The present invention general related to a method and a reusable mold for making a contact lens, comprising a first mold half having a first mold surface in contact with a hydrogel contact lens forming composition and a second mold half having a second mold surface in contact with the lens forming composition, wherein the first mold half and the second mold half are configured to receive each other such that a cavity is formed between the first mold surface and the second mold surface, wherein the cavity defines the shape of a contact lens to be molded, wherein the lens forming composition is polymerizable and/or crosslinkable by an actinic radiation, wherein at least one of the mold halves having an absorbing antireflective coating, wherein the reusable mold is a non-plastic mold.

The invention provides a method of making ophthalmic lenses with an enhanced quality and enhanced yield achieved by using molds having been treated on back surface of mold with corona discharge technique. The method comprises the steps of obtaining a mold for cast-molding contact lenses from a lens formulation, wherein the mold comprises a first mold half having a first molding surface and a first back surface, a second mold half having a second molding surface and a second back surface, wherein when the first and second mold are configured to receive each other such that a lens forming cavity is formed between the first molding surface and the second molding surface and applying a corona discharge on one of the first and second back surfaces so that the molding surface of the mold with the treated back surface has an average water contact angle smaller than the molding surface of the mold with untreated mold by about 0.1 degrees to about 6 degrees.

A method for thermally bonding together a cover film (3) of an ophthalmic lens package (1) and a base part (2) of the ophthalmic lens package (1), such as a contact lens package, in particular a soft contact lens package, including the steps of providing a package holder (9) supporting a base part (2) and a cover film (3) arranged thereon, the base part (2) comprising a depression (4) containing an ophthalmic lens (5) immersed in a liquid (6); mechanically pressing the cover film (3) and the base part (2) together along a bonding area (7) having a shape completely enclosing the depression (4) while applying heat to the bonding area (7), thereby thermally bonding together the cover film (3) and the base part (2) along the bonding area (7);
wherein the step of providing the package holder (9) includes arranging a flexible support element (18) on an upper surface (10) of the package holder (9) to form a support area (19) corresponding in shape to and being arranged in alignment with the bonding area (7), with the flexible support element (18) having a flexibility higher than the flexibility of the base part (2).

Ophthalmic lens molds made from at least one vinyl alcohol copolymers with high amorphous content, ophthalmic lenses including silicone hydrogel contact lenses formed using these molds, packaged ophthalmic lenses present in a solution comprising the at least one vinyl alcohol copolymer with high amorphous content, and related methods are described. The methods of manufacturing ophthalmic lenses can use wet demolding, delensing or demolding and delensing processes involving dissolving the molds in water or an aqueous solution.

Ophthalmic device molds made from at least one highly amorphous vinyl alcohol polymer, ophthalmic devices such as ocular inserts and contact lenses and including silicone hydrogel devices formed using these molds, and related methods are described. The methods of manufacturing ophthalmic devices can use dry or wet demolding processes, or dry or wet delensing processes.

A method for making a colorant film providing eye care includes following steps of providing a plurality of microcapsules containing hydrogen peroxide aqueous solution; mixing a hydrophilic monomer, a cross-linking agent, and an initiator to form a mixture; mixing the microcapsules, the mixture, a pigment, and a solvent to form a colorant material; printing the colorant material into a mold; and heating or irradiating the colorant material in the mold to copolymerize the hydrophilic monomer, the initiator, and the cross-linking agent. A colorant film, and the manufacture of an ophthalmic lens are also provided.

Ophthalmic device molds made from at least one vinyl alcohol copolymer and having a static sessile drop contact angle of less than 70 degrees, ophthalmic devices such as ocular inserts and contact lenses and including silicone hydrogel devices formed using these molds, and related methods are described. The methods of manufacturing ophthalmic devices can use dry or wet demolding processes, or dry or wet delensing processes.

A method for making a silicone hydrogel contact lens is provided. In one embodiment, a prepolymer mixture is polymerized in a lens mold in an atmosphere having less than about 10000 ppm oxygen to form a silicone hydrogel contact lens suitable for extended wear as characterized by producing less than 10% corneal swelling after a period of continuous wear of 7 days including normal sleep periods. In one embodiment, the prepolymer mixture comprises at least one oxyperm material containing hydrophilic groups, wherein the at least one oxyperm material is a siloxane-containing macromer or monomer, at least one ionperm material, and a cross-linking agent. In certain embodiments, the polymerization of the prepolymer mixture may be carried out in an atmosphere having less than about 1000 ppm oxygen.

An apparatus for spin casting lenses includes a rotatable tube, the rotatable tube defining a longitudinal cavity, wherein the longitudinal cavity is configured to receive molds. According to one exemplary embodiment, the rotatable tube is made of metal and includes a plurality of apertures configured to permit the transmission of actinic radiation.

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.