# US 12,759,249 B2 · Optimization of process parameters for lens with micro-lens design

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- Number: US 12,759,249 B2
- Document ID: US12759249B2
- Status: Granted
- Kind: B2
- Application number: 18/561,514
- Filed: 2022-05-17
- Published: 2024-07-11
- Granted: 2026-10-13
- Earliest claimed: 2021-05-19
- Assignees: Essilor International
- Applicants: Essilor International
- Inventors: Tareq Haque; Timothy Holton; Thomas Clark
- Web page: https://patentgrep.com/patent/US12759249B2

## CPC

- B29D 11/0049: {Double sided moulds}
- B29C 33/02: with incorporated heating or cooling means
- B29C 35/007: {Tempering units for temperature control of moulds or cores, e.g. comprising heat exchangers, controlled valves, temperature-controlled circuits for fluids (B29C35/0294 takes precedence)}
- B29C 45/561: {Injection-compression moulding}
- B29D 11/00125: {Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere}
- B29L 2011/0016: {Lenses}
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

Injection-compression molding apparatus and methods to form a lens in a mold insert by an injecting a polymer into an internal cavity of the mold insert until a pressure of the internal cavity exceeds a predetermined force value, the first mold side being fixed and the second mold side being moveable and configured to apply a force generating the internal cavity pressure. The method includes controlling a first temperature of the first mold side to be in a range of 4 degrees Fahrenheit to 10 degrees Fahrenheit greater than a second temperature of the second mold side and controlling a coining compression distance of the second mold side to be in a range of 0.008 inches to 0.018 inches.

## Claims

### Claim 1

An injection-compression molding apparatus for molding a lens, comprising:
a mold insert having a first mold side having a concave surface patterned with microstructures, wherein the microstructures have a height between 0.1 μm-50 μm, a width of between 0.5 μm-1.5 mm, and a length of between 0.5 μm-1.5 mm and are arranged in multiple concentric rings, with no space between the microstructures;
a second mold side having a convex surface, wherein the concave surface and the convex surface face each other, and an internal cavity formed between the concave surface of the first mold side and the convex surface of the second mold side, the first mold side being fixed and the second mold side being moveable;
a gate connected to the internal cavity;
an injection unit connected to the gate, the injection unit configured to inject a polymer into the internal cavity;
an alignment post:
springs attached to the alignment post; and
at least one spacer, wherein the at least one spacer is positioned between the springs.

### Claim 2 (depends on 1)

The injection-compression molding apparatus of claim 1, further comprising:
an injection pressure sensor communicating with the internal cavity.

### Claim 3 (depends on 2)

The injection-compression molding apparatus of claim 2, further comprising:
an injection controller connected to a resin reservoir, pressure lines and gas source.

### Claim 4 (depends on 1)

The injection-compression molding apparatus of claim 1, further comprising:
a first coolant channel in the first mold side and a second coolant channel and in the second mold side.

### Claim 5

An injection-compression molding system for molding a lens, comprising:
a mold insert having a first mold side having a concave surface patterned with microstructures, wherein the microstructures have a height between 0.1 μm-50 μm, a width of between 0.5 μm-1.5 mm, and a length of between 0.5 μm-1.5 mm and are arranged in a pattern multiple concentric rings, with no space between the microstructures;
a second mold side having a convex surface, wherein the concave surface and the convex surface face each other, and an internal cavity formed between the concave surface of the first mold side and the convex surface of the second mold side, the first mold side being fixed and the second mold side configured to be moveable;
an injection unit configured to inject a polymer into the internal cavity;
a temperature controller connected to the first mold side and a second mold side;
an alignment post;
springs attached to the alignment post; and
at least one spacer, wherein the at least one spacer is positioned between the springs.