CA1135464A - Cast resin lenses - Google Patents

Cast resin lenses

Info

Publication number
CA1135464A
CA1135464A CA000361576A CA361576A CA1135464A CA 1135464 A CA1135464 A CA 1135464A CA 000361576 A CA000361576 A CA 000361576A CA 361576 A CA361576 A CA 361576A CA 1135464 A CA1135464 A CA 1135464A
Authority
CA
Canada
Prior art keywords
lens
lens body
post
coating
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000361576A
Other languages
French (fr)
Inventor
Norman U. Laliberte
Don H. Rotenberg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sola International Inc
Original Assignee
Norman U. Laliberte
Don H. Rotenberg
Sola International, Inc.
American Optical Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Norman U. Laliberte, Don H. Rotenberg, Sola International, Inc., American Optical Corporation filed Critical Norman U. Laliberte
Application granted granted Critical
Publication of CA1135464A publication Critical patent/CA1135464A/en
Expired legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0222Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould the curing continuing after removal from the mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00Producing optical elements, e.g. lenses or prisms
    • B29D11/00009Production of simple or compound lenses
    • B29D11/00432Auxiliary operations, e.g. machines for filling the moulds
    • B29D11/00442Curing the lens material
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00Processes of treating or compounding macromolecular substances
    • C08J3/24Crosslinking, e.g. vulcanising, of macromolecules
    • C08J3/244Stepwise homogeneous crosslinking of one polymer with one crosslinking system, e.g. partial curing
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31507Of polycarbonate

Landscapes

  • Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Physics & Mathematics (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Thermal Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Eyeglasses (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Surface Treatment Of Glass (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)

Abstract

Abstract Of The Disclosure The method of making a post-cured cast resin lens comprising the steps of: casting an allyl diglycol carbonate resin in a mold to the shape desired of the lens; partially curing the resin in the mold to produce a lens body; removing the partially cured lens body from the mold; coating the partially cured lens body with a readily removable material which is impervious to oxygen; exposing the coated lens body to a post-curing temperature above room temperature until substantially complete polymerization of all portions and surfaces of the lens body beneath the coating takes place;
and removing the coating for exposure and use of the post-cured lens which features high surface cure and abrasion resistance,

Description

.35;~

I~I~ROVEM~Nl:~'S I~l CAST F~S IN LENSES

BAC~CGROU~D O~ THE Il~rVEl`JTTO~

Field of the Invention:
.
Manufacture or cast resin lenses with particular re~erence to im~rovements in post-cure procedures.

Discussion of the Prior Art:
In the manufacture of lenses of cast allyl diglycol carbonate and copolymers o~ the monomer and other rasins, it is desirable to remove the castings early in the cure cycle for ease o~ separation from the molds and to prevent costly ~reaXage of molds at separation. This ear7y removali however, requires post-curing of ~he caa~t lenses wherein exposure to oxygen normally inhibits further polymerization of the sur~aces - of the lenses A Accordingly, the lenses are left vulnerable to surface abrasion and are dir~icult to dye to uniform color densities.
In view of the foregoing, an object of this i~vention is to avoid the usual low sur~ace cure of post cured lenses that have been removed from their molds early in the pre-liminary curing cycle.
A further object is to accomplish grea~er than usualyield and quality of cast lens products with ~inimal cost and 35~

complication of equipment and/or procedure.
Other objects and advan-tayes of the invention will become appaxent from the following description.
According to an aspec-t OL the invention there is provided the method oE making a post-cured cast resin lens comprising the steps of: casting an allyl diglycol carbonate resin in a mold to the shape desired of the lens; partlally curing the resin in the mold to produce a lens body; removiny the partially cured lens body from the mold; coating the partially cured lens body with a readily removable material which is impervious to oxygen; exposing the coated lens body to a post curing temperature above room temperature until substantially complete polymerization of all portions and surfaces of the lens body beneath the coating takes place; and removing the aforesaid coating for exposure and use of the post-cured l.ens which features high surface cure and abrasion resistance.
DESCRIPTION OF THE D.RAWINGS
Fig. 1 is an illustratlon in cross-section of the apparatus and method used to cast resin lenses;

ms/
,.. .

~IL35~
Fig. 2 illustrates part:ial removal of a lens from its castiny apparatus;
Fig. 3 illustrates dip coating of the lens after complete remova~ from i~_s castin~ apparatus;

dm~ 3a -, .. .
.

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Fig~ 4 depicts a post-curing oven in,o which the coated lens is placed ~or post-curing;
Fig. 5 illustrates removai of the coasing material after final lens curing; and Fig. 6 illustrates, in cross section, an a7ternative form of lens to which the present invention is especially applicable.

DXSCR-LPTION OF THE PREFE~RED E~ODIl~EL~S
.

With the discovery ~hat o~ygen inhibits polymari~ation of surraces of cast resin lenses in post curing operations, this invention has devissd a post cure procedure which avoids the usual inade~uate surface pol~merization. To k~is end, a lens L cast in a cell 10 between a paix o mold halves 12 and 14 i5 removed, i.e. "picked", early in tha curing c~cle for purposes or easing its removal and to free the mold halves for easy cleaning and reuse as well as to prevent moldpiece breakage by excessive lens material adherence which may result from full curins in the moldpieces~
Early removal of a cast lens from a castin~ mold is herein considered as being any time prior to completion o~
polymeri~ation of the casting precursor but after there has been sufficient gelation to permit handling. It is also pointed out that the casting cell may be designed to produce ,~

~3S~

finished ophthalmic surfaces on one or both sides of lens L.
Hence~ use of the ter~.. "lens" herein is intended to include all forms of the article, i.e. ei.her cor,lpletely surface finished or finished on one side only as in the case o' lens articles which are co~only called blanks.
The removed partially cured lens must, however, be further cured for completion of i~s polymerization into a usable article~ In view 07' exposure to oxygen which inhibits surface polymerization in ordinary post-curing lQ operations, the picked lens is herein provided wi~h coating 16 (Figs. 3 and 4) by dipping (Fig. 3) in~o a readil~ re-movable inert coating material 18 (Fig. 3) sucn as polyvinyl alcohol which is impervious to oxygen. Coating 16, which may alternatively be painted or sprayed in place, protects lens surface 20 from e~posure to environmental oxygen so th~t post curing in oven 22 ~Fig. 4) can proceed with an assurance of full curing (polymerization) o~ all lens sur~aces as wel~ a~
theinterior. By such means, the lenses are arforded im-proved scratch resistance and an adaptabilit~ to eas~ and uniform dyeing.
Post curing in oven 22 at a temperature oi~ approximately 200F for approximately one to th~ee hours will produce de-sirable final polymeriz~tion of lenses or blan~s of the well recognized normal size and~or shape. Greater than usual lens ~r blanX sizes may require longer cycling ana/or higher ~l~35~

curing temperatu es for comple~e in~ernal cure. This would be immediately reco~nized b~ those of ordinar skill in the art who would further Lind no difLiculty in determining proper extensions of post-curing time.
Removal of coating 16, e.g. in a warm aqueous alkaline solution 24 of 1% sodium carbonate, renders t'ne lens ready for use. It may be alternatively or additionally washed in clear warm water if desired. Warming of the aqueous alkaline solution or clear water to approximately 190F will produce desirable results.
Userul coating materials 18 (Fig. 3) are:

1% PU~ Distilled (Polyvinyl alcohol) Wa~er1,000 grams PV~ 10 grams Wetting Agent4 arops
2% PV~ Distilled Water 1,000 gxams PU~ 20 grams Wetting Agent 4 drops 4% PU~ Distilled Water ~,000 grams PU~ 40 grams We~ting Agen~ 4 drops In the foregoing examples of coating solutions, the use of polyvinyl alcohols of molecular weights between 10,000 ,, . :-, ~
3~9~6~

and 90,000 are preferred~ Sui'able ~,etting agents are alXyl aryl sodium sul~onate, sodium lauryl sulrate, octylphenyl poly-thoxye~hanol and/or othe- high molecular weigh~ sulfones.
Solu~ion 24 of sodium carbonate ~Fig. 5) w~ich is used to remove coating 16 may alternatively comprise one vr co~.-binations OI sodium hydroxide, potassium hydroxide and potassiu~ car'.oonate in approximately from 1% to 5% solutions~
Plain water may also be used.
While Figs. 1~5 of the drawings have illustrated lens L
as having smooth, i.e. uninterrupted, opposite si~e surfaces, it should be und~rstood that this invention is equally appli-cable to the post-curing of all of the other ror~s of lenses encountered in the field such as those ~no~n as multifocals, for example. These lenses may have one or more sharp ledges 1, 26 cast partially or fully ac:ross one of their sides as illustrated in Fig. 6~ Ledged lenses, being somewhat more dirficult to remove from casting molds than continuous surface lenses, are particular candidates for.early removal and post-curing according to this inve.ntion.
~hile this invention has been directed more particularly to lenses cast of allyl diglycol car'~onate or copolymers or the mono~er, it should be understood that it is equally appli-cable to the post-curing of articles formed by means or method other than casting and/or materials other than allyl digl~col ,~ car~onate which may be similarly adversely af~ected by ex-~L35~

posure to atmospheric gases during post curing. Also, those seeXing details of prior art lens cas-ting ope.rations ma~
refer to U.S. Patents 2,542,386; 3,13~,000 3,056,166 and/or .
3,8~1,683 as examples.
It is intended that the foregoing disclosure and ac-compan~ing illustrations be exemplar~ or the in~ren~ion and not dellmiting OL its scope~ All modifications of process or equipment apparent to those s~illed in the art are con- .
sidered to be within the scope of this invention.

Claims (9)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. The method of making a post-cured cast resin lens comprising the steps of:
casting an allyl diglycol carbonate resin in a mold to the shape desired of said lens;
partially curing said resin in said mold to produce a lens body;
removing the partially cured lens body from said mold;
coating the partially cured lens body with a readily removable material which is impervious to oxygen;
exposing the coated lens body to a post curing temperature above room temperature until substantially complete polymerization of all portions and surfaces of said lens body beneath said coating takes place; and removing the aforesaid coating for exposure and use of the post-cured lens which features high surface cure and abrasion resistance.
2. The method according to claim 1 wherein said lenses are coated with polyvinyl alcohol.
3. The method according to claim 2 wherein said lenses are coated by dipping in a solution of polyvinyl alcohol.
4. The method according to claim 3 wherein said solution comprises approximately from 1% to 4% polyvinyl alcohol in water.
5. The method according to claim 3 wherein said solution includes a wetting agent.
6. The method according to claim 1 wherein said coatings are removed with an approximately 1% to 5% solution in water of an ingredient selected from the group consisting of sodium carbonate, sodium hydroxide, potassium hydroxide and potassium carbonate.
7. The method according to claim 6 wherein said solution is warmed for improved coating removal.
8. The method according to claim 7 wherein said warmed solution is approximately 1% sodium carbonate at a temperature of approximately 190°F.
9. The method according to claim 1 wherein said cast lenses comprise at least one optically finished surface over which said coatings are applied.
CA000361576A 1979-10-25 1980-10-02 Cast resin lenses Expired CA1135464A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US06/088,318 US4273809A (en) 1979-10-25 1979-10-25 Method of preparing cast resin lenses
US088,318 1979-10-25

Publications (1)

Publication Number Publication Date
CA1135464A true CA1135464A (en) 1982-11-16

Family

ID=22210671

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000361576A Expired CA1135464A (en) 1979-10-25 1980-10-02 Cast resin lenses

Country Status (6)

Country Link
US (1) US4273809A (en)
BR (1) BR8006852A (en)
CA (1) CA1135464A (en)
DE (1) DE3040221A1 (en)
FR (1) FR2467679A1 (en)
GB (1) GB2061982B (en)

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Also Published As

Publication number Publication date
FR2467679A1 (en) 1981-04-30
GB2061982B (en) 1983-08-17
US4273809A (en) 1981-06-16
FR2467679B1 (en) 1984-01-06
BR8006852A (en) 1981-04-28
DE3040221A1 (en) 1981-05-14
GB2061982A (en) 1981-05-20

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