Abstract: A method for producing embedded hydrogel contact lenses comprises at least the following steps: depositing a small drop of a viscous lens-forming composition in the center of a female lens mold half; placing a preformed insert on top of the small drop precisely in the center of the female lens mold half so that the insert is held by capillary forces due to the presence of a thin layer of the viscous lens-forming composition between the insert and the molding surface of the female lens mold half; dosing an amount of another less viscous lens-forming composition on top of the insert to immerse the insert in the female lens mold half; closing tightly a male lens mold half onto the top of the female lens mold half halves to form a molding assembly; curing both the lens-forming compositions in the molding assembly to form an embedded hydrogel lens precursor.

Abstract: The invention relates to a method for producing embedded hydrogel contact lenses each having an insert that comprises alignment features capable of capable of aligning the insert in depth and radial position in a female mold half during cast molding of an embedded hydrogel contact lens. The alignment features protrude from the front surface, are rotationally symmetric with respect to the central axis of the insert and independently have a shape having a curvature being greater than 2 folds of the curvature of the molding surface so as to minimize contacting area between the alignment features and the molding surface. The use of such an insert can simplify the process for producing embedded hydrogel contact lenses and enable the process to be implemented readily in an automatic production.

Abstract: Systems, devices, and methods are disclosed for fabricating a hybrid contact lens product having a lens insert embedded at a precisely controlled location within a lens body. A mold engagement and support base engages and retains a lens forming mold in a substantially fixed position. An insert placement and positioning device includes an insert pickup head with a contact face configured for releasable engagement of the lens insert and at least one suction opening in the contact face for applying suction to engage the insert on the contact face. A positioning housing interacts with the mold and/or the support base to provide precise locational positioning of the lens insert within the mold. A lens body forming material is delivered to the mold to encapsulate the lens insert.

Abstract: The invention relates to a method for producing embedded hydrogel contact lenses involving a set of 3-mold halves consisting essentially of: one female lens mold half having a molding surface defining the anterior surface of a contact lens; one male lens mold half having a molding surface defining the posterior surface of the contact lens; and an insert mold half having a molding surface defining one of the front and back surfaces of an insert. One of the lens mold halves is used twice: first with the insert mold half for molding an insert during first curing process and then with the other lens mold half for molding an embedded hydrogel contact lens with the molded insert embedded partially or fully therein during second curing process. The invention also relates to embedded hydrogel contact lenses produced from a method of the invention.

Abstract: The invention is directed to an embedded hydrogel contact lens, which comprises an insert sandwiched between two layers of hydrogel materials and can be produced according to a cast molding method including the procedures involving two females halves (FC1 and FC2) and two male halves (BC1 and BC2) and three consequential molding steps involving three molding assemblies: the 1st one formed between FC1 and BC1 for molding an insert; the 2nd one formed between FC1 and BC2 for molding a lens precursor having the molded insert embedded in a layer of a hydrogel material in a way that the front surface of the molded insert merges with the convex surface of the lens precursor; and the 3rd one formed between FC2 and BC2 for molding an embedded hydrogel contact of the invention.

Abstract: A method of manufacturing of an astigmatic contact lens having a toric portion and a thickness differential feature to provide lens orientation on eye portion such that said thickness differential causes the toric portion of the contact lens to properly orient in the eye of the wearer. The toric lenses are manufactured by an effective process control method for cylinder power in toric lens production by determining an amount of a mold cylinder compensation which is caused by processes in a toric lens manufacturing system including tool making, injection molding, casting and curing, wherein the mold cylinder is defined as the difference in measured radius of curvature at two orthogonal directions. A control metric is established by using the amount of a mold cylinder compensation and tolerance range and reject mold out of the control limits and improve the production yield for toric lens manufacturing.

Abstract: A method of manufacturing of an astigmatic contact lens having a toric portion and a ballast portion such that said ballast portion causes the toric portion of the contact lens to properly orient in the eye of the wearer. The toric lenses are manufactured by an effective process control method for cylinder axis angle in toric lens production by modifying the target cylinder angle for mold rotation by eliminating the accumulative cylinder axis error from all previous steps including tool making, tool assembly, and molding. The amount modifying the target angle is determined by accurately determine the true cylinder axis on the corresponding mold by using a high-resolution interferometer, such as FISBA FS10M or equivalent models from Trioptics ?Shape® vertical series.

Abstract: A method of manufacturing of an astigmatic contact lens having a toric portion and a thickness differential feature to provide lens orientation on eye portion such that said thickness differential causes the toric portion of the contact lens to properly orient in the eye of the wearer. The toric lenses are manufactured by an effective process control method for cylinder power in toric lens production by determining an amount of a mold cylinder compensation which is caused by processes in a toric lens manufacturing system including tool making, injection molding, casting and curing, wherein the mold cylinder is defined as the difference in measured radius of curvature at two orthogonal directions. A control metric is established by using the amount of a mold cylinder compensation and tolerance range and reject mold out of the control limits and improve the production yield for toric lens manufacturing.

Abstract: A method of manufacturing of an astigmatic contact lens having a toric portion and a ballast portion such that said ballast portion causes the toric portion of the contact lens to properly orient in the eye of the wearer. The toric lenses are manufactured by an effective process control method for cylinder axis angle in toric lens production by modifying the target cylinder angle for mold rotation by eliminating the accumulative cylinder axis error from all previous steps including tool making, tool assembly, and molding. The amount modifying the target angle is determined by accurately determine the true cylinder axis on the corresponding mold by using a high-resolution interferometer, such as FISBA FS10M or equivalent models from Trioptics ?Shape® vertical series.

Abstract: The present invention provides methods for lathing at room temperature a silicone hydrogel material, in particular silicone hydrogel material having a high oxygen permeability and made of a polymerizable composition containing a relative large amount of oxyperm component, into contact lenses.

Abstract: The present invention is related to manufacturing surfaces with an axis decentered from the spindle axis. In particular, the present invention is related to compensating for tool geometry in cutting processes that involve an oscillating tool.

Abstract: The present invention is directed to a contact lens design where the optics position relative to the pupil is controlled by the lens relationship to the lower lid.

Abstract: A contact lens having visually perceptible light-reflective particles encapsulated within the lens body. The particles reflect light in an irregular manner, producing a sparkle or glitter effect.