Abstract: The present application discloses a method for three-dimensional deposition printing to manufacture optical elements including ophthalmic devices by controlling the level of oxygen in the polymerization mixture and the printing environment to achieve precision in form and smoothness of surface for image quality optical performance.

Abstract: The present application discloses a method for three-dimensional deposition printing to manufacture optical elements including ophthalmic devices by controlling the level of oxygen in the polymerization mixture and the printing environment to achieve precision in form and smoothness of surface for image quality optical performance.

Abstract: The present application discloses a method for three-dimensional deposition printing to manufacture optical elements including ophthalmic devices by controlling the level of oxygen in the polymerization mixture and the printing environment to achieve precision in form and smoothness of surface for image quality optical performance.

Abstract: A production control system provides real-time monitoring of process parameters in an automated production line that manufactures contact lenses, the line and having a plurality of process stations with each process station having one or more process control devices that control production operations at each respective process station and generates production parameter data therefrom. The system includes a line monitor device for receiving an externally generated production order including a lot number, product type, and quantity, and further coordinates manufacturing processes at each of the plurality of process stations, and tracks order production. A plurality of cell monitor devices retrieves the production data from one or more process control devices and processes the data to ensure that production parameters are within predefined limits.

Abstract: An automated method and apparatus is provided to mold, cure and package soft contact lenses. A conveyor system transports an array of molds through a plurality of automated work stations. The front curve mold halves are partially filled with a polymerizable monomer or monomer mixture and assembled and clamped to displace any excess hydrogel from the mold cavity. The assembly is precured and then transported through a cure station using UV radiation to complete polymerization, The assemblies are then pried apart in an automated station, with any excess monomer adhering to the removed mold half. The newly molded lens is then hydrated and separated from the front curve mold half in a hydration station. Following hydration the array of lens is automatically deposited into a plurality of packages with a robotic transfer device having a plurality of figures which transfer the lenses.

Abstract: This invention provides packaging for housing at least one prescription product comprising customized graphics on at least some surface area of said packaging, said customized graphics being selected by the individual doctor prescribing said prescription product or the patient to receive said prescription product.

Abstract: An apparatus and method for partially curing a polymerizable monomer or monomer mixture to form a soft contact lens includes a transport device for transporting a plurality of contact lens molds to a precure station in a low oxygen environment, each contact lens mold including a first and second mold half with a polymerizable monomer or monomer mixture therebetween. A clamping member having a plurality of mold engagement members clamps a first contact lens mold half against a second contact lens mold half for a predetermined pressure and time. While the mold halves of the contact lens mold are clamped, the polymerizable monomer or monomer mixture is exposed to a radiant energy source for polymerizing the polymerizable monomer or monomer mixture contained in each contact lens mold.

Abstract: This invention discloses an apparatus and method for hydrating or washing ophthalmic devices, comprising the step of directing to an ophthalmic device having a higher concentration of impurities fluid which has previously been directed to ophthalmic device having a lower concentration of impurities.

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: An automated method and apparatus is provided to mold and cure soft contact lenses. A molding station injection molds first and second mold parts for the production of the lenses and these mold parts are transferred to an inert gas or low oxygen environment wherein a series of automated stations receive the mold parts, deposit a polymerizable hydrogel within the first mold part, assemble and clamp the first and second mold parts together, apply radiant energy for polymerizing the hydrogel and subsequently separate the mold parts.

Abstract: An apparatus and method for partially curing a polymerizable monomer or monomer mixture to form a soft contact lens includes a transport device for transporting a plurality of contact lens molds to a precure station in a low oxygen environment, each contact lens mold including a first and second mold half with a polymerizable monomer or monomer mixture therebetween. A clamping member having a plurality of mold engagement members clamps a first contact lens mold half against a second contact lens mold half for a predetermined pressure and time. While the mold halves of the contact lens mold are clamped, the polymerizable monomer or monomer mixture is exposed to a radiant energy source for polymerizing the polymerizable monomer or monomer mixture contained in each contact lens mold.

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: Methods and apparatus which are utilized for the production of ophthalmic lenses, and more particularly, a method for the removal or demolding of molded ophthalmic contact lenses from the individual molds in which they are produced. The apparatus implements the demolding of such ophthalmic lenses, the latter of which may consist of suitable hydrogel contact lenses or other types of high-precision ophthalmic lenses; for example, such as intraocular contact lenses. Mechanical prying apart of such mating mold half portions, and to facilitate this procedure at a reduced application of force, while concurrently potentially preventing or at least appreciably ameliorating the extent of any possible sticking together of the mold half portions is effected in that mechanical leverage applied to the upper mold half portion, in addition to the application of the heating action thereto.

Abstract: An apparatus and method for curing a polymerizable monomer or monomer mixture to form a soft contact lens includes a transport device for transporting a plurality of contact lens molds to a precure station in a low oxygen environment, each contact lens mold including a first and second mold half with a polymerizable monomer or monomer mixture therebetween. A clamping member clamps a first contact lens mold half against a second contact lens mold half for a predetermined pressure and time. While the mold halves of the contact lens mold are clamped, the polymerizable monomer or monomer mixture is exposed to a radiant energy source for partially polymerizing the polymerizable monomer or monomer mixture contained in each contact lens mold.

Abstract: A method of manufacturing complex optical surfaces in soft contact lenses includes a first step of defining the complex optical surfaces with a computer assisted drafting program using a mix of patient determined parameters and selected manufacturing process determined parameters to define a mathematical "meta lens". A machine code data set is then generated to machine a plurality of contact lens mold inserts to define a complex optical surface on each of the inserts. The machining step is conducted with a single point diamond lathe having submicron precision and repeatability. A first and second plurality of intermediate contact lens mold halves are then molded with said contact lens mold inserts to define said complex optical surfaces on said mold halves having micron range transitions between optical surfaces. The complex geometric forms and optical surfaces include bifocal lenses, aspheric lenses, and toric lenses wherein the lenses may include parabolic or elliptical geometry.

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: 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: An automated method and apparatus is provided to mold and cure soft contact lenses. At a first station, front curve mold halves are partially filled with a polymerizable monomer. At a second station, a surfactant coating may be applied to a flange on the front curve mold half to provide subsequent preferential adhesion of any excess hydrogel to a back curve mold half at the time the mold halves are separated. At a third station, the mold halves are assembled under vacuum, and clamped to displace any excess hydrogel from the mold cavity. This clamping step firmly seats the back curve mold half, severs any excess monomer from the monomer in the cavity, defines the lens edge, and seals the cavity in a vacuum. Following assembly of the mold halves, the assembly is transported to a precure station and reclamped, and the monomer is precured with actinic radiation, such as UV, to partially cure the monomer to a gel like consistency.

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 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.