A machine for disassembling a lens mold assembly including a first mold part, a second mold part, and a molded-lens sandwiched therebetween. The machine includes a centering unit to center the lens mold assembly. The machine includes a disassembling module having a mold engagement mechanism to engage the first and second mold parts to clamp and move the lens mold assembly. The disassembling module includes a molded-lens holder mechanism having at least two clamping members to clamp the molded-lens of the lens mold assembly. The machine includes an alignment guidance module to detect relative positions between the molded lens of the lens mold assembly and the molded-lens holder mechanism to align the molded lens for clamping by the molded-lens holder mechanism. The mold engagement mechanism is configured to hold the first and second mold parts individually and to separate the first and second mold parts from the molded lens.

The invention is generally related to a method for producing, in a relatively efficient and consistent manner, embedded or hybrid silicone hydrogel contact lenses, and also to unprocessed embedded or hybrid silicone hydrogel contact lenses, according to conventional cast-molding technologies. A method of the invention involve use of a polymeric non-reactive diluent in preparing a polymerizable composition for forming the silicone hydrogel material of the unprocessed embedded or hybrid silicone hydrogel contact lens, which is cast-molded with a lens mold. The unprocessed cast-molded embedded or hybrid silicone hydrogel contact lens has no or a minimal water-swelling degree, so that lens distortion or delamination during the hydration of the unprocessed embedded or hybrid silicone hydrogel contact lens.

The invention provides a method for producing photochromic silicone hydrogel (SiHy) contact lenses based on thermal cast-molding technology in a relatively efficient and consistent manner. The method is characterized by selecting a high radical-reactive hydrophilic acrylic monomer while eliminating any low radical-reactive hydrophilic N-vinyl amide monomer in a lens formulation (polymerizable composition), by selecting a weight ratio of low-radical-reactive hydrophilic N-vinyl amide monomer to a high radical-reactive hydrophilic acrylic monomer in a lens formulation if the low radical-reactive hydrophilic N-vinyl amide monomer is needed, and/or by using a relatively high temperature thermal initiator in a lens formulation, to control the lens properties (e.g., water content, elastic modulus, etc.) and lens processability (capability of dry-delensing from molds) of thermally cast-molded SiHy contact lenses while minimizing loss in photochromic ability of resultant SiHy contact lenses.

A machine for disassembling a lens mold assembly including a first mold part, a second mold part, and a molded-lens sandwiched therebetween. The machine includes a centering unit to center the lens mold assembly. The machine includes a disassembling module having a mold engagement mechanism to engage the first and second mold parts to clamp and move the lens mold assembly. The disassembling module includes a molded-lens holder mechanism having at least two clamping members to clamp the molded-lens of the lens mold assembly. The machine includes an alignment guidance module to detect relative positions between the molded lens of the lens mold assembly and the molded-lens holder mechanism to align the molded lens for clamping by the molded-lens holder mechanism. The mold engagement mechanism is configured to hold the first and second mold parts individually and to separate the first and second mold parts from the molded lens.

Disclosed in this specification is a casting cup assembly comprising frontcurve and basecurve molds which of which includes a ring that circumscribes the respective concave and convex mold surface. When the casting cup is assembled, the rings align and minimize de-centering and tilting of the concave and convex mold surfaces which, in turn, reduces edge defects.

A contact lens manufacturing method for removing a contact lens from a pair of molds, the contact lens being produced by polymerizing a monomer included in the pair of molds which are obtained by assembling a lower mold for forming a front curve of the contact lens and an upper mold for forming a base curve of the contact lens, the method including: (A) a first peeling step to peel the contact lens from the lens formation surface of the upper mold; (B) a separation step to separate the contact lens from the lens formation surface of the upper mold; (C) a second peeling step to peel the contact lens whose periphery sticks to the lens formation surface of the lower mold; and (D) a third peeling step to peel the contact lens, whose periphery has been peeled, from the lens formation surface of the lower mold.

Disclosed in this specification is a casting cup assembly comprising frontcurve and basecurve molds which of which includes a ring that circumscribes the respective concave and convex mold surface. When the casting cup is assembled, the rings align and minimize de-centering and tilting of the concave and convex mold surfaces which, in turn, reduces edge defects.

In the method and the apparatus for releasing a molded article from a mold according to the embodiments, the lateral of the molded article in the mold is pressed, so that it is possible to minimize the damage of the mold and the molded article at the time of the release, while the amount of a mold release agent used is minimized.

In manufacturing a contact lens, a contact lens mould arrangement in which the engagement between the mould halves is unconstrained and at least one mould half is sufficiently pliable or flexible that during the curing of the contact lens composition at one mold half may move or flex relative to the other to define a post-cure mould cavity of smaller volume than the precure mould cavity and during which the curvatures of the first and/or second mould surfaces are allowed to change provides a significantly more efficient manufacturing process and enables one mould half to be readily utilized as a blister cup for contact lens packaging.

In manufacturing a contact lens, a contact lens mould arrangement in which the engagement between the mould halves is unconstrained and at least one mould half is sufficiently pliable or flexible that during the curing of the contact lens composition at one mold half may move or flex relative to the other to define a post-cure mould cavity of smaller volume than the pre-cure mould cavity and during which the curvatures of the first and/or second mould surfaces are allowed to change provides a significantly more efficient manufacturing process and enables one mould half to be readily utilized as a blister cup for contact lens packaging.