1. A method of forming an ophthalmic lens, the method comprising:
providing a volume of reactive mixture material into a container the shape of which does not influence the shape of the ophthalmic lens;
placing a male mold having an optical quality surface at least partially within said volume of reactive mixture such that at least a part of a convex surface of said male mold is submerged within said reactive mixture;
creating a digital 3-D mathematical model defining corrective needs of an eye;
generateing a script comprising multiple projection paths and time durations of actinic radiation; and
projecting a first pattern of actinic radiation comprising UV light through the male mold along at least a part of the submerged convex surface of said male mold, wherein the first programmed pattern is based upon the control of a digital mirror device via said generated script, wherein said first programmed patterns of UV light cures a selected portion of said volume of reactive mixture in a free-form manner on a voxel by voxel basis to form gelled reactive mixture such that a distal side of the gelled reactive mixture from the male mold surface does not contact a mold surface, and wherein the gelled reactive mixture forms a first side of said ophthalmic lens that is an optical quality arcuate shape which is generally defined by said male mold surface and which extends on a voxel by voxel basis to a surface based upon a depth of cure of each respective voxel reaching a gel point on the distal second side;
subsequently processing a fluent media in fluid contact with the second side to form a second, optical quality opposing side of said ophthalmic lens.
2. The method of claim 1, wherein the digital mirror device apparatus comprises at least three digital mirror device chips.
3. The method of claim 1, wherein the first actinic radiation is transmitted in a static pattern over a predetermined duration of time.
4. The method of claim 1, wherein the first actinic radiation comprises light in a spectrum of between 360 nM and 435 nM.
5. The method of claim 1, wherein the transmission of the first actinic radiation is controlled by a processor in communication with the pattern generator.
6. The method of claim 1, wherein the reactive mixture comprises a radiation absorbing component capable of absorbing the first actinic radiation.
7. The method of claim 1, additionally comprising the step of calculating via a controller executing software, a length of time and an intensity of respective beams of actinic radiation to be applied through particular locations of the substrate to polymerize voxels of the reactive mixture and form multiple voxels to the respective calculated desired depths of cure.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A loading dock seal system comprising:
a closed-cell foam buffer;
a foam padding disposed adjacent the closed-cell foam buffer and affixed thereto thereby forming a bolster;
a fabric cover having a front portion, a rear portion, a first side portion, a second side portion and an interior volume accessible via an access aperture, wherein the bolster is disposed within the interior volume such that the closed-cell foam buffer is proximate the rear portion and the foam padding is proximate the front side portion, and wherein the fabric cover is free of overlapping members at least proximate the loading dock structural wall surface;
at least one fabric fastener configured to close and open the aperture through the fabric cover, and wherein the aperture is sized to receive and to release the bolster from the interior volume; and
a plurality of loading dock structure-engaging fabric tabs connected to the fabric cover proximate the rear portion and the first side portion as well as the rear side portion and the second side portion, wherein the plurality of fabric tabs extend away from the rear side when engaged with a docking wall surface, wherein the system is free of wall mounting brackets to engage the cover with a docking wall surface.
2. The loading dock seal system of claim 1, wherein each of the plurality of fabric tabs includes at least one grommet, and wherein the fabric tabs are flexible and capable of being bent by hand without the use of tools.
3. The loading dock seal system of claim 1, wherein a portion of the plurality of fabric tabs includes a pocket with front and back fabric walls surrounding and enclosing a support substrate member within the pocket, wherein each support substrate member at least partially maintains the portion of the plurality of fabric tabs in an orientation substantially parallel to and extending away from the fabric cover.
4. The loading dock seal system of claim 1, wherein the fabric aperture is a slit and wherein the fastener is a zipper that closes and opens the slit wherein the slit extends from a location proximate a bottom end of the rear side of the fabric cover to a location proximate a top end of the rear side of the fabric cover.
5. The loading dock seal system of claim 1, wherein a front surface of the closed-cell foam buffer is engaged with a rear surface of the foam padding to form an integral foam composite bolster, wherein the closed-cell foam buffer and the foam padding are coextensive with one another.
6. The loading dock seal system of claim 1, wherein each of the plurality of fabric tabs are sewn into direct physical engagement with the fabric cover proximate along the junction of (1) the rear portion and the first side portion and (2) the rear portion and the second side portion.
7. The loading dock seal system of claim 1, wherein the closed-cell foam buffer is a substantially rigid foam adapted to substantially conform to the loading dock structural wall surface to form a substantially water-tight seal between the fabric cover and the loading dock structural wall surface.
8. The loading dock seal system of claim 5, wherein the closed-cell foam buffer has a density of from about 2.1 pounds per cubic foot to about 4.3 pounds per cubic foot, and wherein the foam padding has an average density of approximately 0.92 pounds per cubic foot.
9. The loading dock seal system of claim 8, wherein the material of the closed-cell foam buffer has a compressive strength of approximately 7 pounds per square inch to approximately 20 pounds per square inch.
10. The loading dock seal system of claim 8, wherein the material of the closed-cell foam buffer has a compressive strength of approximately 13 pounds per square inch to approximately 24 pounds per square inch.
11. A loading dock seal system comprising:
a fabric cover free of outwardly-protruding overlapping portions, having front, rear, left and right sides and defining an interior volume having a rectangular prism shape, and further comprising:
a fabric connector configured to repeatedly open and close an aperture within the fabric cover, the fabric connector being free of overlapping portions and extending from a location proximate a bottom end of the rear side of the fabric cover and extending to a location proximate a top end of the rear side when in a mounted position of the fabric cover, wherein the mounted position of the fabric cover is defined by the rear side of the fabric cover at least partially engaging a loading dock structural wall surface;
a plurality of spaced fabric tabs extending away from the fabric cover and adapted to connect the fabric cover to the loading dock structural wall surface in the mounted position free of mounting brackets, wherein each of the plurality of spaced fabric tabs includes at least one grommet that engages a corresponding fastener of the loading dock structural wall surface, and wherein the spaced fabric tabs are flexible and capable of being bent by hand without the use of tools;
a foam composite bolster within the interior volume of the fabric cover and comprising:
a closed-cell foam buffer disposed adjacent a rear portion of the interior volume and proximate the rear side of the fabric cover, wherein the closed-cell foam buffer includes a material having a density of from about 2.1 pounds per cubic foot to about 4.3 pounds per cubic foot, and wherein the closed-cell foam buffer is a substantially rigid member adapted to substantially conform to a shape of the loading dock structural wall surface to form a substantially water-tight seal between the fabric cover and the loading dock structural wall surface; and
a foam pad disposed within a front portion of the interior volume and permanently affixed to the closed-cell foam buffer, wherein the foam pad includes a material having an average density of from about 0.8 pounds per cubic foot to about 1.1 pounds per cubic foot, wherein the closed-cell foam buffer and the foam pad are coextensive with one another and form a single integral piece.
12. The loading dock seal system of claim 11, wherein each of the plurality of spaced fabric tabs includes a corresponding support substrate member, wherein each support substrate member is disposed within a pocket defined between front and back fabric walls of each of the plurality of spaced fabric tabs that surround and enclose the support substrate member, wherein each support substrate member at least partially maintains a corresponding spaced fabric tab of the plurality of spaced fabric tabs in an orientation parallel to and extending away from the rear side of the fabric cover.
13. The loading dock seal system of claim 11, wherein the fabric connector is one of a tie and a zipper, and wherein the foam composite bolster is adapted to be inserted into and removed from the interior volume of the fabric cover through the fabric connector by a single individual, by hand and without the use of tools.
14. The loading dock seal system of claim 12, wherein each of the plurality of spaced fabric tabs are sewn into direct physical engagement with the fabric cover, and wherein each support substrate member is made of one or more of metal, plastic, and rubber.
15. The loading dock seal system of claim 14, wherein the fabric cover with the foam composite bolster is adapted to be installed onto the loading dock structural wall surface by a single individual by attaching one or more of the plurality of spaced fabric tabs to the loading dock structural wall surface via the fasteners of the loading dock structural wall surface.
16. A method for installing a loading dock seal system onto a loading dock structural wall surface, the method comprising the steps of:
providing a fabric cover having front, rear, left and right sides and defining an interior volume having a rectangular prism shape, wherein the fabric cover is free of outwardly-protruding overlapping portions proximate the rear side, and further comprising:
a fabric connector and an aperture within the fabric cover extending from a location proximate a bottom end of the rear side of the fabric cover and extending to a location proximate a top end of the rear side of the fabric cover, the fabric connector being free of overlapping portions;
a plurality of spaced fabric tabs extending away from the fabric cover, wherein each of the plurality of spaced fabric tabs includes at least one grommet defining a tab aperture, and wherein the spaced fabric tabs are flexible and capable of being bent by hand without the use of tools;
providing a first foam composite bolster comprising:
a closed-cell foam buffer portion including a material having a density within a range of at least about 2.1 pounds per cubic foot to about 4.3 pounds per cubic foot; and
a foam pad portion engaged with the closed-cell foam buffer, wherein the foam pad portion of the foam composite bolster includes a material having an average density of from about 0.8 to about 1.1 pounds per cubic foot;
disposing the foam composite bolster through the aperture such that the closed-cell foam buffer portion is disposed adjacent an inside surface of the rear side, and wherein the foam pad portion is disposed within a front portion of the interior volume;
closing the fabric connector to at least substantially or entirely encase the foam composite bolster within the interior volume of the fabric cover;
disposing the rear side of the fabric cover against the loading dock structural wall surface, proximate a dock opening such that the plurality of spaced fabric tabs extends away from the rear side of the fabric cover, and wherein a back surface of each of the plurality of spaced fabric tabs is positioned in at least partial engagement with the loading dock structural wall surface; and
fastening each of the plurality of spaced fabric tabs to the loading dock structural wall surface by engaging the plurality of spaced fabric tabs against the loading dock structural wall surface using a wall fastener positioned through the at least one grommet and engaging the wall fastener with the loading dock structural wall surface, wherein fixing the plurality of spaced fabric tabs to the loading dock structural wall surface substantially presses the rear side against the loading dock structural wall surface to form a substantially water-tight seal between the fabric cover and the loading dock structural wall surface.
17. The method of claim 16, wherein the step of disposing the foam composite bolster through the aperture and into the interior volume of the fabric cover and the step of closing the fabric connector is done by a single individual, by hand and without the use of tools.
18. The method of claim 16, wherein the fabric cover with the foam composite bolster disposed within the interior volume can be mounted onto the loading dock structural wall surface by a single individual.
19. The method of claim 16, further comprising the steps of:
removing the plurality of spaced fabric tabs from engagement with the wall fasteners anchored to the loading dock structural wall surface;
refastening the spaced apart fabric;
removing the first foam composite bolster from the interior volume;
disposing a second foam composite bolster within the interior volume; and
refastening the plurality of spaced apart tabs to the loading dock structural wall surface by re-engaging the wall fasteners and the at least one grommet of the tabs; and
wherein the second foam composite bolster comprises:
a closed-cell foam buffer portion including a material having a density within a range of at least about 2.1 pounds per cubic foot to about 4.3 pounds per cubic foot; and
a foam pad portion engaged with the closed-cell foam buffer, wherein the foam padding portion of the foam composite bolster includes a material having an average density of from about 0.8 to about 1.1 pounds per cubic foot, wherein the closed-cell foam buffer portion and the foam pad are coextensive with one another and form a single integral piece.
20. The method of claim 16, further comprising the step of bending at least some of the fabric tabs around a corner portion of the loading dock structural wall surface such that the bent fabric tabs are engaged to a different loading dock structure wall surface than the rear side of the fabric cover.