Method for casting glass-plastic lenses comprising allyl diglycol carbonate plastic

Claim 1

A direct casting process for making a glass-plastic laminated lens comprising at least one glass layer and at least one plastic layer consisting of a cured allyl diglycol carbonate resin bonded to the glass layer, the process comprising the steps of positioning a glass sheet for the glass layer in a mold, injecting liquid allyl diglycol carbonate resin for the plastic layer into the mold and against the glass sheet, and heat curing the resin while in contact with the glass and mold to provide the glass-plastic laminated lens, wherein: (a) the portion of the mold contacted by the plastic resin upon casting and during heat curing is fabricated from a glass-ceramic material having a surface roughness not exceeding one micron, a abraded modulus of rupture strength of at least about 10,000 psi, a thermal conductivity of at least about 0.0040 cal/sec.cm.°C., and an average linear coefficient of thermal expansion not exceeding about 60×10 -7 /°C. over the temperature range of 0°-300° C., and (b) the glass-plastic laminated lens is cooled in the mold, following heat curing, for a cooling interval at least sufficient to reduce the temperature of the lens to about 40° C.