Method for manufacturing by molding an ophthalmic device and apparatus configured to equip a manufacturing system for molding the ophthalmic device

Abstract

The disclosure relates to a method for manufacturing by molding an ophthalmic device, comprising providing a molding shell comprising molding portions at least partially moveable one relative to each other in a predetermined direction; providing (121) a locking device configured to indivually lock in position and unlock the molding portions; providing (122) a single actuating and supporting member configured to be at least temporarily connected to the molding portions and to move each of the molding portions from a rest position to an individual determined position of molding; displacing (124) the single actuating and supporting member from an initial position in which the molding portions are unlocked and connected to the actuating and supporting member in the respective rest position, to a final position in which the molding portions have been moved to reach the respective individual determined positions of molding wherein the molding portions are locked in position and disconnected from the actuating and supporting member.

Description

[0001] Method for manufacturing by molding an ophthalmic device and apparatus configured to equip a manufacturing system for molding the ophthalmic device

[0002] FIELD OF THE DISCLOSURE

[0003] The disclosure relates to a method for manufacturing by molding an ophthalmic device and to a method for setting a mold for use in a manufacturing system configured for molding an ophthalmic device.

[0004] The disclosure also relates to an apparatus configured to equip such a manufacturing system for molding an ophthalmic device, and to the manufacturing system itself, which is configured for molding the ophthalmic device and which comprises the apparatus.

[0005] BACKGROUND ART

[0006] Manufacturing an ophthalmic device, such as a spectacle lens, can be made according to several technologies, including for instance machining and / or additive manufacturing and / or molding.

[0007] Depending on properties of the ophthalmic device to manufacture, such as material, optical function, roughness or other properties, machining and additive manufacturing can be time consuming, while molding generally requires to provide dedicated molds for obtaining the required properties of the ophthalmic device.

[0008] Therefore, in the field of molding, including injection molding and / or casting, a large number of molds can be required to provide a large number of ophthalmic devices having different properties, thus being not necessarily cost efficient for instance if the need for a specific ophthalmic device is reduced.

[0009] European patent EP 1 534 497 discloses a process for molding optical lenses from a thermosettable plastic material, wherein two molding shells having surfaces of a predetermined shape are arranged at a distance relative to one another and are sealed at their periphery, the plastic material being brought into the gap enclosed by the surfaces between the molding shells.

[0010] At least one of the surfaces is mechanically deformed by means of a plurality of mechanically operated positioning elements, from an initial shape into the predetermined shape immediately prior to the bringing in of the plastic material and as a function of predetermined data.

[0011] The deformation of the surface is sensed directly, or sensed indirectly by simultaneously deforming the surface and a reference surface located on a reference shell and by sensing the deformation of the latter, and the surface is deformed in a closed loop control circuit.

[0012] In this respect, the deformation sensing means are configured as a wave front sensor and dedicated micro manipulators comprising a large number of the mechanically operated positioning elements are used for deforming the shell(s).

[0013] European patent EP 4 337 454 discloses a method of manufacturing a spectacle lens, comprising collecting data of a surface of the spectacle lens to be produced, providing a first mold for the spectacle lens to be produced, the first mold having a first mold surface whose shape is determined depending on the data of the surface of the spectacle lens to be produced, wherein providing the first mold comprises determining the shape of an adaptive surface based on the data of the surface of the spectacle lens to be produced, generating the adaptive surface with the determined shape by means of a surface deformation device, and using the adaptive surface to create or form the first mold surface, then forming the spectacle lens from a curable ophthalmic lens material using the first mold, and curing the ophthalmic lens material, the surface deformation device being separated from the first mold during curing.

[0014] In patent EP 4 337 454, the adaptive surface forms the surface of a deformable membrane, and generating the adaptive surface comprises fixing or stabilizing the shape of the membrane by means of a thermal process and / or by locking a plurality of movable stamps in contact with the membrane.

[0015] The movable stamps are connected for instance via mechanical means and are each coupled to an actuator device and moved or driven by the actuator device. The actuator device may include a plurality of actuators, each actuator being coupled to a stamper or a group of stampers, or it is also possible to use one actuator that is coupled successively to the individual stamps, that is to say one after the other. In addition, the stamps can be locked simultaneously or one after the other, and after locking the stamps, the adaptive surface can be separated from the actuator device which moves the stamps.

[0016] In this respect, the stamps are held by means of a holding device which is designed to fix the position of the stamps after adjusting the shape of the adaptive surface. The holding device can accordingly also comprise a fixing device or serve as a fixing device.

[0017] SUMMARY OF THE DISCLOSURE

[0018] The disclosure is directed to a method for manufacturing by molding an ophthalmic device, carrying out a shaping of at least one mold, which is easy and convenient to implement.

[0019] The disclosure accordingly provides, according to a first aspect, a method for manufacturing by molding an ophthalmic device, comprising the steps of:

[0020] - providing at least one molding shell comprising a plurality of molding portions at least partially moveable one relative to each other in a predetermined direction;

[0021] - providing a locking device configured to individually lock in position and unlock the plurality of molding portions;

[0022] - providing a single actuating and supporting member configured to be at least temporarily connected to the plurality of molding portions and to move each of the plurality of molding portions from a rest position to an individual determined position of molding;

[0023] - displacing the single actuating and supporting member from an initial position in which the plurality of molding portions are unlocked and connected to the single actuating and supporting member in the respective rest position, to a final position in which the plurality of molding portions have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions are locked in position and disconnected from the single actuating and supporting member. According to the disclosure, each molding portion is moved from a rest position to a respective individual determined positions of molding, so that to create a determined shape of the at least one molding shell, thanks to the single actuating and supporting member which moves from its initial position in which all the molding portions are in the respective rest position to its final position in which all the molding portions are in the respective individual determined positions of molding.

[0024] In other words, all the molding portions are displaced together simultaneously until each molding portion reaches its respective individual determined position of molding in which the molding portion is locked in position and disconnected from the single actuating and supporting member.

[0025] The single actuating and supporting member can thus place individually, accurately and quickly all the molding portions of the molding shell itself, during a single displacement of the single actuating and supporting member, from its initial position to its final position.

[0026] It is to be noted that for only some of the molding portions, the respective individual determined position can be the same as the rest position, so that these molding portions are not moved as such because these molding portions are disconnected from the single actuating and supporting member when the latter is in its initial position.

[0027] More generally, the disclosure further relates to a method for setting a mold for use in a manufacturing system configured for molding an ophthalmic device.

[0028] The method for setting such a mold comprises the steps of:

[0029] - providing at least one molding shell comprising a plurality of molding portions at least partially moveable one relative to each other in a predetermined direction;

[0030] - providing a locking device configured to indivually lock in position and unlock the plurality of molding portions;

[0031] - providing a single actuating and supporting member configured to be at least temporarily connected to the plurality of molding portions and to move each of the plurality of molding portions from a rest position to an individual determined position of molding;

[0032] - displacing the single actuating and supporting member from an initial position in which the plurality of molding portions are unlocked and connected to the single actuating and supporting member in the respective rest position, to a final position in which the plurality of molding portions have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions are locked in position and disconnected from the single actuating and supporting member.

[0033] Advantageous and convenient features of the methods are described below.

[0034] The plurality of molding portions may be successively and / or at least partially simultaneously locked in position and disconnected from the single actuating and supporting member, depending on the respective individual determined positions of molding.

[0035] The molding portions may have longitudinal extension parts and mold shaping sections at free first ends of the longitudinal extension parts, and the locking device may be configured to individually lock in position and unlock the longitudinal extension parts of the plurality of molding portions.

[0036] The single actuating and supporting member may be formed by a plate located either in front of the free first ends of the longitudinal extension parts, or in front of second ends of the longitudinal extension parts which are opposite to the free first ends.

[0037] The single actuating and supporting member may drive the plurality of molding portions either by the respective free first ends or second ends of the longitudinal extension parts.

[0038] The method may comprise providing and locating a deformable membrane on the mold shaping sections of the molding portions.

[0039] The method may comprise connecting the single actuating and supporting member in the initial position to each of the plurality of molding portions in the respective rest position thanks to dedicated connecting members, and disconnecting the single actuating and supporting member in intermediate positions from each of the plurality of molding portions in the respective individual determined positions of molding, thanks to the dedicated connecting members.

[0040] The method may comprise unlocking each of the plurality of molding portions in the respective rest position thanks to dedicated locking members, and locking each of the plurality of molding portions in the respective individual determined positions of molding, thanks to the dedicated locking members.

[0041] It is to be noted that the locking device can comprise both dedicated locking members and dedicated connecting members, or that the dedicated locking members and the dedicated connecting members can be the same member.

[0042] The single actuating and supporting member may have, in section, a rectangular shape or at least partially a curved shape.

[0043] The method may comprise providing a predetermined volume of material, injecting and / or casting the predetermined volume of material into a mold having at least one of the molding shell, and curing the predetermined volume of material into the mold.

[0044] The disclosure further provides, according to a second aspect, an apparatus configured to equip a manufacturing system for molding an ophthalmic device, comprising at least one molding shell comprising a plurality of molding portions at least partially moveable one relative to each other in a predetermined direction; a locking device configured to individually lock in position and unlock the plurality of molding portions; a single actuating and supporting member configured to be at least temporarily connected to the plurality of molding portions and to move each of the plurality of molding portions from a rest position to an individual determined position of molding; the single actuating and supporting member being configured to be displaced from an initial position in which the plurality of molding portions are unlocked and connected to the single actuating and supporting member in the respective rest position, to a final position in which the plurality of molding portions have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions are locked in position and disconnected from the single actuating and supporting member.

[0045] According to the disclosure, each of the plurality of molding portions can be moved from a rest position to respective individual determined positions of molding, so that to create a determined shape of the at least one molding shell, thanks to the single actuating and supporting member which is configured to move from its initial position in which all the molding portions are in the respective rest position to its final position in which all the molding portions are in the respective individual determined positions of molding.

[0046] In other words, all the molding portions can be displaced together simultaneously until each molding portion reaches its respective individual determined positions of molding in which the molding portion is configured to be locked in position and to be disconnected from the single actuating and supporting member.

[0047] The single actuating and supporting member can thus place individually, accurately and quickly all the molding portions of the molding shell itself, during a single displacement of the single actuating and supporting member, from its initial position to its final position.

[0048] Advantageous and convenient features of the apparatus are described below.

[0049] The molding portions may have longitudinal extension parts and mold shaping sections at free first ends of the longitudinal extension parts, and the locking device may be configured to individually lock in position and unlock the longitudinal extension parts of the plurality of molding portions.

[0050] The single actuating and supporting member may be formed by a plate located either in front of the free first ends of the longitudinal extension parts, or in front of second ends of the longitudinal extension parts which are opposite to the free first ends.

[0051] The single actuating and supporting member may be configured to drive the plurality of molding portions either by the respective free first ends or second ends of the longitudinal extension parts. The single actuating and supporting member may have, in section, a rectangular shape or at least partially a curved shape.

[0052] The apparatus may comprise a deformable membrane configured to be located on the mold shaping sections of the molding portions.

[0053] The locking device may comprise dedicated locking members configured to unlock each of the plurality of molding portions in the respective rest position and to lock each of the plurality of molding portions in the respective individual determined positions of molding, so that the plurality of molding portions are successively and / or at least partially simultaneously locked in position and disconnected from the single actuating and supporting member, depending on the respective individual determined positions of molding.

[0054] The apparatus may comprise dedicated connecting members configured to connect the single actuating and supporting member in the initial position to each of the plurality of molding portions in the respective rest position, and to disconnect the single actuating and supporting member in intermediate positions from each of the plurality of molding portions in the respective individual determined positions of molding.

[0055] The disclosure further provides, according to a third aspect, a manufacturing system configured for molding an ophthalmic device, comprising an apparatus having at least one molding shell comprising a plurality of molding portions at least partially moveable one relative to each other in a predetermined direction; a locking device configured to individually lock in position and unlock the plurality of molding portions; a single actuating and supporting member configured to be at least temporarily connected to the plurality of molding portions and to move each of the plurality of molding portions from a rest position to an individual determined position of molding; the single actuating and supporting member being configured to be displaced from an initial position in which the plurality of molding portions are unlocked and connected to the single actuating and supporting member in the respective rest position, to a final position in which the plurality of molding portions have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions are locked in position and disconnected from the single actuating and supporting member.

[0056] The manufacturing system may comprise a mold having at least one of the molding shell which defines at least partially a molding cavity, an edge gate for receiving a predetermined volume of material by injection and / or casting and communicating with the molding cavity, and a curing device configured to cure the predetermined volume of material into the mold.

[0057] The locking force applied by the locking device can lock in position all the molding portions in the respective individual determined positions of molding both during the displacement of the single actuating and supporting member from its initial position to its final position and during molding.

[0058] For instance, the locking device can be configured to apply a first locking force to each molding portion in the respective individual determined position of molding during the displacement of the single actuating and supporting member from its initial position to its final position; and to apply a second locking force, greater than the first locking force, to all the molding portions in the respective individual determined positions of molding, during molding.

[0059] The manufacturing system may further comprise a command and control unit including system elements configured to run a computer program in order to implement at least a displacement of the single actuating and supporting member from the initial position in which the plurality of molding portions are unlocked and connected to the single actuating and supporting member in the respective rest position, to the final position in which the plurality of molding portions have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions are locked in position and disconnected from the single actuating and supporting member.

[0060] BRIEF DESCRIPTION OF THE DRAWINGS

[0061] The description of the disclosure now continues with a detailed description of advantageous embodiments given hereinafter by way of nonlimiting example and with reference to the appended drawings. Figure 1 schematically depicts a manufacturing system, such as a molding machine, configured to carry out steps of a method for manufacturing an ophthalmic device, according to the disclosure.

[0062] Figure 2 diagrammatically shows a client-server communication interface comprising system parts configured for transferring at least one configuration parameter determined by the method according to the disclosure to a remote data processing system.

[0063] Figure 3 is a block diagram illustrating operating steps of a method for manufacturing the ophthalmic device by molding thanks to the manufacturing system and / or to the client-server communication interface illustrated in Figures 1 and 2.

[0064] Figure 4 is a block diagram illustrating in detail further operating steps carried out thanks to a setting apparatus configured to equip the manufacturing system and / or to the client-server communication interface illustrated in Figures 1 and 2.

[0065] Figures 5 to 7 illustrate schematically the setting apparatus configured to equip the manufacturing system, in different configurations.

[0066] Figures 8 to 12 illustrates schematically alternative embodiments of the setting apparatus configured to equip the manufacturing system.

[0067] Figures 13 to 17 represent schematically in top view molding shapes generated thanks to the apparatus illustrated in Figures 5 to 12.

[0068] DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0069] The disclosure is directed to a method, an apparatus and a manufacturing system for manufacturing by molding an ophthalmic device.

[0070] Figure 1 illustrates a manufacturing system 1 configured to carry out molding steps of an ophthalmic device, such as for instance a spectacle lens.

[0071] The ophthalmic device has for instance a predetermined optical function and is made from a predetermined material.

[0072] The manufacturing system 1 comprises a molding machine 2 and system parts generally formed by at least one command and control unit 3 configured to communicate with a data processing system (or control unit) of the molding machine 2 and configured to run a computer program having instructions configured to implement at least some steps of the method, when said computer program is run by a computer.

[0073] The molding machine 2 here comprises an injection tool 4, for instance for injecting and / or casting a predetermined volume of the material, a mold 5 comprising molding shelves, at least of which comprising a plurality of molding portions at least partially moveable one relative to each other in a predetermined direction, an apparatus 6 for setting the at least one molding shell comprising the movable molding portions, and a data processing system or a control unit (not shown) configured for controlling the setting apparatus 6 and / or the injection tool 4.

[0074] The mold 5 defines at least partially a molding cavity in which is made an edge gate for receiving the predetermined volume of material by injection and / or casting and communicating with the molding cavity.

[0075] The command and control unit 3 comprises a microprocessor 7 having a memory 8, in particular a non-volatile memory, allowing it to load and store the computer program, also called software, which when it is executed in the microprocessor 7, allows the implementation of the method according to the disclosure and thus the use of the molding machine 2.

[0076] This non-volatile memory 8 is for example of the ROM (“read only memory”) type.

[0077] The command and control unit 3 further comprises a memory 9, in particular a volatile memory, allowing data to be stored during the execution of the software and the implementation of the method.

[0078] This volatile memory 9 is for example of the RAM or EEPROM type (respectively "random access memory" and "electrically erasable programmable read only memory”).

[0079] The command and control unit 3 may be only at least partially integrated into the molding machine 2. In other words, the command and control unit 3 may be arranged in part, or in whole, outside the molding machine 2. In particular, the command and control unit 3 may comprise one or a plurality of command and control modules located inside and / or outside the molding machine 2.

[0080] The molding machine 2 is here configured for molding and curing the predetermined volume of material into the mold 5 in order to form the ophthalmic device. The molding machine 2 thus comprises a curing device which is not represented.

[0081] In this respect, the command and control unit 3 is also configured to command and control at least some of steps of a molding method and a setting method described below in reference to Figures 3 and 4.

[0082] Figure 2 shows a client-server communication interface 10 comprising for instance a so-called supplier-side 1 1 a and another, so-called client-side 11 b, and these two sides communicating via for instance an internet interface 12.

[0083] The supplier-side 11 a comprises a supplier server 13a linked to a data processing system or a command and control unit 3a of the same type as that in Figure 1 , this server 13a being configured to communicate with the internet interface 12.

[0084] The client-side 11 b also comprises a client server 13b which is configured to communicate with the internet interface 12, and which is linked to a data processing system or a command and control unit 3b of the same type as that of the supplier-side .

[0085] In addition, the command and control unit 3b on the client-side 1 1 b is linked to a molding machine 2b of the same type as that in Figure 1 , and is configured to set a mold 5b having at least one molding shell comprising movable molding portions, and to mold an ophthalmic device thanks to this mold 5b.

[0086] For instance, the command and control unit 3a on the client-side 1 1 a is configured for receiving by a user some parameters about the ophthalmic device to be molded and about the movable molding portions of the molding shell of the mold 3b to be set for molding the ophthalmic device.

[0087] For instance, the parameters about the ophthalmic device may include geometrical characteristics and / or optical function and / or roughness and / or other ophthalmic properties of an ophthalmic surface of the ophthalmic device intended to be manufactured and / or at least one information representative of intrinsic parameter of a material of the ophthalmic device.

[0088] For instance, the parameters about the mold 5b includes information representative of the movable molding portions of the molding shell, such as a number, shapes, geometrical characteristics, positions, displacement speed and / or displacement distance of the molding portions, etc.

[0089] In this respect, the command and control unit 3b on the client-side 11 b, using the internet interface 12 and both client server 13b and supplier server 13a, sends the data received by the command and control unit 3b on the client-side 1 1 b, to the command and control unit 3a on the supplier-side 1 1 a for the determination of a setting file representative of locations of the molding portions of the molding shell of the mold 3b and / or of operational parameters.

[0090] The command and control unit 3a on the supplier-side 11 a executes the computer program that it contains in order to determine the setting file and / or operational parameters.

[0091] Using the supplier server 13a and the internet interface 12, the command and control unit 3a on the supplier-side 1 1 a sends the setting file and operational parameters to the command and control unit 3b on the client-side 1 1 b.

[0092] The command and control unit 3b on the client-side 1 1 b is here configured to execute software for implementing the other steps of the setting and molding methods for manufacturing by molding the ophthalmic device using the setting file and operational parameters thanks to the manufacturing system 2b.

[0093] In an alternative embodiment, a step of determining the setting file representative of the locations of the molding portions of the molding shell of the mold 5b can be carried out by the command and control unit 3b on the client-side 1 1 b.

[0094] In another alternative embodiment, the molding machine 2b can be located on the supplier-side 11 a so that the command and control unit 3a on the supplier-side 1 1 a is further configured to mold the ophthalmic device. Figure 3 shows steps of a manufacturing method 100 by molding of the ophthalmic device.

[0095] The manufacturing method 100 comprises the step of providing 101 the mold 5 having at least one molding shell comprising the plurality of molding portions at least partially moveable one relative to each other in a predetermined direction.

[0096] The manufacturing method 100 comprises the step of setting 102 the molding shell of the mold 5 by displacing at least some of the molding portions of the molding shell so that the molding shell and thus the mold 5 has a determined shape.

[0097] The manufacturing method 100 comprises the step of providing and injecting and / or casting 103 the predetermined volume of material into the molding cavity defined by the mold 5 having the molding shell with the determined shape.

[0098] The manufacturing method 100 next comprises the step of curing 104 the predetermined volume of material into the mold 5.

[0099] Figure 4 shows in detail the setting step 102, or setting method, of the molding shell of the mold 5, for use in the manufacturing system 1 configured for molding the ophthalmic device.

[0100] The setting step 102 is carried out thanks to the setting apparatus 6.

[0101] The setting method 102 for setting the mold 5 comprises the step of providing 121 a locking device of the setting apparatus 6, the locking device being configured to individually lock in position and unlock the plurality of molding portions of the mold 5.

[0102] The setting method 102 for setting the mold 5 comprises the step of providing 122 a single actuating and supporting member of the setting apparatus 6, the single actuating and supporting member being configured to be at least temporarily connected to the plurality of molding portions and to move each of the plurality of molding portions from a rest position to an individual determined position of molding. The setting method 102 for setting the mold 5 optionally comprises the step of providing and locating 123 a deformable membrane on the plurality of molding portions of the molding shell of the mold 5.

[0103] The setting method 102 for setting the mold 5 further comprises the step of displacing 124 the single actuating and supporting member from an initial position in which the plurality of molding portions are unlocked and connected to the single actuating and supporting member in the respective rest position, to a final position in which the plurality of molding portions have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions are locked in position and disconnected from the single actuating and supporting member.

[0104] The step of displacing 124 the single actuating and supporting member can be performed so that the plurality of molding portions are successively and / or at least partially simultaneously locked in position and disconnected from the single actuating and supporting member, depending on the respective individual determined positions of molding.

[0105] It is to be noted that the combination of all the respective individual determined positions of molding of the molding portions of the molding shell of the mold 5 defines the determined shape of the molding shell.

[0106] The step of displacing 124 the single actuating and supporting member comprises the step of connecting the single actuating and supporting member in the initial position to each of the plurality of molding portions in the respective rest position thanks to dedicated connecting members of the setting apparatus, and the steps of disconnecting the single actuating and supporting member in intermediate positions from each of the plurality of molding portions in the respective individual determined positions of molding, thanks to the dedicated connecting members, until the single actuating and supporting member reaches its final position wherein all the molding portions are located so that the molding shell has its determined shape.

[0107] The step of displacing 124 the single actuating and supporting member comprises the step of unlocking each of the plurality of molding portions in the respective rest position thanks to dedicated locking members of the locking device of the setting apparatus 6, and the step of locking each of the plurality of molding portions in the respective individual determined positions of molding, thanks to the dedicated locking members.

[0108] Figures 5 to 7 illustrate schematically the setting apparatus 6 which is configured to equip the manufacturing system, as an at least partially integrated apparatus or as an at least partially distinct apparatus.

[0109] The apparatus 6 comprises the at least one molding shell 15 used in the mold of the molding machine.

[0110] The at least one molding shell 15 comprises the plurality of molding portions 16.

[0111] The molding portions 16 are at least partially moveable one relative to each other in a predetermined direction.

[0112] The molding portions 16 have longitudinal extension parts 17 and mold shaping sections 18 at free first ends 19 of the longitudinal extension parts 17.

[0113] The apparatus 6 further comprises the single actuating and supporting member 20 configured to be at least temporarily connected to the plurality of molding portions 16 and to move each of the plurality of molding portions 16 from the rest position (Figure 5) to the respective individual determined position of molding (Figure 7).

[0114] The single actuating and supporting member 20 is here formed by a plate located in front of the free first ends 19 of the longitudinal extension parts 17.

[0115] The plate forming the single actuating and supporting member 20 may have for instance a rectangular shape in section.

[0116] The single actuating and supporting member 20 is thus configured to drive the plurality of molding portions 16 by the respective free first ends 19 of the longitudinal extension parts 17.

[0117] The single actuating and supporting member 20 is configured to be displaced from the initial position in which the plurality of molding portions 16 are unlocked and connected to the single actuating and supporting member in the respective rest position (Figure 5), to the final position in which the plurality of molding portions 16 have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions 16 are locked in position and disconnected from the single actuating and supporting member 20 (Figure 7).

[0118] The apparatus 6 thus comprises the locking device 25 which is configured to individually lock in position and unlock the plurality of molding portions 16 and in particular the longitudinal extension parts 17 of the plurality of molding portions 16.

[0119] The locking device 25 may include both dedicated locking members 26 and dedicated connecting members 27.

[0120] In particular, the dedicated locking members 26 are configured to unlock each of the plurality of molding portions 16 in the respective rest position and to lock each of the plurality of molding portions 16 in the respective individual determined positions of molding.

[0121] In addition, the dedicated connecting members 27 are configured to connect the single actuating and supporting member 20 in the initial position to each of the plurality of molding portions 16 in the respective rest position (Figure 5), and to disconnect the single actuating and supporting member 20 in the intermediate positions from each of the plurality of molding portions 16 in the respective individual determined positions of molding (Figure 6).

[0122] Therefore, the plurality of molding portions 16 are successively and / or at least partially simultaneously locked in position and disconnected from the single actuating and supporting member 20, depending on the respective individual determined positions of molding (Figure 6).

[0123] In particular, in Figure 5, all the molding portions 16 are in the respective rest positions, unlocked, and connected to the single actuating and supporting member 20 which is in its initial position. In Figure 6, some molding portions 16 (the two on the left and the three on the right) are in the respective individual determined positions of molding, locked and disconnecting from the single actuating and supporting member 20 which is in an intermediate position. In Figure 7, all the molding portions 16 are in the respective individual determined positions of molding, locked and disconnecting from the single actuating and supporting member 20 which is in its final position. It is to be noted that in the configuration of Figure 7, the locking device 25 can be configured to apply a locking force on all the molding portions 16 in the respective individual determined positions of molding, in addition to the individual locking thereof.

[0124] The locking force applied by the locking device 25 can be used to lock in position all the molding portions 16 in the respective individual determined positions of molding both during the displacement of the single actuating and supporting member 20 from its initial position to its final position and during molding.

[0125] For instance, the locking device 25 can be configured to apply a first locking force to each molding portion 16 in the respective individual determined position of molding during the displacement of the single actuating and supporting member 20 from its initial position to its final position; and to apply a second locking force, greater than the first locking force, to all the molding portions 16 in the respective individual determined positions of molding, during molding.

[0126] The apparatus 6, also called setting apparatus, is thus configured to set the at least one molding shell 15 comprising the movable molding portions 16 of the mold 5, by locating each of the molding portions 16 in the individual determined positions of molding in which the molding portions 16 define the determined shape of the molding shell for molding the ophthalmic device.

[0127] In this respect, the command and control unit 3 of the manufacturing system 1 (Figure 1 ) is thus configured to run a computer program in order to implement at least a displacement of the single actuating and supporting member 20 from the initial position in which the plurality of molding portions 16 are unlocked and connected to the single actuating and supporting member 20 in the respective rest position, to the final position in which the plurality of molding portions 16 have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions 16 are locked in position and disconnected from the single actuating and supporting member 20.

[0128] In particular, the step of displacing 124 the single actuating and supporting member in reference to Figure 3 can be performed so that the single actuating and supporting member 20 drives the plurality of molding portions 16 by the respective free first ends 19 of the longitudinal extension parts 17.

[0129] It is to be noted that the displacement of the single actuating and supporting member 20 and thus of the plurality of molding portions 16, depending on the determined shape to obtain for the molding shell, can be controlled with a tolerance equal to + / - 0,1 pm.

[0130] The apparatus 6 can also comprise a measuring device (not represented) which is configured to measure and check the displacement of each of the plurality of molding portions 16.

[0131] In an alternative embodiment (not illustrated), the single actuating and supporting member 20 can be located in front of second ends of the longitudinal extension parts 17 which are opposite to the free first ends 19. The single actuating and supporting member 20 can be configured to drive the plurality of molding portions 16 by the second ends opposite to the free first ends 19 of the longitudinal extension parts 17. The step of displacing 124 the single actuating and supporting member can be performed so that the single actuating and supporting member 20 drives the plurality of molding portions 16 either by the second ends of the longitudinal extension parts 17.

[0132] It is to be noted that the longitudinal extension parts 17 of the plurality of molding portions 16 can be radially located at a distance one to each other which can vary for instance between 1 mm to 10 mm, depending on a density of distribution of the molding portions 16 to create the determined shape of the molding shell 15, and taking into account that the distances between each adjacent longitudinal extension parts 17 can be similar or different.

[0133] For instance, the density of longitudinal extension parts 17 can be higher on a center of the molding shell than on edges of the molding shell.

[0134] Figures 8 to 12 illustrate alternative embodiments of the setting apparatus 6.

[0135] In Figure 8, which shows the apparatus 6 in a similar configuration as to Figure 6, the apparatus 6 further comprises a deformable membrane 30 which is configured to be located on the mold shaping sections 18 of the molding portions 16. The deformable membrane 30 can be sandwiched between the mold shaping sections 18 of the molding portions 16 and the single actuating and supporting member 20, and thus displaced with these elements.

[0136] In variant, the deformable membrane 30 can be located on the mold shaping sections 18 of the molding portions 16 when they are all in the respective individual determined positions of molding.

[0137] In Figure 9, which also shows the apparatus 6 in a similar configuration as to Figures 6 and 8, the single actuating and supporting member 20 is configured to drive the plurality of molding portions 16 by the second ends 22 of the longitudinal extension parts 17, rather than the first free ends 19 on which are located the mold shaping sections 18.

[0138] In addition, the apparatus 6 also comprises a deformable membrane 30 which is configured to be located on the mold shaping sections 18 of the molding portions 16, but which is not sandwiched between the mold shaping sections 18 of the molding portions 16 and the single actuating and supporting member 20.

[0139] In Figure 10, which also shows the apparatus 6 in a similar configuration as to Figures 6, 8 and 9, the single actuating and supporting member 20 of the apparatus 6 has in section a curved shape comprising for instance a concave face 23 located in front of the first free ends 19 on which are located the mold shaping sections 18 of the molding portions 16, and a convex face 24 opposite to the concave face 23.

[0140] In this embodiment, the distance travelled by the single actuating and supporting member 20 from its initial position to its final position and thus by the molding portions 16 from the respective rest positions and the respective individual determined positions of molding can be reduced.

[0141] In Figure 1 1 , which also shows the apparatus 6 in a similar configuration as to Figures 6 and 8 to 10, the dedicated locking members 26 are formed by circular clamps and the dedicated connecting members 27 are formed by springs, both being mounted around the longitudinal extension parts 17 of the plurality of molding portions 16. The clamps can be for instance mechanically actuated, or pneumatically actuated, or electrically actuated, or magnetically actuated.

[0142] When a clamp is not actuated, the molding portions 16 is biased by a corresponding spring against the single actuating and supporting member 20, so that the molding portion 16 is unlocked and connecting to the single actuating and supporting member 20.

[0143] When a clamp is actuated, the molding portions 16 is locked and unmovable, so that the molding portion 16 is locked and disconnecting from the single actuating and supporting member 20.

[0144] In Figure 12, which also shows the apparatus 6 in a similar configuration as to Figures 6 and 8 to 1 1 , the molding portions 16 when unlocked are connecting to the single actuating and supporting member 20 by gravity.

[0145] In others alternatives embodiments, the connexion between the molding portions 16 and the single actuating and supporting member 20 can be performed for instance thanks to magnetics and / or electrical members.

[0146] Figures 13 to 17 represent schematically in top view molding shapes generated thanks to the apparatus illustrated in Figures 5 to 12 and corresponding globally to a pattern 35 of the determined shape to obtain for the molding shell 15, thanks to the mold shaping sections of the molding portions.

[0147] In Figure 13, the pattern 35 is formed by a plurality of triangular sections 36 adjacent one to each other.

[0148] In Figure 14, the pattern 35 is formed by a plurality of square sections 37 adjacent one to each other.

[0149] In Figure 15, the pattern 35 is formed by a plurality of hexagonal sections 38 adjacent one to each other.

[0150] In Figures 13 to 15, each pattern 35 is formed by a regular distribution of the molding portions, corresponding to an unvariable density thereof.

[0151] In other alternatives embodiments, the pattern 35 is formed by a plurality of circular sections or polygonal sections adjacent one to each other, or a mix of triangular and / or square and / or hexagonal and / or circular and / or polygonal sections. Figures 16 and 17 show further patterns 35 formed by irregular distributions of the molding portions, corresponding to a variable density thereof.

[0152] In Figure 16, the pattern 35 is formed by a plurality of semi-circular sections 39 adjacent one to each other and having different sizes.

[0153] The pattern 35 is divided here in concentric annular rings, and the semi-circular sections 39 are greater in the most external annular ring than in the most internal ring.

[0154] In particular, in Figure 16, the semi-circular sections 39 are progressively smaller from the most external annular ring to the most internal ring, that is to say from an edge to a center, and the density of semi-circular sections 39 decreases from the center to the edge.

[0155] Such a distribution can be usable for instance for a single vision spectacle lens.

[0156] In Figure 17, the pattern 35 is formed by a plurality of rectangular sections 40 adjacent one to each other and having different sizes.

[0157] The pattern 35 is divided here in many regions and comprises at least a first region 41 corresponding for instance to a far vision area of a spectacle lens, a second region 42 corresponding for instance to a near vision area of the spectacle lens, a third region 43 corresponding for instance to an intermediate vision area of the spectacle lens which is located between the first region 41 and the second region 42, and a plurality of fourth regions 44 located around the first region 41 , the second region 42 and the third region 43.

[0158] In particular, in Figure 17, the rectangular sections 40 are smaller in the first region 41 , second region 42 and third region 43, than in the fourth regions 44; and the density of rectangular sections 40 is greater in the first region 41 , second region 42 and third region 43 than in the fourth regions 44.

[0159] Such a distribution can be usable for instance for a multiple visions spectacle lens.

[0160] Figures 13 to 17 are only examples and the patterns may be formed by sections having different shapes or combinations of shapes, and different variable or unvariable density of sections. The patterns 35 shown in Figures 13 to 17 can be formed directly by the mold shaping sections 18 of the molding portions 16, or by the deformable membrane 30, or by intermediate molding members (not represented) of the molding shell 15 located on the mold shaping sections 18 of the molding portions 16 when the latter are all in the respective individual determined positions of molding.

[0161] In a variant embodiment which is not illustrated, the apparatus can comprise an additionnal locking device which is configured to globally lock in position all the molding portions in the respective individual determined positions of molding.

[0162] The locking device can either hold the locking force applied on all the molding portions in the respective individual determined positions of molding, or at least partially release the locking force applied on all the molding portions in the respective individual determined positions of molding, the plurality of molding portions being however locked thanks to the additionnal locking device.

[0163] For instance, the locking force applied by the locking device can be used to lock in position all the molding portions in the respective individual determined positions of molding during the displacement of the single actuating and supporting member from its initial position to its final position; while the locking force applied by the additionnal locking device is greater than the locking force applied by the locking device so as to lock in position all the molding portions in the respective individual determined positions of molding during molding.

[0164] To be noted that the locking device and additionnal locking device can be distinct or made of a single device.

[0165] In another variant embodiment which is not illustrated, either the locking device or the additionnal locking device can be formed by a locking material in contact with the molding portions.

[0166] The apparatus may comprise an activating device so as to activate and / or desactivate the locking material and then lock and / or unlock the molding portions, individually and / or globally. For instance, the locking material is a hardenable material and the activating device is a curing device configured to harden the hardenable material so as to lock the molding portions.

[0167] More generally, the locking material can be activated and / or desactivated by acting on UV properties, temperature properties, electric properties and / or magnetic properties thereof.

[0168] According to the disclosure, each of the plurality of molding portions 16 are moved from the rest position to the respective individual determined positions of molding, so that to create the determined shape of the molding shell 15, thanks to the single actuating and supporting member 20 which moves from its initial position in which all the molding portions 16 are in the respective rest position to its final position in which all the molding portions 16 are in the respective individual determined positions of molding.

[0169] In other words, all the molding portions 16 are displaced together simultaneously until each molding portion 16 reaches its respective individual determined position of molding in which the molding portion 16 is locked in position and disconnected from the single actuating and supporting member 20.

[0170] The single actuating and supporting member 20 can thus place individually, accurately and quickly all the molding portions 16 of the molding shell 15 itself, during a single displacement of the single actuating and supporting member 20, from its initial position to its final position.

[0171] It is to be noted that for only some of the molding portions 16, the respective individual determined position can be the same as the rest position, so that these molding portions 16 are not moved as such because these molding portions 16 are disconnected from the single actuating and supporting member 20 when the latter is in its initial position.

[0172] The single actuating and supporting member can be formed by an optical substrate or any optical element on which is overmolded the predetermined volume of material, rather than a plate.

[0173] It should be noted more generally that the disclosure is not limited to the examples described and represented.

Claims

CLAIMS1. Method for manufacturing by molding an ophthalmic device, comprising:- providing (101 ) at least one molding shell (15) comprising a plurality of molding portions (16) at least partially moveable one relative to each other in a predetermined direction;- providing (121 ) a locking device (25) configured to individually lock in position and unlock the plurality of molding portions (16);- providing (122) a single actuating and supporting member (20) configured to be at least temporarily connected to the plurality of molding portions (16) and to move each of the plurality of molding portions from a rest position to an individual determined position of molding;- displacing (124) the single actuating and supporting member (20) from an initial position in which the plurality of molding portions (16) are unlocked and connected to the single actuating and supporting member (20) in the respective rest position, to a final position in which the plurality of molding portions (16) have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions (16) are locked in position and disconnected from the single actuating and supporting member (20).

2. Method according to claim 1 , wherein the plurality of molding portions (16) are successively and / or at least partially simultaneously locked in position and disconnected from the single actuating and supporting member (20), depending on the respective individual determined positions of molding.

3. Method according to one of claims 1 and 2, wherein the molding portions (16) have longitunal extension parts (17) and mold shaping sections (18) at free first ends (19) of the longitudinal extension parts (17), and wherein thelocking device (25) is configured to individually lock in position and unlock the longitudinal extension parts (17) of the plurality of molding portions (16).

4. Method according to claim 3, wherein the single actuating and supporting member (20) is formed by a plate located either in front of the free first ends (19) of the longitudinal extension parts (17), or in front of second ends (22) of the longitudinal extension parts (17) which are opposite to the free first ends (19).

5. Method according to one of claims 3 and 4, comprising providing and locating (123) a deformable membrane (30) on the mold shaping sections (18) of the molding portions (16).

6. Method according to any one of claims 1 to 5, comprising providing and injecting and / or casting (103) a predetermined volume of material into a mold (5, 5b) having at least one of the molding shell (15), and curing (104) the predetermined volume of material into the mold.

7. Apparatus configured to equip a manufacturing system (1 ) for molding an ophthalmic device, comprising at least one molding shell (15) comprising a plurality of molding portions (16) at least partially moveable one relative to each other in a predetermined direction; a locking device (25) configured to individually lock in position and unlock the plurality of molding portions (16); a single actuating and supporting member (20) configured to be at least temporarily connected to the plurality of molding portions (16) and to move each of the plurality of molding portions (16) from a rest position to an individual determined position of molding; the single actuating and supporting member (20) being configured to be displaced from an initial position in which the plurality of molding portions (16) are unlocked and connected to the single actuating and supporting member (20) in the respective rest position, to a final position in which the plurality of molding portions (16) have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions (16) are locked in position and disconnected from the single actuating and supporting member (20).

8. Apparatus according to claim 7, wherein the molding portions (16) have longitudinal extension parts (17) and mold shaping sections (18) at free firstends (19) of the longitudinal extension parts (17), and wherein the locking device (25) is configured to individually lock in position and unlock the longitudinal extension parts of the plurality of molding portions (16).

9. Apparatus according to claim 8, wherein the single actuating and supporting member (20) is formed by a plate located either in front of the free first ends (19) of the longitudinal extension parts (17), or in front of second ends (22) of the longitudinal extension parts (17) which are opposite to the free first ends (19).

10. Apparatus according to claim 9, wherein the single actuating and supporting member (20) is configured to drive the plurality of molding portions (16) either by the respective free first ends (19) or second ends (22) of the longitudinal extension parts (17).1 1 . Apparatus according to any one of claims 7 to 10, comprising a deformable membrane (30) configured to be located on the mold shaping sections of the molding portions (16).

12. Apparatus according to any one of claims 7 to 1 1 , wherein the locking device (25) comprises dedicated locking members (26) configured to unlock each of the plurality of molding portions (16) in the respective rest position and to lock each of the plurality of molding portions (16) in the respective individual determined positions of molding, so that the plurality of molding portions (16) are successively and / or at least partially simultaneously locked in position and disconnected from the single actuating and supporting member (20), depending on the respective individual determined positions of molding.

13. Apparatus according to any one of claims 7 to 12, comprising dedicated connecting members (27) configured to connect the single actuating and supporting member (20) in the initial position to each of the plurality of molding portions (16) in the respective rest position, and to disconnect the single actuating and supporting member (20) in intermediate positions from each of the plurality of molding portions (16) in the respective individual determined positions of molding.

14. Manufacturing system configured for molding an ophthalmic device, comprising an apparatus (6) comprising at least one molding shell (15)comprising a plurality of molding portions (16) at least partially moveable one relative to each other in a predetermined direction; a locking device (25) configured to indi vually lock in position and unlock the plurality of molding portions (16); a single actuating and supporting member (20) configured to be at least temporarily connected to the plurality of molding portions (16) and to move each of the plurality of molding portions (16) from a rest position to an individual determined position of molding; the single actuating and supporting member (20) being configured to be displaced from an initial position in which the plurality of molding portions (16) are unlocked and connected to the single actuating and supporting member (20) in the respective rest position, to a final position in which the plurality of molding portions (16) have been moved in the predetermined direction to reach the respective individual determined positions of molding wherein the plurality of molding portions (16) are locked in position and disconnected from the single actuating and supporting member (20).

15. Manufacturing system according to claim 14, further comprising a mold (5, 5b) having at least one of the molding shell (15) which defines at least partially a molding cavity, an edge gate for receiving a predetermined volume of material by injection and / or casting and communicating with the molding cavity, and a curing device configured to cure the predetermined volume of material into the mold.

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