Plastic lens systems, compositions, and methods

An apparatus for preparing an eyeglass lens, 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 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;
• a lens curing unit configured to direct activating light toward the mold members during use;
• and
• a post-cure unit configured to apply heat and activating light to the eyeglass lens.

An apparatus for curing an eyeglass lens, 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 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;
• a coating unit configured for applying a coating to at least one of the mold members or the eyeglass lens during use;
• a lens curing unit configured to direct activating light toward the mold members during use;
• a post-cure unit configured to apply heat and activating light to the eyeglass lens;
• and
• a programmable controller configured to substantially simultaneously control operation of the coating unit, the lens curing unit, and the post-cure unit during use.

A system for preparing an eyeglass lens, 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 adapted 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;
• a lens forming composition adapted 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;
• a photoinitiator that initiates curing of the monomer in response to being exposed to activating light during use;
• a coating unit for applying a coating to at least one of the mold members or the eyeglass lens during use;
• and
• a lens curing unit configured to cure at least a portion of a lens forming composition into the eyeglass lens by directing activating light toward mold members during use.

A system for preparing an eyeglass lens, 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 adapted 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;
• a lens forming composition adapted 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;
• a photoinitiator that initiates curing of the monomer in response to being exposed to activating light during use;
• a lens curing unit configured to cure at least a portion of a lens forming composition into the eyeglass lens by directing activating light toward mold members during use;
• and
• a post-cure unit configured to apply heat and activating light to the eyeglass lens to substantially complete curing of the eyeglass lens during use.

A system for preparing an eyeglass lens, 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 adapted 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;
• a lens forming composition adapted 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;
• a photoinitiator that initiates curing of the monomer in response to being exposed to activating light during use;
• a coating unit configured to produce a coating on at least one of the mold members or the eyeglass lens during use;
• a lens curing unit configured to cure at least a portion of a lens forming composition into the eyeglass lens by directing activating light toward mold members during use;
• a post-cure unit configured to apply heat and activating light to the eyeglass lens to substantially complete curing of the eyeglass lens during use;
• and
• a programmable controller configured to substantially simultaneously control operation of the coating unit, the lens curing unit, and the post-cure unit during use.

A programmable logic controller for controlling a lens forming apparatus, the lens forming apparatus 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 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;
• a coating unit configured to produce a coating on at least one of the mold members or the eyeglass lens during use;
• and
• a lens curing unit configured to direct activating light toward the mold members during use;
• wherein the controller is configured to control the operation of the lens curing unit.

A programmable logic controller for controlling a lens forming apparatus, the lens forming apparatus 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 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;
• a coating unit configured to produce a coating on at least one of the mold members or the eyeglass lens during use;
• a lens curing unit configured to direct activating light toward the mold members during use;
• and
• a post-cure unit configured to apply heat and activating light to the eyeglass lens;
• wherein the programmable logic controller is configured to substantially simultaneously control the operation of the coating unit, the lens curing unit, and the post-cure unit.

A method for making a plastic eyeglass lens, comprising:

• engaging a gasket with a first mold set for forming a first lens of a first power, wherein the first mold set comprises a front mold member and a back mold member, and wherein the front mold member, the back mold member, and the gasket at least partially define a mold cavity for retaining a lens forming composition, and wherein the gasket comprises at least four discrete projections arranged on an interior surface thereof for spacing the first and second mold members;
• introducing a lens forming composition into the mold cavity;
• and
• curing the lens forming composition.

A method of forming a non-photochromic lens under photochromic lens forming conditions comprising:

• placing a liquid lens forming composition in a mold cavity defined by at least a first mold member and a second mold member, the lens forming composition comprising:
• a monomer that cures by exposure to activating light to form the eyeglass lens during use;
• an ultraviolet/visible light absorbing compound;
• a co-initiator that activates curing of the monomer to form the eyeglass lens during use;
• and
• a photoinitiator that is activated upon exposure to activating light;
• and
• directing activating light toward the mold cavity, wherein the photoinitiator activates the co-initiator in response to being exposed to the activating light during use, and wherein activation of the co-initiator causes the lens forming composition to at least partially cure to form a non-photochromic lens during use.

A method of forming a plastic eyeglass lens comprising:

• placing a liquid lens forming composition in a mold cavity defined by at least a first mold member and a second mold member, the lens forming composition comprising:
• a monomer that cures by exposure to activating light to form the eyeglass lens during use;
• a photoinitiator that initiates curing of the monomer in response to being exposed to activating light during use;
• directing activating light toward the mold cavity, the activating light causing the lens forming composition to at least partially cure;
• and
• filtering the activated light with a filter, the filter comprising a liquid crystal display panel, wherein the liquid crystal display panel is configured to vary an intensity of activating light as the activating light is directed toward the mold members.

A composition curable by exposure to activating light to form a photochromic plastic eyeglass lens, the composition comprising:

• a monomer that cures by exposure to activating light to form the eyeglass lens during use;
• a photoinitiator that initiates curing of the monomer in response to being exposed to activating light during use;
• a first photochromic composition adapted, when cured in an eyeglass lens and subsequently exposed to photochromic activating light during use, to exhibit a first color;
• a second photochromic composition adapted, when cured in an eyeglass lens and subsequently exposed to photochromic activating light during use, to exhibit a second color;
• a light effector composition, wherein the light effector composition is adapted to affect the activated color of the photochromic plastic eyeglass lens such that the photochromic plastic eyeglass lens, when exposed to photochromic activating light, selectively exhibits the first color, the second color, or a third color during use.

A composition curable by exposure to activating light to form a photochromic plastic eyeglass lens, the composition comprising:

• a monomer that cures by exposure to activating light to form the eyeglass lens during use;
• a photoinitiator that initiates curing of the monomer in response to being exposed to activating light during use;
• a first photochromic composition adapted, when cured in an eyeglass lens and subsequently exposed to photochromic activating light during use, to exhibit a first color;
• a second photochromic composition adapted, when cured in an eyeglass lens and subsequently exposed to photochromic activating light during use, to exhibit a second color;
• a light effector composition, wherein the light effector composition is adapted to affect the activated color of the photochromic plastic eyeglass lens such that the photochromic plastic eyeglass lens, when exposed to photochromic activating light, selectively exhibits a third color which substantially differs from the first and second colors during use.

A composition curable by exposure to activating light to form a photochromic plastic eyeglass lens, the composition comprising:

• a monomer composition comprising an aromatic containing bis(allyl carbonate)-functional monomer;
• a co-initiator composition configured to activate curing of the monomer composition to form the eyeglass lens during use comprising an acrylated amine;
• and
• a photoinitiator configured to activate the co-initiator composition in response to being exposed to activating light during use;
• and
• a dye composition adapted to, when cured in an eyeglass lens, cause the eyeglass lens to exhibit a second color;
• and
• wherein the dye composition acts as a light effector composition on the photochromic composition such that the photochromic activity of the photochromic compound is reduced, and wherein a color of the
• photochromic plastic eyeglass lens, when exposed to activating light, exhibits a third color.

A method of altering an activated color of a photochromic lens comprising:

• mixing a first photochromic composition adapted, when cured in an eyeglass lens and subsequently exposed to photochromic activating light during use, to exhibit a first color, with a second photochromic composition adapted, when cured in an eyeglass lens and subsequently exposed to photochromic activating light during use, to exhibit a second color, to form a first polymerizable lens forming composition;
• adding a light effector composition to the polymerizable lens forming composition to form a second polymerizable lens forming composition;
• and
• curing the second polymerizable lens forming composition to form an eyeglass lens;
• wherein the activated color of the eyeglass lens differs from an activated color of an eyeglass lens formed from the first polymerizable lens forming composition.

A kit for preparing a composition curable by exposure to activating light to form a photochromic plastic eyeglass lens, the kit comprising:

• a base composition 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 first photochromic composition adapted, when cured in an eyeglass lens and subsequently exposed to photochromic activating light during use, to exhibit a first color;
• a second photochromic composition adapted, when cured in an eyeglass lens and subsequently exposed to photochromic activating light during use, to exhibit a second color;
• at least two light effector compositions;
• wherein a first light effector composition is adapted, when mixed with the first photochromic composition, the second photochromic composition, and the base composition, and after such mixture is cured to form an eyeglass lens, to affect the activated color of the eyeglass lens such that the eyeglass lens, when exposed to photochromic activating light, selectively exhibits a third color during use;
• and wherein a second light effector composition is adapted, when mixed with the first photochromic composition, the second photochromic composition, and the base composition, and after such mixture is cured to form an eyeglass lens, to affect the activated color of the eyeglass lens such that the eyeglass lens, when exposed to photochromic activating light, selectively exhibits a fourth color during use.

A method for making a plastic eyeglass lens, comprising:

• placing a liquid lens forming composition in a mold cavity defined by at least a first mold member and a second mold member, the lens forming composition comprising:
• a monomer composition comprising an aromatic containing polyethylenic polyether functional monomer;
• and
• a photoinitiator configured to initiate polymerization of the monomer composition in response to being exposed to activating light during use;
• and
• directing activating light toward at least one of the mold members to cure the lens forming composition to form the eyeglass lens.

A lens forming composition curable upon exposure to activating light to form a plastic eyeglass lens, comprising:

• a monomer composition comprising an aromatic containing polyether polyethylenic functional monomer containing groups selected from acrylyl or methacrylyl;
• a co-initiator composition configured to activate curing of the monomer composition to form the eyeglass lens during use, the co-initiator comprising an acrylyl amine;
• and
• a photoinitiator configured to activate the co-initiator composition in response to being exposed to activating light during use.

A method for making a plastic eyeglass lens, comprising:

• placing a liquid lens forming composition in a mold cavity defined by at least a first mold member and a second mold member, the lens forming composition comprising:
• a monomer composition comprising an aromatic containing polyether polyethylenic functional monomer containing groups selected from acrylyl or methacrylyl;
• a co-initiator composition configured to activate curing of the monomer composition to form the eyeglass lens during use, the co-initiator composition comprising an acrylyl amine;
• and
• a photoinitiator configured to activate the co-initiator composition in response to being exposed to activating light during use;
• and
• directing activating light toward at least one of the mold members to cure the lens forming composition to form the eyeglass lens.

A lens forming composition curable upon exposure to activating light to form a plastic eyeglass lens, comprising:

• a monomer composition comprising an aromatic containing polyether polyethylenic functional monomer;
• a co-initiator composition configured to activate curing of the monomer composition to form the eyeglass lens during use, the co-initiator composition comprising an amine;
• and
• a photoinitiator configured to activate the co-initiator composition in response to being exposed to activating light during use.

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 comprising an aromatic containing polyether polyethylenic functional monomer;
• a co-initiator composition configured to activate curing of the monomer composition to form the eyeglass lens during use, the co-initiator composition comprising an amine;
• and
• a photoinitiator configured to activate the co-initiator composition in response to being exposed to activating light during use;
• 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 defined by at least a front mold member and a back mold member, the lens forming composition comprising:
• a monomer composition comprising an aromatic containing polyether polyethylenic functional monomer;
• a co-initiator composition configured to activate curing of the monomer composition to form the eyeglass lens during use, the co-initiator composition comprising an amine;
• and
• a photoinitiator configured to activate the co-initiator composition in response to being exposed to activating light during use;
• and
• substantially simultaneously directing light toward at least one of the mold members and heat toward both of the mold members to form the eyeglass lens.

A programmable logic controller for controlling a lens forming apparatus, the lens forming apparatus comprising:

• a front mold member having a casting face, a non-casting face and a front mold identification marking;
• a back mold member having a casting face, a non-casting face and a back mold identification mark, the back mold member being spaced apart from the front mold member by a gasket during use, the gasket comprising a gasket identification marking, wherein the casting faces of the front mold member and the back mold member and an inner surface of the gasket at least partially define a mold cavity which defines a shape corresponding to an eyeglass prescription;
• and
• a lens curing unit configured to direct activating light toward the mold members during use;
• the controller comprising:
• an input device for obtaining information from an user;
• and
• an output device for transmitting information to the user;
• wherein the controller is configured to determine the front mold identification marking, the back mold identification marking and the gasket identification marking in response to the eyeglass prescription being entered through the input device, and wherein the controller is configured to transmit via the output device the front mold identification marking, the back mold identification marking and the gasket identification marking, and wherein the controller is configured to control the operation of the lens curing unit during use.

A system for preparing an eyeglass lens, 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 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;
• a lens forming composition adapted to be disposed within the mold cavity during use, comprising:
• a monomer composition comprising an aromatic containing polyether polyethylenic functional monomer;
• a co-initiator composition configured to activate curing of the monomer composition to form the eyeglass lens during use;
• and
• a photoinitiator configured to activate the co-initiator composition in response to being exposed to activating light during use;
• a lens curing unit configured to direct activating light and heat toward the mold members during use;
• and
• a coating unit for applying a coating to an eyeglass lens.

An apparatus for preparing an eyeglass lens, 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 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;
• a lens curing unit configured to direct activating light and heat toward the mold members during use;
• and
• a coating unit for applying a coating to an eyeglass lens.

An apparatus for preparing an eyeglass lens, comprising:

• a front mold member having a casting face, a non-casting face and a front mold identification marking;
• a back mold member having a casting face, a non-casting face and a back mold identification mark, the back mold member being spaced apart from the front mold member by a gasket during use, the gasket comprising a gasket identification marking, wherein the casting faces of the front mold member and
• the back mold member and an inner surface of the gasket at least partially define a mold cavity which defines a shape corresponding to an eyeglass prescription;
• a coating unit for applying a coating to the eyeglass lens during use;
• a lens curing unit configured to direct activating light and heat toward the mold members during use;
• a controller comprising an input device for obtaining information from an user and an output device for transmitting information to the user, wherein the controller is configured to determine the front mold identification marking, the back mold identification marking and the gasket identification marking in response to the eyeglass prescription being entered through the input device, and wherein the controller is configured to transmit via the output device the front mold identification marking, the back mold identification marking and the gasket identification marking, and wherein the controller is configured to control the operation of the lens curing unit during use.

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

• a body, the body being configured to hold the lens forming composition;
• a heating system coupled to the body for heating the monomer solution;
• a conduit coupled to the body for transferring the lens forming composition out of the body, the conduit comprising an inlet and an outlet,
• the inlet being positioned proximate the body the outlet being positioned distal to the body;
• an elongated member positioned within the conduit, wherein the elongated member is positionable within the conduit in a closed position, wherein the elongated member in the closed position inhibits flow of the lens forming composition through the conduit, and wherein the elongated member is positionable within the conduit in an open position, wherein the elongated member in an open position allows flow of the lens forming composition flows through the conduit during use;
• an elastic member coupled to the elongated member, the elastic member being configured to exert a force on the elongated member such that the elongated member moves from the closed position positioned to the open position during use;
• and
• a movable member coupled to the conduit and the elongated member, wherein the elongated member contacts the movable member at a first position such that the elongated member is in the closed position, and wherein the elongated member contacts the movable member at a second position such that the elongated member is in the open position, and wherein the movable member is movable such that contact between the movable member and the elongated member can be varied from the first position to the second position.

A method for making a flat-top bifocal eyeglass lens, the flat top bifocal eyeglass lens comprising a near vision correction zone and a far vision correction zone, 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 front mold member comprising a near vision correction zone;
• directing activating light toward at least one of the mold members to initiate curing of the lens forming composition, wherein the curing is initiated such that the lens forming composition in the near vision correction zone of the front mold is substantially gelled before the lens forming composition in the far vision correction zone proximate the front mold member is substantially gelled;
• 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.