Systems and methods for producing contact lenses from a polymerizable composition
First Claim
1. A system for producing silicone hydrogel contact lenses from a polymerizable composition, the system comprising:
- a housing defining a chamber having an inlet portion and an outlet portion, and a length extending from the inlet portion to the outlet portion;
a carrier movable in the chamber between the inlet portion and the outlet portion, the carrier being configured to carry a plurality of contact lens mold assemblies;
a plurality of contact lens mold assemblies containing a polymerizable silicone hydrogel contact lens precursor composition provided on the carrier, each contact lens mold assembly comprises a front surface mold section and a back surface mold section assembled together to provide a concave lens forming surface and a convex lens forming surface;
a first light source located in the housing spaced apart from and generally facing a first side of the carrier for providing light effective to facilitate polymerization of the polymerizable composition in the plurality of contact lens mold assemblies;
a second light source located in the housing spaced apart from and generally facing a substantially opposing second side of the carrier for providing light effective to facilitate polymerization of the polymerizable composition in the plurality of contact lens mold assemblies;
a first optical surface spaced apart from the plurality of contact lens mold assemblies and positioned in the housing to provide a substantially uniform intensity of light from the first light source over the contact lens mold assemblies positioned substantially perpendicular to the length of the chamber;
a second optical surface spaced apart from the plurality of contact lens mold assemblies and positioned in the housing to provide a substantially uniform intensity of light from the second light source over the contact lens mold assemblies positioned substantially perpendicular to the length of the chamber and wherein the first optical surface and the second optical surface each comprises a substantially planar surface extending across contact lens mold assemblies provided on the carrier substantially perpendicular to the length of the chamber and extending across contact lens mold assemblies provided on the carrier substantially parallel to the length of the chamber; and
the carrier being configured to allow each of the plurality of contact lens mold assemblies provided on the carrier to be exposed to light from both the first light source and the second light source.
4 Assignments
0 Petitions
Accused Products
Abstract
Systems and methods of manufacturing ophthalmic lenses, for example, soft, extended wear silicone hydrogel contact lenses, are provided. The systems generally include a housing having an illuminated chamber, a carrier, for example a tray, movable in the illuminated chamber from an inlet portion to an outlet portion of the housing, and the tray configured to carry a plurality of contact lens molds. Polymerizing light energy is provided, for example, by multiple fluorescent lamps, to the molds at an intensity effective to at least initiate polymerization of a monomer composition located in each of the molds. The light may be illuminated onto two opposing sides of each mold. In some cases, the intensity of the light provided to one side of the mold may be different to the light intensity provided to the opposing side of the mold. In addition, the system may include features that are effective to provide for an instantaneous start and an instantaneous end to the light induced cure of the monomer in the molds. The system may include DALI protocol based technology for controlling the fluorescent lamps.
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Citations
21 Claims
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1. A system for producing silicone hydrogel contact lenses from a polymerizable composition, the system comprising:
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a housing defining a chamber having an inlet portion and an outlet portion, and a length extending from the inlet portion to the outlet portion; a carrier movable in the chamber between the inlet portion and the outlet portion, the carrier being configured to carry a plurality of contact lens mold assemblies; a plurality of contact lens mold assemblies containing a polymerizable silicone hydrogel contact lens precursor composition provided on the carrier, each contact lens mold assembly comprises a front surface mold section and a back surface mold section assembled together to provide a concave lens forming surface and a convex lens forming surface; a first light source located in the housing spaced apart from and generally facing a first side of the carrier for providing light effective to facilitate polymerization of the polymerizable composition in the plurality of contact lens mold assemblies; a second light source located in the housing spaced apart from and generally facing a substantially opposing second side of the carrier for providing light effective to facilitate polymerization of the polymerizable composition in the plurality of contact lens mold assemblies; a first optical surface spaced apart from the plurality of contact lens mold assemblies and positioned in the housing to provide a substantially uniform intensity of light from the first light source over the contact lens mold assemblies positioned substantially perpendicular to the length of the chamber; a second optical surface spaced apart from the plurality of contact lens mold assemblies and positioned in the housing to provide a substantially uniform intensity of light from the second light source over the contact lens mold assemblies positioned substantially perpendicular to the length of the chamber and wherein the first optical surface and the second optical surface each comprises a substantially planar surface extending across contact lens mold assemblies provided on the carrier substantially perpendicular to the length of the chamber and extending across contact lens mold assemblies provided on the carrier substantially parallel to the length of the chamber; and the carrier being configured to allow each of the plurality of contact lens mold assemblies provided on the carrier to be exposed to light from both the first light source and the second light source. - View Dependent Claims (2, 3, 4, 5, 6, 13, 15, 16, 17)
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7. A system for producing silicone hydrogel contact lenses from a polymerizable composition, the system comprising:
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a housing defining a chamber having an inlet portion and an outlet portion, and a length extending from the inlet portion to the outlet portion; a carrier received in the housing chamber, the carrier being configured to carry a plurality of contact lens mold assemblies; a plurality of contact lens mold assemblies containing a polymerizable silicone hydrogel contact lens precursor composition provided on the carrier; a light assembly located in the housing and structured to provide light effective to facilitate polymerization of the polymerizable composition in the plurality of contact lens mold assemblies, the light assembly comprising a plurality of elongated light emitting tubes extending substantially perpendicular to the length of the chamber; and an optical surface assembly spaced apart from the plurality of contact lens mold assemblies and comprising at least one substantially planar surface extending across contact lens mold assemblies provided on the carrier substantially perpendicular to the length of the chamber and extending across contact lens mold assemblies provided on the carrier substantially parallel to the length of the chamber, the optical surface assembly being effective to provide a substantially uniform intensity of light from the light assembly over the plurality of contact lens mold assemblies provided on the carrier. - View Dependent Claims (8, 9, 10, 11, 12, 14, 18, 19, 20, 21)
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Specification