Abstract: Ophthalmic lens molds made from one or more thermoplastic polymer having a low level of UV light transmittance (UV % T) ophthalmic lenses including silicone hydrogel contact lenses molded using these thermoplastic polymer having low UV % T, and methods of manufacturing ophthalmic lenses by cast molding a polymerizable composition in mold members formed of these thermoplastic polymers having low UV % T and curing the polymerizable composition using UV light are described.

Abstract: Methods of manufacturing contact lenses using ophthalmic lens molds having a molding surface comprising a thermoplastic polymer, the molding surface having a percent polarity from 3% to 20% and a surface energy from about 25 mN/m to about 40 mN/m to cast mold a polymerizable composition having a surface tension from about 20 mN/m to about 25 mN/m, wherein a surface energy differential of the surface tension of the polymerizable composition less the surface energy of the molding surface less than or equal to zero (0); and silicone hydrogel contact lens bodies so manufactured are described.

Abstract: Ophthalmic lens molds made from one or more thermoplastic polymers with average polarities from about 1% to about 7%, ophthalmic lenses including silicone hydrogel contact lenses molded using these less polar thermoplastic polymers, and related methods are described. When the molds are used to cast mold silicone hydrogel contact lenses, the resulting polymerized lens bodies have ophthalmically acceptably wettable surfaces.

Abstract: Methods and apparatus for separating mold sections, removing a lens product from the separated mold sections, and transferring the lens product to a processing tray are provided and include contacting assembled mold sections with a warm fluid to break fused portions between the mold sections, and using one or more wedge shaped elements to pry apart and separate the mold sections, one from the other. A vacuum head having multiple vacuum ports is employed for lifting the newly molded lens product from a mold section and for releasing the lens from the vacuum head into a processing tray. A cylinder of flowing air directed around the circumference of the lens is effective to maintain the lens in an unfolded position as the lens is being released into the processing tray. A tray set including multiple trays holding multiple lenses is provided and includes features for enabling visual and/or mechanical distinction of the trays and lenses held thereby.

Abstract: Ophthalmic lens molds made from one or more thermoplastic polymer having a low level of UV light transmittance (UV % T) ophthalmic lenses including silicone hydrogel contact lenses molded using these thermoplastic polymer having low UV % T, and methods of manufacturing ophthalmic lenses by cast molding a polymerizable composition in mold members formed of these thermoplastic polymers having low UV % T and curing the polymerizable composition using UV light are described.

Abstract: Ophthalmic lens molds made from one or more thermoplastic polymers with average polarities from about 1% to about 7%, ophthalmic lenses including silicone hydrogel contact lenses molded using these less polar thermoplastic polymers, and related methods are described. When the molds are used to cast mold silicone hydrogel contact lenses, the resulting polymerized lens bodies have ophthalmically acceptably wettable surfaces.

Abstract: Methods of manufacturing contact lenses using ophthalmic lens molds having a molding surface comprising a thermoplastic polymer, the molding surface having a percent polarity from 3% to 20% and a surface energy from about 25 mN/m to about 40 mN/m to cast mold a polymerizable composition having a surface tension from about 20 mN/m to about 25 mN/m, wherein a surface energy differential of the surface tension of the polymerizable composition less the surface energy of the molding surface less than or equal to zero (0); and silicone hydrogel contact lens bodies so manufactured are described.

Abstract: Systems and methods for producing silicone hydrogel contact lenses are described. Certain of the present systems include a contact lens mold forming station, a station for filling a contact lens mold section with a lens precursor composition and for placing a second mold section on the filled mold section to form a contact lens mold assembly, a curing station for forming a contact lens, a mold assembly separation station, and an extraction/hydration station. Certain of the present methods include forming a plurality of mold sections, placing a lens precursor composition on a surface of a first mold section, placing a second mold section on the first mold section, polymerizing the lens precursor composition, separating the first and second mold sections, removing the silicone hydrogel contact lens from one of the mold sections, extracting extractable components from the contact lens, and hydrating the contact lens.

Abstract: Systems and methods for producing silicone hydrogel contact lenses are described. Certain of the present systems include a contact lens mold forming station, a station for filling a contact lens mold section with a lens precursor composition and for placing a second mold section on the filled mold section to form a contact lens mold assembly, a curing station for forming a contact lens, a mold assembly separation station, and an extraction/hydration station. Certain of the present methods include forming a plurality of mold sections, placing a lens precursor composition on a surface of a first mold section, placing a second mold section on the first mold section, polymerizing the lens precursor composition, separating the first and second mold sections, removing the silicone hydrogel contact lens from one of the mold sections, extracting extractable components from the contact lens, and hydrating the contact lens.

Abstract: Systems and methods for producing silicone hydrogel contact lenses are described. Certain of the present systems include a contact lens mold forming station, a station for filling a contact lens mold section with a lens precursor composition and for placing a second mold section on the filled mold section to form a contact lens mold assembly, a curing station for forming a contact lens, a mold assembly separation station, and an extraction/hydration station. Certain of the present methods include forming a plurality of mold sections, placing a lens precursor composition on a surface of a first mold section, placing a second mold section on the first mold section, polymerizing the lens precursor composition, separating the first and second mold sections, removing the silicone hydrogel contact lens from one of the mold sections, extracting extractable components from the contact lens, and hydrating the contact lens.

Abstract: Compositions, such as lens precursor compositions, and methods for producing lens precursor compositions have been invented. The present methods include forming a premix composition, which can include one or more monomeric components, forming a macromer composition, which includes one or more silicon containing macromers, forming a premix/initiator composition, which can include a photoinitiator, and contacting the premix/initiator composition with the macromer composition to form a polymerizable monomer-containing composition useful in the production of producing silicone hydrogel contact lenses.

Abstract: The present contact lens treating systems and methods effectively remove extractable materials from contact lenses, for example, newly formed contact lenses, so that the lenses can be safely and conveniently worn, for example, for extended periods of time. Such treatment methods and the present extraction medium reprocessing methods allow lens treatment while reducing extraction medium losses, thereby reducing costs of these materials and the burden of such treatment on the environment. The present methods can also be useful for manufacturing a heat stabilized contact lens, for example, a water swelled contact lens including a Vitamin E component which is insoluble in the lens in a hydrated state.

Abstract: The present contact lens treating systems and methods effectively remove extractable materials from contact lenses, for example, newly formed contact lenses, so that the lenses can be safely and conveniently worn, for example, for extended periods of time. Such treatment methods and the present extraction medium reprocessing methods allow lens treatment while reducing extraction medium losses, thereby reducing costs of these materials and the burden of such treatment on the environment. The present methods can also be useful for manufacturing a heat stabilized contact lens, for example, a water swelled contact lens including a Vitamin E component which is insoluble in the lens in a hydrated state.