Method and apparatus for casting lenses

Abstract

An apparatus for manufacturing a lens with a predetermined prescription from a number of lens molds, a gasket, and a source of a fluid material. The apparatus includes a device for selecting a first lens mold and a second lens mold based upon the prescription, a device for positioning the lens molds within the gasket, a device for inserting an amount of the fluid material within the gasket and between the molds, a device for curing the fluid material so as to form the lens, and a device for advancing the lens molds along a predetermined path through the selecting device, the positioning device, the fill device, and the cure device.

We claim:  
     
         1 . An apparatus for manufacturing a lens with a predetermined prescription from a plurality of lens molds, a gasket, and a source of a fluid material, said apparatus comprising: 
 a means for selecting a first lens mold and a second lens mold from said plurality of lens molds based upon said predetermined prescription;    a means for positioning said first lens mold and said second lens mold within said gasket based upon said predetermined prescription;    a means for inserting a predetermined amount of said fluid material within said gasket and between said first lens mold and said second lens mold based upon said predetermined prescription;    a means for curing said fluid material so as to form said lens based upon said predetermined prescription; and    a means for advancing said first lens mold and said second lens mold along a predetermined path through said selecting means, said positioning means, said fill means, and said cure means.    
     
     
         2 . The apparatus of  claim 1 , further comprising a control system for operating said selecting means, said positioning means, said fill means, and said cure means.  
     
     
         3 . The apparatus of  claim 2 , wherein said control system comprises a personal computer.  
     
     
         4 . The apparatus of  claim 2 , wherein said control system comprises a database.  
     
     
         5 . The apparatus of  claim 2 , wherein said control system comprises a means for input and output of data.  
     
     
         6 . The apparatus of  claim 2 , wherein said selecting means comprises a conveyor advancing along said predetermined path.  
     
     
         7 . The apparatus of  claim 6 , wherein said selecting means comprises one or more transport pallets positioned along said conveyor.  
     
     
         8 . The apparatus of  claim 7 , wherein said selecting means comprises a storage carousel for storing said plurality of lens molds.  
     
     
         9 . The apparatus of  claim 8 , wherein said selecting means comprises an automated access arm for transporting said first lens mold and said second lens mold from said storage carousel to said pallet.  
     
     
         10 . The apparatus of  claim 9 , wherein said access arm comprises a gantry for movement thereon.  
     
     
         11 . The apparatus of  claim 9 , wherein said access arm comprises a plurality of gripper heads.  
     
     
         12 . The apparatus of  claim 11 , wherein each of said plurality of gripper heads comprises a plurality of gripper arms for gripping said first lens mold and said second lens mold.  
     
     
         13 . The apparatus of  claim 11 , wherein each of said plurality of gripper heads comprises an optical device.  
     
     
         14 . The apparatus of  claim 13 , wherein said optical device comprises a fiber optic sensor.  
     
     
         15 . The apparatus of  claim 2 , wherein said positioning means comprises a positioning station.  
     
     
         16 . The apparatus of  claim 15 , wherein said positioning station comprises an optical device and wherein each of said plurality of lens molds comprises a tic mark positioned thereon for detection by said optical device.  
     
     
         17 . The apparatus of  claim 16 , wherein said optical device comprises a camera-based vision system.  
     
     
         18 . The apparatus of  claim 16 , wherein said positioning station comprises a positioning stage for rotating said first lens mold and said second lens mold according to said tic mark.  
     
     
         19 . The apparatus of  claim 15 , wherein said positioning means comprises an assembly station.  
     
     
         20 . The apparatus of  claim 19 , wherein said assembly station comprises a retractable assembly stage such that said assembly stage can insert said first lens mold within said gasket at a first predetermined depth and insert said second lens mold within said gasket at a second predetermined depth.  
     
     
         21 . The apparatus of  claim 19 , wherein said assembly station comprises a gasket mount positioned about said assembly stage.  
     
     
         22 . The apparatus of  claim 19 , wherein said positioning means comprises a gasket supply with a plurality of said gaskets.  
     
     
         23 . The apparatus of  claim 22 , wherein said positioning means comprises one or more access arms for maneuvering said first lens mold, said second lens mold, and said gasket therethrough.  
     
     
         24 . The apparatus of  claim 23 , wherein said one or more access arms comprise a first access arm for positioning said first lens mold and said second lens mold on said positioning station, a second access arm for maneuvering said first lens mold and said second lens mold between said positioning station and said assembly station, and a third access arm for maneuvering said gasket between said gasket supply and said assembly station and for removing said first lens mold, said second lens mold, and said gasket from said assembly station.  
     
     
         25 . The apparatus of  claim 23 , wherein said one or more access arms comprise a gantry for movement thereon.  
     
     
         26 . The apparatus of  claim 23 , wherein said one or more access arms comprise a pair of gripper arms for gripping said first lens mold, said second lens mold, and said gasket.  
     
     
         27 . The apparatus of  claim 2 , wherein said inserting means comprises one or more fill stations.  
     
     
         28 . The apparatus of  claim 27 , wherein said one or more fill stations comprise a needle for piercing said gasket.  
     
     
         29 . The apparatus of  claim 27 , wherein said one or more fill stations comprise a pump in communication with said source of fluid material and said gasket.  
     
     
         30 . The apparatus of  claim 29 , wherein said pump comprises a variable speed pump such that said pump supplies said fluid material to said gasket at multiple rates.  
     
     
         31 . The apparatus of  claim 27 , wherein said inserting means comprises one or more access arms.  
     
     
         32 . The apparatus of  claim 2 , wherein said cure means comprises one or more cure stations.  
     
     
         33 . The apparatus of  claim 32 , wherein said one or more cure stations comprise one or more radiation sources.  
     
     
         34 . The apparatus of  claim 33 , wherein said one or more radiation sources comprise one or more ultraviolet or visible light sources.  
     
     
         35 . The apparatus of  claim 34 , wherein said one or more radiation sources comprise a first radiation source and a second radiation source.  
     
     
         36 . The apparatus of  claim 33 , wherein said one or more radiation sources comprise one or more shutters.  
     
     
         37 . The apparatus of  claim 36 , wherein said one or more shutters comprise a first shutter and a second shutter and wherein said control system operates said first shutter and said second shutter independently of one another.  
     
     
         38 . The apparatus of  claim 2 , further comprising a means for identifying said first lens mold and said second lens mold.  
     
     
         39 . The apparatus of  claim 38 , wherein said identifying means comprises an access arm positioned along said predetermined path to grasp said first lens mold and said second lens mold.  
     
     
         40 . The apparatus of  claim 39 , wherein said first lens mold and said second lens mold each comprise an indicator thereon and wherein said identifying means comprises an optical device so as to read said indicator.  
     
     
         41 . The apparatus of  claim 40 , wherein said optical device comprises a bar code reader.  
     
     
         42 . The apparatus of  claim 39 , wherein said first lens mold and said second lens mold each comprise one or more tic marks, said one or more tic marks indicating the orientation of said first lens mold and said second lens mold, and wherein said optical device comprises a camera-based vision system such that said optical device can determine the orientation of said first lens mold and said second mold.  
     
     
         43 . The apparatus of  claim 42 , wherein said access arm comprises one or more gripper arms such that said gripper arms can grasp said first lens mold and said second lens mold and also rotate said first lens mold and said second lens mold.  
     
     
         44 . The apparatus of  claim 39 , wherein said access arm comprises a printer thereon so as to print a further indicator on said first lens mold or said second lens mold.  
     
     
         45 . The apparatus of  claim 2 , further comprising a means for removing said lens and said first lens mold and said second lens mold from said gasket, said removing means positioned along said predetermined path.  
     
     
         46 . The apparatus of  claim 45 , wherein said removing means comprises a pair of movable degasketing arms, said pair of movable degasketing arms capable of grabbing and stretching said gasket.  
     
     
         47 . The apparatus of  claim 46 , wherein said removing means comprises an extendable plunger, said extendable plunger capable of pushing said lens and said first lens mold and said second lens mold out of said gasket.  
     
     
         48 . The apparatus of  claim 47 , wherein said removing means comprises one or more access arms for placing said gasket with said lens, said first lens mold, and said second lens mold therein on said plunger and for removing said lens, said first lens mold, and said second lens mold from said plunger.  
     
     
         49 . The apparatus of  claim 2 , further comprising a means for separating said lens, said first lens mold, and said second lens mold.  
     
     
         50 . The apparatus of  claim 49 , wherein said separating means comprises a plurality of heating and cooling stations.  
     
     
         51 . The apparatus of  claim 1 , further comprising a means for coating said lens with a scratch resistant treatment.  
     
     
         52 . The apparatus of  claim 1 , further comprising a means for verifying said predetermined prescription of said lens.  
     
     
         53 . The apparatus of  claim 1 , further comprising a means for cleaning said first and second lens molds.  
     
     
         54 . A method for manufacturing a lens with a predetermined prescription from a plurality of lens molds, a gasket, and a source of a fluid material, said method comprising the steps of: 
 selecting a first mold and a second mold from said plurality of lens molds based upon said predetermined prescription;    advancing said first lens mold along a predetermined path;    positioning said first lens mold within said gasket based upon said predetermined prescription;    advancing said second lens mold along said predetermined path;    positioning said second lens mold within said gasket based upon said predetermined prescription;    advancing said first lens mold, said second lens mold, and said gasket along said predetermined path;    inserting a predetermined amount of said fluid material within said gasket and between said first lens mold and said second lens mold based upon said predetermined prescription; and    curing said fluid material so as to form said lens based upon said predetermined prescription.    
     
     
         55 . A storage and retrieval station for use with a plurality of lens molds for making lenses, comprising: 
 a control system;    a conveyor controlled by said control system;    a storage rack for storing said plurality of the lens molds positioned adjacent to said conveyor; and    an access arm controlled by said control system for transporting a predetermined lens mold from said plurality of lens molds on said storage rack to said conveyor;    said access arm comprising an optical device thereon so as to confirm that said access arm has picked up one of said plurality of said lens mold from said storage rack.    
     
     
         56 . The storage and retrieval station of  claim 55 , wherein said storage rack comprises a rotatable storage carousel.  
     
     
         57 . The storage and retrieval station of  claim 56 , wherein said control system controls said rotatable storage carousel in coordination with said access arm.  
     
     
         58 . The storage and retrieval station of  claim 55 , wherein said access arm comprises a gantry for movement thereon.  
     
     
         59 . The storage and retrieval station of  claim 58 , wherein said access arm comprises a gripper head for rotation about said gantry.  
     
     
         60 . The storage and retrieval station of  claim 59 , wherein said gripper head comprises a pair of gripper arms so as to acquire said predetermined lens mold.  
     
     
         61 . The storage and retrieval station of  claim 55 , wherein said optical device comprises a fiber optic sensor.  
     
     
         62 . An assembly apparatus for positioning a first lens mold and a second lens mold into a gasket so as to form a lens of a predetermined prescription, said first and said second lens molds each comprising a positioning mark thereon, comprising: 
 a positioning station positioned along a predetermined path for observing said positioning mark on said first lens mold and said second lens mold;    a gasket supply with said gasket therein positioned along said predetermined path to supply said gasket;    an assembly station positioned along said predetermined path to position said first lens mold and said second lens mold within said gasket; and    an access arm system for transporting said first lens mold, said second lens mold, and said gasket along said predetermined path.    
     
     
         63 . The assembly apparatus of  claim 62 , further comprising a control system for operating said positioning station, said assembly station, and said access arm system.  
     
     
         64 . The assembly apparatus of  claim 63 , wherein said positioning station comprises an optical device for observing said positioning mark on said first lens mold and said second lens mold.  
     
     
         65 . The assembly apparatus of  claim 64 , wherein said optical device comprises a camera-based vision system.  
     
     
         66 . The assembly apparatus of  claim 64 , wherein said positioning station comprises a positioning stage surrounding said optical device.  
     
     
         67 . The assembly apparatus of  claim 66 , wherein said positioning station rotates said first lens mold and said second lens mold as directed by said control system based upon said positioning mark.  
     
     
         68 . The assembly apparatus of  claim 63 , wherein said assembly station comprises a gasket mount sized to support said gasket.  
     
     
         69 . The assembly apparatus of  claim 68 , wherein said assembly station comprises an assembly stage positioned within said gasket mount, said assembly stage positioning said first lens mold and said second lens mold into said gasket at a depth as determined by said control system based upon said predetermined prescription.  
     
     
         70 . The assembly apparatus of  claim 63 , wherein said access arm system comprises a gantry.  
     
     
         71 . The assembly apparatus of  claim 70 , wherein said access arm system comprises a plurality of access arms positioned on said gantry from movement thereon.  
     
     
         72 . The assembly apparatus of  claim 71 , wherein said plurality of access arms comprise a first access arm for positioning said first lens mold and said second lens mold on said positioning station, a second access arm for maneuvering said first lens mold and said second lens mold between said positioning station and said assembly station, and a third access arm for maneuvering said gasket between said gasket supply and said assembly station and for removing said first lens mold, said second lens mold, and said gasket from said assembly station.  
     
     
         73 . The assembly apparatus of  claim 71 , wherein each of said plurality of access arms comprises a plurality of gripper arms to grip said first lens mold, said second lens mold, and said gasket.  
     
     
         74 . A device for filling a mold with a fluid material and curing said fluid material, said device comprising: 
 a fill station;    said fill station comprising a pump for delivering said fluid material to said mold;    said fill station comprising an insertion device for inserting said fluid material within said mold; and    a cure station;    said cure station comprising a plurality of light sources; and    said cure station comprising a plurality of shutters, each of said plurality of shutters positioned over one of said plurality of light sources and each of said plurality of shutters operating independently of one another.    
     
     
         75 . The device for filling a mold of  claim 74 , further comprising a control system for controlling said fill station and said cure station.  
     
     
         76 . The device for filling a mold of  claim 75 , further comprising a plurality of cure stations.  
     
     
         77 . The device for filling a mold of  claim 75 , wherein said insertion device comprises a non-coring needle.  
     
     
         78 . The device for filling a mold of  claim 75 , wherein said pump comprises a positive displacement pump.  
     
     
         79 . The device for filling a mold of  claim 75 , wherein said pump comprises a multispeed pump.  
     
     
         80 . The device for filling a mold of  claim 75 , wherein said plurality of light sources comprises a plurality of ultraviolet light sources or a plurality of visible light sources.  
     
     
         81 . The device for filling a mold of  claim 75 , further comprising a movable bracket for maneuvering said mold between said fill station and said cure station.  
     
     
         82 . A device for removing a gasket from around a mold, said gasket comprising a plurality of support brackets, said device comprising: 
 a plunger capable of movement in a first direction; and    a plurality of degasketing arms surrounding said plunger, said plurality of degasketing arms capable of movement in a second direction;    said plurality of degasketing arms comprising a plurality of gripper arms to grip said support brackets of said gasket such that said plurality of degasketing arms stretch said gasket in said second direction while said plunger forces said mold out of said gasket in said first direction.    
     
     
         83 . The device for removing a gasket of  claim 82 , further comprising a control system for controlling said plunger, said plurality of degasketing arms, and said plurality of gripper arms.  
     
     
         84 . The device for removing a gasket of  claim 82 , further comprising an access arm for removing said mold from said plunger.  
     
     
         85 . A device for identifying and orienting a lens mold, said lens mold advancing along a conveyor positioned along a predetermined path, said lens mold further comprising an identification indicator thereon and a positioning mark thereon, said device comprising: 
 an access arm positioned along said predetermined path to grasp said lens mold;    an optical device positioned on said access arm so as to read said identification indicator and view said positioning mark; and    a printer positioned on said access arm to print a further indicator on said lens mold on a predetermined location thereon.    
     
     
         86 . The device of  claim 85 , further comprising a control system for controlling said access arm, said optical device, and said printer.  
     
     
         87 . The device of  claim 86 , wherein said optical device comprises a bar code reader to read said indicator.  
     
     
         88 . The device of  claim 86 , wherein optical device comprises a camera-based vision system to view said positioning mark.  
     
     
         89 . The device of  claim 88 , wherein said access arm comprises one or more gripper arms such that said gripper arms can grasp said lens mold and also rotate said lens mold.  
     
     
         90 . The apparatus of  claim 86 , wherein said printer comprises an ink jet printer.