CN1122277A - 隐形眼镜的模塑成型及包装 - Google Patents
隐形眼镜的模塑成型及包装 Download PDFInfo
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Abstract
一种模塑成型生产隐形眼镜的模具包括具有阳模表面(14)的第一杯形件(11)和具有阴模表面(19)的第二杯形件(16)。两杯形件(11、16)构成了一活塞和气缸并用在压力容器(26)中,以便施加负载压力,将模子表面(14、19)挠曲变形,保持该表面与镜片表面接触。模子打开时,表面(14)朝上。水合液(35)加到第一杯形件(11)内,一封闭物(34)密封到第一杯形件(11)的顶部。
Description
本发明涉及模塑隐形眼镜,特别是涉及制造和包装该镜片的设备和方法。
模塑成形是生产隐形眼镜的一种已知的方法。与其他方法,如车削加工和离心铸造相比它具有很高的加工质量且成本低廉。模塑成形还是一种可多次重复的加工方法。
在模塑成形加工中,在模具件之间维持一个良好的密封非常重要,它可以防止用来制造镜片的单体中的挥发成份泄漏并给模塑的镜片提供一清洁的边缘轮廓。使用现有的方法,模具件通常是靠机械装置夹持在一起。但是,在固化过程中,模具件可能会松驰,导致非均匀的密封载荷产生。另外,设计这样的模具也很困难,即,它能将足够的压力施加到模具件之间的密封口上,以便处于溢料腔内的多余的单体和镜片腔内的单体分开。不良的密封会导致损坏镜片并需要耗费人力物力的检验工序以剔除次品。
在模塑成形加工中,补偿在聚合固化过程中单体的收缩,以防止由于空洞作用产生的气泡或空穴形成也很重要。为减低上述影响,已知的方法是给其中一个模具件提供一柔性边缘,该边缘在聚合过程中收缩。其他系统允许来自模具中一储藏腔中的单体在收缩的抽吸效应下流回镜片腔,并允许模具表面在抽吸效应下相向运动。不过,柔性边缘和储藏腔的方法影响了密封,产生了次品镜片和边缘需打磨的镜片。这种模具表面运动的加工方法比其他方法的优点在于它可使密封口保持完好,但模壳必须仔细设计,以便在抽吸力下收缩均匀。模具厚度、材料或固化温度的变化将会影响模具的刚性,进而改变收缩程度。由单体收缩产生的抽吸必须克服模具结构本身的刚性,又不能例如抽吸进来自模具周围溢料腔内的单体。在模塑加工中,在模具装置内必须设置一个或几个空腔,用来容纳当模具件闭合时,挤出的过量的单体。在固化过程中,这些过量的单体构成了溢料,在包装前,这些溢料必须与镜片分离开。在某些情况下,通过设置一抓取环,溢料容易附着在一个模子上,但一般来说分离过程是手工进行且耗费成本的。
在模塑加工中,在固化后,镜片随机地趋向于粘到其中一个模子上,除非模具设计成将镜片保持在选定的那个模子上。当模子在固化工序后分开时,能够控制或将镜片限定在选定的一个模子中是有利的。依靠柔性边缘补偿单体收缩的模具,倾向于将镜片保持在具有柔性边缘的那个模子中。这是由于通常该柔性边缘弯入镜片腔,而镜片腔周围的单体硬化的缘故。尽管在某种程度上,可以利用该方法将镜片固定到一个模子上,但该边缘的净效应将使镜片边缘变形,导致镜片边缘轮廓不一致,产生次品并使那些从模子中通过机械方法取出的未损坏的镜片仍需将边缘打磨均匀。将镜片保持在一选定模子的另一方法是在镜片腔边缘产生一个折返形状以禊住硬的透镜。例如:一凹模内的镜片腔可具有一折返状的边缘轮廓,它可保持住硬的透镜。然而,这大大限制了透镜边缘轮廓的设计,并使透镜边缘厚度大大增加。
在模塑成形加工中,某些批产品需要着色。有许多着色系统,但都需要仔细地定位和支承镜片,以使墨水或染料能精确地施加到镜片表面,通常是前凸表面,而不会损坏镜片。如果欲将次品减到最小,这种镜片的定位就需要耗费很大的劳动并需要操作者具有一定技术。
在模塑成形加工中,可能要求对镜片进行某些处理,如表面处理。当镜片仍然保持在一个模子中时进行这种操作是低成本而高质量的,但必须能够保证镜片被保持在该模子中。
在模塑成形加工中,当镜片经历检验、倍率测量、精选、水合,然后到成品包装,通常是一玻璃瓶时,这些工序是在不同的容器中完成的。如果这些操作能在一个模具中进行,该模具还是成品包装的一主要组成部分,则可以实现低成本和高质量。如果构成部分包装的模子设计成镜片恰当取向,让使用者能容易地取出,则具有更大地优越性。这可以通过使镜片的凸面在最上面而获得。另外,在容纳镜片并让使用者可容易地拿出镜片的包装中提供一个“篮子”或携载装置,可能会有些优越性。
在模塑成形中,保护模子的光学表面极为重要,因为最轻微的伤痕也会转移到镜片上而导致次品。当模具从模塑机器上弹起时,就会产生损伤。同样地。出于健康原因,将光学表面与既使是柔软物体的接触的可能性降到最小也很重要。
本发明的一个目的是为模塑成形隐形眼镜提供一种改进的设备和方法,进而提供改进的隐形眼镜和改进包装的隐形眼镜。
本发明的另一目的是提供一种改进的方法和装置,其中,当开模时,模塑的镜片是支承在阳模表面并通过将镜片密封在由一部分模具构成的容器内形成一种有效地包装。
本发明所提供的模塑成形生产隐形眼镜的方法包括:
在第一模具件的阳模表面和第二模具件的阴模表面构成的模腔中聚合单体;
打开模具,露出模塑的镜片同时使其支承在阳模表面;
通过将一封闭物密封到第一模具件上而将镜片密封包装好。
最好当阴模表面朝上时将单体送入模腔中,然后将模具倒过来,使得在开模时,阳模表面朝上。
本发明还包括一个用于上述方法的模具,其中,该模具包括一具有阳模表面的第一模具件和具有阴模表面的第二模具件,每一模具件有一基座,模塑成形表面分别形成在各自的基座上,一圆形壁从该基座向上延伸,第一和第二模具件的圆形壁设置成象滑动配合那样的接合方式,因而,两模具件可象活塞和气缸那样运动以开合模具。
最好,在第一模具件基座内的阳模表面与第一模具件的圆形壁隔开,使得在该圆形壁内围绕该阳模表面形成一环槽。
本发明所提供的模塑成形生产隐形眼镜的另一方法包括:
在具有一由可相对运动的阳模和阴模表面之间形成的模腔的模具中聚合单体;
一刚性肩部用来在两模具表面之间形成边缘密封以封闭模腔;
至少一个模子表面在负载压力下是柔性的;
该方法特征在于将单体注入模腔,然后将其封闭,在一压力容器中施加一起大气压使得负载压力作用到模子表面并在刚性肩部周围形成一加压密封,接着固化单体,在聚合过程中,随着单体收缩,负载压力使得一个模子表面收缩,保持该表面与镜片接触。
最好阳模和阴模的表面形成在各自的模具件上,该模具件设置成以滑动的活塞和气缸装置的形式来接合,施加的超大气压作用在两个模具件上,迫使阳模和阴模表面相向运动。
本发明还包括一种模塑成形生产隐形眼镜的方法,它包括:
在阳模和阴模的表面之间形成的模腔中聚合单体;
打开模具,露出模塑完的镜片同时使其支承在一个模子表面;
利用来自激元激光器的激光束给镜片打孔,以提供一所需孔数的镜片;
将药品放到镜片上,使镜片上携带的药品剂量由孔洞的数量和药品的浓度决定;
并通过将一封闭物密封到支承镜片的模具件上面将镜片密封包装好。
本发明还提供一个用于上述方法的模塑成形隐形眼镜的装置。该装置最好包括一由两部分组成的模具。其中,一阳模表面设置在一杯形件中,阴模件设置在一在杯形件中滑动的活塞件上。最好杯形件上设置一朝外的突缘,以使阳模件的上表面位于突缘的下面,因而,在镜片成形后,一封闭物可密封到该突缘上,使支承在阳模表面上的镜片位于该封闭物下。
本发明的若干实施例将通过举例的方式并参考附图描述如下。
图1为本发明中所用的模具装置在置于一压力容器前的横截面图;
图2为图1中所示装置中两模具件之间密封的放大图;
图3为图1所示装置放入一压力容器后的示图;
图4为图1中模具装置的第一模具件带有模塑的镜片,在模具翻转并将模具打开后的示图;
图5为本发明的带有水合模塑镜片的密封包装的示图;
图6、7和8为本发明的不同形式的穿孔镜片。
本实施例涉及模塑隐形眼镜的制造,它是通过在一位于第一模具件内的阳模表面和第二模具件内的阴模表面之间的模腔中聚合单体来完成的。在附图中,第一模具件11包括一具有基座12的杯形件,基座周围是圆形壁13。阳模表面14形成在基座12中央并与圆形壁13隔开,使得一环槽区15在圆形壁13和阳模表面14之间形成。第二模具件16也为杯形,它具有一基座17,圆形壁18在基座17周围。阴模表面19形成在基座区17中,通过平环形区20与圆形壁18隔开。第二模具件16的圆形壁18设置成在第一模具件11的圆形壁13内形成紧滑动配合。这样,如图1所示两模具件可以配合在一起形成一活塞气缸装置,其中,两模具件可相对滑动,以开合模具。阳模表面14设置成朝向第一模具件的杯内,而阴模表面19朝向第二模具件的杯外,使当两模具件如图1所示配合在一起时,一模腔21形成在阴阳模表面之间。第一模具件11的圆形壁13在其远离基座12的端部具有一环状凸缘22。
构成阳模表面14和阴模表面19的壁部具有足够的刚性,他们不会在由模腔21中的单体收缩产生的吸力下产生较大挠曲变形,但能在施加选定的负载压力下,挠曲变形到与收缩的单体保持接触。该负载压力可通过在压力炉或其他压力容器中将超大气压施加到两个模具件上而获得。阴模表面19周围有刚性肩部25,如图2所示。刚性肩25邻接阳模表面14,以便在阴、阳模表面之间,形成一可靠的密封,在压力施加到两个模具件上产生的聚合操作中,该密封不会畸变或挠曲变形。
图1所示的模具是注射模,为适用的塑料材料如聚丙烯注塑成形的。
在使用中,当阴模表面19朝上时,将液态单体注入阴模的凹形表面。然后,如图1所示,上模向下运动封住下模,直至阳模表面14接触到刚性肩部25。此时,阳模11处于最上部。任何多余的液态单体都被挤出阴阳模的光学表面之间,进入环形槽23,以便从孔24排出。
然后,如图3所示,将该装置放入一压力容器26。容器内的压力通过从压缩气体源27施加的压力而增加,使两模具件11和16受迫相向运动。容器内的压力最好比大气压高0.2至1巴。特别是,阴阳模表面14和19通过施加的压力受迫相向运动,如箭头30和31所示。两模具件之间的接合力集中在肩部25附近,由于接合面积相当小,因此,构成了有效的密封。这种密封使镜片具有一清洁的边缘并构成了一隔绝层,以防止模子空腔中来自镜片单体的易挥发成份漏出。在容器26内施加超大气压保证了一令人满意的负载压力被施加到阴阳模表面14和19,使得在聚合过程中他们可以随镜片单体的体积收缩而产生挠曲变形。这样,阴阳模的光学表面在单体从液态通过胶态变为固态的整个过程中,始终保持与其接触。施加的超大气压产生了一个更有效的密封并使模子表面挠曲变形进而始终与单体接触,这是仅靠单体收缩产生的吸力不可能达到的。制造本实施例的阴阳模壁厚所需的厚度和工艺程序控制并不需十分严格,因为壁厚对运动的阻力无需与单体收缩的抽吸效应相匹配。模具件的运动阻力是靠施加超大气压力而克服的,该气压很容易控制,从获得所需的挠曲变形。
阳模的光学表面14,在本例中,是经过火焰加工的,这是一种提高表面光洁度和增加表面能量的方法。它保证了聚合的镜片与凸阳模件保持接触以便后续加工。如图3所示,在压力炉26中处理后,模具翻转并分开成两半。将模子16拿开,如图4所示,模塑的镜片32保持在杯形件13内的阳模表面14上,低于突缘22的表面。这样,模塑的镜片被方便地保持住,其外光学表面露出,以便进一步加工。在图4的实例中,一可选择的印刷头33位于模塑镜片的上方,使得任何印刷处理可施加到镜片的外表面上。当镜片被保持在图4所示位置时,后续加工可进一步包括加颜色到镜片前表面上。在这个意义上,镜片32的前表面为凸表面。由图4可见,模具件11的圆形壁13向上延伸,高于阳模表面14,使得当模子打开时,圆形壁13上端的突缘22高于阳模表面上的镜片32。当镜片保持在杯状件13内时,模具和镜片可以精确定位,不会产生象镜片与模具分开放置时可能产生的损坏。杯状件13为精馏的和/或水合液提供了接受空间,这些液体用来从模子光学表面取下镜片并使其不受损伤。模具和镜片可由自动加工设备有效地把持,没有易碎镜片具有的那些危险。而且,镜片适于定位在图4所示位置,以便激光打孔或其他加工。
在经过表面处理后,镜片32经过水合处理,同时仍保持在杯形件13内。这包括向杯形件内的槽形区15注入盐溶液,但无需拿开镜片。由于单体收缩中的气隙和溢料滞留到镜片边缘的问题在本发明中被避免了,可产生出高质量镜片,使得可采用抽样检验技术而无需采用目前镜片工业生产中采用的100%检验方法。这样,就会比那些具有相同质量而需大量检验工作的生产方式花费较低的成本。
最后,将一个可活动的盖子34密封到模具件11的突缘22上,使得镜片32和盐溶液35密封在包装内。盖子的材料和密封都具有相当好的隔绝特性,以保证被密封的溶液经过很长时间也不会变坏。如图5所示,选择的包装材料能够承受消毒环境如高压蒸气消毒。
在使用中,盖子34可以从容纳镜片32的杯状件上撕开。盖子拿开后,盐溶液可以从包装中倒出,将镜片32保持在阳模表面14上的包装位置。其特别有益之处在于,镜片的朝向相对于包装的位置是预定好的,这使按一已知的方向取出镜片变得容易的多。这就避免了在拿起镜片放入眼睛之前,需要将镜片从容器中倒出,处于一未知的朝向。而且,镜片的外表面在包装中是朝上的,然后,可以用手接触而不会在将镜片放入眼睛之前,将其污染。
在阳模表面14周围设置环形槽15有助于将模塑的镜片从包装中拿出。因为环槽在镜片周围提供了足够的空间,帮助使用者持住镜片并将其从包装中拿出。
如上所述,镜片可以进一步打上许多微孔,这是利用激光束,如短波激元激光束来完成的。这些激光束可以打破化学键并贯穿镜片而不会溶化镜片或使其材料流动或产生碎片及其他热效应。这种方法被称为光清洗分解法。这可通过以短脉冲持续时间,施加短波激光束来实现。这样打出的孔避免了孔带有毛刺和破烂的外边。这些缺陷使镜片的配带者觉得非常难受。图6、7和8表示了通过激元激元器而形成的不同的孔洞图案。这些孔洞有利于改善透气性或镜片的渗透性。孔洞的数量和位置会改变成品镜片的气通量。泪流、耐久性和可湿性。因此,镜片设计者可以通过适当打孔来优化镜片的性能。在本实例中,由激光束形成的孔36均为约150微米的矩形孔。可以让孔布满整个镜片,只在边缘留很小的一块以保持镜片边缘的完整,如图6所示。还可以如图7所示仅在中央光学区37形成孔洞。还可以如图8所示在非光学区,即在中央光学区外面的环状区38形成孔洞,但在镜片边缘留出一小块。孔洞可形成在水合前的干镜片上或形成在水合后的湿镜片上。
如图5所示,包装密封前的处理步骤包括当镜片被保持在图4所示的暴露位置时,给镜片放上药物。
如上所述,通过激元激光器打孔的镜片可作为一种药物海绵,其中,所吸收的药物的数量,依赖于镜片打孔的程度和送入镜片所在的杯状件内的药物的强度。镜片可以加工成具有所需孔洞程度和吸收所需药物数量,使得当密封成如图5所示结构时,该包装包括一含有所需剂量药物的镜片。这样,所需剂量的药物可预包装在可随意使用的镜片规格中。
如图6、7和8所示的用激元激光器打孔。可用于由异于图1至5所示的方法和设备制造的模塑隐形眼镜。
本发明的优越性还在于,它可使用需要紫外线固化或其他非热固化以及热处理固化的单体。应该知道,当利用热处理固化时,模子表面对单体收缩中产生的挠曲有较小的阻力。但是,当使用非热固化单体时,模子表面将对挠曲有较大阻力,而且仅由单体收缩产生的力不足以保证当单体收缩时,模子表面保持与其接触。然而,超大气压的使用可控制在大气压之上所需的程度,使其足以让模子表面挠曲并且既使在如紫外线固化这样的非热处理时也能保持与单体接触。
本发明并不限于上述实例的内容。
例如,阴模和阳模表面可经过火焰抛光,以改善镜片两面的表面光洁度。为了从模子上放开镜片另在放开后控制由那个表面支承镜片,模子可以部分打开,以增加阴阳模表面之间的空腔并且通过开口24的一边注入盐溶液而通过开口24的另一边排出该溶液,同时模子翻转。盐溶液的流动将放开镜片,并且在盐溶液排出前,通过将模子翻转到竖直或翻倒位置,放开的镜片将落到并支承在所需的阳模或阴模表面上。
Claims (24)
1.一种模塑成形生产隐形眼镜的方法包括在一模腔中聚合一种单体,该模腔处于第一模具件的阳模表面和第二模具件的阴模表面之间,打开模具将模塑完的镜片露出,同时支承在阳模表面,通过将一封闭物密封到第一模具件上而将镜片密封在一包装中。
2.按照权利要求1的方法,特征在于当阴模表面朝上时,将单体注入该模腔,然后倒转模具使打开模具时,阳模表面朝上。
3.按照权利要求1或2的方法,特征在于第一和第二模具件是相对滑动接合的,象活塞和气缸装置以开合模具,第一模具件构成一具有基座部分的杯形件,基座被一配合第二模具件的直立圆形壁围绕,阳模表面形成在基座上并在圆形壁内且与其隔开以形成一槽区,以便模具打开时,将水合液送入该槽,水合该镜片。
4.按照权利要求2的方法,特征在于封闭物密封到该圆形壁的上缘。
5.按照权利要求1的方法,特征在于阳模表面经过火焰抛光,有助于当模子打开时将镜片保持在阳模表面。
6.按照权利要求1的方法,特征在于阴模表面经过火焰抛光,有助于当模子打开时将镜片保持在阴模表面。
7.按照权利要求5或6的方法,特征在于,模子打开后,镜片保持成暴露在模具表面并在暴露的镜片外表面上,接受进一步处理。
8.按照权利要求7的方法,特征在于进一步处理包括颜色或印刷。
9.按照权利要求7的方法,特征在于进一步处理包括通过应用短波激光束形成贯穿镜片厚度的一或多个孔。
10.按照权利要求9的方法,特征在于该激光束是一激元激光束。
11.按照权利要求9的方法,特征在于在镜片上可形成许多孔以形成一具有所需孔数的镜片。
12.按照权利要求9的方法,特征在于在镜片上可形成许多孔,以提供一具有所需耐久性的镜片。
13.按照权利要求11的方法,特征在于将所需剂量的药物放入由孔洞形成的多孔结构中。
14.按照权利要求1的方法,特征在于在一阳模和阴模表面之间的模腔中聚合一种单体,打开模子,露出模塑完的镜片,同时使其支承在其中一个模子表面上,利用一激光束给镜片打孔,以提供具有所需孔数的镜片,往镜片上施加药物,使镜片所携带的药物的剂量由孔洞的多少和药物的浓度决定,通过将一封闭物密封到支承镜片的部分模子上面将镜片密封在一包装中。
15.按照权利要求14的方法,特征在于在上述剂量的药物施加后,该镜片经受水合处理。
16.一种按照权利要求14的方法,特征在于在打开模子时,模塑好的镜片支承在阳模表面,该表面由一具有突出到高于镜片的圆形壁的杯形围绕,当镜片支承在阳模表面上时,将水合液送入杯形件以水合该镜片,一覆盖件密封到杯形件上,高于镜片,以便在杯形件中形成包装好的镜片。
17.一种按照权利要求14至16之一的方法,特征在于激光器是激元激光器。
18.一种用于按照前述任意一顶权利要求的方法的模具,该模具包括一具有阳模表面的第一模具件和具有阴模表面的第二模具件,每一模具件具有一基座,各自的模子表面就形成在该基座上,一圆形壁从该基座向上伸出第一和第二模具件的圆形壁设置成象滑配合那样的相互配合,因而,两模具件可象活塞和气缸装置那样运动以开合模具。
19.按照权利要求18的模具,特征在于阳模表面形成在第一模具件的基座部分,该表面在第一模具件的;圆形壁内并与其隔开,以便在围绕阳模表面的圆形壁内形成一槽区。
20.按照权利要求18或19的模具,特征在于第一模具件的圆形壁上端有一突缘,用于密封的封闭物可密封在该突端上。
21.按照权利要求20的模具,特征在于第一模具件的圆形壁延伸到高于阳模表面。
22.一种隐形眼镜包装,包括:
a.一整体成形的阳模件,它具有:
一凸模表面,
一围绕上述凸模表面的环形表面,它形成一槽的基部,
一带有凸缘的环形壁围绕该槽;
b.一带有面对上述凸模表面的凹表面的隐形眼镜置于该包装中,该眼镜的边缘处于上述槽中,
c.一可除去的盖密封在上述凸缘上,以将所述隐形眼镜密封在上述包装中。
23.按照权利要求22的隐形眼镜包装,还包括密封在上述包装中的水合流体,以保持该隐形眼镜处于水合状态。
24.按照权利要求23的隐形眼镜包装,其中,该水合流体为盐溶液,以保持该隐形眼镜处于水合和无菌状态。
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1993
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1995
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1997
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1998
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CN100556773C (zh) * | 2001-08-17 | 2009-11-04 | 美你康株式会社 | 用于一次性柔软隐形眼镜的包装、包装方法和包装组件 |
CN1980582B (zh) * | 2001-08-17 | 2010-12-22 | 美你康株式会社 | 用于用后即弃式软隐形眼镜的包装 |
US7967133B2 (en) | 2002-08-17 | 2011-06-28 | Menicon Singapore Pte Ltd. | Packaging for disposable soft contact lenses |
US8104608B2 (en) | 2002-08-17 | 2012-01-31 | Menicon Singapore Pte Ltd. | Duo packaging for disposable soft contact lenses using a substrate |
US8763794B2 (en) | 2002-08-17 | 2014-07-01 | Stephen D. Newman | Packaging for disposable soft contact lenses |
US8955672B2 (en) | 2002-08-17 | 2015-02-17 | Menicon Singapore Pte Ltd. | Packaging for disposable soft contact lenses |
US9615639B2 (en) | 2002-08-17 | 2017-04-11 | Menicon Singapore Pte Ltd. | Packaging for disposable soft contact lenses |
US10786057B2 (en) | 2002-08-17 | 2020-09-29 | Menicon Singapore Pte Ltd. | Packaging for disposable soft contact lenses |
CN101909865A (zh) * | 2008-01-08 | 2010-12-08 | Lg伊诺特有限公司 | 透镜单元、透镜组件、相机模块、相机模块和透镜组件的制造方法、光学部件的制造方法以及光学部件的制造设备 |
CN103237651A (zh) * | 2010-12-01 | 2013-08-07 | 诺瓦提斯公司 | 其上具有常压等离子体涂层的镜片模具 |
CN103237651B (zh) * | 2010-12-01 | 2016-02-10 | 诺瓦提斯公司 | 其上具有常压等离子体涂层的镜片模具 |
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