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: A packaging arrangement for packaging products such as contact lenses in packages such as blister packs. The packaging arrangement includes an intermittently indexed, linearly driven endless conveyor which includes a plurality of identical support pallets, equally spaced apart along the endless conveyor. Each support pallet is designed to support and align an array of individual package bases. The arrangement is such that each support pallet with an array of individual package bases thereon is sequentially stopped at a plurality of spaced work stations along the endless conveyor.

Abstract: The present invention is directed to a composition of polystyrene or polypropylene with at least 0.5% (w/w)of an additive or wetting agent, the article of manufacture comprised thereof, such as a mold for making contact lenses and the mold assembly containing said mold, and the use of such mold so to minimize defects, such as holes, puddles, chips and tears in the lens.

Abstract: Improved homogeneity and uniformity of surface energy characteristics in a mold surface for hydrophilic contact lens production is achieved with the temporal application of a surface active agent such as Tween 80, to facilitate wetting of the optical surface of the mold, especially the convex mold, with the reactive monomer mix.

Abstract: An apparatus for separating individual contact lens mold assemblies, the assemblies each being a front curve mold half and a back curve mold half, each mold half having annular circumferential flanges, is included. The apparatus includes a device for applying steam to the back curve mold half to form a temperature gradient from the front mold half to the back mold half. The apparatus also includes a second device to pry the mold halves apart.

Abstract: Concentric lens designs are disclosed for astigmatic presbyopes which comprise at least one surface which has a circular central portion and a plurality of concentric annular rings with at least three separate optical powers corresponding to a prescription for a patient and corresponding to 1) a basic distance spherical prescription Rx, 2) a near add spherical prescription Rx, and 3) a spherical prescription corresponding to the full, or preferably a fraction of the, cylindrical prescription Rx. An astigmatic presbyopic prescription contains an astigmatic correction, normally in the nature of a cylindrical prescription which specifies both the cylindrical optical power and the orientation of the cylindrical axis. The cylindrical prescription is taken into account in the design of the lens, but not with a cylindrical optical surface.

Abstract: A production line tracking and quality control system and method thereof comprises a series of pallets for carrying one or more first contact lens mold halves or one or more complementary second contact lens mold halves throughout a contact lens fabrication facility. Each pallet of the series is transported on a conveyor device throughout the fabrication facility, and each pallet includes a unique identifying code. The fabrication facility includes one or more process stations and a control device provides real time monitoring of contact lens fabrication processes at the one or more process stations. The control device further includes a tracking device for identifying the unique code of each of the pallets at one or more process stations while continually receiving monitored process condition values at each station.

Abstract: An automated means for hydrating a molded hydrophilic contact lens is provided in which a first robotic assembly removes a plurality of contact lens molds from a production line carrier, each of the lens molds having a contact lens adhered therein. The first robotic assembly transports the molds to a first staging area where the lens molds are sandwiched between a lens mold carrier and a top chamber plate to form a first hydration carrier. A first rotary transfer device then hands the first hydration carrier to a second robotic assembly which immerses the first hydration carrier in a hydration bath to hydrate the lens and to release the lens from the lens mold. While the lens is immersed in the hydration bath, each lens is transferred from its respective mold to a lens transfer means found within the top chamber plate.

Abstract: A method of and apparatus for employing a surfactant which is provided in order to assist in the release from each other of mold components of a multi-part mold employed in the molding of polymeric articles; for instance, such as a hydrophilic contact lens, upon completion of the molding process for the polymeric articles. The surfactant is applied in the form of a film or coating on surface portions of one of the mold components in order to facilitate the disengagement between the mold components during demolding, and the removal of excess polymeric molding material adhesively deposited on surfaces thereon.

Abstract: A design family of contact lenses includes a central area utilized for distance vision, surrounded by multiple alternating annuli of near and distance optical powers, surrounded by a peripheral distance zone. The design can also be used in intraocular lenses (IOL). The distance optical power is constant across the design family of lenses, but the near optical power increases as a subject's presbyopia increases. The design family of contact lenses can be fitted to a patient in a standard fashion by fitting both eyes to the best distance visual acuity (VA), and obtaining near acuity from the near annuli. A modified monovision method fits the patient's dominant eye with a contact lens as described having the full prescription distance power and fitting the nondominant eye with a contact lens as described having a distance optical power between the full prescription distance optical power and the near optical power.

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: A method of continuously and automatically inspecting ophthalmic lenses. The lenses are continuously moved along a predetermined path to move each of the lenses, one at a time, into a lens inspection position. Each time one of the lenses moves into the lens inspection position, a light source is activated to generate a one light pulse, that light pulse is directed through the one lens and onto an array of pixels and a set of signals is generated representing the intensity of light incident on the pixel array. The set of signals is processed according to a predetermined program to determine at least one condition of the lens, and an output signal is generated representing that one condition.

Abstract: A base member for a blister package for the containment of a contact lens includes a planar flange extending outwardly about a cavity for housing the contact lens. Proximate the peripheral edge of the flange, there is formed a continuous groove into which there is pressed the material of a flexible cover sheet of the blister package so as to clampingly engage the base member.

Abstract: Demolding apparatus for reliably and repeatedly mechanically separating contact lens mold assemblies without damaging the contact lens formed therebetween. The mold assembly includes a frontcurve mold having a central mold section with a surrounding flange, and a corresponding backcurve mold also having a central mold section with a surrounding flange, with a contact lens being molded therebetween. The demolding apparatus includes a conductive heating probe which contacts the backcurve mold of the lens mold assembly to conductively heat the backcurve mold. Heat is conducted by the backcurve mold to cause a temperature gradient between the backcurve mold and the lens being demolded. The temperature gradient causes a differential expansion and shifting of the surface of the backcurve mold relative to the surface of the lens to lessen the adhesion therebetween to assist in separation of the molds, while leaving the lens in the frontcurve mold.

Abstract: An apparatus is provided for removing and transporting articles, such as contact lens sections from a manufacturing line to inspection and packaging stations. The lenses are deposited in a transparent plastic primary package which carries the lenses through the inspection station and becomes part of the primary package when a cover is sealed thereto. The invention includes various assemblies, including lens transfer assemblies, deionized water filling and removal assemblies, a water degassing assembly, a lens inspection assembly, and a lens package sealing assembly. The lenses are removed from pallets at a post hydration station, transported and spatially redistributed, and deposited in the primary packages disposed on a second set of pallets. The packages on the second set of pallets are filled with degassed deionized water. The contact lenses and packages are then transported to an inspection station.

Abstract: An apparatus and method for removing a molded ophthalmic lens from between the mold portions in which it is produced. A source of intense electromagnetic radiation is applied to at least one of the mold portions in a predetermined scanning pattern through the intermediary of galvanometer-driven mirrors. Differential expansion of the heated mold polymer relative to the cooler polymer shifts one surface with respect to the other, and the shear force breaks the polymerized lens/polymer mold adhesion and assists in the separation of mold portions. The greater the temperature gradient between the surfaces of the mold portions, the greater the shearing force and the easier the mold portions separate. The heated back mold portion is promptly removed so that very little energy is transferred to the polymer lens, avoiding the possibility of thermal decomposition of the lens.

Abstract: A system for providing diffuse illumination in the inspection of ophthalmic lenses for use in conjunction with a computer-based lens inspection apparatus. Below a package containing an ophthalmic lens in deionized water is an optical diffuser made of flashed opal and below that a light source such as a strobe light. The strobe lamp firing is initiated by the image processing system which is in turn triggered by a signal generated by the arrival of a package containing a lens to be inspected. In the preferrerd embodiment, an arc tube is employed wherein light output diminishes by darkening only in one end of the tube, that end placed outside the reflector.

Abstract: A system for inspecting ophthalmic lenses and including transport, illumination, imaging and image processing subsystems. The transport system moves a multitude of ophthalmic lenses along a predetermined path to move each of those lenses, one at a time, into a lens inspection position, and the illumination subsystem generates a series of light pulses and directs a respective one light pulse through each ophthalmic lens. The imaging subsystem generates a set of signals representing selected portions of the light pulses transmitted through the ophthalmic lenses, and the image processing subsystem receives those signals from the imaging subsystem and processes those signals according to a predetermined program to identify at least one condition of each of the lenses.

Abstract: Combined multifocal toric lens designs are disclosed which combine a correction for astigmatism, either corneal or lenticular, with a correction for presbyopia. One of the front and back surfaces of the lens defines a toric surface for an astigmatic optical correction, and one of the front and back surfaces, which can be the same surface or the opposite surface, defines a multifocal surface for a presbyopic optical correction, to provide visual acuity for astigmatic presbyopes. Embodiments are disclosed wherein one surface of the lens design has a combined concentric annular ring, multifocal toric surface, and the other surface of the lens design has a spherical or aspherical surface.