Johnson & Johnson Vision Products Inc.

Johnson and Johnson Vision Care, Inc.

Svend Christensen

Daniel Tsu-Fang Wang

Ture Kindt-Larsen

Kaj Bjerre

Wallace Anthony Martin

Craig William Walker

Michael Francis Widman

Finn Thrige Andersen

Jonathan Patrick Adams

Darren S Keene

Timothy P Newton

Richard W Abrams

Russell J Edwards

John Mark Lepper

Borge Peter Gundersen

Mary L Dolan

Victor Lust

Stephen Robert Beaton

Kiyoshi Imai

David Dolan

Allan G Jensen

Katsuaki Yoshida

Thomas Christian Ravn

Mark E Schlagel

Stephen C Pegram

Junichi Fukuchi

David Clarence Byram

Gary Hall

Thomas C Ravin

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.

Consolidated contact lens molding

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.

Mold clamping and precure of a polymerizable hydrogel

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.

Contact lens production line pallet system

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.

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.

An automated apparatus for controlling the automatic packaging of contact lenses in a contact lens fabrication facility includes: a first robotic transfer device for periodically transferring a first predetermined amount of individual packages from an inspection station to an intermediate consolidation buffer and depositing the packages on the consolidation buffer; a control device for tracking and identifying each individual contact lens conveyed from the inspection station to the consolidation buffer and including memory and logic circuits for storing the identity of individual packages containing contact lenses that have been previously determined at the inspection station as being out of specification, and, generating a signal to enable the first robotic device to discard any individual package identified as out of specification; and; a second robotic assembly for periodically transferring a second predetermined amount of individual packages from the consolidation buffer to a second processing station, the control device enabling the first robotic device to provide a sufficient amount of individual packages to the consolidation buffer to enable the second robotic assembly to continuously transfer the second predetermined amount of packages to the second processing station in every period.

Automated apparatus and method for consolidating products and packaging

An automated means for hydrating a molded hydrophilic contact 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. A first rotary transfer device then hands the first hydration carrier to a second robotic assembly which immerses the first hydration carrier in a hydration bath to hydrate the lens and to release the lens from the lens mold. While the lens is immersed in the hydration bath, each lens is transferred from its respective mold to a lens transfer means found within the top chamber plate. After a predetermined period of time, the second robotic assembly removes the first hydration carrier from the hydration bath and hands the hydration carrier off to a second rotary transfer device which rotates the first hydration carrier and aligns it for transfer to a third robotic assembly. The third robotic assembly then carries the top chamber plate and contact lenses through a series of steps in which the lens mold carrier and lens molds are removed from the top chamber plate. The lenses carried on the lens transfer means are then flushed and transported for assembly with a hydration base member to form a second hydration carrier for processing the lens in subsequent extraction stations. The second 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 transfer means from the hydration base member, to provide fully hydrated lenses in a concave lens holding means ready for transfer to inspection and packaging stations.

Automated method and apparatus for hydrating soft contact lenses

An automated apparatus for controlling the automatic packaging of contact lenses in a contact lens fabrication facility includes: a first robotic transfer device for periodically transferring a first predetermined amount of individual packages from an inspection station to an intermediate consolidation buffer and depositing the packages on the consolidation buffer; a control device for tracking and identifying each individual contact lens conveyed from the inspection station to the consolidation buffer and including memory and logic circuits for storing the identity of individual packages containing contact lenses that have been previously determined at the inspection station as being out of specification, and, generating a signal to enable the first robotic device to discard any individual package identified as out of specification; and, a second robotic assembly for periodically transferring a second predetermined amount of individual packages from the consolidation buffer to a second processing station, the control device enabling the first robotic device to provide a sufficient amount of individual packages to the consolidation buffer to enable the second robotic assembly to continuously transfer the second predetermined amount of packages to the second processing station in every period.

Automated apparatus and method for consolidating products for packaging

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. The pallets of lens assemblies are transported through an extended cure station using heat and UV radiation to complete polymerization. The lens mold assemblies are then separated by applying a temperature gradient to the back curve mold half through the use of lasers or high energy steam and then pried apart in an automated station, with any excess monomer adhering to the removed back curve mold half. The front curve mold half, and the newly molded lens is then hydrated and separated from the front curve mold half in a subsequent apparatus.

Automated apparatus for hydrating soft contact lenses

An automated apparatus for controlling the automatic packaging of contact lenses in a contact lens fabrication facility includes: a first robotic transfer device for periodically transferring a first predetermined amount of individual packages from an inspection station to an intermediate consolidation buffer and depositing the packages on the consolidation buffer; a control device for tracking and identifying each individual contact lens conveyed from the inspection station to the consolidation buffer and including memory and logic circuits for staring the identity of individual packages containing contact lenses that have been previously determined at the inspection station as being out of specification, and, generating a signal to enable the first robotic device to discard any individual package identified as out of specification; and, a second robotic assembly for periodically transferring a second predetermined amount of individual packages from the consolidation buffer to a second processing station, the control device enabling the first robotic device to provide a sufficient amount of individual packages to the consolidation buffer to enable the second robotic assembly to continuously transfer the second predetermined amount of packages to the second processing station in every period.

An automated method for high speed production rates in the hydration of soft contact lenses. The method includes the use of robotic transfer equipment to transfer contact lens molds containing contact lenses to and from a hydration station and a flushing station.

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Allinge, Denmark

Svend Christensen