0198] Inventive Concept 36: The method as described in any of the foregoing inventive concepts, wherein the first surface is characterized at least in part by zero curvature.

[0199] Inventive Concept 37: The method as described in any of the foregoing inventive concepts, wherein the first surface is characterized by a plurality of different curvatures and / or includes one or more facets.

[0200] Inventive Concept 38: The method as described in any of the foregoing inventive concepts, wherein the optical article includes a colorant.

[0201] Inventive Concept 39: The method as described in any of the foregoing inventive concepts, wherein the optical article comprises a spectacle lens with a maximum size between 30 mm and 85 mm, or a spectacle lens blank with a diameter between 40 mm and 100 mm, wherein the first curvature is characterized at least in part by a convex spherical shape.

[0202] Inventive Concept 39A: The method of Inventive Concept 39 has a non-zero refractive power through its optical axis, wherein the refractive power of at least half an area of ​​the optical article differs from the non-zero refractive power through the optical axis by ±0.25 diopters.

[0203] Inventive Concept 39B: The method of Inventive Concept 39 has a non-zero refractive power through its optical axis, wherein the refractive power of a circular portion surrounding the optical axis that constitutes 30%, 40%, 50%, 60%, or 70% of the area of ​​the optical article differs from the non-zero refractive power through the optical axis by ±0.25 diopters.

[0204] Inventive Concept 39C: The method as described in Inventive Concept 39B, wherein the difference between the refractive power of the annular region defined by the outer periphery of the circular portion and the peripheral portion of the optical article and the non-zero refractive power through the optical axis exceeds ±0.25 diopters, i.e., is greater than or less than the non-zero refractive power.

[0205] Inventive Concept 39D: The method of Inventive Concept 39 has a non-zero refractive power through its optical axis, wherein the refractive power of a circular portion surrounding the optical axis that constitutes 30%, 40%, 50%, 60%, or 70% of the area of ​​the optical article differs from the non-zero refractive power through the optical axis by at most 5%, or at most 3%, or at most 2%, or at most 1%, or at most 0.5%.

[0206] Inventive Concept 39E: The method as described in Inventive Concept 39D, wherein the difference between the refractive power of the annular region defined by the outer periphery of the circular portion and the peripheral portion of the optical article and the non-zero refractive power through the optical axis exceeds 0.5%, or exceeds 1%, or exceeds 2%, or exceeds 3%, or exceeds 5%, i.e., is greater than or less than the non-zero refractive power.

[0207] Inventive Concept 39F: The method as described in any one of Inventive Concepts 39B or 39D, wherein the circular portion has a diameter of 30 mm.

[0208] Inventive Concept 39G: The method as described in any one of Inventive Concepts 39B or 39D, wherein the circular portion has a diameter of 35 mm.

[0209] Inventive Concept 39H: The method as described in any one of Inventive Concepts 39B or 39D, wherein the circular portion has a diameter of 40 mm.

[0210] Inventive Concept 39I: The method of Inventive Concept 39 has a non-zero refractive power through its optical axis, wherein the refractive power of at least half an area of ​​the optical article differs from the non-zero refractive power through the optical axis by ±0.125 diopters.

[0211] Inventive Concept 39J: The method of Inventive Concept 39 has a non-zero refractive power through its optical axis, wherein the refractive power of a circular portion surrounding the optical axis that constitutes 30%, 40%, 50%, 60%, or 70% of the area of ​​the optical article differs from the non-zero refractive power through the optical axis by ±0.125 diopters.

[0212] Inventive Concept 39K: The method as described in Inventive Concept 39I, wherein the difference between the refractive power of the annular region defined by the outer periphery of the circular portion and the peripheral portion of the optical article and the non-zero refractive power through the optical axis exceeds ±0.125 diopters, i.e., is greater than or less than the non-zero refractive power.

[0213] Inventive Concept 39L: The method of any one of Inventive Concepts 39B to 39K, wherein the refractive power of the circular portion is the mean refractive power.

[0214] Inventive Concept 39M: The method as described in any one of Inventive Concepts 39C, 39E or 39K, wherein the refractive power of the annular region is the mean refractive power.

[0215] Inventive concept 40: The method of any one of inventive concepts 39 and 39A to 39M is configured to incorporate prism correction.

[0216] Inventive Concept 41: An apparatus for performing the method as described in any one of Inventive Concepts 1 to 40, the apparatus comprising a power-driven rotatable mold and a source of polymerization radiation arranged to subject the polymerizable composition to the polymerization radiation.

[0217] Inventive Concept 42: A manufacturing system configured to perform the method as described in any one of Inventive Concepts 1 to 40, the manufacturing system comprising a power-driven rotatable mold and a source of polymeric radiation.

[0218] Inventive Concept 43: An automated manufacturing system comprising a power-driven rotatable mold, a source of polymeric radiation, and a control system programmed to perform introduction, rotation, and treatment as described in any one of Inventive Concepts 1 to 40.

[0219] Inventive Concept 44: An apparatus for manufacturing optical articles from a radiation-polymerizable composition, the apparatus comprising: (a) a power-driven rotatable mold shaped to receive a quantity of the radiation-polymerizable composition, the mold comprising: a bottom wall portion disposed thereon for forming a first surface of the optical article; and a peripheral wall portion having a minimum height at least 1 mm higher than the maximum point of the bottom wall portion; and (b) a source of polymerization radiation disposed thereon for irradiating at least a portion of the polymerizable composition with the polymerization radiation to solidify the polymerizable composition, wherein, in a first operating mode of the apparatus, when the mold rotates at a speed between 10 and 200 revolutions per minute with a radiation-polymerizable composition having a viscosity between 20 and 2000 cP at room temperature residing therein, the rotation effectively alters the profile of a second surface of the polymerizable composition to form a concave parabolic shape.

[0220] Inventive Concept 45: The apparatus as described in Inventive Concept 44, the apparatus further comprising a container arranged to store a supply of the radiation-polymerizable composition.

[0221] Inventive Concept 46: The apparatus as described in any one of Inventive Concepts 44 or 45, the apparatus further comprising a fluid delivery device for supplying a quantity of the radiation-polymerizable composition to the rotatable mold via the fluid delivery device.

[0222] Inventive Concept 47: The device as described in Inventive Concept 46, wherein the fluid delivery device includes a metering or measuring device for metering or measuring the amount of the radiation-polymerizable composition.

[0223] Inventive Concept 48: The device as described in any one of Inventive Concepts 44 to 47, wherein the mold includes a non-destructive removable element, the non-destructive removable element including the bottom wall portion.

[0224] Inventive Concept 49: The device as described in any one of Inventive Concepts 44 to 47, wherein the bottom wall portion is permanently fixed to the mold.

[0225] Inventive Concept 50: The device as described in any one of Inventive Concepts 40 to 47, wherein the bottom wall portion is integrally formed with the mold.

[0226] Inventive Concept 51: The device as described in any one of Inventive Concepts 44 to 50, wherein the minimum height of the wall portion of the mold is at least 2 mm higher than the highest point of the bottom wall portion.

[0227] Inventive Concept 52: The device as described in any one of Inventive Concepts 44 to 51, wherein the mold includes a non-destructive removable element that constrains the peripheral contour of the optical article.

[0228] Inventive Concept 53: The device as described in Inventive Concept 52, wherein the minimum height of the removable element constraining the peripheral contour is at least 2 mm higher than the highest point of the bottom wall portion.

[0229] Inventive Concept 54: The device as described in any one of Inventive Concepts 44 to 53, the device comprising a motor configured to rotate the mold at a constant speed of less than 500 revolutions per minute.

[0230] Inventive Concept 55: The device as described in any one of Inventive Concepts 44 to 53, the device comprising a motor configured to rotate the mold at a constant speed between 10 revolutions per minute and 300 revolutions per minute.

[0231] Inventive Concept 56: The device as described in any one of Inventive Concepts 54 or 55, wherein the speed can be selected in increments of no more than 10 revolutions per minute.

[0232] Inventive Concept 57: The device as described in any one of Inventive Concepts 44 to 56, wherein the source of the polymerizing radiation is wavelength selectable.

[0233] Inventive Concept 58: The device as described in any one of Inventive Concepts 44 to 57, wherein the source of the polymerizing radiation is directional.

[0234] Inventive Concept 59: The device as described in any one of Inventive Concepts 44 to 57, wherein the source of said polymeric radiation includes an adjustable or replaceable mask.

[0235] Inventive Concept 60: The apparatus of any one of Inventive Concepts 44 to 59, wherein the source of the polymerization radiation is arranged to irradiate a portion of the polymerizable composition not on the upper surface.

[0236] Inventive Concept 61: A method of manufacturing an optical article, the method comprising: (a) introducing a radiation-curable composition into a mold, the bottom wall portion of the mold being shaped to form a first surface of the optical article thereon; (b) rotating the mold about its center of rotation to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape; and (c) subjecting the curable composition to curing radiation to solidify the composition.

[0237] Inventive Concept 62: The method as described in Inventive Concept 61, wherein the solidification effectively maintains the concave parabolic shape.

[0238] Inventive Concept 63: The method as described in Inventive Concept 61, wherein the second surface of the optical article is characterized by a concave parabolic curvature.

[0239] Inventive Concept 64: The method of any one of Inventive Concepts 61 to 63, wherein the optical article includes corrective spectacle lenses.

[0240] Inventive Concept 65: The method as described in Inventive Concept 64, wherein the optical article includes a progressive lens.

[0241] Inventive Concept 66: The method as described in Inventive Concept 64, wherein the optical article includes a multifocal lens.

[0242] Inventive Concept 67: The method as described in Inventive Concept 64, wherein the optical article includes a bifocal lens.

[0243] Inventive Concept 68: The method of any one of Inventive Concepts 61 to 67, wherein the first surface is characterized at least in part by spherical curvature.

[0244] Inventive Concept 69: The method of any one of Inventive Concepts 61 to 67, wherein the first surface is characterized at least in part by aspherical curvature.

[0245] Inventive concept 70: The method of any one of inventive concepts 61 to 67, wherein the first surface is characterized at least in part by zero curvature.

[0246] Inventive Concept 71: The method of any one of Inventive Concepts 61 to 67, wherein the first surface is characterized by a plurality of different curvatures.

[0247] Inventive Concept 72: The method of any one of Inventive Concepts 61 to 67, wherein the first surface is characterized by comprising one or more facets.

[0248] Inventive Concept 73: The method of any one of Inventive Concepts 61 to 72, wherein the optical article comprises a colorant.

[0249] Inventive Concept 74: The method of any one of Inventive Concepts 61 to 73, wherein the solidification effectively maintains the concave parabolic shape.

[0250] Inventive Concept 75: The method of any one of Inventive Concepts 61 to 74, wherein the optical article includes a lens.

[0251] Inventive Concept 76: The method of any one of Inventive Concepts 61 to 75, the method further comprising: selecting a bottom wall portion based on parameters of the optical article.

[0252] Inventive Concept 77: The method of any one of Inventive Concepts 61 to 75, the method further comprising: selecting a mold based on the shape of the bottom wall portion, the selection being based on parameters of the optical article.

[0253] Inventive Concept 78: The method of any one of Inventive Concepts 61 to 77, wherein subjecting the polymerizable composition to the polymerization radiation comprises subjecting substantially all of the upper surface to the polymerization radiation.

[0254] Inventive Concept 79: The method of any one of Inventive Concepts 61 to 77, wherein subjecting the polymerizable composition to the polymerization radiation comprises selectively subjecting a first portion of the upper surface to the polymerization radiation while not subjecting a second portion of the upper surface to the polymerization radiation.

[0255] Inventive Concept 80: The method as described in Inventive Concept 79, wherein the selective exposure includes shielding the polymeric radiation so that it cannot reach the second portion.

[0256] Inventive Concept 81: The method of Inventive Concept 79, wherein the selective exposure includes using a directional radiation source to emit the aggregated radiation.

[0257] Inventive Concept 82: The method of any one of Inventive Concepts 61 to 81, wherein subjecting the polymerizable composition to the polymerization radiation comprises subjecting at least a portion of the lower surface of the polymerizable composition to the polymerization radiation.

[0258] Inventive Concept 83: The method of any one of Inventive Concepts 61 to 81, the method further comprising: mounting in the mold a non-destructive removable element that constrains the peripheral contour of the optical article.

[0259] Inventive Concept 84: The method as described in Inventive Concept 83, the method further comprising: selecting the removable element constraining the peripheral contour of the optical article based on parameters of the optical article.

[0260] Inventive Concept 85: The method of Inventive Concept 83, the method further comprising: manufacturing the removable element constraining the peripheral contour of the optical article.

[0261] Inventive Concept 86: The method of any one of Inventive Concepts 61 to 85, the method further comprising performing at least one of the following: machining, grinding, stamping, polishing and buffing the edges of the solidified composition.

[0262] Inventive Concept 87: The method of any one of Inventive Concepts 61 to 86, the method further comprising performing at least one of the following: machining, grinding, polishing and buffing the main surface of the solidified composition.

[0263] Inventive Concept 88: The method of any one of inventive concepts 61 to 87, the method further comprising performing at least one of the following: coating, printing, or depositing on at least one of the first main surface and the second main surface.

[0264] Inventive Concept 89: The method of any one of Inventive Concepts 61 to 88, the method further comprising: further curing the solidified composition.

[0265] Inventive Concept 90: The method of any one of Inventive Concepts 61 to 89, wherein the manufacture of the optical article is completed by subjecting the polymerizable composition to the polymerization radiation.

[0266] Inventive Concept 91: The method of any one of Inventive Concepts 61 to 90, wherein the method further comprises: mounting the optical article in an eyeglass frame.

[0267] Inventive Concept 92: The method of any one of Inventive Concepts 61 to 91, wherein the rotation is at a speed of less than 300 revolutions per minute.

[0268] Inventive Concept 93: The method of any one of Inventive Concepts 61 to 92, wherein the rotation is at a speed between 10 and 300 RPM.

[0269] Inventive Concept 94: The method of any one of Inventive Concepts 61 to 93, wherein the rotation is at a speed between 40 and 100 RPM.

[0270] Inventive Concept 95: The method of any one of Inventive Concepts 61 to 94, the method further comprising: adding a colorant to the radiation-polymerizable composition.

[0271] Inventive Concept 96: The method as described in Inventive Concept 95, wherein the colorant is added to the mold.

[0272] Inventive Concept 97: The method as described in Inventive Concept 95, wherein the colorant is added during the rotation.

[0273] Inventive Concept 98: The method of any one of Inventive Concepts 61 to 94, wherein the composition comprises a colorant.

[0274] Inventive Concept 99: The method of any one of Inventive Concepts 95 to 98, wherein the colorant comprises a photochromic dye.

[0275] Inventive Concept 100: The method of any one of Inventive Concepts 61 to 99, wherein at least a portion of subjecting the polymerizable composition to the polymerization radiation is performed during the rotation.

[0276] Inventive Concept 101: The method of any one of Inventive Concepts 61 to 100, wherein the solidification effectively maintains the concave parabolic shape.

[0277] Inventive Concept 102: The method of any one of Inventive Concepts 61 to 101, wherein the second surface of the optical article is characterized by a concave parabolic curvature.

[0278] Inventive Concept 103: The method of any one of Inventive Concepts 61 to 102, wherein the optical article includes corrective spectacle lenses.

[0279] Inventive Concept 104: The method of any one of Inventive Concepts 61 to 103, wherein the optical article comprises a progressive lens.

[0280] Inventive Concept 105: The method of any one of Inventive Concepts 61 to 103, wherein the optical article comprises a multifocal lens.

[0281] Inventive Concept 106: The method of any one of Inventive Concepts 61 to 103, wherein the optical article comprises a bifocal lens.

[0282] Inventive Concept 107: The method of any one of Inventive Concepts 61 to 106, wherein the first surface is characterized at least in part by spherical curvature.

[0283] Inventive Concept 108: The method of any one of Inventive Concepts 61 to 106, wherein the first surface is characterized at least in part by aspherical curvature.

[0284] Inventive Concept 109: The method of any one of Inventive Concepts 61 to 106, wherein the first surface is characterized at least in part by zero curvature.

[0285] Inventive Concept 110: The method of any one of Inventive Concepts 61 to 109, wherein the first surface is characterized by a plurality of different curvatures.

[0286] Inventive Concept 111: The method of any one of Inventive Concepts 61 to 110, wherein the first surface is characterized by comprising one or more facets.

[0287] Inventive Concept 112: The method of any one of Inventive Concepts 61 to 111, wherein the optical article comprises a colorant.

[0288] Inventive Concept 113. A system for manufacturing an optical article, the system comprising: (a) a molding assembly including: (i) a rotatable mold adapted to produce the optical article from a radiation-polymerizable composition therein, wherein the production includes forming a parabolic shape on a surface of the radiation-polymerizable composition by rotating the mold; and (ii) a source of polymerization radiation arranged to solidify at least a portion of the polymerizable composition by irradiating the at least a portion thereof; and (b) electronic circuitry configured to adjust the operation of the molding assembly in response to input received via a user interface, the input defining one or more shape and / or compositional parameters of the optical article.

[0289] Inventive Concept 114: The system as described in Inventive Concept 113, the system further comprising: a material supply assembly including one or more containers for storing the radiation-polymerizable composition; and a conveying device for supplying a quantity of the radiation-polymerizable composition to the rotatable mold via the conveying device.

[0290] Inventive Concept 115: The system as described in Inventive Concept 114, wherein the electronic circuitry is further configured to regulate the operation of the material supply assembly.

[0291] Inventive Concept 116: The system as described in any one of Inventive Concepts 113 to 115, wherein the user interface includes an interactive input device.

[0292] Inventive Concept 117: The system as described in any one of Inventive Concepts 113 to 116, wherein the electronic circuit communicates with a product database.

[0293] Inventive Concept 118: A system as described in any one of Inventive Concepts 113 to 117, wherein the electronic circuitry is configured to determine operating parameters at least in part based on one or more of the inputs.

[0294] Inventive Concept 119: The system as described in Inventive Concept 118, wherein the operating parameters include the rotational speed of the mold.

[0295] Inventive Concept 120: The system as described in Inventive Concept 118, wherein the operating parameters include the amount of the radiation-polymerizable composition.

[0296] Inventive Concept 121: The system as described in Inventive Concept 118, wherein the operating parameters include the rotation time for forming the parabolic shape.

[0297] Inventive Concept 122: The system as described in Inventive Concept 121, wherein the electronic circuitry is programmed to initiate the irradiation of the polymerizable composition with the polymerization radiation after the rotation time.

[0298] Inventive Concept 123: A system as described in Inventive Concept 121, wherein the electronic circuitry is programmed to initiate the irradiation of the polymerizable composition with the polymerizing radiation in response to an input from a sensor.

[0299] Inventive Concept 124: The system as described in Inventive Concept 123, the system further comprising a visual sensor configured to monitor the liquid level of the radiation-polymerizable composition.

[0300] Inventive Concept 125: A system as described in any one of Inventive Concepts 118 to 124, wherein one or more inputs include prescription data for the optical article.

[0301] Inventive Concept 126: A system as described in any one of Inventive Concepts 118 to 125, wherein one or more inputs include the refractive index of the radiation-polymerizable composition.

[0302] Inventive Concept 127: The system as described in any one of Inventive Concepts 118 to 126, wherein the one or more inputs include color.

[0303] Inventive Concept 128: A system as described in any one of Inventive Concepts 118 to 127, wherein one or more inputs include the shape of the optical article.

[0304] Inventive Concept 129: The system as described in any one of Inventive Concepts 118 to 128, wherein the one or more inputs include the model name of the lens and / or eyeglass frame.

[0305] Inventive Concept 130: The system as described in any one of Inventive Concepts 113 to 129, the system further comprising a fluid bath for post-processing.

[0306] Inventive Concept 131: The system as described in any one of Inventive Concepts 113 to 130, the system further comprising a printing system for post-processing.

[0307] Inventive Concept 131A: The system as described in any one of Inventive Concepts 113 to 131, the system further comprising a 3D printer for manufacturing removable elements that constrain the peripheral contour of the optical article.

[0308] Inventive Concept 132: The system as described in any one of Inventive Concepts 113 to 131A, wherein the system further includes any one of the structural features described in Inventive Concepts 1 to 112.

[0309] Inventive Concept 133. An apparatus for manufacturing an optical article from a radiation-polymerizable composition, the apparatus comprising: (a) a mold shaped to receive an amount of the radiation-polymerizable composition, the mold including a bottom wall portion arranged for forming a first surface of the optical article thereon, and configured, upon electrical activation, to rotate at a selectable speed to generate a centrifugal force, the centrifugal force combined with gravity to alter the profile of a second surface of the polymerizable composition received in the mold to a concave parabolic shape; and (b) a source of polymerization radiation aligned with the mold to irradiate at least a portion of the polymerizable composition upon activation with the polymerization radiation to cause the portion to solidify.

[0310] Inventive Concept 134: The apparatus as described in Inventive Concept 133, the apparatus further comprising a container arranged to store a supply of the radiation-polymerizable composition.

[0311] Inventive Concept 135: The apparatus as described in any one of Inventive Concepts 133 or 134, the apparatus further comprising a fluid delivery device for supplying a quantity of the radiation-polymerizable composition to the rotatable mold via the fluid delivery device.

[0312] Inventive Concept 136: The device as described in Inventive Concept 135, wherein the fluid delivery device includes a metering or measuring device for metering or measuring the amount of the radiation-polymerizable composition.

[0313] Inventive Concept 137: The device as described in any one of Inventive Concepts 133 to 136, wherein the mold includes a non-destructive removable element, the non-destructive removable element including the bottom wall portion.

[0314] Inventive Concept 138: The device as described in any one of Inventive Concepts 133 to 136, wherein the bottom wall portion is permanently fixed to the mold.

[0315] Inventive Concept 139: The device as described in any one of Inventive Concepts 133 to 136, wherein the bottom wall portion is integrally formed with the mold.

[0316] Inventive Concept 140: The device as described in any one of Inventive Concepts 133 to 139, wherein the minimum height of the wall portion of the mold is at least 2 mm higher than the highest point of the bottom wall portion.

[0317] Inventive Concept 141: The device as described in any one of Inventive Concepts 133 to 140, wherein the mold includes a non-destructive removable element that constrains the peripheral contour of the optical article.

[0318] Inventive Concept 142: The device as described in Inventive Concept 141, wherein the minimum height of the removable element constraining the peripheral contour is at least 2 mm higher than the highest point of the bottom wall portion.

[0319] Inventive Concept 143: The device as described in any one of Inventive Concepts 133 to 142, the device comprising a motor configured to rotate the mold at a constant speed of less than 300 RPM.

[0320] Inventive Concept 144: The device as described in any one of Inventive Concepts 133 to 142, the device comprising a motor configured to rotate the mold at a constant speed between 10 and 300 RPM.

[0321] Inventive Concept 145: The device as described in any one of Inventive Concepts 143 or 144, wherein the speed can be selected in increments not exceeding 10 RPM.

[0322] Inventive Concept 146: The device as described in any one of Inventive Concepts 133 to 145, wherein the source of the polymerizing radiation is wavelength selectable.

[0323] Inventive Concept 147: The device as described in any one of Inventive Concepts 133 to 146, wherein the source of the polymerizing radiation is directional.

[0324] Inventive Concept 148: The device as described in any one of Inventive Concepts 133 to 147, wherein the source of said polymeric radiation includes an adjustable or replaceable mask.

[0325] Inventive Concept 148A: The device as described in any one of Inventive Concepts 133 to 148, wherein the source of the polymerization radiation is arranged to irradiate a portion of the polymerizable composition not on the upper surface.

[0326] Inventive Concept 149: The device as described in any one of Inventive Concepts 133 to 148A, wherein the device further includes any one of the structural features described in Inventive Concepts 1 to 132.

[0327] Inventive Concept 150. An optical article comprising: a first main surface characterized at least in part by a convex spherical curvature; and a second main surface characterized at least in part by a concave parabolic curvature.

[0328] Inventive Concept 150A. An optical article as described in Inventive Concept 150, wherein at least a portion of the curvature of the convex spherical surface is aligned with at least a portion of the curvature of the concave parabolic surface such that a straight line parallel to the optical axis of the optical article passes through both portions.

[0329] Inventive Concept 151. An optical article comprising: a first primary surface characterized at least in part by an aspherical curvature; and a second primary surface characterized at least in part by a concave parabolic curvature.

[0330] Inventive Concept 151A. An optical article as described in Inventive Concept 151, wherein at least a portion of the curvature of the aspherical spherical surface is aligned with at least a portion of the curvature of the concave parabolic surface, such that a line parallel to the optical axis of the optical article passes through both portions.

[0331] Inventive Concept 152. An optical article comprising: a first main surface characterized at least in part by zero curvature; and a second main surface characterized at least in part by concave parabolic curvature.

[0332] Inventive Concept 153: An optical article comprising: a first main surface characterized at least in part by a plurality of different curvatures; and a second main surface characterized at least in part by a concave parabolic curvature.

[0333] Inventive Concept 154: An optical article comprising: a first main surface characterized at least in part by a concave spherical curvature; and a second main surface characterized at least in part by a concave parabolic curvature.

[0334] Inventive Concept 155: An optical article as described in any one of Inventive Concepts 150 to 154, wherein the second surface comprises the parabolic vertex of the parabolic curvature.

[0335] Inventive Concept 156: An optical article as described in Inventive Concept 155, wherein the optical axis of the optical article passes through the vertex of the parabola.

[0336] Inventive Concept 156A: An optical article as described in any one of Inventive Concepts 155 or 156, wherein the vertex of the parabola is not located at the centroid of the optical article.

[0337] Inventive Concept 157: An optical article as described in any one of Inventive Concepts 150 or 156A, wherein the optical article is produced by a method according to any one of the inventive concepts provided above.

[0338] Inventive Concept 158: A method for manufacturing an eyeglass lens blank, the method comprising: (a) introducing a radiation-curable composition into a mold surrounding a cavity with a diameter of at least 50 mm, the bottom wall portion of the mold being shaped to form a first surface of the eyeglass lens thereon; (b) rotating the mold about its rotation center at a speed of at least 30 rpm and not exceeding 120 rpm to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape; and (c) subjecting the curable composition to curing radiation to solidify the composition.

[0339] Inventive Concept 159: The method as described in Inventive Concept 158, wherein the minimum thickness of the solidified composition is at least 1 mm.

[0340] Inventive Concept 160: The method as described in any one of Inventive Concepts 158 or 159, wherein the average thickness of the solidified composition is at least 2 mm.

[0341] Inventive Concept 161: The method of any one of Inventive Concepts 158 to 160, wherein the amount introduced has a volume of at least 6 cc.

[0342] Inventive Concept 162: The method of any one of Inventive Concepts 158 to 161, wherein the spectacle lens blank comprises a single-vision lens blank.

[0343] Inventive Concept 163: The method of any one of Inventive Concepts 158 to 162, wherein the spectacle lens blank comprises a finished lens blank.

[0344] Inventive Concept 164: The method of any one of Inventive Concepts 158 to 163, the method further comprising: selecting the bottom wall portion based on at least one of the refractive power and refractive index of the spectacle lens blank; and mounting the bottom wall portion in the mold.

[0345] Inventive Concept 165: The method of any one of Inventive Concepts 158 to 164, wherein the bottom wall portion is separable from the mold without damage.

[0346] Inventive Concept 166: The method of any one of Inventive Concepts 158 to 165, the method further comprising: selecting the mold based on at least one of the refractive power and refractive index of the spectacle lens blank.

[0347] Inventive Concept 167: The method of any one of Inventive Concepts 158 to 166, wherein subjecting the polymerizable composition to the polymerization radiation comprises subjecting at least a portion of the lower surface of the polymerizable composition to the polymerization radiation.

[0348] Inventive Concept 168: The method of any one of Inventive Concepts 158 to 167, wherein at least a portion of subjecting the polymerizable composition to the polymerization radiation is performed during the rotation.

[0349] Inventive Concept 168a: The method as described in any one of Inventive Concepts 158 to 168, the method comprising any method steps of any of the inventive concepts provided above.

[0350] Inventive Concept 169: An apparatus for performing the method as described in any one of Inventive Concepts 158 to 168a, the apparatus comprising: a power-driven rotatable mold surrounding a cavity with a diameter of at least 50 mm; and a source of polymerization radiation arranged to subject the polymerizable composition to the polymerization radiation.

[0351] Inventive Concept 170: The device as described in Inventive Concept 169, the device including a motor operable to cause the mold to rotate at a constant speed between 30 and 120 revolutions per minute.

[0352] Inventive Concept 171: A manufacturing system comprising: a power-driven rotatable mold surrounding a cavity with a diameter of at least 50 mm; a source of polymeric radiation; and a control system programmed to perform introduction, rotation, and exposure as described in any one of Inventive Concepts 158 to 168.

[0353] Inventive Concept 172: A spectacle lens blank, said spectacle lens blank being manufactured using any of the methods described in Inventive Concepts 158 to 168.

[0354] Inventive Concept 173: A system for manufacturing spectacle lens preforms from a radiation-polymerizable composition, the system comprising: (a) a rotatable mold surrounding a cavity with a diameter of at least 50 mm, the mold including: a bottom wall portion disposed thereon for forming a first surface of the spectacle lens preform; and a peripheral wall portion having a minimum height at least 1 mm higher than the maximum point of the bottom wall portion; (b) an electric motor operable to rotate the mold at a constant speed between 30 and 120 revolutions per minute; and (c) a source of polymerization radiation disposed thereon to irradiate at least a portion of the polymerizable composition with the polymerization radiation, wherein in a first operating mode of the system, when the viscosity of the mold is between 20 and 2000 at room temperature... When the radiation-polymerizable composition between cPs resides in the cavity and rotates at a speed between 30 and 120 revolutions per minute, the rotation effectively alters the profile of the upper surface of the polymerizable composition to form a concave parabolic shape, the radiation-polymerizable composition having a volume between 0.25 and 0.35 cc per cm² cavity area.

[0355] Inventive Concept 174: The system as described in Inventive Concept 173, the system further includes electronic circuitry configured to regulate the operation of at least one of the power-driven rotatable mold and the source of the polymeric radiation in response to an input received via a user interface, the input defining one or more shape and / or composition parameters of the spectacle lens blank.

[0356] Inventive Concept 175: A system as described in Inventive Concept 174, wherein the electronic circuitry is configured to determine operating parameters based at least in part on one or more of the inputs.

[0357] Inventive Concept 176: The system as described in Inventive Concept 175, wherein the operating parameters include at least one of the following: the rotational speed of the mold, the amount of the radiation-polymerizable composition, and the rotational time for forming the parabolic shape.

[0358] Inventive Concept 177: A system as described in any one of Inventive Concepts 175 or 176, wherein the one or more inputs include at least one of the following: the refractive power of the spectacle lens blank, the refractive index of the radiation-polymerizable composition, and the diameter of the cavity of the mold.

[0359] Inventive Concept 178: A system as described in any one of Inventive Concepts 174 to 177, wherein the electronic circuitry is programmed to initiate the irradiation of the polymerizable composition with the polymerizing radiation after a determined rotation time.

[0360] Inventive Concept 179: A system as described in any one of Inventive Concepts 174 to 178, wherein the electronic circuitry is programmed to initiate the irradiation of the polymerizable composition with the polymerizing radiation in response to an input from a sensor.

[0361] Inventive Concept 180: The system as described in any one of Inventive Concepts 173 to 179, the system further comprising: a material supply assembly including one or more containers for storing the radiation-polymerizable composition; and a conveying device for supplying a quantity of the radiation-polymerizable composition to the rotatable mold via the conveying device.

[0362] Inventive Concept 181: The system as described in any one of Inventive Concepts 173 to 180, wherein the system further includes any one of the structural features of the inventive concepts provided above.

[0363] Inventive Concept 182: An optical article comprising: a spectacle lens having a maximum size between 30 mm and 85 mm, the optical article comprising: a first surface characterized at least in part by a convex spherical shape; and a second surface characterized at least in part by a concave parabolic shape.

[0364] Inventive Concept 182A: An optical article comprising: a spectacle lens blank having a diameter between 40 mm and 100 mm, the optical article comprising: a first surface characterized at least in part by a convex spherical shape; and a second surface characterized at least in part by a concave parabolic shape.

[0365] Inventive Concept 183: An optical article as described in Inventive Concept 182 or 182A, the optical article comprising a radiation-cured polymer.

[0366] Inventive Concept 184: An optical article as described in any one of Inventive Concepts 182 to 183, the optical article comprising a photoinitiator or its reaction product.

[0367] Inventive Concept 185: An optical article as described in any one of Inventive Concepts 182 to 184, the optical article having a non-zero refractive power through its optical axis, wherein the refractive power of at least half an area of ​​the optical article differs from the non-zero refractive power through the optical axis by ±0.25 diopters.

[0368] Inventive Concept 185A: An optical article as described in any one of Inventive Concepts 182 to 184, the optical article having a non-zero refractive power through its optical axis, wherein the refractive power of a circular portion surrounding the optical axis that constitutes 15%, 20%, 25%, 30%, 40%, 50%, 60%, or 70% of the area of ​​the optical article differs from the non-zero refractive power through the optical axis by ±0.25 diopters.

[0369] Inventive Concept 185B: In the optical article as described in Inventive Concept 185A, the circular portion constitutes 15% of the area of ​​the optical article.

[0370] Inventive Concept 185C: In the optical article as described in Inventive Concept 185A, the circular portion constitutes 25% of the area of ​​the optical article.

[0371] Inventive Concept 185D: An optical article as described in any one of Inventive Concepts 185A to 185C, wherein the difference between the refractive power of the annular region defined by the outer periphery of the circular portion and the peripheral portion of the optical article and the non-zero refractive power through the optical axis exceeds ±0.25 diopters, i.e., is greater than or less than the non-zero refractive power.

[0372] Inventive Concept 185E: An optical article as described in any one of Inventive Concepts 182 to 184, the optical article having a non-zero refractive power through its optical axis, wherein the refractive power of a circular portion surrounding the optical axis that constitutes 15%, 20%, 25%, 30%, 40%, 50%, 60%, or 70% of the area of ​​the optical article differs from the non-zero refractive power through the optical axis by at most 5%, or at most 3%, or at most 2%, or at most 1%, or at most 0.5%.

[0373] Inventive Concept 185F: An optical article as described in Inventive Concept 185E, wherein the refractive power differs from the non-zero refractive power through the optical axis by at most 5%.

[0374] Inventive Concept 185G: An optical article as described in Inventive Concept 185E, wherein the refractive power differs from the non-zero refractive power through the optical axis by at most 2%.

[0375] Inventive Concept 185H: An optical article as described in any one of Inventive Concepts 185A to 185G, wherein the difference between the refractive power of the annular region defined by the outer periphery of the circular portion and the peripheral portion of the optical article or the refractive power of the annular region and the non-zero refractive power through the optical axis exceeds 0.5%, or exceeds 1%, or exceeds 2%, or exceeds 3%, or exceeds 5%, i.e., is greater than or less than the non-zero refractive power.

[0376] Inventive Concept 185I: An optical article as described in any one of Inventive Concepts 185A to 185H, wherein the circular portion has a diameter of 30 mm.

[0377] Inventive Concept 185J: An optical article as described in Inventive Concept 185I, wherein the circular portion has a diameter of 35 mm.

[0378] Inventive Concept 185K: An optical article as described in Inventive Concept 185I, wherein the circular portion has a diameter of 40 mm.

[0379] Inventive Concept 186: An optical article as described in any one of Inventive Concepts 182 to 185K, the optical article having a non-zero refractive power through its optical axis, wherein the refractive power of at least half an area of ​​the optical article differs from the non-zero refractive power through the optical axis by ±0.125 diopters.

[0380] Inventive Concept 186A: An optical article as described in any one of Inventive Concepts 182 to 185K, the optical article having a non-zero refractive power through its optical axis, wherein the refractive power of a circular portion surrounding the optical axis that constitutes 30%, 40%, 50%, 60%, or 70% of the area of ​​the optical article differs from the non-zero refractive power through the optical axis by ±0.125 diopters.

[0381] Inventive Concept 186B: An optical article as described in Inventive Concept 186A, wherein the difference between the refractive power of the annular region defined by the outer periphery of the circular portion and the peripheral portion of the optical article and the non-zero refractive power through the optical axis exceeds ±0.125 diopters, i.e., is greater than or less than the non-zero refractive power.

[0382] Inventive Concept 186C: An optical article as described in any of the foregoing inventive concepts, wherein the refractive power of the circular portion is the mean refractive power.

[0383] Inventive Concept 186D: An optical article as described in any of the foregoing inventive concepts, wherein the refractive power of the annular region is the average refractive power.

[0384] Inventive Concept 186E: An optical article as described in any of the foregoing inventive concepts, wherein the ratio of the surface roughness of the second surface to the surface roughness of the first surface is at least 1.1:1.

[0385] Inventive Concept 186F: An optical article as described in Inventive Concept 186E, wherein the ratio of the surface roughness is at least 2:1.

[0386] Inventive Concept 186G: An optical article as described in Inventive Concept 186E, wherein the ratio of the surface roughness is at least 5:1.

[0387] Inventive Concept 186H: An optical article as described in Inventive Concept 186E, wherein the ratio of the surface roughness is at least 30:1.

[0388] Inventive Concept 186I: An optical article as described in Inventive Concept 186E, wherein the ratio of the surface roughness is in the range of 2 to 500.

[0389] Inventive Concept 186J: An optical article as described in Inventive Concept 186E, wherein the ratio of the surface roughness is in the range of 5 to 100.

[0390] Inventive Concept 186K: An optical article as described in any one of Inventive Concepts 186E to 186J, wherein the surface roughness is the average surface roughness (Ra).

[0391] Inventive Concept 186L: An optical article as described in any of the foregoing inventive concepts, wherein a detectable artifact is provided within the optical article, the artifact indicating internal material flow (e.g., traceable to polymerization in a rotating mold).

[0392] Inventive Concept 187: An optical article as described in any of the foregoing inventive concepts, wherein the optical article is shaped to incorporate prism correction.

[0393] Inventive Concept 188: A method of manufacturing an optical article comprising spectacle lenses with a maximum size between 30 mm and 85 mm, or spectacle lens blanks with a diameter of at least 40 mm, the method comprising: a. introducing a radiation-curable composition into a mold, the mold surrounding a cavity and including a bottom wall portion, the bottom wall portion being shaped to form a first surface of the optical article thereon, the first surface being characterized at least in part by a convex spherical shape; b. rotating the mold at a speed of at least 50 rpm and not exceeding 120 rpm to displace a portion of the radiation-curable composition to change the profile of the upper surface of the curable composition to a concave parabolic shape; and c. subjecting the curable composition to curing radiation to solidify the composition.

[0394] Inventive Concept 189: The method as described in Inventive Concept 188, wherein the solidified composition has a minimum thickness of at least 1 mm and an average thickness of at least 2 mm.

[0395] Inventive Concept 190. The method as described in any one of Inventive Concepts 188 or 189, wherein the amount introduced has a volume of at least 6 cc.

[0396] Inventive Concept 191. The method of any one of Inventive Concepts 188 to 190, the method further comprising: selecting the mold based on at least one of the refractive power and refractive index of the solidified composition.

[0397] Inventive Concept 192. The method of any one of Inventive Concepts 188 to 191, wherein subjecting the polymerizable composition to the polymerization radiation comprises subjecting at least a portion of the lower surface of the polymerizable composition to the polymerization radiation.

[0398] Inventive Concept 193. The method of any one of Inventive Concepts 188 to 192, wherein at least a portion of subjecting the polymerizable composition to the polymerization radiation is performed during the rotation.

[0399] Inventive Concept 194. The method of any one of Inventive Concepts 188 to 193, wherein the optical article comprises finished lens blanks.

[0400] Inventive Concept 195. The method of any one of Inventive Concepts 188 to 194, wherein the optical article comprises spectacle lens blanks with a diameter of up to 100 mm.

[0401] Inventive Concept 196. The method of any one of Inventive Concepts 188 to 195, wherein subjecting the polymerizable composition to the polymerization radiation comprises selectively subjecting a first portion of the upper surface to the polymerization radiation while not subjecting a second portion of the upper surface to the polymerization radiation.

[0402] Inventive Concept 197. An apparatus for performing the method as described in any one of Inventive Concepts 188 to 196, the apparatus comprising: a power-driven rotatable mold surrounding a cavity with a diameter of at least 40 mm; and a source of polymerization radiation arranged to subject the polymerizable composition to the polymerization radiation.

[0403] Inventive Concept 198. The device as described in Inventive Concept 197, wherein the mold is tilted or tiltable for manufacturing an optical article shaped to incorporate prism correction.

[0404] Inventive Concept 199. The device as described in any one of Inventive Concepts 197 or 198, wherein the mold is arranged or may be arranged to rotate about an eccentric rotation axis for manufacturing an optical article shaped to incorporate prism correction.

[0405] Inventive Concept 200. A system for manufacturing an optical article comprising a spectacle lens preform or spectacle lens from a radiation-polymerizable composition, the system comprising: a. a rotatable mold surrounding a cavity having a diameter of at least 40 mm and at most 100 mm, the mold comprising: a bottom wall portion disposed thereon for forming a first surface of the spectacle lens preform; and a peripheral wall portion having a minimum height at least 1 mm higher than the maximum point of the bottom wall portion; b. an electric motor operable to rotate the mold at a constant speed between 50 rpm and 120 rpm; and c. a source of polymerization radiation disposed thereon to irradiate at least a portion of the polymerizable composition with the polymerization radiation, wherein in a first operating mode of the system, when the viscosity of the mold at room temperature is between 20 and 2000... When the radiation-polymerizable composition between cPs resides in the cavity and rotates at a speed between 50 and 120 revolutions per minute, the rotation effectively alters the profile of the upper surface of the polymerizable composition to form a concave parabolic shape, the radiation-polymerizable composition having a volume between 0.25 and 0.35 cc per cm² cavity area.

[0406] Inventive Concept 201. The system as described in Inventive Concept 200, the system further comprising electronic circuitry configured to regulate the operation of at least one of the power-driven rotatable mold and the source of the polymeric radiation in response to an input received via a user interface, the input defining one or more shape and / or composition parameters of the spectacle lens blank.

[0407] Inventive Concept 202. The system as described in Inventive Concept 201, wherein the electronic circuitry is configured to determine operating parameters of the first operating mode based at least in part on one or more of the inputs.

[0408] Inventive Concept 203. The system as described in Inventive Concept 202, wherein the operating parameters include at least one of the following: the rotational speed of the mold, the amount of the radiation-polymerizable composition, the rotational time for forming the parabolic shape before initiating the irradiation, and the duration of the irradiation.

[0409] Inventive Concept 204. The system as described in any one of Inventive Concepts 202 or 203, wherein the one or more inputs include at least one of the following: diopter, refractive index of the radiopolymerizable composition, diameter of the cavity of the mold, and model name of the lens and / or eyeglass frame.

[0410] The invention has been described in detail using embodiments thereof, which are provided by way of example and are not intended to limit the scope of the invention. The described embodiments include various features, and not all features are necessary in all embodiments of the invention. Some embodiments of the invention utilize only some features or possible combinations of said features. Those skilled in the art will conceive of variations of the described embodiments of the invention, as well as embodiments of the invention that include different combinations of the features indicated in the described embodiments.

Claims

1. A method for manufacturing spectacle lens blanks, the method comprising: a. Introducing a radiation-curable composition into a mold, the mold surrounding a cavity with a diameter of at least 50 mm, the bottom wall portion of the mold being shaped to form a first surface thereon of the spectacle lens blank; b. Rotate the mold about its center of rotation at a speed of at least 30 rpm and not more than 120 rpm to displace a portion of the radiation-curable composition in order to change the profile of the upper surface of the curable composition into a concave parabolic shape; as well as c. Exposing the curable composition to curing radiation to solidify the composition.

2. The method of claim 1, wherein the minimum thickness of the solidified composition is at least 1 mm.

3. The method of any one of claims 1 or 2, wherein the average thickness of the solidified composition is at least 2 mm.

4. The method as described in any of the preceding claims, wherein the volume of the introduced radiation-curable composition is at least 6 cc.

5. The method as claimed in any of the preceding claims, wherein the spectacle lens blank comprises a single-vision lens blank.

6. The method of any of the preceding claims, wherein the spectacle lens blank comprises a finished lens blank.

7. The method as described in any one of the preceding claims, wherein the method further comprises: The bottom wall portion is selected based on at least one of the refractive power and refractive index of the spectacle lens blank; And the bottom wall portion is installed in the mold.

8. The method as described in any of the preceding claims, wherein the bottom wall portion is separable from the mold without damage.

9. The method of any one of claims 1 to 6, wherein the method further comprises: The mold is selected based on at least one of the refractive power and refractive index of the spectacle lens blank.

10. The method of any of the preceding claims, wherein subjecting the polymerizable composition to the polymerization radiation comprises subjecting at least a portion of the lower surface of the polymerizable composition to the polymerization radiation.

11. The method of claim 10, wherein subjecting at least a portion of the lower surface to the polymerization radiation comprises reflecting the polymerization radiation through a mold bottom wall that is at least 90% transparent to the polymerization radiation.

12. The method of any of the preceding claims, wherein at least a portion of subjecting the polymerizable composition to the polymerization radiation is performed during the rotation.

13. An apparatus for performing the method as described in any of the preceding claims, the apparatus comprising: A power-driven rotatable mold, the rotatable mold surrounding a cavity with a diameter of at least 50 mm; and a source of polymerization radiation, the source of polymerization radiation being arranged to subject the polymerizable composition to the polymerization radiation.

14. The apparatus of claim 13, wherein the apparatus includes a motor operable to rotate the mold at a constant speed between 30 and 120 revolutions per minute.

15. A manufacturing system, the manufacturing system comprising: A power-driven rotatable mold, the rotatable mold surrounding a cavity with a diameter of at least 50 mm; A source of converging radiation; And a control system, which is programmed to perform introduction, rotation and undergoing as described in any one of claims 1 to 12.

16. A system for manufacturing spectacle lens preforms from a radiation-polymerizable composition, the system comprising: a. A rotatable mold surrounding a cavity with a diameter of at least 50 mm, the mold comprising: a bottom wall portion disposed thereon for forming a first surface of the spectacle lens blank; and a peripheral wall portion having a minimum height at least 1 mm higher than the highest point of the bottom wall portion; b. An electric motor, operable to rotate the mold at a constant speed between 30 and 120 revolutions per minute; and c. A source of polymerization radiation, said source of polymerization radiation being arranged to irradiate at least a portion of the polymerizable composition with said polymerization radiation. In the first operating mode of the system, when the mold is rotated at a speed between 30 and 120 revolutions per minute while the radiation-polymerizable composition with a viscosity between 20 and 2000 cP at room temperature resides in the cavity, the rotation effectively alters the profile of the upper surface of the polymerizable composition to form a concave parabolic shape, and the radiation-polymerizable composition has a volume between 0.25 and 0.35 cc per cm² cavity area.

17. The system of claim 16, further comprising electronic circuitry configured to regulate the operation of at least one of the power-driven rotatable mold and the source of the polymeric radiation in response to input received via a user interface, the input defining one or more shape and / or composition parameters of the spectacle lens blank.

18. The system of claim 17, wherein the electronic circuitry is configured to determine operating parameters based at least in part on one or more of the inputs.

19. The system of claim 18, wherein the operating parameters include at least one of the following: the rotational speed of the mold, the amount of the radiation-polymerizable composition, and the rotational time for forming the parabolic shape.

20. The system of any one of claims 18 or 19, wherein the one or more inputs include at least one of: the refractive power of the spectacle lens blank, the refractive index of the radiation-polymerizable composition, and the diameter of the cavity of the mold.

21. The system of any one of claims 17 to 20, wherein the electronic circuitry is programmed to initiate the irradiation of the polymerizable composition with the polymerizing radiation after a determined rotation time.

22. The system of any one of claims 17 to 21, wherein the electronic circuitry is programmed to initiate the irradiation of the polymerizable composition with the polymerizing radiation in response to an input from a sensor.

23. The system of any one of claims 16 to 22, wherein the system further comprises: A material supply assembly, the material supply assembly comprising one or more containers for storing the radiation-polymerizable composition; And a conveying device for supplying a certain amount of the radiation-polymerizable composition to the rotatable mold via the conveying device.

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