Abstract: A contact lens mold half injection molding machine (60) comprises a plurality of tool cavities (54a, 54b), each tool cavity defining a space into which molten polymer can be injected so as to form a contact lens mold half (2, 4). The machine (60) also comprises an injection unit (103) in communication with the tool cavities (54a, 54b), the injection unit (103) being configured to melt a polymer and inject it into the tool cavities (54a, 54b). Further, the machine (60) comprises a controller (150). The plurality of tool cavities (54a, 54b) comprises a first subset of tool cavities (54a) and a second subset of tool cavities (54b). The machine (60) is configurable to injection mold contact lens mold halves (2, 4), by injecting molten polymer into the tool cavities (54a, 54b) and allowing the polymer to solidify, with one or more process parameters differing in value between the first subset of tool cavities and the second subset of tool cavities.

Abstract: An apparatus (60) for injection molding of mold halves (2, 4) for use in the manufacture of contact lenses comprises one or more first tool halves (22) mounted on a first support (80), and one or more second tool halves (24) releasably mounted on a second support (82). With the second support (82) in an operative orientation, the first and second supports (80, 82) are movable between a closed position in which the first and second tool halves (22, 24) engage one another to provide corresponding mold cavities (54) therebetween, and an open position in which the first and second tool halves (22, 24) are aligned with one another across a part removal gap (86). The second support (82) is movable between the operative orientation, and a reloading orientation in which the second tool halves (24) are located in a tool change area (64) that is out of alignment with the first tool halves (22).

Abstract: A method of removing an ophthalmic lens from a lens mold portion is provided and includes reciprocally displacing a region of the mold portion and thereby causing an edge portion of the ophthalmic lenses to become detached from the mold portion. Related apparatus, methods of manufacturing ophthalmic lenses, delensing stations, and manufacturing times are provided.

Abstract: Apparatus and methods are described for manufacturing contact lenses by forming a contact lens mold half, and removing the mold half. The mold half can then be combined with a complementary mold half and used to cast-mold a contact lens. The apparatus includes first and second plates each carrying tool halves. The plates reciprocate between an open, spaced apart configuration, and a closed configuration in which they hold complementary tool halves in contact with one another. When the plates are opened after forming a mold half, a gripper plate removes the mold half from the first plate or the second plate.

Abstract: A tray (20) for holding contact lens mold assemblies (70) during thermal curing of a contact lens precursor material in an oven (210) to form contact lenses. The tray (20) comprises a plurality of plates (60) and a frame (25) supporting the plates (60). The frame (25) is configured to be stacked vertically with a plurality of identical frames to form a tray stack (10). Each plate (60) is a carbon-fiber reinforced polymer plate and comprises a plurality of support structures (110) each arranged to support one contact lens mold assembly (70) during curing and a plurality of channels (90, 100) connecting the support structures (110), to allow gases to flow between them in the tray stack (10) during curing.

Abstract: Methods and apparatus for exchanging tools and/or tool assemblies used to form different types of molds for in injection-molding machines, are described. The exchange of tools and/or tool assemblies is made using a robot. Contact lens mold halves and assemblies for molding contact lenses of different powers or types can be made with a single injection-molding apparatus.

Abstract: Apparatus and methods for manufacturing ophthalmic lenses by bringing together a pair of mold halves to form a closed mold assembly, are described. The method includes measuring a force applied to bring the mold halves together. The apparatus includes at least one force sensor in operative communication with a single pair of mold halves, and a controller for controlling a velocity of movement of a mold half and for determining when a measured force or average measured force is greater than or equal to a predetermined threshold force.

Abstract: A tray (20) for holding contact lens mold assemblies (70) during thermal curing of a contact lens precursor material in an oven 210 to form contact lenses. The tray (20) comprises a plurality of plates (60) and a frame (25) supporting the plates (60). The frame (25) is configured to be stacked vertically with a plurality of identical frames to form a tray stack (10). Each plate (60) is a carbon-fiber reinforced polymer plate and comprises a plurality of support structures (110) each arranged to support one contact lens mold assembly (70) during curing and a plurality of channels (90, 100) connecting the support structures (110), to allow gases to flow between them in the tray stack (10) during curing.

Abstract: A contact lens mold part and a contact lens mold assembly (1) are provided. The contact lens mold assembly includes a first mold part (2) and a second mold part (3) assembled together. Each mold part has a lens-forming surface with a circumferential edge, a stop surface extending from the circumferential edge, an intermediate region extending from the stop surface, and an alignment surface extending from the intermediate region. The mold parts can be made to fit together with an interference fit. A method of making a contact lens using the contact lens mold assembly is also provided.

Abstract: A method of removing an ophthalmic lens from a lens mold portion is provided and includes reciprocally displacing a region of the mold portion and thereby causing an edge portion of the ophthalmic lenses to become detached from the mold portion. Related apparatus, methods of manufacturing ophthalmic lenses, delensing stations, and manufacturing times are provided.

Abstract: A contact lens mold part and a contact lens mold assembly (1) are provided. The contact lens mold assembly includes a first mold part (2) and a second mold part (3) assembled together. Each mold part has a lens-forming surface with a circumferential edge, a stop surface extending from the circumferential edge, an intermediate region extending from the stop surface, and an alignment surface extending from the intermediate region. The mold parts can be made to fit together with an interference fit. A method of making a contact lens using the contact lens mold assembly is also provided.

Abstract: Methods and apparatus for exchanging tools and/or tool assemblies used to form different types of molds for in injection-molding machines, are described. The exchange of tools and/or tool assemblies is made using a robot. Contact lens mold halves and assemblies for molding contact lenses of different powers or types can be made with a single injection-molding apparatus.

Abstract: Apparatus and methods for manufacturing ophthalmic lenses by bringing together a pair of mold halves to form a closed mold assembly, are described. The method includes measuring a force applied to bring the mold halves together.

Abstract: Methods and apparatus for manufacturing contact lenses, including demolding contact lens mold assemblies, are described. The apparatus can include a curved wedge separator having an increasing thickness circumferentially from a leading end towards a trailing end, and an increasing radial thickness from an outer circumferential edge towards a central axis. The apparatus can also include a driver. The method can include rotating the separator around a concentric central axis and directing the separator to wedge the separator between or against one or more different mold portions of a mold assembly.

Abstract: Apparatus and methods are described for manufacturing contact lenses by forming a contact lens mold half, and removing the mold half. The mold half can then be combined with a complementary mold half and used to cast-mold a contact lens. The apparatus includes first and second plates each carrying tool halves. The plates reciprocate between an open, spaced apart configuration, and a closed configuration in which they hold complementary tool halves in contact with one another. When the plates are opened after forming a mold half, a gripper plate removes the mold half from the first plate or the second plate.