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 process for providing degassed complementary concave and convex lens molds to filling and mold assembly stations in a continuous or semicontinuous automated soft contact lens manufacturing system. The process includes injection molding the lens molds, immediately transferring the lens molds to an inert gas atmosphere, degassing the lens molds, and filling the lens molds with a polymerizable monomer under the inert gas prior to mold assembly.

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: The present invention, which relates to the transfer of contact lenses in post hydration processing of the lenses. A lens transfer and insertion assembly removes contact lenses from lens hydration pallets, alters their spatial distribution, and deposits them into packaging elements. The lenses are transferred with fluid and retained on the transfer assembly by surface tension.

Abstract: A packaging arrangement for the containment of at least one hydrophilic contact lens in a sterile aqueous solution. More specifically, pursuant to the packaging arrangement, a plurality of disposable hydrophilic contact lenses are contained in a specific number of individual packaging arrangements collectively housed in a box-like container or carton so as to provide a specified or essentially measured supply of contact lenses for use by a consumer over a predetermined period of time.

Abstract: An apparatus for separating individual contact lens mold assemblies that each contain a contact lens mold between a front curve mold half and a back curve mold half, each of the mold halves having annular circumferential flanges, is disclosed. The apparatus comprises a first device for applying steam at a first temperature to the back curve mold half to form a temperature gradient ranging from about 2.5.degree. C. to 6.0.degree. C. between the back curve mold half relative to the front curve mold half, and, a second device including a set of pry tools that are inserted between the circumferential flanges of the front mold and back mold halves of the contact lens mold assembly, the pry tools including a first set of pry fingers for retaining the front curve mold half and a second set of pry fingers for biasing the back curve mold half upwardly at a predetermined force with respect to the front curve mold half to effectively remove the back mold half therefrom.

Abstract: The present invention is directed to a composition comprising polystyrene with at least 0.1% (w/w) of an additive, the article of manufacture thereof, such as a mold for making contact lenses and the mold assembly containing said mold, and the use of such mold so to facilitate demolding from a two mold assembly in the process of making contact lenses.

Abstract: An automated method for high speed production rates in the hydration of soft contact lenses. The method includes the use of robotic transfer equipment to transfer contact lens molds containing contact lenses to and from a hydration station and a flushing station.

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 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 for forming contact lenses, wherein front curve mold halves are filled with a hardenable transparent material, such as a polymerizable hydrogel, and back curve mold halves are coupled to the front curve, therein forming a lens. More particularly, the apparatus includes a conveyor for transporting pallets of mold halves to the apparatus, an array of piston structures for raising and aligning the back curves with respect to the filled front curve halves, a mechanism for reciprocating the piston array to couple pairs of front and back curves, and a vacuum chamber for maintaining a vacuum around the curves during coupling. In addition, there is provided individual spring biasing to each reciprocating element whereby sensitivity to thickness variations and pallet misfeeds may be minimized. Further, there is provided a vacuum sleeve, through which the pistons reciprocate within the vacuum chamber, which sleeve preserves the vacuum within the chamber.

Abstract: An apparatus for filling and assembling mold parts for a contact lens includes a first automated station for receiving a plurality of front curve contact lens mold parts and depositing in each front curve mold a predetermined amount of a polymerizable monomer or monomer mixture, and, a second automated station for receiving the plurality of front curve mold parts and assembling each front curve mold part with a back curve mold part under vacuum to prevent entrapment of gas between the mold parts. The front curve mold parts are transported to the first and to the second automated stations by a pallet having registration guides that cooperate with the second station to register the pallet prior to assembly of the mold parts.

Abstract: The present invention, which relates to post hydration processing of contact lenses and the packages into which the lenses are placed, includes several assemblies which are ideally suited to performing the various steps which are associated with post hydration processing.

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 multipart 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 cover-forming laminated structure interconnecting a plurality of containers, such as the base members of blister packages each of which is adapted to contain a hydrophilic contact lens in a sterile aqueous solution. More specifically, disclosed is an array of such containers which are interconnected by a single laminated multi-layered material constituting a covering label for the containers, wherein the material may be severed intermediate each of the containers along weakening lines formed by micro-perforations provided therein so as to provide a separate packaging arrangement. The material is imprinted over the surface extent thereof covering the plurality of containers with a specific pattern of indicia and legends configured with the intent of thwarting diverters upon separation of any of the packaging arrangements from the array, through visual evidence afforded by an inspection of the printing pattern.

Abstract: Articles for the controlled delivery of an active substance into an aqueous phase by erosion of surfaces of the articles at a substantially constant and pH-independent rate, the articles comprising a matrix of crystalline polyethylene glycol polymer and a non-ionic emulsifier having an HLB value in the range of from about 4 to about 16 dispersed in the matrix in an amount of between about 2% and 50% by weight of the crystalline polyethylene glycol polymer and the emulsifier, the emulsifier having at least one domain which enables the emulsifier to become emulsified in the melted crystalline polyethylene glycol polymer and being selected from the group consisting of a fatty acid ester and a fatty alcohol ether, the active substance being dispersed in the matrix or located in geometrically well-defined zones within the crystalline PEG phase or dispersed in the emulsifier and, optionally, a filler.

Abstract: A method and apparatus for molding contact lenses by curing polymerizable compositions in suitably dimensioned molds using ultraviolet or other polymerization-inducing radiation and heat. The molds are moved along a source of radiation such that the intensity of the radiation to which the composition is exposed rises and falls several times, thereby achieving superior results by balancing the initiation and the propagation of the polymerization.

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: 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.