Abstract: Contact lens delensing methods are described, and the present delensing methods include using a gas to facilitate separation of a polymerized contact lens product from a contact lens mold member. The contact lens mold member is compressed to deform a portion of the mold member, and gas, such as air, is directed toward the polymerized contact lens product in contact with the portion. The contact lens mold member can be compressed as the mold member and lens product rotate. A vacuum device can be used to separate the polymerized contact lens product from the contact lens mold member after compressing the portion of the mold member and directing the gas towards the mold member. Delensing systems used to practice the present methods are also described.

Abstract: Contact lens curing systems and methods are described. A contact lens curing system includes an oven that has a plurality of curing zones, a mold advancement system for moving the contact lens mold assemblies between the plurality of zones, and a controlled atmosphere within the curing zones that provides a substantially chemically inert environment in which contact lens precursor materials can be polymerized in contact lens mold assemblies located in the curing zones. Methods of producing contact lenses include curing contact lens precursor materials in contact lens mold assemblies in the lens curing system.

Abstract: Methods and systems are provided for making an ophthalmic lens. The present methods and systems are effecting in coupling two mold sections together at two or more discrete regions. Embodiments of the methods and systems form a bore that extends completely through one of the mold sections and only partially through the other mold section. During formation of the bore, the mold material in proximity to the bore being foamed becomes molten and diffuses from the bore. A portion of the molten mold material is provided at a contact point between the two mold sections and when the molten material cools, the material foams a spot weld between the mold sections. By foaming multiple hollow spot welds in a mold assembly, the two mold sections can be securely coupled to each other during the manufacture of an ophthalmic lens, such as a silicone hydrogel contact lens.

Abstract: A hydrophilic polysiloxane macromonomer containing polyoxyethylene as a hydrophilic side chains pendant to a polysiloxane main chain for imparting transparency, oxygen permeability, and hydrophilic properties to a contact lens is disclosed. The properties of the material are controlled by regulating the length of the polysiloxane main chain, the length of the hydrophilic polyoxyethylene side chains, and the number of the side chains.

Abstract: Contact lenses, such as hydrogel contact lenses, are described. The present contact lenses include a lens body that is the reaction product of a polymerizable composition. The polymerizable composition includes one or more monomers and a crosslinker that crosslinks the one or more monomers during polymerization. The polymerization of the one or more monomers occurs in the presence of a hydrophilic polymer that is present in the polymerizable composition, which comprises a polymer of 2-methacryloyloxyethyl phosphorylcholine. The present lenses are capable of releasing the hydrophilic polymer from the contact lens for prolonged periods of time and also have a reduced surface friction compared to similar lenses without the hydrophilic polymer. The present invention also relates to packaging systems for use with such lenses and methods of producing such lenses.

Abstract: Contact lenses, such as hydrogel contact lenses, are described. The present contact lenses include a lens body that is the reaction product of a polymerizable composition. The polymerizable composition includes one or more monomers and a crosslinker that crosslinks the one or more monomers during polymerization. The polymerization of the one or more monomers occurs in the presence of a hydrophilic polymer that is present in the polymerizable composition, which comprises a polymer of 2-methacryloyloxyethyl phosphorylcholine. The present lenses are capable of releasing the hydrophilic polymer from the contact lens for prolonged periods of time and also have a reduced surface friction compared to similar lenses without the hydrophilic polymer. The present invention also relates to packaging systems for use with such lenses and methods of producing such lenses.

Abstract: Contact lens molds and methods of producing soft cast-molded contact lens products are provided. The methods include placing a soft hydrophilic contact lens-forming composition in a cavity formed between a first mold member and a second mold member, subjecting the composition in the cavity to conditions effective to form a contact lens product from the composition, and repeating the placing and subjecting steps a plurality of times, thereby producing a plurality of soft contact lens products. At least the first mold members, and advantageously all of the first and second mold members, are injection-molded with a nucleated thermoplastic polyolefin resin having a melt flow rate in a range of 10 g/10 min to about 40 g/10 min.

Abstract: A method for inspecting lenses, especially wet contact lenses provided in a volume of liquid inside a container is described. A first image of the lens at a first position in the container is obtained, the lens then being moved to a second position within the container where a second image is obtained. A computer algorithm processes the first and second images to compare features that have moved with the lens to those features that have not moved with the lens whereby lenses are rejected if a feature has moved with the lens but is not a normal feature of the lens.

Abstract: Methods of producing silicone hydrogel ophthalmic lenses include contacting one or more delensed silicone hydrogel ophthalmic lens with a liquid composition that contains alcohol, water, and a surfactant. The methods can be steps of an extraction/hydration procedure used in the production of silicone hydrogel contact lenses. In some examples, contacting silicone hydrogel ophthalmic lens products with a liquid composition that contains alcohol, water, and a surfactant can significantly reduce or prevent surface distortion of the ophthalmic lens resulting from the extraction procedure. Some methods include subsequently contacting the silicone hydrogel ophthalmic lens with a liquid composition consisting essentially of water and a surfactant.

Abstract: Silicone hydrogel contact lenses, when hydrated, have a plurality of depressions on one or more of the lens surfaces. The depressions have a depth less than 1 micrometer, or less than 100 nanometers. The silicone hydrogel contact lenses have not been subject to treatment with plasma. Methods of manufacturing the silicone hydrogel contact lenses are also disclosed.

Abstract: Contact lens curing systems and methods are described. A contact lens curing system includes an oven that has a plurality of curing zones, a mold advancement system for moving the contact lens mold assemblies between the plurality of zones, and a controlled atmosphere within the curing zones that provides a substantially chemically inert environment in which contact lens precursor materials can be polymerized in contact lens mold assemblies located in the curing zones. Methods of producing contact lenses include curing contact lens precursor materials in contact lens mold assemblies in the lens curing system.

Abstract: Systems and methods for producing silicone hydrogel contact lenses are described. Certain of the present systems include a contact lens mold forming station, a station for filling a contact lens mold section with a lens precursor composition and for placing a second mold section on the filled mold section to form a contact lens mold assembly, a curing station for forming a contact lens, a mold assembly separation station, and an extraction/hydration station. Certain of the present methods include forming a plurality of mold sections, placing a lens precursor composition on a surface of a first mold section, placing a second mold section on the first mold section, polymerizing the lens precursor composition, separating the first and second mold sections, removing the silicone hydrogel contact lens from one of the mold sections, extracting extractable components from the contact lens, and hydrating the contact lens.

Abstract: Contact lens curing systems and methods are described. A contact lens curing system includes an oven that has a plurality of curing zones a mold advancement system for moving the contact lens mold assemblies between the plurality of zones and a controlled atmosphere within the curing zones that provides a substantially chemically inert environment in which contact lens precursor materials can be polymerized in contact lens mold assemblies located in the curing zones. Methods of producing contact lenses include curing contact lens precursor materials in contact lens mold assemblies in the lens curing system.

Abstract: Contact lenses ready for use in an eye are provided including a contact lens body containing a hydrophilic polymeric component and a water soluble polymer component. Such contact lenses, which preferably are wet cast molded, are particularly useful as disposable or single use lenses. New contact lens packaging systems and production methods are also provided.

Abstract: Methods for producing a junctionless ophthalmic lens are provided. Additionally, ophthalmic lenses having junctionless, three dimensional surfaces, for example, asymmetrical anterior and/or posterior surfaces, as well as molding tools used in the production of such lenses, are also provided. The method generally include providing sample data points to define a surface contour, and interpolating between these data points using an algorithm to produce a simulated three dimensional surface. The simulated three dimensional surface is used in producing an ophthalmic lens, for example, in cast molding a contact lens.

Abstract: Contact lenses ready for use in an eye are provided including a contact lens body containing a hydrophilic polymeric component and a water soluble polymer component. Such contact lenses, which preferably are wet cast molded, are particularly useful as disposable or single use lenses. New contact lens packaging systems and production methods are also provided.

Abstract: Contact lens molds and systems and methods for producing contact lens molds are described. The contact lens mold sections include two optical quality surfaces, a flange circumscribing at least a portion of the two optical quality surfaces, and an elongate member extending from the flange. Two mold sections can contact one another to form a mold assembly having a contact lens shaped cavity. The mold sections are structured to form a contact lens having an edge that does not require further physical modification before placement on an eye. Systems and methods are described which direct a molten polymeric material into cavities corresponding to the mold sections.

Abstract: Contact lens delensing methods are described, and the present delensing methods include using a gas to facilitate separation of a polymerized contact lens product from a contact lens mold member. The contact lens mold member is compressed to deform a portion of the mold member, and gas, such as air, is directed toward the polymerized contact lens product in contact with the portion. The contact lens mold member can be compressed as the mold member, and lens product, rotate. A vacuum device can be used to separate the polymerized contact lens product from the contact lens mold member after compressing the portion of the mold member and directing the gas towards the mold member. Delensing systems used to practice the present methods are also described.

Abstract: A biomedical device carrier includes multiple recesses for holding a plurality of polymerized biomedical devices, such as polymerized ophthalmic lenses, during an extraction procedure. A biomedical device extraction assembly includes multiple biomedical device carriers. The structure of the individual carriers and the arrangement of the carriers in the assembly provide sufficient extraction of an extractable component from the biomedical devices during an extraction procedure using relatively small amounts of extraction media per biomedical device. Methods of extracting biomedical devices include providing polymerized biomedical devices in the present carriers and assemblies and contacting the devices with an extraction composition.

Abstract: Compositions and methods for improving demolding polar resin molds used in the production of silicone hydrogel materials are described. The present compositions and methods include the use of one or more reactive demolding agents. The reactive demolding agents react with components of a polymerization mixture to produce a polymerized silicone hydrogel device containing a reactant product of the demolding agent and the other components of the polymerization mixture. Polar resin molds used during the polymerization of the polymerization mixture are more easily separated than substantially identical molds used in the polymerization of a substantially identical material without a reactive demolding agent. The present compositions and methods may be used in the manufacture of silicone hydrogel lenses, such as contact lenses. The demolding aids may also be useful as delensing aids.