Johnson & Johnson Vision Products Inc.

Johnson and Johnson Vision Care, Inc.

Olin W Calvin

Ture Kindt-Larsen

Craig William Walker

Darren S Keene

Mark E Schlagel

Michael Francis Widman

Richard W Abrams

Wallace Anthony Martin

John B Enns

Gary S Hall

John C Heaton

Thomas G Davis

Denwood F Ross

David Dolan

Russell J Edwards

Gregory Scott Duncan

Terry L Spaulding

Jeffrey Steven

Jeffrey D Caltrider

Joseph W Ricard

Jeffrey E Steven

Novel methods and apparatus are disclosed for handling carriers for soft contact lenses in a lens manufacturing system. In accordance with a first aspect of the invention, article handling devices are located beneath a pre-cure station and a curing station of the system to move lens carriers within those stations. Pursuant to a second aspect of the invention, in a preferred embodiment multiple sets of assemblies are provided for moving a multitude of lens carriers into, through, and out from the pre-cure station and the curing station. In accordance with a third aspect of the invention, the curing station is provided with an intelligent buffer.

Apparatus and method for handling lens carriers

Novel methods and apparatus are disclosed for handling carriers for soft contact lenses in a lens manufacturing system. In accordance with a first aspect of the invention, article handling devices are located beneath a pre-cure station and a curing station of the system to move lens carriers within those stations. As a result of locating these devices beneath these stations, the desired movement of the carriers can be achieved without increasing the footprint of the station. Pursuant to a second aspect of the invention, a complete set of assemblies is provided for moving a multitude of lens carriers into, through, and out from the pre-cure station and the curing station. This set of assemblies accomplishes this movement in a completely automated, high speed, mass production basis. In accordance with a third aspect of the invention, the curing station is provided with an intelligent buffer. This buffer allows the lens carriers to accumulate in the curing station, and then discharges the carriers from the station in an ordered manner at the appropriate time. This enables the output or throughput of the curing station to be controlled or adjusted to accommodate changing conditions or circumstances occurring in the manufacturing system downstream of the curing station.

This invention provides a method of manufacturing a contact lens comprising the step of: dosing a contact lens mold comprising optical mold surfaces with an oxygen-sensitive reaction mixture, wherein said optical surfaces of said contact lens mold have between from 0.13&times;10 to 2.6&times;10 moles/cm O available to interfere with the reaction of said reaction mixture. This invention further provides a method of manufacturing a contact lens comprising the steps of: dosing a contact lens mold comprising optical mold surfaces with a reaction mixture, and sealing said reaction mixture and said optical mold surfaces away from a gaseous environment, wherein said optical surfaces of said contact lens mold were exposed to said gaseous environment comprising greater than 0.5 percent oxygen just prior to said sealing step.

Process of manufacturing contact lenses with measured exposure to oxygen

A method of casting polymer contact lenses between two mold halves in an ambient (air) environment containing molecular oxygen (O,) in which the mold halves forming the cast geometry are exposed to the environment where the air exposure time, the time between which the injection mold used to form the mold halves is opened until the mold halves are assembled is less than 70 seconds, more preferably 40 seconds or less, and most preferably 24 seconds or less.

Process of manufacturing contact lenses in ambient environment

An automated means for hydrating and packaging a molded hydrophilic contact lens in one of the mold parts used to mold the lens is provided in which a first robotic assembly removes a plurality of contact lens molds from a production line carrier, each of the lens molds having a contact lens adhered therein. The first robotic assembly transports the molds to a first staging area where the lens molds are sandwiched between a lens mold carrier and a top chamber plate to form a first hydration carrier. The hydration carrier is then transported through a plurality of flushing or extraction stations wherein fresh deionized water is introduced into the hydration chambers at each hydration station to flush leachable substances from the hydration chamber. At each flushing station, fresh deionized water is introduced into the hydration chamber to remove previously extracted impurities and the products of hydrolysis. A final robotic dis-assembly device separates the top chamber plate and lens molds in the mold carrier plate, to provide fully hydrated lenses in a concave lens mold ready for transfer to inspection and packaging stations. Following inspection of the lens, the concave lens mold is dosed with saline and used to form part of the package used to distribute the lens.

Automated method and apparatus for single sided hydration of soft

An apparatus and a method for removing a liquid from a container having a bowl and a flange, the bowl holding the liquid and containing a hydrophilic ophthalmic lens, wherein there is provided a nozzle with a central face and a shoulder around the periphery of the face. The shoulder has a sealing means which is sized to fit on the flange of the container, where it forms a sealed volume above the container bowl, this volume including the volume of the bowl itself. The central face has through it at lease one fluid entrance passage and at least one fluid exit passage arranged so that the flow is distributed substantially symmetric about the center axis of the lens. The apparatus includes a lens retainer which resiliently urges the lens into engagement with the bowl so that when the purging fluid is introduced into the sealed volume, there is no migration of the lens. There is connected to the entrance passage a source of purging fluid that has a pressure and flow sufficient to remove substantially all the liquid through the exit passage.

Solution removal nozzle

Described is an apparatus and method for removing a molded ophthalmic lens from between the mold portions in which it is produced. A source of intense electromagnetic radiation, preferably a carbon dioxide (CO.sub.2) laser of about 80 Watts at a wavelength of 10.6 .mu.m, is applied to at least one of the mold portions. The exposure of the mold portion to the laser is between one half and one second. Differential expansion of the heated mold polymer relative to the cooler polymer shifts one surface with respect to the other, and the shear force breaks the polymerized lens/polymer mold adhesion and assists in the separation of mold portions. The greater the temperature gradient between the surfaces of the mold portions, the greater the shearing force and the easier the mold portions separate. The heated back mold portion is promptly removed so that very little energy is transferred to the polymer lens, avoiding the possibility of thermal decomposition of the lens.

Laser assisted demolding of ophthalmic lenses

An apparatus and method for removing a molded ophthalmic lens from between the mold portions in which it is produced. A source of intense electromagnetic radiation, preferably a carbon dioxide (CO.sub.2) laser of about 80 Watts at a wavelength of 10.6 .mu.m, is applied to at least one of the mold portions. The exposure of the mold portion to the laser is between one half and one second. Differential expansion of the heated mold polymer relative to the cooler polymer shifts one surface with respect to the other, and the shear force breaks the polymerized lens polymer mold adhesion and assists in the separation of mold portions. The greater the temperature gradient between the surfaces of the mold portions, the greater the shearing force and the easier the mold portions separate. The heated back mold portion is promptly removed so that very little energy is transferred to the polymer lens, avoiding the possibility of thermal decomposition of the lens.

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Jacksonville, FL, United States of America

Olin W Calvin