Patent ID: 6836384
Filing Date: 2004-12-28
Classification: B29C,B29D,G02B,Y10S

Abstract:
A method for constructing a lens structure, the method comprising:producing a mold so as to define a pliant lens cavity in which a lens portion of the lens structure is to be formed, the pliant lens cavity having an orifice having a transverse dimension less than a transverse dimension of the pliant lens cavity for the lens portion; wherein the mold producing step comprises casting a first catalyzed crosslinkable liquid around a mold core in a form having undercut margins until it is set as the mold, thereafter removing the mold core from the mold after the first catalyzed crosslinkable liquid has set wherein a region of the mold adjacent the orifice is allowed to temporarily deform thereby to permit the mold core to be removed with minimal damage to the mold; thereafter casting a second catalyzed crosslinkable liquid into the mold until it has set; and then removing the lens portion from the mold after the second catalyzed crosslinkable liquid has set wherein the region of the mold adjacent the orifice is allowed to temporarily deform thereby to permit the lens portion to be removed.