Apparatus and system for the production of plastic lenses

An apparatus for preparing an eyeglass lens, comprising:

• a first lens curing unit comprising a first activating light source, wherein the first lens curing unit is configured to produce activating light directed toward a mold assembly during use;
• a second lens curing unit comprising a second activating light source and heating system, wherein the activating light source is configured to direct activating light toward a mold assembly during use;
• and wherein the heat system is configured to heat the interior of the second lens curing unit;
• an anneal unit, the anneal unit comprising an anneal unit heating system, wherein the anneal unit heating system is configured to heat the interior of the anneal unit;
• and
• a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit;
• wherein the apparatus is configured such that a substantially clear eyeglass lens is formed in a time period of less than 1 hour.

A system for dispensing a heated polymerizable lens forming composition comprising:

• a heating apparatus, the heating apparatus comprising:
• a heating apparatus body, the heating apparatus body being configured to hold the lens forming composition, the heating apparatus body comprising an opening for receiving a fluid container and an outlet;
• a heating system positioned within the heating apparatus body for heating the lens forming composition;
• and
• a valve positioned proximate the outlet, wherein the valve comprises an elongated member, wherein the elongated member is positionable within the outlet in a closed position, wherein the elongated member in the closed position inhibits flow of the lens forming composition through the outlet, and wherein the elongated member is positionable within the outlet in an open position, wherein the elongated member in an open position allows flow of the lens forming composition flows through the outlet during use;
• and
• a fluid container configured to hold a lens forming composition, the fluid container comprising:
• a fluid container body and a cap, wherein the cap comprises a fluid control member and an elastic member, wherein the elastic member is coupled to the fluid control member such that the elastic member exerts a force on the fluid control member such that the fluid control member is forced against a top inner surface of the cap;
• wherein the fluid container is insertable into the opening of the heating apparatus, and wherein insertion of the fluid container into the opening causes the fluid control member to be moved to a position such that the lens forming composition flows from the fluid container into the heating apparatus body.

A method for making a plastic eyeglass lens, comprising

• heating a lens forming composition in a heating apparatus comprising:
• a body, the body being configured to hold the lens forming composition, the body comprising an opening for receiving a fluid container and an outlet;
• a heating system positioned within the body for heating the lens forming composition;
• a valve positioned proximate the outlet, wherein the valve comprises an elongated member, wherein the elongated member is positionable within the outlet in a closed position, wherein the elongated member in the closed position inhibits flow of the lens forming composition through the outlet, and wherein the elongated member is positionable within the outlet in an open position, wherein the elongated member in an open position allows flow of the lens forming composition flows through the outlet during use.
• placing the liquid lens forming composition in a mold cavity of a mold assembly, wherein the mold assembly comprises a front mold member and a back mold member, the lens forming composition comprising a monomer composition and a photoinitiator;
• directing activating light toward at least one of the mold members to initiate curing of the lens forming composition;
• and
• directing activating light and heat toward at least one of the mold members subsequent to initiating curing of the lens to form the eyeglass lens.

An eyeglass lens made by the method, comprising

• heating a lens forming composition in a heating apparatus comprising:
• a body, the body being configured to hold the lens forming composition, the body comprising an opening for receiving a fluid container and an outlet;
• a heating system positioned within the body for heating the lens forming composition;
• a valve positioned proximate the outlet, wherein the valve comprises an elongated member, wherein the elongated member is positionable within the outlet in a closed position, wherein the elongated member in the closed position inhibits flow of the lens forming composition through the outlet, and wherein the elongated member is positionable within the outlet in an open position, wherein the elongated member in an open position allows flow of the lens forming composition flows through the outlet during use.
• placing the liquid lens forming composition in a mold cavity of a mold assembly, wherein the mold assembly comprises a front mold member and a back mold member, the lens forming composition comprising a monomer composition and a photoinitiator;
• directing activating light toward at least one of the mold members to initiate curing of the lens forming composition;
• and
• directing activating light and heat toward at least one of the mold members subsequent to initiating curing of the lens to form the eyeglass lens.

A method for making a plastic eyeglass lens, comprising:

• placing a liquid lens forming composition in a mold cavity of a mold assembly, wherein the mold assembly comprises a front mold member and a back mold member, the lens forming composition comprising a monomer composition and a photoinitiator;
• placing the mold assembly in a mold assembly holder, the mold assembly holder comprising:
• a body, wherein the body is configured to allow activating light to reach the mold assembly;
• an indentation formed in the body, wherein the indentation is complementary to the shape of the mold assembly.
• directing activating light toward at least one of the mold members to initiate curing of the lens forming composition;
• and
• directing activating light and heat toward at least one of the mold members subsequent to initiating curing of the lens to form the eyeglass lens.

An eyeglass lens made by the method, comprising:

• placing a liquid lens forming composition in a mold cavity of a mold assembly, wherein the mold assembly comprises a front mold member and a back mold member, the lens forming composition comprising a monomer composition and a photoinitiator;
• placing the mold assembly in a mold assembly holder, the mold assembly holder comprising:
• a body, wherein the body is configured to allow activating light to reach the mold assembly;
• an indentation formed in the body, wherein the indentation is complementary to the shape of the mold assembly.
• directing activating light toward at least one of the mold members to initiate curing of the lens forming composition;
• and
• directing activating light and heat toward at least one of the mold members subsequent to initiating curing of the lens to form the eyeglass lens.

A method of operating a fluorescent lamp, comprising:

• coupling the fluorescent lamp to a ballast system, the ballast system comprising:
• an instant start ballast, wherein the instant start ballast is configured to deliver a striking voltage to the fluorescent lamp, and wherein the instant start ballast is further configured to regulate the current to the fluorescent lamp when the fluorescent lamp is on;
• and
• a transformer, wherein the transformer is configured to deliver voltage to a filament of the fluorescent lamp when the fluorescent lamp is off;
• operating the transformer such that voltage is delivered to the filament of the fluorescent lamp;
• operating the instant start ballast such that a striking voltage is applied to the fluorescent lamp casing the fluorescent lamp to produce light.

A system for preparing an eyeglass lens, comprising:

• a mold assembly comprising:
• a first mold member having a casting face and a non-casting face;
• a second mold member having a casting face and a non-casting face, the second mold member being configured to be spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member at least partially define a mold cavity;
• an apparatus for curing a lens forming composition, comprising:
• a first lens curing unit comprising a first activating light source, wherein the first lens curing unit is configured to produce activating light toward a mold assembly during use;
• a second lens curing unit comprising a second activating light source and heating system, wherein the activating light source is configured to direct activating light toward a mold assembly during use;
• and wherein the heat system is configured to heat the interior of the second lens curing unit;
• and
• a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit.

A system for preparing an eyeglass lens, comprising:

• a mold assembly comprising:
• a first mold member having a casting face and a non-casting face;
• a second mold member having a casting face and a non-casting face, the second mold member being configured to be spaced apart from the first mold member during use such that the casting faces of the first mold member and the second mold member at least partially define a mold cavity;
• an apparatus for curing a lens forming composition, comprising:
• a first lens curing unit comprising a first activating light source, wherein the first lens curing unit is configured to produce activating light toward a mold assembly during use;
• a second lens curing unit comprising a second activating light source and heating system, wherein the activating light source is configured to direct activating light toward a mold assembly during use;
• and wherein the heat system is configured to heat the interior of the second lens curing unit;
• and
• a conveyor system configured to convey the mold assembly from the first lens curing unit into and through the second lens curing unit;
• and
• a lens forming composition configured to be disposed within the mold cavity during use, comprising:
• a monomer that cures by exposure to activating light to form the eyeglass lens during use;
• and
• a photoinitiator that initiates curing of the monomer in response to being exposed to activating light during use.

A computer-implemented method for controlling formation of an eyeglass lens, the method comprising:

• receiving prescription information, wherein the prescription information defines an eyeglass prescription;
• analyzing the prescription information;
• and
• determining a front mold identification marking, a back mold identification marking, and a gasket identification marking of an appropriate front mold, back mold and gasket for producing the eyeglass lens in response to analyzing the prescription information;
• wherein the front mold, the back mold and the gasket together are operable to produce a mold cavity, the mold cavity being configured to hold a lens forming composition which is curable to produce the eyeglass lens from the prescription, the front mold member comprising the front mold identification marking, the back mold member comprising the back mold identification marking, and the gasket member comprising the gasket identification marking.

A computer-implemented method for controlling formation of an eyeglass lens, the method comprising:

• receiving prescription information, wherein the prescription information defines an eyeglass prescription;
• analyzing the prescription information;
• determining curing conditions for the eyeglass lens in response to analyzing the prescription information;
• controlling a curing unit, the curing unit being configured to cure at least a portion of a lens forming composition in a mold;
• and
• controlling a post-cure unit, the post-cure unit being configured to substantially complete curing of the eyeglass lens.

A computer-implemented method for monitoring a device configured to cure a lens forming composition disposed in a mold assembly to produce an eyeglass lens from a prescription, the method comprising:

• monitoring operating conditions for one or more components of the device;
• detecting an operating error for one or more of the one or more components of the device;
• and
• displaying a message on a display device coupled to the device, the message describing the operating error for the one or more of the one or more components of the device.

A system comprising:

• a device configured to cure a lens forming composition in a mold to produce an eyeglass lens from a prescription;
• a controller computer coupled to the device;
• and
• controller software executable on the controller computer, wherein the controller software is operable to:
• receive prescription information, wherein the prescription information defines an eyeglass prescription;
• analyze the prescription information;
• and
• determine a front mold identification marking, a back mold identification marking, and a gasket identification marking of an appropriate front mold, back mold and gasket for producing the eyeglass lens in response to analyzing the prescription information;
• wherein the front mold, the back mold and the gasket together are operable to produce a mold cavity, the mold cavity being configured to hold a lens forming composition which is curable to produce the eyeglass lens from the prescription, the front mold member comprising the front mold identification marking, the back mold member comprising the back mold identification marking, and the gasket member comprising the gasket identification marking.

A system comprising:

• a device configured to cure a lens forming composition in a mold to produce an eyeglass lens from a prescription, the device comprising:
• a curing unit configured to cure the lens forming composition;
• and
• a post-cure unit configured to substantially complete curing of the eyeglass lens;
• a controller computer coupled to the device;
• and
• controller software executable on the controller computer, wherein the controller software is operable to:
• receive prescription information, wherein the prescription information defines an eyeglass prescription;
• analyze the prescription information;
• determine curing conditions for the eyeglass lens in response to analyzing the prescription information;
• control the curing unit during the curing of at least a portion of the lens forming composition;
• and
• control the post-cure unit during the substantially completing of the curing of the eyeglass lens.

A system comprising:

• a device configured to cure a lens forming composition disposed in a mold assembly to produce an eyeglass lens from a prescription, wherein the device comprises one or more components;
• a display device coupled to the device;
• a controller computer coupled to the device;
• and
• controller software executable on the controller computer, wherein the controller software is operable to:
• monitor operating conditions for the one or more components of the device;
• detect an operating error for one or more of the one or more components of the device;
• and
• display a message on the display device, the message describing the operating error for the one or more of the one or more components of the device.

A carrier medium comprising program instructions, wherein the program instructions are computer-executable to implement a method for controlling formation of an eyeglass lens, and wherein the method comprises:

• receiving prescription information, wherein the prescription information defines an eyeglass prescription;
• analyzing the prescription information;
• and
• determining a front mold identification marking, a back mold identification marking, and a gasket identification marking of an appropriate front mold, back mold and gasket for producing the eyeglass lens in response to analyzing the prescription information;
• wherein the front mold, the back mold and the gasket together are operable to produce a mold cavity, the mold cavity being configured to hold a lens forming composition which is curable to produce the eyeglass lens from the prescription, the front mold member comprising the front mold identification marking, the back mold member comprising the back mold identification marking, and the gasket member comprising the gasket identification marking.

A carrier medium comprising program instructions, wherein the program instructions are computer-executable to implement a method for controlling formation of an eyeglass lens, and wherein the method comprises:

• receiving prescription information, wherein the prescription information defines an eyeglass prescription;
• analyzing the prescription information;
• determining curing conditions for the eyeglass lens in response to analyzing the prescription information;
• controlling a curing unit, the curing unit being configured to cure at least a portion of a lens forming composition in a mold;
• and
• controlling a post-cure unit, the post-cure unit being configured to substantially complete curing of the eyeglass lens;

A carrier medium comprising program instructions, wherein the program instructions are computer-executable to implement a method for monitoring a device configured to cure a lens forming composition disposed in a mold assembly to produce an eyeglass lens from a prescription, and wherein the method comprises:

• monitoring operating conditions for one or more components of the device;
• detecting an operating error for one or more of the one or more components of the device;
• and
• displaying a message on a display device coupled to the device, the message describing the operating error for the one or more of the one or more components of the device.