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Patent US2644985 - Contact lens and method and apparatus for making same - Google Patents
www.google.comhttp://www.google.com/patents/US2644985?utm_source=gb-gplus-sharePatent US2644985 - Contact lens and method and apparatus for making same
Publication number US2644985 A
Filing date Mar 22, 1947
Priority date Mar 22, 1947
Publication number US 2644985 A, US 2644985A, US-A-2644985, US2644985 A, US2644985A
Inventors Harry D Crandon
Patent Citations (24), Referenced by (16), Classifications (19)
Contact lens and method and apparatus for making same
US 2644985 A
H. D. CRANDON July 14, 1953 CONTACT LENS AND METHOD AND, APPARATUS FOR MAKING SAME Filed March 22, 1947 3 Sheets-Sheet l v INVENTOB HARRY 0. C/PA/VDON wyzi ATTORNEYS July 14, 1953 H. D. CRANDON CONTACT LENS AND METHOD AND APPARATUS FOR MAKING SAME Filed March 22, 1947 s sheds-sheet 2 INVENTOR HARRY D. CIP/M/flON ATTORNEYS July 14, 1953 H. D. CRANDQN CONTACT LENS AND METHOD AND APPARATUS FOR MAKING SAME Filed March 22, I547 3 Sheets-Sheet 5 INVENYD]? .c A/YDON' M I Q v z'i.
ATTORNEYS HARRY D 2% Patented July 14, 1953 CONTACT LENS AND METHOD AND APPA- RATUS FOR MAKING SAME Harry D. Crandon, Woodstock, Conn., assignor to American Optical Company,
Mass., a voluntary association of Massachusetts Application March 22, 1947, Serial No. 7 36,507
20 Claims. (Cl. 1855.05)
This invention relates generally to optical elements such as lenses, lens blanks prisms and the like and particularly relates to contact lenses and blanks therefor, as Well as to a method and apparatus for making such optical elements.
7 It is not unusual in the ophthalmic art to make contact lenses partly or entirely of plastic material and several different methods, such as molding, machining and polishing, and heating and pressing, have been employed in attempts to more economically and accurately produce such lenses. Contact lenses, however, embody several different partsor portions which must be accurately formed and finished, and since each of these parts may vary appreciably, depending upon the characteristics of the individual eye being fitted, the making of a good contact lens has been a difficult task. None of the methods mentioned above have proved to be satisfactory for various reasons, such as the time and skill required for producing a satisfactory finished article and the number of trial fittings and subsequent alterations required before an acceptable and comfortable fit was obtained.
Contact lenses embody generally acentral or corneal portion arranged tooverlie the cornea and limbus area of the Wearers eye anda scleral portion surrounding the central portion and arranged to overlie the sclerotic or White part of the 'eye. In order to provide the greatest of comfort to the wearer, as well as improved visual acuity, the corneal portion of the lens should be formed so as to position the posterior surface thereof a known predetermined distance from the cornea of the eye and should extend in spaced relation to beyond the super-sensitive limbus area surrounding the cornea. The po terior surface should also be spherically formed to a predetermined curvature and finished to optical accuracy. The anterior surface of the corneal portion should likewise be accurately formed and finished to a similar or a differing predetermined spherical curvature as well as accurately spaced a known amount axially from the inner or posterior surface. Additional requirements of such a contact lensare that the scleral or rim portion of the lens should be of appreciable width and have a curvature which will closely or exactly fit the varying curvature of the sclerotic of the individual eye being fitted so as to provide a uniform pressure of small intensity against all contacted parts of the eye ball. Also, it should peripherally fit the eye ball closely so as to retain in place before the eye the saline'or tear solutionnormally used to form a liquid lens between the contact lens and the cornea. Furthermore, it is often desirable to have the optic built into the corneal portion of the contact lens in such a way as to be decentered from the corneal curvature of the lens, in order that the optical axis thereof will be coincident with the patients line of sight, even though this line of sight may not be axially aligned with the center of the cornea. Another important requirement of a good contact lens iS that the corneal and scleral portions thereof should be as thin in section as possible while performing their intended functions thereby causing a minimum of displacement of the eye lid and thus a minimum of pressure or sensation upon the eye ball. Of course they must be, at the same time, of sufiicient rigidity to permanently retain their desired shape and prescribed optical properties. It is desirable that the inner and outer corneal and scleral curvatures respectively should blend or join smoothly together and without the junction thereof bein noticeable. And furthermore, in contact lenses, it is necessary that the plastic material be'so formed that it will be substantially free from internal strains, graininess, bubbles or the like which might otherwise detrimentally affect the optic of the lens or cause the lens over a period of time to change its given shape.
Heretofore, the embodying of these several desirable features into a single finished plastic contact lens has been a tedious if not impossible job. It is, accordingly, an object of the present invention to provide an improved plastic contact lens embodyin the several desirable fe tures mentioned above as Well as to providean improved method and apparatus for making same.
It is an additional object of the invention to provide a unitary plastic preform or lens blank having an optic provided therein and formed f such predetermined size and shape that it may be readily used in the manufacture of contact lenses arranged to exactly fit individual eye characteristics. The invention also includes a method and apparatus for making such preforms. Other objects and advantages of the invention will appear from the detailed description that follows when taken in connection with the accompanying drawings, in which:
Fig. 1 is a front view of a plastic contact lens made in accordance with the present invention;
Fig. 2 is a slightly enlarged transverse sectional view taken substantially on the line 2-2 of Fig. 1, the inner and outer corneal curvatures thereof being such as to provide no power 01 correction in this lens section;
Figs. 3 and 4 are cross-sectional views of contact lens made in accordance with the p ent invention but embodying respectively minus and plus optical corrections in the corneal portions;
Fig. 5 is a plan view of a clamping ring which may be used in forming the contact lenses of the invention;
Fig. 6 is a transverse sectional view taken substantially on line E6 of Fig. 5 and showing a disc of thermoplastic material in place therein;
Fig. '7 is a sectional view of drawing or stretching means for forming the plastic disc into a bell-shaped member or preform;
Fig. 8 is an enlarged partially broken away view of the plastic material formed into the gen-' erally bell-shaped member or preform;
Fig. 9 is one form of forming mechanism which may be employed for accurately forming predetermined optical curvatures upon the cornealportion of the preformed plastic member of Fig. 8 as well as an oversized thin walled spherical surface adjacent said corneal portion;
Fig. 10 is a fragmentary view ofa part of Fig. 9 to show the position of the plastic member after it has been reformed;
Fig. 11 is an enlarged View of parts of forming dies which may be employed in making an optic in the corneal portion having a negative correction or power;
Fig. 12 is a view similar to Fig. 11 but showing dies for making an optic having a positive power or correction formed therein;
Fig. 13 is a sectional view of molding or casting members which may be employed in forming an oversized preform or lens blank;
Fig. 14 is a mechanism for accurately positioning a positive cast of a patients eye in axial alignment upon a centering jig for drilling purposes;
Fig. 15 shows the jig holding the centered positive cast in axial alignment upon a drill press work support;
Fig. 16 is a cast and spacingcap supporting device which may be used in forming trial and custom contact lenses;
Fig. 17 is a device for centering the marked line of sight of a trial lens and for forming an impression thereof; and Y Fig. 18 is a supporting device for said impres-' sion'and an oversized preform with an optic of predetermined power therein positioned over heating means for forming a custom contact lens.
Referring to the drawings in detail and particularly to Figs. 1 and 2, it will be seen that a contact lens 8 made in accordance with the present invention may comprise a central or corneal portion I0, an intermediate portion II and an integral scleral portion 12 formed'entirelyof plastic material. These portions may be so shaped and spaced that a spherical or aspheric inner or posterior surface i4 is formed on the corneal portion and outwardly thereof a second spherical or aspheric surface I5 may be formed with these two surfaces substantially evenly spaced to provide a no-power optic in the lens and arranged to smoothly merge into the inner and outer surfaces I6 and II, respectively, of the scleral portion [2 in such a manner that no sharp edge or noticeable groove is formed at the intermediate portion where these inner and outer corneal and scleral surfaces merge or intimately blend, such as might otherwise cause discomfort to the wearers eye ball or lid when the lens is in place for use. It will also be noted that the scleral portion gradually tapers from the region adjacent the intermediate portion toward its outer peripheral edge, as indicated at [8, so that a very small thicknessis afforded adjacent its outer marginal edge thereby providing a lens of greater comfort for the wearer.
While Figs. 3 and 4 show cross-sections of lenses somewhat similar to that of Fig. 2 and having their inner and outer corneal surfaces spherically or aspherically formed, it will be noted that the radii of such curvatures may be varied for providing various prescribed optical powers, when desired,'for either plus or minus corrections. It will be seen that lenses 20 and 22 differ respectively from Fig. 2 in providing spherical or aspheric curvatures 24, 25 and 24', 25' for the corneal portions thereof which give plus and minus corrections to the optics provided there- 'by. The lenses of Figs. 2, 3 and 4 may be formed readily by the method and apparatus of the present invention as will appear from the description which follows.
In putting into effect the preferred method of the invention there is provided, as best shown by Figs. 5 and 6, a metallic'clamping ring 21 comprising two ring parts 23 and 28'for supporting a disc of transparent thermoplastic material from which'the contact lens may be formed. The ring part 28 is provided with an annular recess 29 formed internally thereof so as to receive a cast disc 30 of plastic material which is of such diameter as to fit closely within this annular recess. A convenient size plastic disc has been found to be approximately 2 inches in diameter although as little as a 1% inch disc or a disc appreciably larger than 2 inches can be used, if desired (with proper adjustments as to the size of apparatus employed). While several different types of thermoplastic materials may be employed, such as polystyrene and polycyclohoxyl methacrylate, as the material for forming the disc 38, the preferred plastic is polymeric methyl methacrylate and this may be purchased under such commonly known trade names as Plexiglas and Lucite. The ring part 28 is internally threaded as indicated at '32 and arranged "to 'receive'thepart 28 which may be screwed into place in part 28 for clamping the marginal portion of the plastic disc '30 in place. The parts 28 and 28 are provided with central openings 3| for exposing the central part of the gripped disc while subsequent processing steps are being performed thereon. Spaced holes or the like '35 and '36 may be provided in these two'rings so that they may be easily turned and clamped against the disc.
When the disc 39 has been properly placed in the ring 2'! the disc is heated rapidly to soften the exposed plastic material within the ring without materially changing the temperature of the ring or the plastic clamped therebetween. A convenient and satisfactory heater for such purpose-has been found to be an electrical resistance grill providingradiant heat and located'within a heat insulating box having an opening of the same size as theopenings 31 in its top wall. Such a heater is shown inFig. 18 and will be described in more detail hereinafter. When the ring and disc have been centered over the opening in the heater for a matter of twenty to thirty seconds depending largely upon the thickness of plastic employed the exposed plastic willlbe rendered sufficiently soft andpliable that it may be immediately stretched or drawn into an elongated substantially bell-shaped member which for convenience is hereinafter referred to as a preformed member or a preform.
In the forming of such a preformed member for making a contact lens in accordance with the present invention, it is desirable to prevent too much stretching out of the plastic material near .the center thereof, for reasons to be presently described, and at the same time desirable to produce a considerable stretching out of the plastic in the area surrounding the central portion (and inwardly of the clamped peripheral edge). To accomplish such results there is provided, as best shown in Fig. '7 an upstanding tubular member 37 of such outside diameter that the opening 3| of ring 21 will fit closely thereover with the plastic disc resting upon the upper relatively thin edge of member 31. Within the member 31 is a forming member or molding block 38 of special predetermined internal ,or concaved shapes as indicated for example at 39 and 39' and at the lower end of the block is provided a passage 48. An internal shoulder 4| is provided upon the tubular member for supporting the molding block 38 in definite spaced relation to the plane of the top edge of member 37. A convenient manner of adjusting the position of block 38 for different lengths of drawing of the plastic material may be had by use of a plurality of shims 42 of various thicknesses positioned between the block and said shoulder.
The passage 40 communicates with an enclosed vacuum chamber 43 secured to a fixed base plate 44 and pipe 45 extending from the chamber is connected to a conventional control valve 46. A rod 47 is axially aligned with the disc 3%, the forming block 38 and the concavities 39 and 33 therein and is guided during axial movement by a fixed housing 48. While it is possible to control the movement of the rod manually or by other means and still have it perform its intended function, it has been found advantageous to form housing 48 in the form of a vacuum-cylinder and provide therein a piston 49 carried by rod 4?. Movement of rod 41 may thus be controlled by the vacuum control valve 46. A pipe 58 extends from valve 46 to the housing 48 at a location above the upper limit of travel of the piston. A
pipe 5| connects valve 46 with a source of vacuum (not shown) and short pipes 52 and 53 are provided in the valve 46 for communication with the atmosphere.
The concave shapes 39 and 39' in the molding block 38, the size and shape of the end 41 of rod 4! and the axial length of drawing of the plastic are carefully controlled so as to providea substantially bell like shape in the plastic material of adequate size, shape and wall thickness, as will be presently described. After the plastic disc 30 has been properly heated and placed over the end of tube 31, as mentioned above, valve handle 45 is moved from the full line position shown toward the dotted line position. During the first part of this movement the connection between pipe 50 and 5| is shut off and thereafter pipe 50 is connected to short pipe 52 to allow atmospheric pressure t enter pipe 5% and the housing 48 behind piston 49. The weight of rod 41 and piston 49 will cause the spherically shaped and polished lower end 41' of rod 4! to approach the plastic disc. Since this rod, or at least its lower end 41', is formed of a material having high heat conductivity, such as brass, and is atroom temperature it will rapidly cool the plastim material at the centerof the disc as it;
chamber 43 to create a differential pressure cause ing the exposed part of the plastic disc to move downwardly until it is limited by the curved surfaces within the molding block 38. Since the periphery and the central portion of the disc, are relativelycool, the stretching out effect which takes place in the plastic occurs substantially entirely in the material betweenrthese two parts.-.
Referringto Fig.7 a, it will be seen that the.
plastic material of disc 3i! has been drawn out into a bell-shaped preformed member 54 and,
that very little,,if any, stretching out or thinning out. of the plastic material at or near the center 55 has occurred while nearer the edge 56 of the central portion the material has thinned somewhat. Careful choosing of the proper thickness of plastic disc, initially, will supply an adequate thickness at the center 55. This initial thickness will depend largely upon the type of lens being formedand generally a thickness of 1.0 to ,2.5 millimeters will be preferred. The curvature of the wall of the forming member 38 and its spacing from the plane of the top of member 31 con trol the amount of thinning down or tapering of the side wall portion 5"! of the bell-like member. The side wall portion 51 thus embodies arelatively thin cross-section or wall thickness adjacent the central portion, as indicated at 58, and a somewhat thinner cross-section at points furtherremoved from the center, as indicated by numeral 60, this being the approximate location the lens will be subsequently cut.
The size and shape of the concavities in the member 38 are so chosen as to produce in the. plastic bell-shaped member 54 a main cavityEZ. somewhat larger than that desired for the scleral portion of the lens blank to be formed therefrom or the finished contact lens formedfrom said blank. An auxiliary cavity 63 of approximately 7.0 to 9.5 millimeters .radius is provided 'atthe.
center. This drawing requires not more than a few seconds and as soon as the plastic has cooled sufficiently to cause it to set the ring 21 and plastic member may be removed from the drawing or forming apparatus.
The oversized bell-shaped member 54 may be employed for forming any size and scleral shape desired as well as arranged to embody in its central portion any combination of corrective curvatives required for fulfilling the normal range of plus and minus optical powers prescribedby the ophthalmic profession. After the preform orv bell-shaped member has been made-the next step in the formation of the contact lens embodies forming the optical or corneal portion of the lens and forming a scleral portion having a spherical curvature which is slightly larger than that required for accommodating the largest size profession that normally an interior or posterior surface may be provided in the corneal portion quiring the use of contact lenses, Obviously a at which,
eye cast. It has been found in the ophthalmic littlesmaller or little larger radius could be used if desired but "probably would not exceed'a range from 7.0 'to9l5 millimeters. The outer oranterior curvature of the corneal portion, however, may be-given any one of alarge number of curvatures to-provi'd'e a series of plus and minus corrections. Accordingly, the invention employs means for forming such interior and exterior curvatures of predetermined radii as well as means for forming said oversize scleral shape. As best shown'in Fig. 9,-one such means or device'com'prises a forming tool '66 which has a threaded bearing 61 arrangedto axially'receive-a post 68. The lower end of "the'post is arranged to receive a forming member 68 which has accurately formed thereon a spherical curvature is which is slightly larger thanthat normally required to lit the scleral portion of the largest eye cast. Concentric with the postB'B'iand the forming'member 69 is a forming button "H provided with a second spherical or aspheric curvature 72 for forming the posterior corneal curvature of the contact lens.
. The button ll ispreferably formed of glass and has its surface 52 accurately ground andpolished. The button is inserted into the forming'tool 69 so as to project approximately one half millimeter outwardly of the curvature of the surface Hi. Thisoutward spacing provides approximately the clearance required in the finished lens between the posterior lens surface and the cornea of the eye. Glassis employed at this location since it is necessary in order to provide in the formed lens a finished posterior surface of high optical properties. The forming member '89, however, is formed preferably of brass since it takes a high polish and may be easily and accurately formed. The button Il may be' retained seated in the member 69 by friction and the member 69 may be adjustably held in place upon the post 68 by a set-screw 13 orthe like.
' The bearing 6! has threaded engagement with a supporting frame or plate M carried'by either three or four equally spaced upstanding columns fixedly secured to a base member '16. Centrally positioned within these columns is suitable means such as a recess H for accurately center- 7 ing any one of a plurality of. different forming dies "18; said dies being circular in'shape and having "formedcentrally in their upper surfaces,
respectively, 'a graduated series of spherical or aspheric curvatures of predetermined radii, one
of which is'indicated at 78'. Surrounding each of the columns is a removable spacing ring E9 of such height that together they engage the outer, edgeportion ofga removable limiting ring 80 and maintain same in place. The limiting ring 80 is-of such diameter as to be accurately centered by the columns 15 and may have secured thereto vertical centering pins 82 which are of. such spacingas to accurately axially locate the clamp-.
ing ring 21 and the bell-shaped member 54 when they'are inserted into the device. At such time the ring 21 will be spaced somewhat above, the.
uppersurface of the limiting ring 80 while the center of the bell-shaped member 54 will be in contact with thespherical surfac in the die 18.
Sinceqthe size and shape of the cavity 62, of
the bell-shaped member is slightly larger (see Fig. 9) than'the spherical surface it. of the forming member 69,-the member may be located within the cavity (when the parts are properly adjusted in supporting plate 14) with its curvedv surface-l2 in engagement with the center of the.
bell-shaped member. .At such time, the plate 14 will be positioned over the threaded upper ends 86 of the columns 15 and may be clamped against Generally speaking, however, a 2 millimeterthickness in the plastic stock will suffice for all lenses with minus corrections and for most of the plus lenses.
When the structure shown by Fig. 9 has been assembled for use, an engagement will be effected upon the opposite sides of the plastic preform 5 1 atthe center thereof by the spherical surface '18 and the spherical surface 12. A nut 89 may be provided for locking the forming tool in adjusted position and a screw 90 retains the post 68 in place within the bearing 61. A calibrated flange 9! may be provided upon the upper end of this bearing and a pointer 92 secured to plate M serves as means for indicating the various positions of adjustment of the surface. 12 relative to the surface 78'.
The assembled structure with the preformed member 54 in place are then placed in a conventional oven which is at a temperature ranging from l to 200 C. and heated from approximately 5 to 7 minutes. The assembly is then removed from the oven and cooled, preferably rapidly, to room temperature before the ring and plastic member are removed. During the heatingv step, care must be exercised to avoid heatingfor too long a period for fear of fracturing the plastic material at its thin scleral section. Because of the phenomena known as .plastic memory, the plastic material which has been drawn or stretched into the bell-shaped member 54 tends to return or move back, when thus heated, into its original shape. In so doing while in the device of Fig. 9, this plastic memory will cause the material to return toward its original. shape until it is restrained or confined by the members 59, H and 18., and by the clamping ring 21 moving into engagement with the limiting ring 80. The preform 54 will shrinkor draw into intimate contact with the oversized spherical surface 10 of the formingmember 69 and in so doing the plastic material will bridge across between the surfaces 10 and I2, tending to draw tangentially to both curves and thus producing a smooth blending of both inside and outside surfaces of the plastic material where the corneal and scleral. portions join. Fig. loshowsthe plastic material after it has moved into contact with surface 70 and drawn tangent to both curves. In this manner, no sharp edge .or surface requiring further polishing or treatmentis produced. Instead, an oversized lens blank 93 with a finished optic and smooth glassy finished inner and outer junctions,
' which are almost indistinguishable, is produced.
The vertical height of the spacing collars 19 serves to control the distance that the clamping ring 21 can move before it is limited by ring and such limiting of the return of the plastic preform may be used to determine the wall thickness of, the scleralportion as well as the amount of the taperingdown of the plastic wall portions. If a thinner or a thicker cross-section is desired in the scleral portion, different sets of collar 1 9 of greater or less height may be employed. The members 61, 68' and 69 are made.
of brass-,while the columns 15 are made of aluminum. ,The coefficients of expansion of these metals. are differentv and accordingly these metals are employed so that during heating and cooling their respective expansions and contractions will substantially compensate each other and, accordingly, maintain the distance between the center of surface I2 and the center of surface I8 constant. I
Figs. 11 and 12 are intended to show in more detail how both plus and minus powers may be readily formed in the plastic bell-shaped member 54. It will be seen from these two figures that by the use of original plastic stock of different thicknesses and by the different extents of drawing of the plastic, as well as the speed at which the center is cooled and the sidewall portion is drawn, it is possible to form diiferent shapes and amounts of plastic material at the central portion. In Fig. 11, wherein a minus power as indicated by radii r and r is to be formed, although the center thickness at a is not great the adjacent plastic must first be stretched out considerably. This is necessary in order that the plastic, when confined between mold surfaces I2 and I8 and re-heated, will return toward its original shape and, between mold surfaces I2 and I8 where it is prevented from a complete return, it will take'on the shapes of said surfaces. In Fig. 12, a plus correction is indicated by radii 1' and r". While the center thickness at b is greater than a, the plastic adjacent thereto thins out more rapidly toward the edge of the corneal portion. In each case, however, it will be noted, the central portion of the preformed plastic is so shaped relative to its respective molding surface I8 or 18" that the plastic, when re-heated, progressively engages these surfaces from the center outwardly. This is important in order to prevent air being trapped between the plastic and concave mold surface I8 or 18". The behavior of the plastic being drawn out and being returned partially to its original form is much like that which might be expected if a sheet of rubber were stretched out in like manner and then allowed to return, except with the plastic material the steps are performed only while the plastic is rendered soft or pliable by the proper application of heat. Thus preformed bell-shaped members having a large variety of prescribed plus and minus opti cal powers, as well as ones of zero optical powers, may be conveniently and accurately formed by the steps just described. An alternate method of forming an equivalent series of oversized bell-shaped lens blanks may be accomplished in the fOllOWing manner. In Fig. 13 is shown an inner mold half 94 upon which is accurately formed a large curved surface 95 and a smaller curved surface 96 which have their adjacent edges smoothly blending into one another. The smaller curved surface is preferably of an 8.0 or 8.5 millimeter radius, but may be slightly larger or smaller if desired. A series of complementary mold halves may be provided to function with mold half 94 for forming orcasting bell-shaped lens blanks generally similar to drawn lens blank 93 of Fig. 10.
One such complementary or outer mold half is shown at 91 in Fig. 13 and is provided with a large curved surface 98 and a smaller curved surface 99 which blend smoothly together. These curved surfaces on members 94 and 91 thus form a mold cavity I09 of proper size and shape to produce an oversized bell-shaped cast lens blank, when the members are assembled together and centered by a shoulder II]! or the like, and the resultant bell-shaped lens blank will have an optical power at its center depending directly provided by the mold halves. By selectively using with the mold half 94, a plurality of outer mold halves 91 having different curvatures formed at their central portions, it is possible to produce bell-shaped lens blanks having a variety of different accurately formed optical powers in their central portions.
Into the mold cavity I09 is placed or injected, in known manner, a suitable-quantity of a liquid monomer, or a powdered polymer or a mixture of liquid monomer and powdered polymer of one of the plastic materials mentioned previously and by the proper application of pressure, depending upon the type of material being used, while the mold halves are heated to proper molding or casting temperatures, said bell-shaped blanks maybe formed. It is here noted that the foregoing injection and compression molding and casting processes are somewhat more expensive than the drawing process described above due largely to the great expense involved in the accurate forming and polishing of the mold halves 94 and 9'I. Also great care must be exercised to avoid excessive strains in the plastic when high pressures are used and to avoid graininess when compression molding is employed. Furthermore, the casting method is relatively slow. For these reasons, the drawing process is preferred.
Such drawn and cast oversized lens blanks having prescribed optical powers formed in the corneal portions thereof may be modified in the following manner for producing contact lenses which will accurately fit the particular scleral curvatures of any individuals eye. A preferred procedure comprises the taking of animpression or negative reproduction of'the patients eye in known manner, by an ophthalmologist or physician, and from this impression a positive cast or modelor modified plaster of Paris or dental stone may be made. When prescription contact lenses are being ordered, such a cast will be supplied by the physician and marked merely with an L or R. and a line extending transversely across the back surface thereof to indicate the transverse axis of the eye. In order that this original cast will not be in any way injured or damaged, it is desirable, but not necessary, to make a replica or duplicate thereof and such a duplicate cast is indicated by numeral I92 in Fig. 14. If the line on the original cast is traced by an indelible pencil, such reference mark will be automatically transferred to the duplicate. A transverse line may be drawn from the ends thereof across the front face of the duplicate and the corneal portion thereof may be easily traced or outlined on the cast as indicated by a circle at I 03. By drawing one or more diameters I94 across the circle, it
is easy to establish the exact center of the corneal portion.
With such reference marks added to the duplicate cast, it may be placed upon the upper end (of a hollow circular member I95 and readily centered thereon by sighting through the member, at which time the cast and hollow member may be pressed toward the concave surface I 06 of a supporting block IilI having a guiding bore I98 for the hollow member I95 and in so doing the scleral part of the cast will be pressed into adhe sive engagement with plastic molding clay or the like I99 positioned on concave surface N36. The clay serves to temporarily secure the duplicate cast in afixed centered position upon the block IIJ'I "so that it may be supported on a base Iii] and centered by a centering ring H2 secured thereto and thus axially aligned with a drill press (not: shown). While-in this. position-a chuck II4 on the. drill press carryinga small drill H6 may be. brought into engagement with the back surface ofthe duplicate cast and a bore [I8 drilled therein in such amanner that it extends through the, greater part of the cast. Thereafter :3 very fine drill may be employed to forma smaller bore I -from the-bottom of bore I I8 to the front surface of the cast.
After the duplicate cast has been prepared in the manner just described, it may be positioned ,upon a round pin I22 which isof such size that it closely fits the bore II-B. This pin is fixedly carried by acircularsupporting plate I24 provided withv an outer circumference of such a size that it closely fits within a circular recess I25 tion of the cast and .Willgenerally range from 11 to 15: millimeters If desired, a small quantity of wax or other suitable fillermaterial ISI may be putaround the cap I28 and smoothed over to fill the space between the curves on the cap and cast and blend one into the,- other. At times, it may be desirable to form a recast of the cast I02, cap I28 andfiller material Itl (when present), since same obviously will be somewhat stronger than'the' drilled member I02 when subjected to the steps of the method employed. Such a recast may be formed. upon a pin and member likepin I22 andmember I24.
An adjusting'screw I132 carried centrally in the lower part of the supportingframe I26 is in a retracted position when the plate I24, cast I02 and cap I25 are placed'in the frame and thereafter the clamping ring 21 carrying a drawn or cast oversized bell-shaped lensblank, having a plus or a minus or a no power optic at its center, are positioned within and centered by a second recess I33 inframe I26 and secured by clamping screws or the like I34. The screw I32 is then adjusted to" move the. plate, cast and cap upwardlya-nd-to bring the cap I28 into engagement with the optic in theplastic material. filled cap or the like I35. is then placed over the optic in'the plastic member so as to insulate same whenheat is applied to the exposed plastic. Thereafter the assembled structure may be placed over a heater of the type shown in Fig. l18 and heated from 20 to 30 seconds, or just enough to soften the thin plastic wall only. If the plastic member has beenformed by drawing, it will tend to return to'its original shape by plastic memory but if it hasbeen formed by molding or casting it will be necessary to attach a suction line to the-opening I to cause the thin walled member to be drawn inwardly. In either case, the'thin plastic Wall will move while heated into contact with the cast I02 and take on the exact. scleral shape thereof. The assembly is then, cooled to room temperature before the plastic material is removed from the assembly and the ring 21. In this way, the particular curvature of the scleral portion of the cast is given to the inner. surface Awax .quired.)
of the lens blank while at the same time the center portion is definitely spaced a sm'altpredetermined amount from the corneal portionof the cast. The plastic material will bridge more or less tangentially-from the edge of the cap to the surface of the cast and thereby causea smooth blending of the curves at the junctions thus formed. Such a shaped plastic lens blank may then -.be out along predetermined lines andhave its;- edge; polished to provide a contact lens which Will-fit, exactly theparticular shape of an individuals eye.
-If the optic in this lens is the exact power required by the patient, afinished custom contact lens will be the result. However, if only a close approximation of the exact optical power has beenformed into such a contact lens, it may be employed merely as .a trial lens; (Such a trial lens however has great advantage over the ordinary trial lens with a spherical scleral portion ofv only approximate eye size since its spacing before the-cornea may vary greatly and cannot be: readily estimated for refraction purposes. In
the lens of the present invention, the spacing is known and is retained. during the making of a custom contact lens having the exact power re- With, such .a correctly shapedtriallens, the
physician oropthalmologist may test the exactness-or correctness of the scleralfit of the lens and may refract the patients eye with the lens in place. Hemay also mark upon this trial lens the line of sight of the patient and any changes .in. the .marginal limits of thelens which: may
be desired. The marked trial lens indicated by the-numeral I40 inFig. 17 may then be returned to the maker and from this trial lens a custom lens'having the exact power required may be readily produced.
-The lens I40 having'its line of sight marked thereon,:as indicated by the numeral I42, may beareadily centered upon the recasting device -I44-since this; device is provided with a central circular cavity I45 and a central aperture I46. This aperture is of small diameter but of appreciable length and is in direct alignment with .alamp I sothat aneedle of light will shine through the aperture and indicate on the lens I40 'whenethe marked point I42 has been aligned withlsaid aperture.- In order to hold the, trial lens-so alignedover the circular cavity I45, it is provldedwith a duct 1 52' connecting same with a vacuum line -I53 controlled by a shutoff valve I:54. A glass plate IE5 or the like is retained in placebeneath theaperture I46 to prevent air from entering the. aperture I46 and the. cavity I45. Accordingly, when valve I54 is opened, a suction may be applied to the lower surface of the lens I40 to holdthe lens in its properly adjusted and aligned position.
-.When lens I40 has-been so secured, a circular collar I55 may he slipped over an annular shoulder I51 concentric with the aperture I46,
after which plaster of Paris or other suitable materialis poured into the lens I40. A circular plate I58 .having a stud, I60 extending .down- .wardly centrally from its lower. surface is positionedin a. circular opening IBI in the collar I56 and arranged so that its lower end will. ex-
,tend into the plaster of, Paris while still in an screw I52 so as to extend through a plate I64 and into a threaded central opening I65 in the plate I58, with plate I64 being of such diameter that it will engage the upper surface of the collar I56 and limit the inward or downward travel of the plate I58. Rotation of screw I62 will adjust the amount that the stud extends into the plaster of Paris. A groove or the like I66 may be provided on the otherwise rounded lower end of stud I 60 to prevent rotation or movement of the plaster thereon when it has set about the stud.
The plate I58 having a plaster of Paris form I68 secured thereto is then removed from the structure shown in Fig. 17 and placed within a circular chamber or recess I69 in a supporting frame I16. This recess is of such internal diameter that it closely receives said plate. An adjusting screw I12 extending centrally through frame I is at such time retracted so that the clamping ring 21 with an oversized plastic bellshaped cast or drawn lens blank I13, having an accurately formed optic of prescribed optical power formed therein, may be positioned within a circular recess I14 and retained in place by screws or the like I16. Thereafter, adjusting screw I12 is rotated into engagement with the plate I58 and serves to move the plate and the plaster form I68 axially into engagement with the optic I80 of the member I13.
A heat insulating button or cap IBI filled with a low melting wax I82 may be adhered to the exposed surface of the optic and serve to protect the optic while the assembled structure is inverted and placed over an opening I 83 in a heating chamber I84. The chamber is provided with a radiant heatingcoil I 86 having terminals (not shown) adapted to be connected to an external source of electrical energy. The assembly is allowed to remain over the heater for a time suflicient only to heat the exposed thin wall portion of the plastic member I13. No heat should be allowed to reach the optic I 80. Obviously, overheating of the plastic member and the protective button I8I will cause the wax to soften and the button to drop oif and serve as an indication that too much heat has been applied. Heating of the member I13 will only require ordinarily in the neighborhood of to seconds. If the member I13 has been drawn, it will return by plastic memory toward its original shape and assume the scleral shape of the form I68, but if it is a cast bell-shaped member, a suction line may be connected to a connector I88 communicating with chamber I69 and the vacuum within chamber I96 will serve to draw the thin wall of the member I13 into engagement with the form I68. (Obviously, an air pressure could be applied through connector I92 and heating chamber I84 and would serve as readily for producing a differential pressure for effecting movement of the heated plastic material into engagement with the form I68.)
When the plastic member I13 has been caused to fit closely the scleral curvature of the form I 68 and has cooled so that it will retain such shape, it may be out along a predetermined marginal line and polished to provide a custom contact lens having a tapered thin walled scleral portion adapted to closely fit the contour or curvature of an individuals eye, having a properly spaced corneal portion provided with an optic of proper plus or minus prescription and having said optic prop erly aligned with the line of sight of the individual.
While much of the foregoing description relates primarily to the formation of trial and custom contact lenses, it should be understood that the formation of other types of optical elements such as ophthalmic and instrument lenses, prisms and the like could also be readily formed of plastic material by the method employing the phenomena of plastic memory. In forming such lenses, prisms and the like, the plastic material'would be similarly heated and stretched out appreciably, after which forming surfaces would be positioned in predetermined spaced relation adjacent opposite sides of or even in contact with parts of the opposite surfaces of the stretched'plastic and the plastic thereafter allowed to return by plastic memory toward its initial or cast position until parts thereof engage and are confined by said opposed forming surfaces, producing the size and shape of element desired. Also variously shaped optical elements such as Schmidt corrector' plates, toric lenses and even ophthalmic lenses containing prism corrections therein may be readily and accurately formed by following the teachings of the invention. Should a particular case require, it would even be possible to form toric, atoric or prismatic corrections into the corneal portion of a contact lens.
1. The method of forming a' contact lens or the like having an optic of predetermined characteristics formed centrally therein and having a surrounding portion adapted to fit closely the scleral curvature of an individual eye comprising forming an optic having said predetermined characteristics in thecentral portion of a piece of plastic material, protecting said formed optic from the application of heat in such a manner that it will retain its given optical characteristics, subjecting said surrounding portion of the plastic material to the application of heat to render same pliable and'positioning a positive cast of said individual eye in predetermined relation relative to said optic, and causing said heated plastic material to move into engagement with said cast and to thereby assume the particular scleral surface characteristics of said individual eye.
2. The method of forming a contact lens of the proper size, shape and optical prescriptionrequired for accurately fitting the individual characteristics of a persons eye comprising the steps of centering over the corneal portion of a positive cast of said eye a corneal clearance cap having a predetermined thickness, diameter and outer curvature, said cast with the cap providing a bearing surface having a desired compound curvature for the inner shape of the contact lens,
forming plastic material into a unitary bellshaped member having in the central portion thereof an optic of predetermined inner and outer curvatures and having a portion surrounding said central portion which isof a slightly larger size than the size of said bearing surface formed by the cast and cap, positioning said plastic member and said bearing surface formed by the cast and cap in adjacent relationship, with the center of said bearing surface being located adjacent the central portion of said plastic member, heating the surrounding portion of said plastic member to soften same while the central portion is protected from the heat, causing said softened surrounding portion to move into engagement with the adjacent portions of said bearing surface while the central portion thereof remains substantially unchanged, retaining said surrounding portion in contact with said bearing surface until theplastic materialhas cooled sufficiently to set theplastic in its new-position, and trimming and finishing said surrounding-portion along predetermined lines-to produce a contact lens.
3. The method-of forming a contact lens of the proper size, shape and optical prescription remember having in the central portion thereof an optic of predetermined inner and outer curvaturesand having a relatively thin surrounding wall portion which is of a slightly larger size than said bearing surface formed by the outer surfaces 50f said'cast and cap, positioning said plastic member and said bearing surface having such a compound curvature in adjacent relationship, heating the thin walled portion of said plastic member to soften same while protecting the central portion thereof from the heat, causing said softened thin wall portion to move into engagement with adjacent portions of the bearing surface while the central portion thereof remains substantially unchanged, retaining said thin walled portion in contact with said bearing surface until the plastic'material cools sufficiently to set the plastic in its new position and trimming the [plastic-along predetermined'lines to produce a contact lens.
1; The method of forming a-blank for use in the manufacture of a contact lens or the like, which blank Will have an optic of predetermined curvatures and a-surrounding portion embodying a thin wall of concave shape which is of slightly larger size than the sclerotic of a persons eye, comprising the steps of heating an area of a sheet of plastic material of predetermined thickness to render the area pliable, chilling a small area Within said heated area while simultaneously causing said heated area surrounding the small area to stretch and assume a given concaved shape, retaining said stretched plastic substantially unchanged in its concaved shape while confining said small area between accurately formed and located optic producingsurfaces, and
heating said plastic material to soften same and cause it to return partially to its initial shape to thereby form between said surfaces an optic ,havingaccurately formed opposed surfaces.
5; The'method of forming a thin walled bellshaped plastic lens blank having an optic formed adjacent the centerthereofcomprising the steps of clamping a sheet of thermoplastic material of predetermined thickness so as to expose a section thereof, heating the exposed sectionfor a time sufficient to render same pliable, cooling the center of the heated section while simultaneously stretching the heated section to form same into a bell-shaped member having a relatively thin Wall portion surrounding a relatively thicker central portion, holding the plastic material in itsstretched concaved condition until it is cooled sufiiciently to acquire a set therein, positioning the central portion of said member between accurately located opposed molding surfaces of predetermined curvature, heating the plastic material so as to cause the plastic near the center to soften and move into engagement with parts of said: opposed molding, surfaces while preventing any 'substantail change in shape in the thin walledportion, and holding the plastic material in such restrained and confined condition until it has cooled sufficiently to, acquire a set in all parts thereof.
6. The method of forming a contact lens of the proper size, shape and'optical prescription required for accurately fitting the individual characteristics of a persons eye comprising the steps ofcentering over the-corneal portion of a positive cast of said eye a corneal clearance cap having a predetermined thickness-and outer curvature, forming a recast of said cast having the cap seated thereon, saidvrecast having an outer surface duplicating that of, the curved shape of the combined outer surfaces, of said cast and cap seated thereon, forming plastic material into a unitary bell-shaped member having in the central portion thereof a predetermined optical power and a thin walled portion surrounding said central portion which is of a slightly greater size than said recast, positioning; the central portions of said plastic member and said recast inadjacent relationship, heating the surrounding portion of said plastic member to soften same while the central portion thereof is protected from the heat, causing said softened surrounding portion to move into engagement with adjacent portions of said recast While said central portion remains substantially unchanged, and retaining said surrounding portion in contact with the adjacent portions of said recast until said plastic material has cooled suiiiciently to set, the plastic in its newly acquired shape.
'7. The method of forming a contact lens of the proper size, shape and optical prescription required for accuratelyfitting the individual characteristics of a persons eyecomprising the steps of centering over the corneal portion of a positive cast of said eye a'corneal clearance cap having a predetermined thickness, diameter and outer spherical curvature, forming a recast of said cast and cap, said recast having an outer surface duplicating the curved shape of thecombined. outer surfaces of said cast and cap seated thereon, forming plastic material into a unitary transparent bell-shaped member having in the central portion thereof an optic and a'thin walled portion surrounding said central portion which is of'a slightly greater size than said recast, positioning theoptic of said plastic member and said recast in adjacent relationship, heating the surrounding portion of said plastic member to softensame while the central portion thereof is protected from the heat, causing said softened surrounding portion to move into engagement with the adjacent portions of said recast while said central portion remains substantially unchanged, retaining said surrounding portion in contact with said recast until the plastic material thereof has cooled sufficiently to set the plastic, and trimming and finishing said surrounding portion along predetermined lines to produce a contact lens.
8. The method of forming a contact lens or the like having an opticand a surrounding scleral portion of predetermined shape comprising selecting a piece of plastic material of a thickness equal to or slightly greater than the maximum thickness required in the finished lens, heating an exposed section of said piece of plastic to render it pliable, cooling the center of the heated to is being stretched, holding said plastic in its stretched condition until it has cooled sufllciently to acquire a set therein, forming an optic in the material at the center of the plastic material, positioning the stretched plastic material and a positive cast of a persons eye in adjacent predetermined relationship, with the corneal portion of said cast adjacent the portion which has the optic and with the scleral portion of the cast Within the stretched plastic, heating the stretched plastic to cause it to move into intimate contact with parts of the scleral portion of said cast adjacent thereto while protecting said optic from said heat.
9. The method of forming a contact lens of predetermined shape and provided with an optic in its central portion comprising clamping a piece of plastic material of a thickness equal to or slightly greater than the maximum thickness desired in the finished lens so as to expose a section thereof, heating said exposed section of the plastic to render it pliable, rapidly cooling the central portion of said heated section while stretching said heated section so as to produce a bell-shaped member having a relatively thin wall surrounding the central portion, holding said plastic in its stretched condition until it has cooled sufiiciently to acquire a set therein, forming an optic in the material at the'central section, positioning the stretched bell-shaped plastic member containing said optic and a form having the shape of a portion of a persons eye in adjacent relationship, heating the stretched plastic to cause it to move into contact with said form while protecting said optic from the heat, retaining the bell-shaped member in contact with said form until the plastic material has cooled sufficiently to acquire a set therein, and trimming and finishing the bell-shaped member along predetermined'lines to produce said contact lens.
10. A method of forming a contact'lens of predetermined shape and provided with an optic in its central portion comprising the steps of clamping a piece of plastic material so as to expose a section thereof, heating the exposed section for a time sufiicient to render it pliable, cooling the central portion of the heated section while stretching the heated section to form a bellshaped member having a thinned out area surrounding the central portion, holding the plastic in its stretched condition until it has cooled sumciently to acquire a set therein, forming an optic in the material at the central section, heating the stretched section while protecting the formed optic, causing said thinned out area to move into intimate engagement with curved parts of a member having a shape duplicating a part of the sclerotic of a persons eye, and retaining the thinned out area in engagement with said memher until it has cooled and efiected a set to retain the plastic material in its new acquired shape.
11. The method of forming a contact lens of predetermined shape and provided with an optic in the central portion thereof comprising the steps of clamping a, sheet of plastic material so as to expose a section thereof, heating the exposed section for a time suflicient to render it pliable, rapidly cooling the central portion of the heated section in such a manner as to provide a curvature therein of approximate predetermined radius and to prevent excessive thinning out of the plastic thereof while stretching the heated section surrounding the central portion to form a bell-shaped member having a relatively thin wall portion, holding the plastic member in its stretched condition until it has cooled suificiently 1 to acquire a set therein, forming an optic of predetermined optical power at the central portion of said bell-shaped member with said optic hav ing an inner curvature of substantially the same radius as said first mentioned radius, heating the stretched section while protecting the formed optic, causing the thin walled portion to move into engagementwith' a member having a shape "duplicating a part ofthe sclerotic of a persons eye, retaining the thin wall portion in engagement with said member until it has cooled sufiiciently to acquire a set, and trimming and finishing said thin wall portion along a predetermined line to produce said contact lens.
12. The method of forming a contact lens of predetermined scleral shape and provided with an optic of predetermined characteristics in its central portion which is accurately axially aligned with the line of sight'of a persons eye comprising the steps of forming a plastic bellshaped member having an optic in its central portion and having a relatively thin side wall portion, positioning said bell-shaped member adjacent a form of predetermined shape and providing an area duplicating the scleral portion of said persons eye, heating said thin wall portion and causing said thin wall portion to move into intimate engagement with said scleral portion, trimming said plastic member along a predetermined line to form a trial lens, inserting the trial lens in the eye of an individual to test the fit thereof, marking on the trial lens the line of sight of said person, forming a replica thereof upon an aligned supporting member, positioning said replica and member in a predetermined location relative to a plastic bell-shaped member having the prescribed optic formed at its center, heating said bellshaped plastic member while protecting the optic formed therein and causing said member to move into engagement with adjacent portions of said replica, retaining said replica and plastic member in fixed relation-until the plastic material thereof has cooled and acquired a set, and finishing said member along a predetermined line to provide said contact lens.
13. Apparatus for use in the manufacture from heated plastic material of bell-shaped blanks for use in the manufacture of contact lenses or the like comprising holding means for gripping plastic sheet material so as to expose an intermediate portion thereof, forming means spaced from said holding means and in alignment therewith for contacting and shaping the'heated plastic while held by said gripping means, drawing means for causing the plastic to assume the shape of said forming means, and cooling means for simultaneously cooling the central part of said exposed heated portion to prevent undesired thinning out of the central portion while the adjacent plastic is being drawn tothe shape of the forming means.
14. Apparatus for forming bell-shaped blanks having optics positioned-in the central portions thereof for use in the manufacture of plastic contact lenses or the like comprising holding means for supporting plastic sheet material so as to ex pose an area therein, heating means for heating said exposed area of the plastic sheet material, shaping means for causing the exposed area of said plastic to be deformed from its initial shape and to assume a predetermined bell-shaped form, a high heat conducting engagement member for engaging and rapidly cooling the central portion of said heated area while said plastic is assuming said bell-shaped form to thereby prevent undesired thinning out of the central portion, said en- '19 gagement member having a surface shape con-- trolled for forming in said-central portionea surface of predetermined curvatures.
15. Apparatus for providing in a bell-shaped blank of plastic material for usein the forming 3 of contact lenses and the like optic 'of predetermined curvatures, said apparatus comprising a first forming member and a second forming member, said first'forming member being provided with a highly'finishedfirst surface of predetermined curvatureand a second largersurface concentric with said first surface .and spaced slightly axially .of said first surface, said second forming member being provided with a highly finished concaved surface of predetermined curvature axially aligned withsaid first and second surfaces, said first surface and said concave surface being relatively movable and adapted to engage the inner and outer surfacesrespectively of the central portion of said bell-shaped plastic blank, means for releasably maintaining "said forming members in predetermined spaced :relation, holding means for gripping the outer portions of said bell-shaped member for preventing unlimited movement thereof, and heating means for heating the plastic material of said bellshaped member to cause it .to move into contact with said first, secondand concave surfaces.
.16. The method of forming from thermoplastic material an optical element having predetermined optical surface characteristics on the opposite faces thereof, said method comprising fined engagement with portions of said molding surfaces, and retaining said plastic material so confined until the plastic material'has cooled suffi'ciently to acquire a set therein.
17. The method of forming a blank for use in the manufacture of contact lenses, said method comprising the steps of heating an area of a thermoplastic sheet 'to render said area pliable, positioning said sheet with the heated area thereof between a rigid concave molding surface, and a rigid convex molding surface, one of said rigid molding surfaces embodying a circular shaped central surface portion of controlled surface curvature surrounded by an annular-like surface portion of a controlled different surface curvature and the other rigid molding surface having a controlled surface and being of a size and circular shape to substantially coincide with the circular shaped central portion of the first rigid molding surface, said heated area of the sheet being of a size greater than that of said latter molding surface, and moving one of said rigid molding surfaces toward the other to form in the center of said heated area of the sheet surface curvatures on the opposed sides thereof corresponding substantially to the surface curvature of the contacting rigid molding surfaces While restraining the outer portions of said plastic sheet against movement and drawing the heated area of the sheet about said center portion thereof to the ,shape of the annular-like surface portion .of :thefirst rigid molding .surface, and allowing said plastic to cooland :set to said shape.
18. Themethod of forming a contact lens or the like from acup-shaped blank-of plastic material having internal strainstherein capable of being relieved under-the subjection of the blank to heat which :strains-causesaid blank to shrink whenso-heatedcomprising the steps of protecting the central-portion of .said blank from the application ,ofrheat in -such amanner that it will retain "its initialshape and shrinking the surrounding portion of said blank to the shape of an inwardly positioned molding surface under the application of heat, and with said molding-surface being of a :shape controlled to reproduce substantially the scleral-shape of the scleral portion of the individuals eye'with which the finished lens is to be used.
l9.The method of forming a contact lens or the like from'a cup-shaped blank of plastic'material having internal strains therein capable of being relieved when -subjected to .heat of an siredinnercurvature and optical power for said central-portion, protecting said shaped central portion from subsequent application of heat in such a manner that it will retain said shape, and then shrinking the surrounding portion of said blank to the shape of an inwardly positioned molding surface underthe application of heat, said moldingsurface being of a shape controlled totreproduce substantially the scleral shape of the scleral portion of the individuals eye with which the finished lens isto-be used.
20.. Ablank for use in forming a contact type lens BOmDI'lSlHg a bell-shaped member of transparent polymerized -plastic material, said'bellshaped member having a central optic portion formed withan-inner concave and an outer convex surface, the curvature of said outer surface being controlled according to the optical correction characteristics required for the resultant lens to be formed from said blank, said bellshaped member having a continuous side wall surrounding said central optic portion and constituting the sides of said member and terminating in an outwardly extending annular flange-like holding portion, said'side Wall having a thickness progressively'decreasing from adjacent the central optic portion and flange-like holding portion of said member to an area of least thickness intermediate saidportions, theinner surface of said side wall :having varying circumferential dimensionscorresponding approximately to the varying exterior circumferential dimensions of the sclera of the average persons eye whereby the resultant shape of said inner surface approximates the shape of the adjacent exterior of the eye, said circumferential dimensions being of sizes substantially greaterthan the corresponding circumferential dimensions of said average persons eye, and said wall portion further having plastic memory rendering it capable at temperatures substantially above body temperature to shrink in size whereby said blank may under the application of heat be caused to have the inner surface of its side wall accommodated to a molding surface having a shape reproducing substantially the shape of the sclera of a persons eye for which the resultant lens is prescribedv to permit the obtaining of a. lens having a desired scleral fit as Well as optical correction.
HARRY CRANDON.
Number Name Date Thurber Mar. 5, 1901 Rothwell et a1 May 11, 1920 Wigand June 5, 1923 Gluckin et al May 29, 1928 Brown Apr. 16, 1935 Currie Jan. 14, 1936 Helwig Jan. 3, 1939 Lloyd July 18, 1939 McCoy Aug. 8, 1939 Feinbloom Nov. 7, 1939 Hoop July 23, 1940 Strauch Jan. 21, 1941 Mullen Apr. 8, 1941 Gagnon Apr. 29, 1941 Number Q Number Cry-O-Vac Bulletin P-l.
Name Date Moulton May 13, 1941 Wisman Aug. 5, 1941 Dittmer Oct. 27, 1942 Mullen Oct. 5, 1943 Gross et a1. Oct. 26, 1943 Weinberg Dec. 28, 1943 Borkland Sept. 12, 1944 Sheldon Feb. 20, 1945 Borkland July 6, 1948- FOREIGN PATENTS Country Date Great Britain Aug. 8, 1939 OTHER REFERENCES (Copy in Div. 15.)
Printed in U. S. A. 1939.
Obrig: Text Contact Lenses, pages 256 and 257, published by Chilton Co., Philadelphia, Pa.,
(Copy in Division 7.)
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U.S. Classification 264/2.5, 425/808, 264/292, 359/900, 264/2.7, 425/340, 264/222, 425/405.1, 351/159.74, 351/159.2
International Classification B29D11/00, B29C43/02
Cooperative Classification B29D11/00086, B29C43/021, Y10S425/808, B29L2011/0016, Y10S359/90
European Classification B29C43/02B, B29D11/00C4F