Engraving for Characterizing Optical Lenses
Field of the Invention
The present invention concerns the manufacturing of optical lenses, in particular ophthalmic lenses, by molding.
Background Art
Hitherto, plastic ophthalmic lenses are usually cast as blanks and then finalized by a mechanical fine machining process to obtain the desired optical shape. If desired, such mechanically finish-machined lenses can then be marked for identification purposes on the finished optical surface by a post-processing step, such as mechanical engraving.
Due to new production methods allowing the direct molding of finished ophthalmic lenses, fine machining can be avoided completely or at least for a substantial part of the lens surface. Since such production results in a large variety of different ophthalmic lenses, it is very important that any mix-up of lenses during production and preferably also afterwards is avoided.
Disclosure of the Invention
Hence, it is a general object of the invention to provide an improved method for producing optical, in particular ophthalmic lenses comprising characterizing marks . It is a further object of the present invention to provide tools for the characterization of optical, in particular ophthalmic lenses.
Now, in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the method for producing optical, in particular ophthalmic lenses comprising lens-characterizing marks is manifested by the features that a first molding shell and a second molding shell and a molding-shell-connecting part are assembled such that they form a molding cavity, that said molding cavity is filled with a lens forming material, that said lens forming material is cured, and that said first and said second molding shells and said molding-shell- connecting part are disassembled, wherein said first and said second molding shell are both marked on the cavity forming side and within the cavity forming part but out- side the optically used region with at least one molding- shell-characterizing mark, and that said molding cavity is filed with said lens forming material such that the molding-shell-characterizing mark is imprinted to the lens . The molding shells can be provided with such characterizing mark by engraving or by forming a raising or a group of raisings.
Once the molding shells are marked, they can be used several times for lens production.
Brief Description of the Drawings
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings, wherein:
Figure 1 is a cross-section of a preferred mold assembled from two molding shells and a gasket, with both molding shells having an engraved characterizing mark.
Figure 2 shows a lens with lens- characterizing marks and with position marks, produced with radially displaced molding shells.
Figure 3a shows two molding shells with the lens (not shown) between them already formed and the gasket removed, whereby said molding shells comprise reference or position marks, said reference or position mark of the larger molding shell being extended to a circle concentrical with the center of the circular molding shell, and whereby both molding shells are in a basic, i. e. centered and unrotated, position.
Figure 3b shows the molding assembly of Figure 3a with one of the molding shells rotated by an angle about the axis through the center of said molding shells. Figure 3c shows the molding assembly of Figure 3a with a radial displacement of one molding shell.
Figure 3d shows a molding assembly of Figure 3a with one of the molding shells rotated by an angle about the axis through the center of said molding shells (rotationally displaced) and with the same molding shell radially displaced (in off-center position) .
Modes for Carrying out the Invention
In the method for characterizing optical, in particular ophthalmic lenses of the present invention, the following terms are used as synonyms:
- first molding shell, front molding shell, and - in a preferred embodiment with molding shells of different radius - larg(er) molding shell,
- second molding shell, rear molding shell, back molding shell and - in a preferred embodiment with molding shells of different radius - small (er) molding shell,
- cavity forming side, active side,
- third molding-cavity-forming part, molding- shell-connecting part, in particular a gasket,
- characterizing mark, characterization, and
- reference marks, position marks. In a method for the production of ophthalmic lenses, a first molding shell 1 and a second molding shell 2 are usually connected by a third part 3, a molding-shell-connecting part, or several parts together forming such molding-shell-connecting part, such that they form a molding cavity 4. Said molding cavity 4 is then filled with a lens forming material and said lens forming material is then cured.
In the method of the present invention, the first and the second molding shell 1, 2 are both marked - prior to their use as parts of a molding cavity 4 - on the cavity forming or active side 5, 6 within the cavity forming part but outside the optically useful region with a molding-shell-characterizing mark 7, 8. Due to the position and embossed character of the mark, said mark is transferred to the lens 9 as imprint or impression 12, 13, respectively.
Furthermore, since it is preferred that the whole lens characterization can be read from one side of the lens, usually one molding shell is marked with the "mirror image" or "inverse image", respectively, of the finally desired lens characterization 7, 8. It is as well preferred that the two characterizations 7, 8 are not at the same place with regard to a reference position 10, 11, indicating a basic position of the molding shells relative to each other (Figure 3a) , but at least so much separated that they do not overlap at any practical rotation angle by which one of the molding shells may be rotated relative to the other molding shell (see Figure 3b) . Dependent on whether an apparatus or a person is intended to read out the characterization on the molding shell and/or the lens, a bar code or a letter and/or
number code or a combination of bar code and letter/number code may be preferred. It is also possible to combine other signs such as e.g. dots with letter/number codes. A presently preferred encoding is hexadecimal en- coding.
Besides of a bar code any other machine- readable characterization can be used including point marks, stylized numbers etc.
If the characterization is primarily intended for read-out by a person, a letter and/or number code is preferred, especially a code of 6 digits. By 6 digits, all molding shell relevant parameters can be characterized. If further information shall be provided, or if more molding shells with further corrections are used, it is of course also possible to use codes with more digits, or in the contrary case codes with less digits.
A molding shell can be provided with such characterizing marks by engraving, in particular by engraving with a laser, by etching or other material remov- ing method allowing a sufficiently fine and durable marking.
In an as well possible embodiment, raisings instead of engravings can be provided in the molding shells. Raisings may be favourable with respect to de- molding. Since the molding shells are much harder than the molded lenses, raisings in the molding shells are less prone to mechanical damage during demolding than raisings in the lens stemming from engravings in the molding shells. However, the molding shells provided with raisings might be more difficult to produce and handle and could lead to less durable marks on the molding shells.
Methods for producing molding shells with raisings comprise e.g. molding methods with suitably marked or embossed molds, fine machining of surmounting molding shell portions by removal of excess material with a laser, etc.
The method of the present invention also allows the introduction of further marks 14, 15 on the lens (see Figure 2) resulting from respective marks 10, 11 on the molding shells (see e.g. Figure 3c) . Such marks are e.g. reference marks, radial displacement marks, tilting marks, and combinations thereof. For monitoring radial displacement, a radial dash close to the edge is a preferred kind of mark.
Since the engraving can be exactly posi- tioned, the characterizing mark usually can simultaneously be used for tilt and angle of rotation determination, such that no need for other engravings such as reference marks, radial displacement marks, tilting marks, and combinations thereof exists. It is of course also possible to add to the molding shell one or more codes that are exclusively intended for the characterization of the molding shell. In this case, it is not necessary to make said code an inverse or mirror image, and it is also not necessary that such code is in the active area, but it can as well be outside the active area. However, the image/inverse image differentiation allows easy differentiation between front and rear/back molds.
Very often the reference marks and the radial and/or angular displacement marks are identical marks 10, 11, 14, 15, e.g. points, crosses etc., that in basic position, i.e. without any radial or rotational displacement of the molding shells, are e.g. one above the other such that they coincide if viewed from a perpendicular perspective. As soon as a displacement occurs, two marks 10, 11, 14, 15 are visible. If the mark 10 of one molding shell, e.g. molding shell 1, is extended to comprise a circle, said circle being concentric to the center of said molding shell 1, a radial and angular displacement can be visualized simultaneously (see Figure 3d) . The circle facilitates the read out of the displacement of the reference mark 11 of the mating molding shell 2. If
only angular but no radial displacement is present, mark 11 is on the circle 10 (see Figure 3b) . In the presentee of angular and radial displacement, mark 11 is beside said circle 10 (see Figure 3d) . It is also possible to mark the molding shells 1, 2 with a small circle, a cross or several bars in specified distances from the periphery of the mold to indicate tilting of one of the molding shells. The readout of such a marking is simpler, but less accurate than a tilt determination of one of the molding shells 1, 2 e. g. by measuring the thickness on opposite facets (at a thickest and thinnest side) of a molded lens 9 of defined diameter. A lens thickness and therefore molding shell tilting information may be obtained by usual measuring methods .
A further object of the present invention is a molding shell 1, 2, or a set of molding shells, respectively, comprising at least one characterizing mark 7, 8 per shell 1, 2, optionally together with at least one further mark 10, 11 selected from the group consisting of reference marks 10, 11, radial displacement marks 10, 11, tilting marks, and combinations thereof, either in form of a raising or a group of raisings, or, preferably, in form of engravings. Independent on whether the lens 9 is unambiguously characterized by the marks formed thereon during the molding step, each lens 9 can be provided with a certificate or report indicating its full characteristics. Each of said certificates or reports preferably comprises the identification numbers of each of the molding shells 1, 2. Such certificates or rather reports can be in the form of a print-out of the operation unit controlling the mold assembly, and they can provide information on rotational displacement, radial displacement, tilting, or thereby obtained optical corrections.
While there are shown and described presently preferred embodiments of the invention, it is to be dis-
tinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practised within the scope of the following claims.