Abstract: A method for removing a liquid from a container having a bowl and a flange, the bowl holding the liquid and containing a hydrophilic ophthalmic lens, wherein there is provided a nozzle with a central face and a shoulder around the periphery of the face. The shoulder has a sealing means which is sized to fit on the flange of the container, where it forms a sealed volume above the container bowl, this volume including the volume of the bowl itself. The central face has through it at least one fluid entrance passage and at least one fluid exit passage arranged so that the flow is distributed substantially symmetric about the center axis of the lens so that when the purging fluid is introduced into the sealed volume, there is no migration of the lens. There is connected to the entrance passage a source of purging fluid that has a pressure and flow sufficient to remove substantially all the liquid through the exit passage.

Abstract: A contact lens production line pallet system transports contact lens mold materials throughout a facility for producing ophthalmic lenses. Specifically, the contact lens production line pallet system includes a pallet for carrying one or more contact lens mold assemblies throughout a contact lens production line, the pallet having one or more first recesses formed in a surface thereof for receiving either a first mold half or a complementary second mold half, the first and second mold halves when placed together constitute an individual contact lens mold assembly. A conveyor device for transporting the pallet from station to station throughout the production line facility is provided, as is a locating device formed in the pallet surface for enabling precise positioning of the pallet at one or more manufacturing stations in the production line facility.

Abstract: A silicone hydrogel polymer prepared by curing a reaction mixture comprising a hydroxyalkylamine-functional silicone-containing monomer.

Abstract: A highly purified monomer-dye unit is disclosed. A method for producing a highly purified monomer-dye unit is also disclosed. A hydrophilic monomer is reacted with a halotriazine or vinyl sulfone dye in the presence of a base under conditions that yield highly pure monomer-dye units.

Abstract: An interactive control system for controlling the automatic consolidation of contact lenses in a contact lens product flow, the interactive control system comprises a product line having random variations in product flow. A consolidation buffer receives the products from the product line. A controller initiates consolidation of the random variations in the product flow. The consolidation is preferably performed by at least one stacking cylinder.

Abstract: A method and system for verifying the presence of a lens in a transparent package. The method comprises the steps of moving the package into an inspection position, and conducting a light beam through the package and onto an image plane to form an image of the package on the image plane. The method further comprises the steps of generating a set of signals representing the image on the image plane, and analyzing those signals to determine whether a lens is present in the package. This analyzing step, in turn, includes the steps of searching the package image for images of discrete objects; and for each object image found in the package image, identifying values for a plurality of parameters, and analyzing those identified values according to a predetermined procedure to identify the object as a lens or as not a lens.

Abstract: An injection molding process for molding an assembly of a frontcurve molds in a plurality of unitary solid piece of polymer in which plurality of frontcurve molds are arranged symmetrically around a single center polymer injection gate. In this arrangement the molten polymer flows radially outwardly therefrom uniformly in all directions to the four frontcurves to form one common molded piece of polymer. In a compression injection molding process, the pressure on the molten polymer is maintained relatively constant, and the mold is mechanically collapsed during the molding operation. The present invention molds an assembly of frontcurve molds in a manner in which there is a significant reduction of residual stress locked into the resultant assembly of frontcurve molds. This results in a significant reduction in warpage and shrinkage of each frontcurve mold, which is not optically stressed, and results in a subsequent casting of an ophthalmic lens which is not optically stressed.

Abstract: An improved method for imparting a tint or color to a soft, hydrogel contact lens by uniformly dispersing a dye throughout the lens. The dye is a water-soluble halotriazine dye. The dye is reacted with a hydrophilic monomer to prepare a reactive dye containing predominantly monofunctionality. The monomer is then subjected to polymerization in the presence of a homogeneous solution of the reactive dye in the monomer under conditions to yield the hydrophilic polymer from which the lens is formed. The dye becomes bonded to the polymer during polymerization. The finished lens does not require soaking in an aqueous solution of the dye to impart the desired tint or color to the lens. Additionally, the dye uniformly dispersed throughout the lens according to the improved method does not leach out of the lens or migrate within the lens. Furthermore, the lens does not need to be washed with aqueous base to bond the dye to the lens.

Abstract: Methods and apparatus which are utilized for the production of ophthalmic lenses, and more particularly, a method for the removal or demolding of molded ophthalmic contact lenses from the individual molds in which they are produced. The apparatus implements the demolding of such ophthalmic lenses, the latter of which may consist of suitable hydrogel contact lenses or other types of high-precision ophthalmic lenses; for example, such as intraocular contact lenses. Mechanical prying apart of such mating mold half portions, and to facilitate this procedure at a reduced application of force, while concurrently potentially preventing or at least appreciably ameliorating the extent of any possible sticking together of the mold half portions is effected in that mechanical leverage applied to the upper mold half portion, in addition to the application of the heating action thereto.

Abstract: A method and apparatus for the manufacture of optical polymer contact lenses in a closed mold, where a mold cavity is created between a front curve insert and a back curve insert, the side walls of the mold cavity being formed by the inner wall of a movable annular gate collar, the collar being positioned in a retracted position during polymer dosing and then moved prior to polymer cure into an extended position to complete the mold cavity and to separate the polymer curing inside the mold cavity from any waste polymer outside of the mold cavity.

Abstract: An ophthalmic lens provides a cumulative ratio of distance to near focal length that is predominantly distance correction under high illumination, nearly evenly divided between distance and near correction under moderate illumination, and favoring again distance vision correction under low level illumination. The lens is specifically adjusted to match the patient's pupil size as a function of illumination level, in the preferred embodiment by applying pupil size parameters as a function of age. This lens has the properties of matching both the distribution of near and distance focal vision correction to the type of human activity typically undertaken in various illumination conditions, as well as matching particular lens dimensions to suit the size of the pupil as a function of illumination intensity.

Abstract: A rotational indexing base curve deposition array for assembling contact lens base curves and front curves with a prescribed and programmable angular orientation to produce a contact lens having a selected axis placement therein, such as a toric axis for a toric contact lens. An array of front curve molds are arranged in a support pallet with a dosed amount of monomer mixture deposited into each of the front curve molds. An array of deposition tubes, positioned in a support plate and coupled to a vacuum source, is used to pick up and support an array of base curve molds. Each of the deposition tubes is then angularly rotated in to the support plate to a selected angularly indexed position therein. A common angular rotational drive is coupled to each of the deposition tubes in the array to angular index each of the deposition tubes to a precise angular position in the support plate.

Abstract: An apparatus and method for curing a polymerizable monomer or monomer mixture to form a soft contact lens includes a transport device for transporting a plurality of contact lens molds to a precure station in a low oxygen environment, each contact lens mold including a first and second mold half with a polymerizable monomer or monomer mixture therebetween. A clamping member clamps a first contact lens mold half against a second contact lens mold half for a predetermined pressure and time. While the mold halves of the contact lens mold are clamped, the polymerizable monomer or monomer mixture is exposed to a radiant energy source for partially polymerizing the polymerizable monomer or monomer mixture contained in each contact lens mold.

Abstract: Shaped hydrogel articles such as soft contact lenses are prepared by the steps of:(1) molding or casting a polymerization mixture comprising:(a) a monomer mixture comprising a major proportion of one or more hydrophilic monomers such as 2-hydroxyethyl methacrylate, and one or more cross-linking monomers; and(b) an inert, displaceable diluent selected from the group consisting of:(i) ethoxylated alkyl glucoside;(ii) ethoxylated bisphenol A;(iii) polyethylene glycol;(iv) mixture of propoxylated and ethoxylated alkyl glucoside;(v) single phase mixture of ethoxylated or propoxylated alkyl glucoside and C.sub.2-12 dihydric alcohol;(vi) adduct of .epsilon.-caprolactone and C.sub.2-6 alkanediols and triols;(vii) ethoxylated C.sub.3-6 alkanetriol; and(viii) mixtures of one or more of (i) through (vii),under conditions to polymerize said monomer mixture to produce a shaped gel of a copolymer of said monomers and said diluent; and(2) thereafter replacing said diluent with water.

Abstract: A method of double-sided printing, in effect, on opposite or both surfaces of a layer on a multi-layered foil laminate. Moreover, also disclosed is the provision of a novel multi-layered foil laminate having at least one layer, preferably an exterior layer which is constituted of a plastic film material, and which is provided with printing on both surfaces of the layer. In essence, the inventive method of double-sided printing includes initially printing on a first side of an outer layer of a plastic film material, preferably such as polyester, wherein the printing is imparted to the side or surface of the plastic film material facing towards an underlying metallic foil to which it is to be adhered.

Abstract: An apparatus and a method for removing and transporting articles from molds. More specifically, the present invention pertains to such an apparatus and method which is particularly well suited for removing the articles from a molding machine having molds in which they are molded, and thereafter carrying the articles within a very short period of time away from the molds and depositing the articles for further processing in a high speed, automated production system.

Abstract: An interactive control system for controlling the automatic packaging of contact lenses in a contact lens fabrication facility, the interactive control system consisting of a first robot device for periodically transferring individual arrays of a first predetermined amount or discrete contact lens packages each containing a contact lens therein from a first station to an intermediate conveyor where the individual arrays are conveyed to a second station, and a controller for initiating a time stamp for each individual array transferred from the first station and determining elapsed time data for each individual array and for generating position status data indicating a good array or a bad array of defective lenses for each individual array as it is conveyed to the second station, the controller shifting the elapsed time data and position status data for each individual array as it is conveyed on the intermediate conveyor for transfer to the second station.

Abstract: A method of manufacturing complex optical surfaces in soft contact lenses includes a first step of defining the complex optical surfaces with a computer assisted drafting program using a mix of patient determined parameters and selected manufacturing process determined parameters to define a mathematical "meta lens". A machine code data set is then generated to machine a plurality of contact lens mold inserts to define a complex optical surface on each of the inserts. The machining step is conducted with a single point diamond lathe having submicron precision and repeatability. A first and second plurality of intermediate contact lens mold halves are then molded with said contact lens mold inserts to define said complex optical surfaces on said mold halves having micron range transitions between optical surfaces. The complex geometric forms and optical surfaces include bifocal lenses, aspheric lenses, and toric lenses wherein the lenses may include parabolic or elliptical geometry.

Abstract: An automated apparatus for controlling the automatic packaging of contact lenses in a contact lens fabrication facility includes: a first robotic transfer device for periodically transferring a first predetermined amount of individual packages from an inspection station to an intermediate consolidation buffer and depositing the packages on the consolidation buffer; a control device for tracking and identifying each individual contact lens conveyed from the inspection station to the consolidation buffer and including memory and logic circuits for storing the identity of individual packages containing contact lenses that have been previously determined at the inspection station as being out of specification, and, generating a signal to enable the first robotic device to discard any individual package identified as out of specification; and; a second robotic assembly for periodically transferring a second predetermined amount of individual packages from the consolidation buffer to a second processing station, th

Abstract: Male and female members for contact lenses where either member is able to hold the contact lens as it moves from station to station during the hydration process. The female member fits together with the male member forming a chamber. Each of the members contains a line centrally located so that both surfaces of the contact lens are flushed during the hydration process, and drainage takes place radially on the outside of the mated male and female chamber members. These members may be produced on a frame with a plurality of members, usually eight to a frame, to allow ease of processing. Full automation is possible, and complete and positive lens control during and step of the process through the packaging step is achieved.