Method for manufacturing a contact lens

• US 20050167864A1
• Filed: 12/13/2004
• Published: 08/04/2005
• Est. Priority Date: 12/01/2000
• Status: Active Grant

• Current Assignee: Christopher Wildsmith, David C. Turner, Robert B. Steffen, Thomas A. Matiacio
• Original Assignee: Christopher Wildsmith, David C. Turner, Robert B. Steffen, Thomas A. Matiacio
• Inventors: Steffen, Robert B., Turner, David C., Wildsmith, Christopher, Matiacio, Thomas A.
• Granted Patent: US 7,422,710 B2
• Time in Patent Office: Days
• US Class Current: 264/1.320
• CPC Class Codes: B29C 33/42 characterised by the shape of the moulding surface, e.g. ribs or grooves
• CPC Class Codes: B29D 11/00134 Curing of the contact lens material
• CPC Class Codes: B29L 2011/0041 Contact lenses
• CPC Class Codes: C08L 43/04 Homopolymers or copolymers of monomers containing silicon
• CPC Class Codes: C08L 51/085 on to polysiloxanes
• CPC Class Codes: G02B 1/043 Contact lenses
• CPC Class Codes: Y10S 425/808 Lens mold
• CPC Class Codes: Y10T 428/21 Circular sheet or circular blank
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31667 Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product

Abstract

The invention provides molds and mold inserts useful in the production of contact lenses. In particular, the invention provides high optical quality molds and inserts useful for manufacturing silicone hydrogel contact lenses.

Claims

1. A mold insert, comprising at least one optically critical surface, wherein periodic structures on the optically critical surface are of a periodicity of less than about 3 μ

m and an amplitude of less than about 4 nm RMS.

2. The mold insert of claim 1, wherein the insert further comprises pure steel, brass, copper, nickel-plated substrates, chromium, cobalt-nickel, alloyed martensitic steel, or combinations thereof.

3. The mold insert of claim 1, wherein the insert further comprises nickel-plated copper or nickel-plated brass.

4. A mold half for use in molding a contact lens, comprising at least one molding surface, wherein periodic structures on the molding surface are of a periodicity of less than about 3 μ

m and an amplitude of less than about 4 nm RMS.

5. The mold half of claim 4, wherein the mold half further comprises polypropylene, polystyrene, and cyclic polyolefins, polyacrylonitrile materials, or combinations thereof.

6-15. -15. (canceled)

16. A method for manufacturing a silicone hydrogel contact lens, comprising the steps of:

a.) providing a mold insert comprising at least one optically critical surface, wherein periodic structures on the optically critical surface are of a periodicity of less than about 3 μ

m and an amplitude of less than about 4 nm RMS;

b.) producing at least one mold half using the mold insert provided in step a.); and

c.) molding the contact lens using the at least one mold half produced in step b.).

17. The method of claim 16, wherein step a.) is carried out by polishing.

18. The method of claim 17, wherein step a.) is carried out by lathing.

20. The method of claim 17 wherein at least one surface of said silicone hydrogel contact lens comprises a hydrophilic coating.

21. The method of claim 20, wherein the hydrophilic coating comprises a polymer selected from the group consisting of poly(acrylic acid), poly(methacrylic acid), poly(dimeth)acrylamide, poly(acrylamide), or poly(hydroxyethylmethacrylate).

22. The method of claim 20 wherein the hydrophilic coating is poly(acrylic acid).

23. The method of claim 20, wherein the hydrophilic coating is poly(acrylamide).

24. The method of claim 20, wherein the hydrophilic coating is poly(hydroxyethylmethacrylate).

19. A method for manufacturing a silicone hydrogel contact lens, comprising the steps of:

a.) producing at least one mold half comprising at least one molding surface, wherein periodic structures on the molding surface are of a periodicity of less than about 3 μ

m and an amplitude of less than about 4 nm RMS; and

b.) molding the contact lens using the at least one mold half.