Optical lens molding system

Abstract

An optical lens molding system includes a first mold member having a first mating surface and a first molding surface for molding a front surface of an ophthalmic spectacle lens. The optical lens molding system further includes a second mold member comprising a gasket body having a second molding surface for molding a back surface of an ophthalmic spectacle lens and a second mating surface configured to engage the first mating surface to form an air-tight seal therebetween. A molding chamber may be formed between the first molding surface and the second molding surface when the first mold member is received within the gasket body of the second mold member, and the gasket body includes a fill port for directing a flow of liquid optical material into the spectacle lens molding chamber.

Description

Patent Application110000-584B / PCTOPTICAL LENS MOLDING SYSTEMRELATED APPLICATIONS

[0001] This application claims benefit of and priority to U.S. Provisional Application Serial No. 63 / 726,094 filed November 27, 2024 entitled Optical Lens Molding System, which is hereby incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTION

[0002] Optical lens molding systems have become ubiquitous in the manufacture of optical lenses. An example of such a molding system may include a pair of mold members and a central gasket body.

[0003] Generally, each of the mold members are inserted into opposite sides of the gasket body until a portion of each contacts a rim or projection extending outwardly from an inner surface of the gasket body. As each of the mold members enters the gasket body, the mold members engage the gasket body to create an airtight seal therebetween. A liquid optical material, such as a curable casting composition or monomer, is then introduced between the mold members through a fill port of the gasket body. Ultimately, the liquid optical material entirely fills a space (e.g., a lens molding cavity) between the lens-molding surfaces of the mold members.

[0004] Traditionally, the mold members have been made from glass or metallic materials due to their rigidity, durability, and ability to maintain structural integrity and resist deformation under elevated pressures and temperatures. However, efficiently and economically utilizing glass or metallic mold members presents several challenges and limitations.

[0005] As an example, the production of glass and metallic mold members is typically expensive, necessitating specialized machinery to meet the high-quality standards necessary to produce ophthalmic spectacle lenses. Further, glass mold members, which are the most common type of molds used in the production of ophthalmic spectacle lenses, may present significant barriers to the use of- 1 - IIPG-1-146313Patent Application110000-584B / PCT automated production methods for mass-production, such as by requiring surface polishing or other finishing processes necessitating human labor. Still further, the production of both glass and metallic mold members may rely upon the procurement of relatively high-cost raw materials.

[0006] Additionally, as glass and metallic mold members are typically quite heavy, such mold members can be relatively difficult and cumbersome to handle. This can present challenges when manually manipulating such mold members and contribute to the likelihood of damage to the molds and / or the spectacle lenses being molded. Moreover, in this respect, glass mold members are also relatively easy to chip or break, and cannot be reworked, recycled, or otherwise repaired. Further, once polymerized and cured, a molded optical spectacle lens may often resist separation from a glass molding surface, which can require the use of limiting or otherwise specific optical molding materials and / or strong chemical release agents. Finally, glass mold members may limit or hinder the development of new lens designs, such as those incorporating molded microlenses or lenslets, as producing glass mold members including micro or nano scale molding features may be impossible and / or cost prohibitive due to the limited degree of patterning accuracy associated with the production of such molds.SUMMARY OF THE INVENTION

[0007] In some aspects, the techniques described herein relate to an optical lens molding system including: a first mold member including: a first mating surface; a first molding surface for molding a front surface of an ophthalmic spectacle lens; a second mold member including a gasket body, the gasket body defining: a second molding surface for molding a back surface of an ophthalmic spectacle lens; a second mating surface configured to engage the first mating surface to form an airtight seal therebetween when the first mold member is received within the gasket body of the second mold member; wherein the first mold member and the second mold member are configured to form a spectacle lens molding chamber between the first molding surface and the second molding surface when the first mold member is received within the gasket body of the second mold member; and a fill port- 2 - IIPG-1-146313Patent Application110000-584B / PCT configured to direct a flow of liquid optical material into the spectacle lens molding chamber.

[0008] In some aspects, the techniques described herein relate to a system, wherein the gasket body further defines a vent port.

[0009] In some aspects, the techniques described herein relate to a system, wherein the fill port is formed through a sidewall of said gasket body.

[0010] In some aspects, the techniques described herein relate to a system, wherein the fill port includes a chamber extending from an exterior surface of the gasket body.

[0011] In some aspects, the techniques described herein relate to a system, wherein an inner surface of the gasket body includes a radial projection configured to limit translation of the first mold member into the second mold member.

[0012] In some aspects, the techniques described herein relate to a system, wherein the first mold member is made from thermoplastic and the second mold member is made from low density polyethylene.

[0013] In some aspects, the techniques described herein relate to a system, wherein the first mold member and the second mold member are each made from a polymeric material.

[0014] In some aspects, the techniques described herein relate to a system, wherein the polymeric material is selected from the group consisting of a polyetheretherketone, a polyoxymethyelene, a homopolymer, a copolymer, a polyolefin polymer, a polyethylene, a polycarbonate, a polyacrylic, a polystyrene, a polycyclic olefin, or a polypropylene.

[0015] In some aspects, the techniques described herein relate to a method of molding an ophthalmic spectacle lens using a mold system, the method including: inserting a first mold member into a gasket body of a second mold member to form an air-tight seal between a first mating surface of the first mold member and a second mating surface of the second mold member, wherein the gasket body of the- 3 - IIPG-1-146313Patent Application110000-584B / PCT second mold member defines a second molding surface; introducing a liquid optical material through a fill port in the gasket body until a surface area of the first molding surface and a surface area of the second molding surface is in contact with the liquid optical material; and curing the liquid optical material in the mold system to produce the ophthalmic spectacle lens.

[0016] In some aspects, the techniques described herein relate to a method, wherein inserting the first mold member into the gasket body of the second mold member includes forming a spectacle lens molding chamber between a first molding surface of the first mold member and a second molding surface of the second mold member.

[0017] In some aspects, the techniques described herein relate to a method, wherein dispensing the liquid optical material includes venting air from the spectacle lens molding chamber during introduction of the liquid optical material through the fill port.

[0018] In some aspects, the techniques described herein relate to a method, wherein inserting the first mold member into the gasket body includes inserting a polymeric mold member including a polyetheretherketone, a polyoxymethyelene polymer, a homopolymer, a copolymer, a polyolefin polymer, a polyethylene, a polycarbonate, a polyacrylic, a polystyrene, a polycyclic olefin, or a polypropylene into the gasket body.

[0019] In some aspects, the techniques described herein relate to a method, wherein inserting the first mold member into the gasket body includes inserting a glass mold member into the gasket body.

[0020] In some aspects, the techniques described herein relate to a method, further including removing the first mold member from the gasket body and extracting the ophthalmic spectacle lens from the gasket body.

[0021] In some aspects, the techniques described herein relate to a method, wherein extracting the ophthalmic spectacle lens from the gasket body includes introducing a release agent into the gasket body.- 4 - IIPG-1-146313Patent Application110000-584B / PCT

[0022] Other example embodiments are described further below. However, it should be understood that any of the features from any of the above or below example embodiments can be mixed and matched with each other in any combination. Hence, the present invention should not be restricted to only these example embodiments, but any broader combination thereof.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] These and other aspects, features and advantages of which embodiments of the invention are capable of will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which:

[0024] Fig. 1 illustrates a cross-section of a lens-molding system, in accordance with at least one example.

[0025] Fig. 2 illustrates a cross-section of a first mold member of the lens-molding system of Fig. 1 , in accordance with at least one example.

[0026] Fig. 3 illustrates a cross-section of a second mold member of the lensmolding system of Fig. 1 , in accordance with at least one example.

[0027] Fig. 4 illustrates a top view of the second mold member of Fig. 3, in accordance with at least one example.

[0028] Fig. 5 illustrates a top perspective view of the second mold member of Figs. 3-4, in accordance with at least one example.

[0029] Fig. 6 illustrates a bottom perspective view of the second mold member of Figs. 3-5, in accordance with at least one example.

[0030] Fig. 7 illustrates a side perspective view of the second mold member of Figs. 3-6, in accordance with at least one example.

[0031] Fig. 8 illustrates a cross-section of a molding surface including a plurality of molding features, in accordance with at least one example.- 5 - IIPG-1-146313Patent Application110000-584B / PCT

[0032] Fig. 9 illustrates an annular array, in accordance with at least one example.

[0033] Fig. 10 illustrates a hexagonal array, in accordance with at least one example.

[0034] Fig. 11 a plurality of molding features arranged in an annular array, in accordance with at least one example.

[0035] Fig. 12 is a cross-section of a molding insert including a plurality of shaping features, in accordance with at least one example.

[0036] Fig. 13 illustrates a diagram of a method of making a spectacle lens molding system including a plurality of molding features, in accordance with at least one example.DETAILED DESCRIPTION

[0037] Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.

[0038] For the purposes of this specification, use of the terms “about”, “around”, or “approximately” when referring to a value may be understood to mean within 10% of the stated value (either greater or lesser), inclusive.

[0039] In view of the issues set out above, the use of traditional glass and / or metallic surface mold members adapted for use with traditional sealing gaskets or gasket bodies presents a significant barrier to reducing the cost and complexity of producing injection-molded ophthalmic spectacle lenses.- 6 - IIPG-1-146313Patent Application110000-584B / PCT

[0040] The systems and methods shown and / or described herein can help to address these issues, among others, by providing a sealing gasket or body that defines one of the two curved molding surfaces required for shaping an ophthalmic spectacle lens; thereby eliminating one of the two glass or metallic mold members that are normally required to form an optical lens such as a spectacle lens. As may be readily appreciated in view of the above, such an arrangement may significantly reduce the cost and / or complexity associated with both producing and using a gasket-based optical lens molding assembly.

[0041] In further examples, the single remaining mold member adapted for insertion into the sealing gasket or body may be composed of a polymeric material to thereby eliminate the use of any glass and / or metallic materials. In any of the above examples, relative to traditional gasket-based molding systems including two glass and / or metallic molds, the methods, systems, and devices shown and / or described herein may be lighter, more resistant to chipping or cracking, made from less- expensive raw materials, and less likely to adhere to spectacle lens casting materials.

[0042] Further, the methods, systems, and devices shown and / or described herein may reduce or entirely eliminate the need for surface polishing or other finishing processes requiring manual labor. Additionally, the methods, systems, and devices shown and / or described herein may help facilitate the development of new and revolutionary lens designs, such as those incorporating micro or nano scale optical features, by enabling the inclusion of micro or nano scale molding features that would be impossible or otherwise cost prohibitive to incorporate into glass mold members due to the limited degree of patterning accuracy associated with the production of such molds.

[0043] Thus, for at least these reasons, the methods, systems, and devices shown and / or described herein may aid in reducing costs associated with molded spectacle lenses. Moreover, for at least these reasons, the methods, systems, and devices shown and / or described herein may aid in automating some or all of the production process for such spectacle lenses.- 7 - IIPG-1-146313Patent Application110000-584B / PCT

[0044] Specific example embodiments are described further below. However, it should be understood that any of the features from any of the embodiments can be mixed and matched with each other in any combination. Hence, the present invention should not be restricted to only these embodiments, but any broader combination thereof.

[0045] Fig. 1 illustrates an example spectacle lens molding system 100, in accordance with at least one example. As shown in Fig. 1 , the spectacle lens molding system 100 may include a first mold member 102 and a second mold member 104.

[0046] Fig. 2 illustrates a first mold member 102 of an example spectacle lens molding system 100, in accordance with at least one example. The first mold member 102 may be similar to, or may be generally representative of, a variety of different mold members adapted for use with various gasket-type lens molding systems or assemblies currently known in the art. For example, the first mold member 102 may form a circular cross-sectional shape having a diameter similar, or equal, to an outer diameter of the ophthalmic spectacle lens to be molded using the spectacle lens molding system 100.

[0047] Figs. 3-7 illustrate a second mold member 104 of an example spectacle lens molding system 100, in accordance with at least one example. The second mold member 104 may include a gasket body 106. The gasket body 106 may comprise a tubular portion of the second mold member 104 that is adapted to receive the first mold member 102 therein.

[0048] The first mold member 102 may include a first mating surface 108 and the second mold member 104 may include a second mating surface 110. The first mating surface 108 may comprise one or more outer side surfaces of the first mold member 102, and the second mating surface 110 may comprise one or more inner side surfaces of the gasket body 106 of the second mold member 104.

[0049] The first mating surface 108 may be configured to engage the second mating surface 110 to create an air-tight seal (e.g., a mating interface) therebetween when the first mold member 102 is received within the gasket body 106 of the- 8 - IIPG-1-146313Patent Application110000-584B / PCT second mold member 104. For example, the first mating surface 108 and the second mating surface 110 may each define correspondingly sized and shaped three-dimensional cross-sectional shapes.

[0050] As best shown in Figs. 1 and 4-5, the second mold member 104 may include a mold stop 112. The mold stop 112 may be comprised of one or more projections or protrusions extending radially from the second mating surface 110 toward a central axis A1 of the gasket body 106.

[0051] In some examples, such as shown in Fig. 1 , the mold stop 112 may be a single annular projection or protrusion extending entirely around an inner circumference of the gasket body 106. In other examples, such as shown in Fig. 5, the mold stop 112 may be comprised of one or more individual projections or protrusions each spaced circumferentially apart from one another about an inner circumference of the gasket body 106. As may be appreciated, the mold stop 112 may be positioned within the gasket body 106 to support the first mold member 102 in a desired axial position relative to the central axis A1 as shown in Fig. 1 .

[0052] In an alternative example, such as shown in Fig. 3, the gasket body 106 may not include the mold stop 112. In such an example, the second mating surface 110 may be configured to support the first mold member 102 in a desired axial position relative to the central axis, such as by forming a tapered cross-sectional shape to limit axial translation of first mold member 102 relative to second mold member 104.

[0053] In some examples, the gasket body 106 may include any of the additional inner surface features, such as, but not limited to, annular grooves or recesses, or annular projections or protrusions adapted for holding or positioning functional wafers, films, laminates, or any other optical inserts, such as shown and described in U.S. Pat. No. 6,391 ,231 and / or U.S. Pat. Pub. No. 2021 / 0138694, the entire contents of which are hereby incorporated by reference.

[0054] The first mold member 102 may include a first molding surface 116 and the second mold member 104 may include a second molding surface 118. The first molding surface 116 may comprise any curved surface configured (e.g., sized and- 9 - IIPG-1-146313Patent Application1 10000-584B / PCT shaped) to mold a front surface of an optical lens. The second molding surface 118 may comprise any curved surface configured (e.g., sized and shaped) to mold a back surface of an optical lens. In this respect, it should be appreciated that the first molding surface 116 and the second molding surface 118 may either form correspondingly shaped convex surfaces, or alternatively, correspondingly shaped concave surfaces.

[0055] The first molding surface 116 and the second molding surface 118 may be configured to impart various base curvatures to an ophthalmic spectacle lens during an injection-molding process, such as, but not limited to, a 2, 3, 4, 5, 7, 8, 9, 10, 11 , or 12 base shapes.

[0056] In one example, the first molding surface 116 and the second molding surface 118 may be configured to impart a 6 base curve shape to an optical lens. Moreover, in this regard, the first molding surface 116 and the second molding surface 118 may be configured to impart, to an optical lens, any functional shaping characteristic or corrective power known in the art such as, among others, diameter (“DIA”) or diameter of curvature, power (“PWR”), which refers to a positive or a negative number indicating the degree of correction for improving near vision and / or distance vision, cylinder (“CYL”), which refers to a positive or negative number for addressing astigmatism, axis (“AX”), addition (“ADD”), single vision near (“SVN”), single vision distance (“SVD”), or sagitta (“SAG”).

[0057] In still further examples, the first molding surface 116 and the second molding surface 118 may be configured such that an optical lens includes additional technologies such as, but not limited to, polarizing films or laminates, photochromic films or laminates, microlense(s), lenslet(s), and / or segmented, progressive, or other Fresnel features.

[0058] In some such examples, the first molding surface 116 and the second molding surface 118 may be configured to impart, to a molded optical lens, complex and / or non-symmetric functional features, such as, but not limited to, Defocus Incorporated Multiple Segments (hereinafter “DIMS”) or other diffractive or lightmanipulating microstructures or microlenses. For example, the first molding surface- 10 - II PG-1 -146313Patent Application110000-584B / PCT116 and the second molding surface 118 may be configured to produce micro lenses or nano scale surface patterns, such as, e.g., those disclosed in U.S. Pat. No.: 12,019,312 entitled “Spectacle Lens”, or U.S. Pat. No.: 10,386,654 entitled “Ophthalmic Lens with Graded Microlenses”, the entire contents of which are hereby incorporated by reference.

[0059] In some such examples, the first molding surface 116 and the second molding surface 118 may be configured to mold or otherwise produce micro lenses by virtue of defining a plurality of molding features. For example, Fig. 8 illustrates a cross-section of a molding surface 148, which may be representative of the first molding surface 116, which includes a plurality of molding features 150. Each individual molding feature of the plurality of molding features 150 may be sized and shaped to receive a relatively small amount of optical material therein, such as by being laterally offset from an outermost portion 154 of the molding surface 148.

[0060] In some such examples, the maximum depth or lateral offset, relative to the outermost portion 154, of each of the plurality of molding features 150 may be between about, but not limited to, 0.1 micron and about 4 microns. In other examples, the maximum depth or lateral offset, relative to the outermost portion 154, of each of the plurality of molding features 150 may measure up to about 0.1 millimeters. In some examples, a maximum diameter or distance across each of the plurality of molding features 150 may be between about, but not limited to, 0.5 millimeters and about 2 millimeters. In some specific examples, such a distance may be about, but not limited to, 1 millimeter.

[0061] In this way, each molding feature of the plurality of molding features 150 may enable the formation of a molded microlens or nanolens projecting radially outwardly from a front or back surface, or surface defining a base curve, of an optical lens molded using the spectacle lens molding system 100. As may be appreciated, the plurality of molding features 150 may be distributed about the molding surface 148 to collectively form a wide variety of shapes, arrangements, or arrays. In some examples, the plurality of molding features 150 may form a shape, arrangement, or arrays that surrounds or encompasses a central region 156 of the molding surface 148 devoid of any of the plurality of molding features 150.- 11 - IIPG-1-146313Patent Application1 10000-584B / PCT

[0062] In one specific example, such as shown in Fig. 9, the plurality of molding features 150 may form an annular array 152. In another specific example, such as shown in Fig. 10, the plurality of molding features 150 may form a hexagonal array 153. In further examples, the plurality of molding features 150 may form a wide variety of other shapes, arrangements, or arrays, such as, but not limited to, annular, triangular, rectangular, pentagonal, heptagonal, or octagonal shapes or arrangements. In still further examples, the plurality of molding features 150 may form an arrangement or array comprising more than one individual shape, such as, but not limited to, two or more concentric or non-concentric rings, triangles, rectangles, pentagons, hexagons, heptagons, or octagons.

[0063] In some examples, the shape, arrangement, or array formed by the plurality of molding features 150 may define various dimensions. For example, as shown in Fig. 11 , a linear width 158 across the plurality of molding features 150 may be about, but not limited to, 5 millimeters and about 60 millimeters. In one example, the linear width 158 across the plurality of molding features 150 may be about 31 or 32 millimeters. In some examples, a linear width 160 (Fig. 11 ) across the central region 156 may measure between, but not limited to, about 2 millimeters and about 20 millimeters. In one example, the linear width 160 across the central region 156 may be about 10 millimeters. In some examples, the shape and size of each individual molding feature of the plurality of molding features 150 may be identical, or may vary, relative to one another.

[0064] In some such examples, the plurality of molding features 150 may be sized and shaped such that the micro or nano lenses formed by the plurality of molding features 150 may have similar or differing characteristics relative to one another, such as, but not limited to, base diameters, diopters, defocus powers (e.g., the difference in optical power of the base lens and optical power of a micro or nano lenses), stray rates, differing distances between one or more lenses or lenslets, stray rates, or any other characteristic disclosed in U.S. Pat. Nos.: 12,019,312 and 10,386,654 previously incorporated by reference above.

[0065] In some examples, the formation or manufacturing of the molding surface 148, including the plurality of molding features 150, may employ the use of a molding- 12 - II PG-1 -146313Patent Application1 10000-584B / PCT insert 170 (Fig. 12). The molding insert 170 may include a shaping surface 172. The shaping surface 172 may include a central region 174 and plurality of shaping features 176. The shaping surface 172, including the central region 174 and the plurality of shaping features 176, may be sized and shaped to create the molding surface 148, including the plurality of molding features 150, during a casting or an injection molding process used to form the first mold member 102.

[0066] For example, a first mold assembly configured to form the first mold member 102 may first be provided. Such mold assemblies may each include, for example, a pair of mold members receivable in opposite ends of a central sealing gasket to form a cavity in the shape of the first mold member 102. Alternativity, such mold members may be configured to form a cavity in the shape of first mold member 102, respectively, when taped or otherwise fastened to each other.

[0067] Next, the molding insert 170 may be utilized. For example, the molding insert 170 may be sized and shaped for insertion into a central sealing gasket, or to be attached to surface of a mold member, to be used in forming the first mold member 102. Alternatively, the molding insert 170 may be a generally curved molding surface that is integral with a mold member to be used in forming the first mold member 102. In some examples, the molding insert 170 be employed in a manner similar to the molding inserts or mold elements shown and described in U.S. Pat. Pub. No.: 20230136033A1 , the entire contents of which is hereby incorporated by reference.

[0068] In some examples, the molding insert 170 may be comprised of a metallic material, such as, but not limited to, steel. In some examples, such an insert may be nickel phosphorus (“NiP”) plated. In some examples, the molding insert 170 may be fabricated through micro or nano machining of the molding insert 170 to form the plurality of shaping features 176 (e.g., a plurality of microstructures or nanostructures) in relief. Finally, while the shaping surface 172 of the molding insert 170 shown in Fig. 12 forms a generally convex curvature, such as to form the concave example of the molding surface 148 shown in Fig. 8, it is to be appreciated that the shaping surface 172 of the molding insert 170 may alternatively form a concave curvature to produce a convex example of the molding surface 148.- 13 - II PG-1 -146313Patent Application1 10000-584B / PCT

[0069] With regard to any of the above examples, it is to be appreciated that such functional features or microstructures may not be feasibly incorporated into the molding surfaces of traditional glass and / or metallic molds due to the limited degree of patterning accuracy associated with the production of such molds. In at least this regard, the systems, methods, and devices shown and / or described herein may present an improvement over traditional glass and / or metallic molds.

[0070] The first molding surface 116 and the second molding surface 118 may also possess similar, or equivalent, optical characteristics to molding surfaces of traditional glass or metallic spectacle lens molds. For example, the first molding surface 116 and the second molding surface 118 may be smooth and glossy, such as by possessing a surface roughness of between, but not limited to, about 50 nanometers and about 100 nanometers. In some examples, the first molding surface 116 and the second molding surface 118 may have a surface roughness of less than 50 nanometers. In one example, the first molding surface 116 and the second molding surface 118 may have a surface roughness of about 30 nanometers.

[0071] As best shown in Fig. 1 , the first mold member 102 and the second mold member 104 may be configured to form, or collectively define, a spectacle lens molding chamber 120 for retaining or holding an optical material 122 during a lensmolding process. The spectacle lens molding chamber 120 may be comprised of a vertical and / or radial space or gap between the first mold member 102 and the second mold member 104 when the first mating surface 108 is fully engaged with the second mating surface 110. The spectacle lens molding chamber 120 may correspond to the desired size and shape of an ophthalmic spectacle by virtue of being defined by and between the first mating surface 108 and the second mating surface 110.

[0072] In this respect, the vertical height or distance between the first molding surface 116 and the second molding surface 118, which may be dictated by the mold stop 112, or alternatively the position of the first mold member 102 within the second mold member 104 when the first mating surfaces 108 is fully engaged with the second mating surface 110 to prevent further translation of the first mating surface 108 along the second mating surface 110, may define the thickness or depth of an- 14 - II PG-1 -146313Patent Application1 10000-584B / PCT optical lens. As may be appreciated, this vertical height or distance may vary depending on the type or properties of the lens to be produced, as well as the expected degree of material shrinkage associated with polymerization of the optical material 122.

[0073] Further, in this respect, a lateral width or distance across the across the first molding surface 116 and the second molding surface 118, as measured orthogonally to the central axis A1 between the first molding surface 116 and the second molding surface 118 respectively, may generally correspond to the diameter of an ophthalmic spectacle lens. In this respect, it is to be appreciated that the lateral width or distance across the first molding surface 116 and the second molding surface 118 may vary depending on the type or properties of spectacle lens to be produced.

[0074] The gasket body 106 may further include a fill port 124. The fill port 124 may comprise a lumen or an aperture extending through a sidewall and the second mating surface 110 of the gasket body 106. In some examples, the fill port 124 may comprise an opening flush with an exterior surface 126 of the gasket body 106. The fill port 124 may be positioned to direct a flow of liquid optical material into the spectacle lens molding chamber 120. For example, when the first mold member 102 is received within the second mold member 104, the fill port 124 may be located between the first molding surface 116 of the first mold member 102 and the second molding surface 118 of the second mold member 104.

[0075] In alternative examples, when the first mold member 102 is received within the second mold member 104, the fill port 124 may be located above the first mold member 102 or below the second molding surface 118, relative to the central axis A1 . In such examples, the fill port 124 may be a channel extending within a sidewall of the gasket body 106, from a location above the first mold member 102 or below the second molding surface 118, to a location between the first molding surface 116 and the second molding surface 118 to thereby enable the optical material 122 to enter the spectacle lens molding chamber 120.- 15 - II PG-1 -146313Patent Application1 10000-584B / PCT

[0076] In some examples, the gasket body 106 may also include a vent port (not shown). The vent port may be configured to allow the release of gasses and / or excess optical material 122 from between the first molding surface 116 and the second molding surface 118 as the spectacle lens molding chamber 120 fills with optical material 122. In some examples, the vent port may be similar to any of the vent ports shown and / or described in U.S. Pat. No. 6,391 ,231 and U.S. Pat. Pub. No: 2021 / 0138694, both of which have been previously incorporated by reference in their entireties.

[0077] The second mold member 104 may be constructed via any of various known techniques, such as, but not limited to, the injection molding or cast molding techniques traditionally used to manufacture the gasket bodies of gasket-based ophthalmic lens molding systems. Further, the second mold member 104 may be formed from a flexible polymeric or elastomeric material compatible with the optical material 122 (e.g., a casting or molding monomer resin having a suitable refractive index for eyeglass lenses, such as, but not limited to, between about 1.5 and about 1.74) selected to mold an ophthalmic spectacle lens.

[0078] In some examples, the second mold member 104 may be formed from a material possessing a heat distortion temperature of between, but not limited to, about 10 degrees and about 20 degrees Celsius above the solidifying temperature the optical material 122. Such a material may also be selected for possessing a high elongation at yield, such as, but not limited to, about 400 percent to about 800 percent greater than the material of the first mold member 102, and also for its ability to resist a variety of harsh chemicals during various chemical cleaning processes known in art, which may include the use of, among others, organic solvents, acids, and other caustic solutions. In some examples, the second mold member 104 may be made from any of the construction materials used for the gasket bodies described in U.S. Pat. No.: 6,391 ,231 and U.S. Pat. Pub. No: 2021 / 0138694, both of which have been previously incorporated by reference in their entirety. For example, the second mold member 104 may be made from, but not limited to, low density polyethylene (“LDPE”).- 16 - II PG-1 -146313Patent Application1 10000-584B / PCT

[0079] In some examples, the first mold member 102 may be formed from glass or metallic materials. In other examples, as previously noted above, the first mold member 102 may be formed from a thermoplastic polymer-based material (hereinafter “the material”), such as to enable the first mold member 102 to include the plurality of molding features 150 due to the limited degree of patterning accuracy associated with other materials. Such a material may exhibit resistance to a variety of harsh chemicals during various chemical cleaning processes such as, among others, organic solvents, acids, and other caustic solutions. The material may also be selected based on its ability to provide sufficient dimensional and thermal stability under elevated pressures and temperatures, such as by possessing a heat distortion temperature of between, but not limited to, about 10 degrees and about 20 degrees Celsius above the solidifying temperature the optical material 122.

[0080] The material may also be selected based on its ability to provide sufficient dimensional and thermal stability under elevated pressures and temperatures, such as by possessing a heat distortion temperature of between, but not limited to, about 10 degrees and about 20 degrees Celsius above the solidifying temperature the optical material 122 (e.g., a casting or molding monomer resin). Various non-limiting examples of construction materials suitable for manufacturing the first mold member 102 are recited below, but it should be appreciated that other construction materials may be utilized in different examples.

[0081] In one example, the material may be polyetheretherketone, which is well- known to possess outstanding chemical resistance and excellent mechanical and dimensional stability. In some examples, the optical material 122 may be Di-Allyl Carbonate (“ADC”) or CR-39, commonly known as Columbia Resin 39. In such an example, the material may have a heat distortion temperature equal to or above, but not limited to, 80 degrees Celsius. In another examples, the optical material 122 may be a thio-polyurethane, such as, but not limited to, MR-7, MR-8, or MR-10 developed by Mitsui Chemicals. In such examples, the material may be selected to possess a light refraction index of, but not limited to, 1 .60, 1 .67, or 1 .74 and possess a heat distortion temperature of about, but not limited to, 120 degrees Celsius.- 17 - II PG-1 -146313Patent Application1 10000-584B / PCT

[0082] In some examples, the material may comprise a semicrystalline polyoxymethyelene polymer, a homopolymer, or a copolymer. In one such example, the material may comprise polyoxymethylene (POM). In further examples, the material may be comprised of a polyolefin polymer. In some such examples, the material may comprise a homopolymer polypropylene such as, but not limited to, Pro-fax SG702, Pro-fax 6523, Pro-fax 6323, Metocene HM2015, or Metocene HM2089 developed by LyondellBasell. In other such examples, the material may comprise high-density polyethylene (“HDPE”). In some such examples, HDPE 1285 or HDPE 2285 developed by Baystar, DMDA 8007 produced by Unipol, 9006 HID developed by Marlex, or DMDA 8907 developed by Dow. In additional example, the material may comprise Zeonex developed by Zeon, or other cyclic olefin polymers.

[0083] In further specific example, such as an example where the optical material 122 (e.g., an optical monomer resin) will be polymerized by the application of ultraviolet (“UV”) radiation, the optical material 122 may be an amorphous thermoplastic that is transparent to the selected range of UV radiation, and the material of the first mold member 102 may be, but not limited to, a polycarbonate, a polyacrylic, a polystyrene, or a polycyclic olefin.

[0084] In another specific example, such as an example where the optical material 122 will be polymerized via the application of heat, the material of the first mold member 102 may be an amorphous thermoplastic, or otherwise a semicrystalline material such as, but not limited to, a polyetheretherketone (PEEK), or a polyolefin that may include HDPE or polypropylene.

[0085] In some examples, the material of the second mold member 104 may also be selected for possessing different physical properties from a material of the first mold member 102. For example, the material of the second mold member 104 may be selected for possessing a significantly higher elongation at yield (e.g., above 400%), relative to a material used for the first mold member 102, or vice versa, to help establish an air-tight seal between the first mating surface 108 of the first mold member 102 and the second mating surface 110 of the second mold member 104.- 18 - II PG-1 -146313Patent Application1 10000-584B / PCT

[0086] In some examples, the material may possess a hardness characterized under the Shore D standard or the Rockwell R standard. For example, if the Shore D hardness standard is used, the material may be characterized by a value of, but not limited to, between about 60 and about 70. In other examples, if the Rockwell R standard is used, the material may be characterized by a value of, but not limited to, between about 60 and about 90. In still further examples, the polymer-based material used for the first mold member 102 may further be selected to have a yield strength of about 30 MPa (“Megapascals”) or greater.

[0087] The steps or operations of a method for using the spectacle lens molding system 100 are illustrated below in a particular order for convenience and clarity; and many of the discussed operations can be performed by multiple different actors, devices, or systems. It is understood that subsets of the operations discussed in the method can be attributable to a single actor, device, or system and can be considered a separate standalone process or method. Further, it should be appreciated that the order of various steps or operations of such a method may vary in different examples and thus should not be construed as limited in scope by the following descriptions.

[0088] In some examples, the method may begin with inserting the first mold member 102 into the second mold member 104. For example, a user, or automated means, may insert the first mold member 102 into the second mold member 104 until a portion of the first molding surface 116 contacts the mold stop 112, or is otherwise prevented from further translation via the engagement between the first mating surface 108 and the second mating surface 110. Next, a user, or automated means, may heat an optical material 122 (e.g., an optical monomer resin) to a temperature sufficient to maintain the optical material 122 in a liquid state, and then the user or the automated means may proceed to inject or dispense a predetermined volume of the optical material 122 into the second mold member 104 through the fill port 124. Generally, the predetermined volume may be an amount sufficient to entirely fill the spectacle lens molding chamber 120 by covering an entire surface area of the first molding surface 116 and the second molding surface 118.- 19 - II PG-1 -146313Patent Application1 10000-584B / PCT

[0089] Next, the optical material 122 within the spectacle lens molding chamber 120 may be cured to produce an ophthalmic spectacle lens. For example, the spectacle lens molding system 100 may be subjected to, such as manually via user inputs(s) or automatically via automated means, a traditional thermal, UV (ultraviolet light), or other curing process as known in the art. As may be appreciated, the optical material 122 may polymerize and transition from a liquid state to solid state.

[0090] After the optical material 122 has been cured, a user, or robotic automated means, may remove the first mold member 102 from the second mold member 104. For example, a user, or an automated means, may raise the first mold member 102 until the first mating surface 108 is no longer in contact with the second mating surface 110 of the second mold member 104.

[0091] In some examples, if the ophthalmic spectacle lens does not stay adhered to the second molding surface 118 when the first mold member 102 is removed from the second mold member 104, a user, or automated means, may break the surface the surface adhesion that may be present between the second molding surface 118 and the molded ophthalmic optical lens via the use of one or more tools, or through the introduction of a chemical release agent into the second mold member 104.

[0092] Once a molded ophthalmic spectacle lens has been removed from the second mold member 104, it is to be appreciated that the molded ophthalmic spectacle lens may be in a semi-finished state. As such, the method may further include various post-processing stages or operations known in the art, such as, but not limited to, additional lens shaping, polishing, coating, or over molding steps. In some examples, such post-processing may include, among others, any of hard- coating or scratch-resistant coating, anti-reflective coating, anti-fog coating, or ultraviolet treatment coating of the ophthalmic spectacle lens 125.

[0093] Fig. 13 illustrates a diagram of a method of making the spectacle lens molding system 100 including the plurality of molding features 150, in accordance with at least one example. The method 200 may begin with step 210. In some examples, step 210 may include providing a molding means capable of producing- 20 - II PG-1 -146313Patent Application1 10000-584B / PCT the plurality of molding features 150 (Fig. 8) of the molding surface 148. In some examples, such a molding means may be the molding insert 170 shown in Fig. 12.

[0094] In some examples, step 210 may include inserting the molding insert into a first mold assembly that is configured to form the first mold member 102 via an injection molding process. In some examples, such as mold assembly may comprise a pair of mold members insertable into a sealing gasket to form a cavity in the size and shape of the first mold member 102. In some examples, the molding insert 170 may be positioned within the sealing gasket such that a surface of one of the pair of mold members is covered by the molding insert 170 when the mold member is inserted into the sealing gasket. Subsequently, the remaining mold member may be inserted into the sealing gasket in a position opposing the molding insert 170 to prepare the first mold assembly for step 220. Alternatively, the molding insert 170 may comprise one of the two mold members insertable into the sealing gasket.

[0095] At step 220, the first mold assembly may be filled with a material selected for constructing the first mold member 102, such as a thermoplastic or a polymeric material. For example, the material selected for the first mold member 102 may be injected under pressure in a heated or high-temperature molten state into a cavity defined between the molding insert 170 and a curved molding surface of an opposing mold member in an injection molding machine. However, it is also appreciated that the material selected for the first mold member 102 may alternatively be poured into a cavity defined between the molding insert 170 and a curved molding surface of an opposing mold member during a casting process. Next, at step 230, the material may be solidified, such as via cooling, to form the first mold member 102. After the material has solidified, the first mold member 102 may be ejected from the first mold assembly at step 240.

[0096] At step 250, a second mold assembly configured to form the second mold member 104 via an injection molding process may be provided. In some examples, such a mold assembly may comprise a pair of mold members securable and sealable with respect to one another to form a cavity in the size and shape of the second mold member 104. Next, the material, such as LDPE, selected for the- 21 - II PG-1 -146313Patent Application110000-584B / PCT second mold member 104 may be injected under pressure in a heated or high- temperature molten state into the cavity defined between curved molding surfaces of the two mold members in an injection molding machine. However, it is also appreciated that the material selected for the second mold member 104 may alternatively be poured into a cavity defined between the curved molding surfaces of two mold members during a casting process. Next, at step 260, the material may be solidified, such as via cooling, to form the second mold member 104. After the material has solidified, the second mold member 104 may be ejected from the second mold assembly at step 270.

[0097] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.- 22 - IIPG-1-146313

Claims

Patent Application110000-584B / PCTCLAIMSWhat is claimed is:

1. An optical lens molding system comprising: a first mold member including: a first mating surface; a first molding surface for molding a front surface of an ophthalmic spectacle lens; a second mold member comprising a gasket body, the gasket body defining: a second molding surface for molding a back surface of an ophthalmic spectacle lens; a second mating surface configured to engage the first mating surface to form an air-tight seal therebetween when the first mold member is received within the gasket body of the second mold member; wherein the first mold member and the second mold member are configured to form a spectacle lens molding chamber between the first molding surface and the second molding surface when the first mold member is received within the gasket body of the second mold member; and a fill port configured to direct a flow of liquid optical material into the spectacle lens molding chamber.

2. The system of claim 1 , wherein the gasket body further defines a vent port.

3. The system of claim 1 , wherein the fill port is formed through a sidewall of said gasket body.

4. The system of claim 1 , wherein the fill port comprises a chamber extending from an exterior surface of the gasket body.- 23 - IIPG-1-146313Patent Application1 10000-584B / PCT5. The system of claim 1 , wherein an inner surface of the gasket body includes a radial projection configured to limit translation of the first mold member into the second mold member.

6. The system of claim 1 , wherein the first mold member is made from thermoplastic and the second mold member is made from low density polyethylene.

7. The system of claim 1, wherein the first mold member and the second mold member are each made from a thermoplastic polymer.

8. The system of claim 7, wherein the thermoplastic polymer is selected from the group consisting of a polyetheretherketone, a polyoxymethyelene polymer, a homopolymer, a copolymer, a polyolefin polymer, a polyethylene, a polycarbonate, a polyacrylic, a polystyrene, a polycyclic olefin, or a polypropylene.

9. The system of claim 1 , wherein the first molding surface and / or the second molding surface defines a plurality of molding features configured to produce a microlens or nanolens array.

10. The system of claim 9, wherein the plurality of molding are distributed in an annular arrangement about the first molding surface and / or the second molding surface, and wherein the annular arrangement circumferentially encompasses a central region of the first molding surface and / or the second molding surface that is devoid of any the plurality of molding features.

11. A method of molding an ophthalmic spectacle lens using a mold system, the method comprising: inserting a first mold member into a gasket body of a second mold member to form an air-tight seal between a first mating surface of the first mold member and a second mating surface of the second mold member, wherein the gasket body of the second mold member defines a second molding surface;- 24 - II PG-1 -146313Patent Application110000-584B / PCT introducing a liquid optical material through a fill port in the gasket body until a surface area of the first molding surface and a surface area of the second molding surface is in contact with the liquid optical material; and curing the liquid optical material in the mold system to produce the ophthalmic spectacle lens.

12. The method of claim 11 , wherein inserting the first mold member into the gasket body of the second mold member includes forming a spectacle lens molding chamber between a first molding surface of the first mold member and a second molding surface of the second mold member.

13. The method of claim 12, wherein dispensing the liquid optical material includes venting air from the spectacle lens molding chamber during introduction of the liquid optical material through the fill port.

14. The method of claim 11 , wherein inserting the first mold member into the gasket body comprises inserting a thermoplastic mold member comprised of a polyetheretherketone, a polyoxymethyelene polymer, a homopolymer, a copolymer, a polyolefin polymer, a polyethylene, a polycarbonate, a polyacrylic, a polystyrene, a polycyclic olefin, or a polypropylene into the gasket body.

15. The method of claim 11 , wherein inserting the first mold member into the gasket body comprises inserting a glass mold member into the gasket body.

16. The method of claim 11 , further comprising removing the first mold member from the gasket body and extracting the ophthalmic spectacle lens from the gasket body.

17. The method of claim 16, wherein extracting the ophthalmic spectacle lens from the gasket body includes introducing a release agent into the gasket body.

18. The method of claim 11 , wherein introducing the liquid optical material through the fill port includes filling each of a plurality of molding features with the- 25 - IIPG-1-146313Patent Application 110000-584B / PCT liquid optical material, and wherein each of the plurality of molding features is configured to mold a microlens or a nanolens.- 26 - IIPG-1-146313

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