Patent ID: 9481124
Filing Date: 2016-11-01
CPC Classification: B29C,B29D,B32B,G02B,G02C,Y10T

Claim Text:
1. A method of thermoforming an insert device for an ophthalmic lens, the method comprising the steps of: providing at least one sheet of a thermoformable material; aligning and holding the at least one sheet in a fixture; thermoforming a first three-dimensional shape into one of the at least one sheet utilizing a first thermoforming mold; cutting out a first insert piece having the first three-dimensional shape from the at least one thermoformed sheet, wherein the first insert piece is configured for inclusion within an ophthalmic lens; forming a first alignment feature in the first insert piece; thermoforming a second three-dimensional shape into one of the at least one sheet utilizing a second thermoforming mold; cutting out a second insert piece having the second three-dimensional shape from the at least one thermoformed sheet, wherein the second insert piece is configured to attach to the first insert piece; forming an alignment feature in the second insert piece configured to interconnect with the alignment feature in the first insert piece; and combining the first and second insert pieces such that the alignment feature of the first insert piece interconnects with the alignment feature of the second insert piece to form the insert device.