Process and apparatus for the manufacture of a contact lens

• US 5,894,002 A
• Filed: 03/26/1997
• Issued: 04/13/1999
• Est. Priority Date: 12/13/1993
• Status: Expired due to Term

• Current Assignee: Novartis Ag
• Original Assignee: CIBA Vision Corporation (Novartis Ag)
• Inventors: Haase, Lothar, Schafer, Horst, Boneberger, Karlheinz, Steffan, Werner, Zang, Peter
• Primary Examiner(s): Vargot, Mathieu D.
• Application Number:
  US08/824,592
• Time in Patent Office: 748 Days
• Field of Search: 425/174.8 E, 425/174.8 R, 425/808, 425/174.4, 264/1.36, 264/1.7, 264/2.3, 264/2.6, 264/132, 264/2.7, 264/1.38
• US Class Current: 264/1.36
• CPC Class Codes: B29D 11/00057 characterised by the shape or surface condition of the edge, e.g. flashless, burrless, smooth
• CPC Class Codes: B29D 11/00125 Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere
• CPC Class Codes: B29D 11/0048 Moulds for lenses moulds for plastic articles in general B29C33/00
• CPC Class Codes: B29L 2031/757 Moulds, cores, dies
• CPC Class Codes: Y10S 425/808 Lens mold

Abstract

In a process for the manufacture of contact lenses, a polymerizable contact lens material is dispensed into a mould half (1) and the mould is subsequently closed by means of the second mould half (2). The material located between the two mould halves in the moulding cavity (12) is then polymerized, thus forming an as yet unhydrated contact lens (CL). The moulding surface of one of the two mould halves (1, 2) is pre-treated, before use, in a region (20) outside the optically active zone of the contact lens (CL) in such a manner that, when the mould is opened, the contact lens (CL) adheres to the pre-treated mould half.

Claims

1. A process for the manufacture of contact lenses, from a polymerizable contact lens material between two mould halves, comprising the steps of:

a) pre-treating a moulding surface of one of said mould halves, wherein the pre-treating step comprises the steps of;

1) positioning said mould half to be treated between two electrodes, wherein one of said electrodes facing said mould half has an annular face which effectively extends over a region that is to be treated and said region is outside the optical zone of the contact lens to be produced from the pre-treated mould half, and

2) applying a corona discharge such that the pre-treating of said mould half occurs in said region to be treated;

b) dispensing said polymerizable material into one of said mould halves;

c) mating the mould half with the other mould half; and

d) polymerizing said polymerizable material located between the mated two mould halves, thereby forming an as yet unhydrated contact lens,

wherein the corona discharge pre-treating step is performed in such a manner that, when the mated mould is opened, the contact lens adheres to the pre-treated mould half.

2. A process according to claim 1, which comprises pre-treating the male mould half.

3. A process according to claim 1, wherein the unhydrated contact lens adhering to the mould half is tempered in an additional process step while the mould is still closed, the mould is subsequently opened and then the mould half to which the as yet unhydrated contact lens is adhering is passed to a hydration station where the unhydrated contact lens is detached from the mould half and hydrated.

4. A process according to claim 2, wherein the as yet unhydrated contact lens adhering to the male mould half is dyed in the iris region after opening of the mould.

5. A process according to claim 4, wherein a dyeing tampon method is used to dye the as yet unhydrated contact lens.

6. An apparatus for the manufacture of contact lenses, having a mould which comprises two mould halves, the mould halves having a moulding surface each and enclosing in the closed state of the mould a moulding cavity which defines the shape of the contact lens, having a dispensing device for feeding a polymerisable contact lens material into the one mould half, having a light source for exposing the contact lens material enclosed in the moulding cavity after closing the mould to light, whereby the material enclosed in the moulding cavity is polymerised and an as yet unhydrated contact lens is produced, wherein a device for corona discharge pre-treatment is provided which has an electrode with an annular facing and pre-treats the moulding surface of the one mould half in an annular region outside the optical zone of the contact lens in such a manner that, when the mould is opened, the contact lens adheres to the pre-treated mould half without causing adverse effect on the optical zone of the contact lens.

7. An apparatus according to claim 6, wherein the mould half to be treated is the male mould half, and the annular face of the electrode facing the moulding surface is concave.

8. An apparatus according to claim 6, which comprises a tempering oven for the still closed mould with the unhydrated contact lens adhering to the one mould half, and a hydration device for detaching and hydrating the as yet unhydrated contact lens.

9. An apparatus according to claim 7, which further comprises a device for dyeing which dyes the as yet unhydrated contact lens, adhering to the male mould half, in its iris region.

10. An apparatus according to claim 9, wherein the device for dyeing comprises a dyeing tampon which can be pressed onto the iris region of the contact lens in order to dye that region.