Methods and apparatus to form biocompatible energization elements are described. In some examples, the methods and apparatus to form the biocompatible energization elements involve forming cavities composing active cathode chemistry. The active elements of the cathode and anode are sealed with a biocompatible material. In some examples, a field of use for the methods and apparatus may include any biocompatible device or product that requires energization elements.

A lens comprises an internal cavity structure formed by dissolution of a soluble insert material. The internal soluble material may dissolve through a body of a lens such as a contact lens in order to form the cavity within the contact lens. The cavity within the lens can be shaped in many ways, and corresponds to the shape of the dissolved material, such that many internal cavity shapes can be readily fabricated within the contact lens. The insert can be placed in a mold with a pre-polymer material, and the pre-polymer material cured with the insert placed in the mold to form the lens body. The polymerized polymer may comprise a low expansion polymer in order to inhibit expansion of the lens when hydrated. The polymer may comprise a hydrogel when hydrated. The soft contact lens material comprises a sufficient amount of cross-linking to provide structure to the lens and shape the cavity.

A method for designing a flat device to be thermoformed into a shape-retaining non-flat device using a mold is provided. The flat device comprises two concentric annular layers: a carrier layer, having an outer radius (R.sub.Cout) and a carrier layer width (W.sub.C); and a support layer having a support layer width (W.sub.S). The support layer is mechanically attached to the carrier layer wherein an inner distance (GAP) is formed between an inner edge of the carrier layer and an inner edge of the support layer. The method comprises obtaining predetermined values for the outer radius of the carrier layer, the support layer width and the inner distance, obtaining a geometry of the mold, and obtaining material properties of the support layer and the carrier layer. The method further comprises performing at least two simulations of thermoforming a simulated flat device into a non-flat device using the mold, based on the obtained predetermined values, material properties, and geometry of the mold for at least two different carrier layer widths. The method further comprises determining a circumferential strain at an outer edge of the support layer in each of the simulated non-flat devices. The method further comprises determining, based on the determined circumferential strains, a linear relation between the circumferential strain and a dimension ratio defined by

[00001]$\mathrm{ratio}=\left(W_C-\left(W_S+\mathrm{GAP}\right)\right)/R_{\mathrm{Cout}}.$

The method further comprises determining (1070), based on the determined linear relation, a value (ratio.sub.MNB) of the dimension ratio for which the strain is zero and determining, from the dimension ratio for which the strain is zero, the width of the carrier layer in the flat device as

[00002]$W_C=\mathrm{ratio}*R_{\mathrm{Cout}}+W_S+\mathrm{GAP}.$

An automated production line for the production of ophthalmic lenses comprises: a production line front end (1) comprising: a first injection-molding machine (10) and a second injection-molding machine (12) a casting module (14) comprising a filling station (144) and a capping station (145); a stacking module (15) and a curing module (16); a destacking module (17) and a demolding and delensing module a production line back end (2) comprising: a scalable treatment module (20) comprising a number of liquid baths for a liquid bath treatment of the cured lenses (CL) carried by the treatment carrier tray (200) to obtain the ophthalmic lenses, wherein the number of liquid baths are reduced or increased pending on the number of ophthalmic lenses concurrently produced by the production lines.

One embodiment of an ocular lens includes a lens body configured to contact an eye where the lens body has an optic zone shaped to direct central light towards a central focal point of a central region of a retina of the eye. At least one optic feature of the lens body has a characteristic that directs peripheral light off axis into the eye away from the central region of the retina. Another embodiment of an ocular lens has at least one isolated feature of the lens body that has a characteristic of directing peripheral light off axis into the eye away from the central region of the retina. Methods of making contact lenses include forming the features during the manufacturing process.

A contact lens constructed to limit the water transmissibility of at least one area of the lens while maintaining at least a minimum oxygen transmissibility. The water transmissibility maximum and oxygen permeability minimum are achieved by a predetermined lens thickness of a single lens material or by the use of two or more material layers.

The invention provides a method for producing embedded contact lenses involving steps of use of a set of 3 mold halves in two-curing steps. One of the 3 mold halves have been used twice, the first time for molding an insert and the second time for molding the embedded hydrogel contact lens. The twice-used mold half has been treated with a corona plasma or a vacuum UV in a central circular area of its molding surface having a diameter equal to or smaller than the diameter of the insert to ensure that the molded insert consistently adhered to the twice-used mold half. The method also comprises a step of forming a reactive polysiloxane coating that is covalently attached onto the back or front surface of a molded insert adhered on the twice-used mold half before molding the embedded contact lens in the 2.sup.nd curing step.

The invention provides a method for producing embedded diffractive contact lenses involving use of a mold set in two-curing steps. The mold set consists of three mold halves, one of which is used twice, the first time for molding a diffractive insert and the second time for an embedded contact lens with the molded diffractive insert embedded therein. The twice-used mold half has been treated with a corona plasma or a vacuum UV in a central circular area having a diameter equal to or smaller than the diameter of the insert to ensure that the molded insert consistently adheres to the twice-used mold half, even though the other mating insert mold half for molding the diffractive insert has a great tendency to bind strongly the molded insert due to the diffractive structure on its molding surface.

The invention provides a method for producing embedded contact lenses involving a mold set in a two-curing-step process and a fast-curing SiHy lens formulation. The mold set consists of three mold halves, one of which is used twice, the first time for molding an insert from an insert-forming composition and the second time for an embedded contact lens with the molded insert embedded therein from the fast curing SiHy lens formulation that comprises a N,N-dialkylacrylamide, a hydrophilic (meth)acrylamido monomer, and a polysiloxane vinylic crosslinker and being free of any siloxane-containing vinylic monomer.

The invention provides a method for producing delamination-resistant embedded contact lenses involving use of a mold set in two-curing steps and a special lens-forming composition for forming a bulk hydrogel material for embedding a crosslinked polymeric insert. The mold set consists of three mold halves, one of which is used twice, the first time for molding an insert from an insert-forming composition and the second time for an embedded contact lens with the molded insert embedded therein from the special lens-forming composition that a vinylic crosslinking agent and or organic solvent both of which independent of each other can swell an insert by a moderate swelling degree. The resultant embedded hydrogel contact lenses can be free of deformation and delamination.