Method of preparing wafers with stretched polymers for wafer thermoforming and injection molding ophthalmic lenses comprising the wafer

Abstract

To manufacture lenses by injection molding without contaminating a mold.SOLUTION: A method of forming an ophthalmic laminate lens includes the steps of: forming a planar laminate by adhering a first stretched polymer layer 115 to a first side of a thermoplastic elastomer layer 120, and adhering a second polymer layer 125 to a second side of the thermoplastic elastomer layer, the first stretched polymer layer having a thickness greater than 250 pm, the second polymer layer having a thickness greater than 250 pm, and the thermoplastic elastomer layer having a thickness in a range of 15 μm to 150 μm; thermoforming the planar laminate into a curved laminate 105 having a pre-molding curvature; arranging the curved laminate in a mold 145a; and molding, via the mold set at a predetermined temperature and a predetermined pressure, the curved laminate with a polymer melt 140 into a curved lens, wherein the temperature of the polymer melt is above the stretch temperature of the first stretched polymer layer.SELECTED DRAWING: Figure 1D

Images