Windowing type contact lens

Abstract

An apparatus, system, process, and method for manufacturing windowed contact lenses and contact lenses produced thereby are disclosed. A first mold with a convex first boss and a second mold with a convex second boss are joined with a lens molding material contained in a mold cavity between the first mold and the second mold. The first boss and the second boss abut against each other in a mold cavity between the first mold and the second mold to form a window through the lens when the lens material is cured. The abutment between the first boss and the second boss may be located at an intermediate location in the mold cavity between the first mold and the second mold such that any surface irregularities are located within the interior of the lens rather than on the exterior surface of the lens.

Description

[0001] The present invention relates generally to the field of contact lenses, and more particularly to apparatuses, systems, processes, and methods for creating a fenestration within a contact lens and fenestrated contact lenses formed thereby. BACKGROUND

[0002] Contact lenses having a fenestration or opening formed through the lens between the base curve side or back side and the front curve side or front side of the lens allow for fluid transport through the lens and between the two sides of the lens. Fluid transport can help prevent lens deformation and / or prevent adsorption between the lens and the eye, which can cause discomfort to the user and can hinder or prevent removal of the lens from the eye.

[0003] Previously, contact lenses having fenestrations have been produced by milling or drilling the fenestration into the lens after the lens has been molded, turned, or otherwise formed. Adding a fenestration after the lens has been formed can not be suitable for high volume production, or the production speed can not be as desired. It has also been found that, in some cases, forming a fenestration through the lens can leave excess material or burrs on the lens, creating surface irregularities that can cause discomfort to the lens wearer due to contact with these surface irregularities on the cornea or the inner surface of the eyelid.

[0004] Accordingly, it can be seen that there is a need for improved apparatuses, systems, processes, and methods for creating a fenestration within a contact lens, and improved contact lenses formed thereby.

[0005] The present invention is directed, in part, to providing improved apparatuses, systems, processes, and methods for creating a fenestration within a contact lens, and contact lenses formed thereby, to meet these and other needs. SUMMARY

[0006] In example embodiments, the present invention provides improved systems and methods for manufacturing contact lenses having fenestrations. In further example embodiments, the present invention provides improved contact lenses having fenestrations. Some example applications of the present invention can enable high speed or high volume manufacturing of fenestrated lenses, for example, by forming the fenestration as part of the molding process of the lens, rather than milling or drilling the fenestration into a previously formed lens in a separate step. Additionally, example embodiments provide fenestrated lenses that do not have burrs or other significant lens surface irregularities at or around the fenestration.

[0007] An example contact lens is formed by molding within a lens mold having a first mold segment with a first protrusion and a second mold segment with a second protrusion. When the first and second mold segments are pressed together, the first and second protrusions abut, thereby forming a window within and through the lens. In example embodiments, the protrusions have different widths or contact surface areas, such that the width or contact surface area of one of the protrusions is significantly greater than the width or contact surface area of the other protrusion. The size difference allows the two protrusions to abut one another even in the presence of relative translation, rotation, or other misalignment or positional variation between the two molds. Additionally, because the two protrusions each protrude outward from the lens-forming surface of their respective mold segment into the mold cavity, the contact surfaces of the protrusions abut one another during the molding process at a location within the interior of the lens (i.e., within the passageway of the window, within the thickness of the lens), rather than on or around the lens-forming surface. Any excess material or flash resulting from the material pinch-off at the contact surfaces of the protrusions will be within the interior of the lens, rather than on a surface that can cause discomfort to a lens wearer. In some example embodiments, a dish or recess on at least one of the protrusions can help cleanly pinch off material during the molding process, and help compensate for positional misalignment between the two protrusions. In some example embodiments, one or more of the mold segments can have a channel segment in addition to or instead of its respective protrusion, such that a channel is formed within the lens.

[0008] In one aspect, the present invention relates to a system for molding a windowed contact lens. The system preferably includes a first mold segment having a first lens-forming mold surface, a second mold segment having a second lens-forming mold surface, and at least one window-forming protrusion protruding outward from either of the first or second mold segments. The system is configured such that when the two halves of the mold are joined, they form a mold cavity that shapes the contact lens.

[0009] In another aspect, the present invention relates to a contact lens including a first surface, a second surface, and at least one window extending through a thickness of the lens between the first and second surfaces. The window preferably includes a first window segment and a second window segment. The first window segment preferably has a first lateral dimension, and the second window segment has a second lateral dimension, and a transition between the first and second window segments is preferably located at an interior portion of the lens between the first and second surfaces.

[0010] In yet another aspect, the present application is directed to a lens having at least one window formed by a process comprising: providing a first mold section comprising at least a first raised protrusion; providing a second mold section; delivering a lens-forming material into at least one of the first mold section and the second mold section; and joining the first mold section and the second mold section together to define a lens-forming cavity between the first mold section and the second mold section. The lens-forming material is preferably cured in the lens-forming cavity to form the lens, wherein the first raised protrusion extends through a thickness of the lens to form a window extending through the lens.

[0011] In yet another aspect of the present application, the present application is directed to a method for manufacturing a contact lens. The method preferably comprises: providing a first mold section having at least a first raised protrusion; providing a second mold section; delivering a lens material between the first mold section and the second mold section; and joining the first mold section and the second mold section together when the lens material is between the first mold section and the second mold section such that the first raised protrusion forms a window in a contact lens formed therein.

[0012] These and other aspects, features, and advantages of the present application will be understood with reference to the drawings and detailed description herein, and will be realized by means of the different elements and combinations specifically recited in the appended claims. It will be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the application as claimed. BRIEF DESCRIPTION OF DRAWINGS

[0013] Figure 1 is a front perspective view of a contact lens having a window in accordance with an example embodiment of the present application.

[0014] Figure 2 is Figure 1 is a cross-sectional view of the contact lens of

[0015] Figures 3A to 3E (collectively referred to as FIG. 3) illustrate a sequence for forming a windowed contact lens in accordance with an example embodiment of the present application, wherein:

[0016] Figure 3A illustrates a first step in an example process for producing a contact lens having a window.

[0017] Figure 3B illustrates a second step in an example process for producing a contact lens having a window.

[0018] Figure 3C illustrates a third step in an example process for producing a contact lens having a window.

[0019] Figure 3D The fourth step in an example process for producing a contact lens with fenestrations is shown.

[0020] Figure 3E A fifth step in an example process for producing a contact lens having fenestrations is shown.

[0021] Figure 4 is a close-up cross-sectional view of a boss docking portion of a mold set for producing a contact lens having a fenestration, according to an example embodiment of the present invention.

[0022] Figure 5 is a close-up cross-sectional view of another boss-docking portion of a mold set for producing contact lenses having fenestrations, according to an example embodiment of the present invention.

[0023] Figure 6 is a close-up cross-sectional view of yet another boss-docking portion of a mold set for producing a contact lens having a fenestration, according to an example embodiment of the present invention.

[0024] Figure 7 is a close-up cross-sectional view of different boss interface portions of a mold set for producing contact lenses with fenestrations, according to an example embodiment of the present invention.

[0025] Figure 8A is a close-up cross-sectional view of another boss interface portion of a mold set for producing contact lenses having fenestrations, according to an example embodiment of the present invention.

[0026] Figure 8B is a close-up cross-sectional view of another boss interface portion of a mold set for producing contact lenses having fenestrations, according to an example embodiment of the present invention.

[0027] Figure 9 is a close-up cross-sectional view of different boss interface portions of a mold set for producing contact lenses with fenestrations, according to an example embodiment of the present invention.

[0028] Figure 10 is a close-up cross-sectional view of another boss interface portion of a mold set for producing contact lenses having fenestrations, according to an example embodiment of the present invention.

[0029] Figure 11 is a top plan view of the intersection area of ​​raised portions of two mold halves for producing a contact lens having a fenestration, according to an example embodiment of the present invention.

[0030] Figure 12is a top plan view of the intersection area of the raised portions of another set of two half-molds for producing a contact lens with a window according to example embodiments of the present invention.

[0031] Figure 13 is a top plan view of the intersection area of the raised portions of another set of two half-molds for producing a contact lens with a window according to example embodiments of the present invention.

[0032] Figure 14 is a close-up cross-sectional view of a raised portion butt portion of a mold set for producing a contact lens with a window according to example embodiments of the present invention.

[0033] Figure 15 is a close-up cross-sectional view of another raised portion butt portion of a mold set for producing a contact lens with a window according to example embodiments of the present invention. DETAILED DESCRIPTION

[0034] The present invention can be more easily understood and further advantages and benefits can be obtained, when the following detailed description of exemplary embodiments is considered in conjunction with the accompanying drawings, in which the figures form a part of this disclosure. It is to be understood that the invention is not limited to the specific devices, methods, conditions or parameters described and / or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated herein by reference as if fully set forth in this document.

[0035] Further, as used in this specification, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. References to a particular numerical value includes at least that particular value, as this specification is construed to refer to at least one example. Presently articulated ranges include the endpoints and all the legal equivalents of those endpoints. “About” or “approximately” shall mean an acceptable degree of error for the quantity measured considering the measurement in question and any measurement of the like, using such variation as would be expected by one of ordinary skill in the art to be within the scope of practice for the disclosed technology. Furthermore, any method described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. In addition, the composition or mixture wherein any two of the ingredients are optional are contemplated. In other words, compositions or mixtures can contain one, none, or both of the optional ingredients.

[0036] Reference will now be made to the drawings wherein like numerals refer to like parts throughout the several views, Figure 1 and Figure 2An example windowed contact lens 100 produced by a molding process according to an example embodiment of the present invention is shown. Lens 100 includes a first lens segment 101, a second lens segment 102, and windows 103 in the form of openings that form fluid transfer channels or passageways extending through the thickness of the lens body and from one surface to the other. First lens segment 101 is generally hemispherical and has a first lens segment inner surface 108 and a first lens segment outer surface 109. Second lens segment 102 is also generally hemispherical and has a second lens segment inner surface 106 and a second lens segment outer surface 107. Second lens segment 102 is integrally formed with first lens segment 101 such that first lens segment 101 generally surrounds and surrounds the perimeter of second lens segment 102. First lens segment 101 has a first curvature, and second lens segment has a second curvature that is generally steeper than the first curvature. In other embodiments, the first and second lens segments may have the same curvature. In further embodiments, the lens may or may not have multiple different lens segments or multiple curvatures. In still further embodiments, the lens may have more than two segments or different curvatures.

[0037] When lens 100 is worn by a human or animal user in the intended manner, the concave back surface of the lens that contacts or faces the surface of the eye can be referred to as the base curve side of the lens and can include inner surfaces 106 and 108. The opposite convex front surface of the lens, which faces away from the eye and can contact the inner surface of the user's eyelid when blinking or closing the eye, can be referred to as the front curve side of the lens and can include outer surfaces 107 and 109. Fenestrations 103 within lens 100 allow fluid (e.g., tears, air, eye drops, etc.) to flow between outer surface 107 and inner surface 106 of lens 100. This fluid transfer from one surface of the lens to the other can help prevent the lens from deforming or locking due to adsorption on the user's eye. Furthermore, fluid transfer allows the lens to assume more than one state and can also allow for adjustments to the user's tear film, enhance oxygen permeability, and improve wearer comfort.

[0038] exist Figure 1 and Figure 2In the example embodiment shown, the window 103 extends between the outer surface 107 and the inner surface 106 of the second lens section 102 of the lens 100. The window 103 of the depicted embodiment 100 has a first window section 104 and a second window section 105. In this depicted embodiment, the first window section 104 has a smaller lateral dimension or diameter than the second window section 105. In other embodiments, the first window section 104 can have a larger diameter than the second window section 105. In other embodiments, the window sections 104 and 105 can have the same size or substantially the same size. In yet other embodiments, there can be only one window section, or there can be more than two window sections. In some particular example embodiments, the inner diameter or width of the window can be between about 0.010 mm to about 0.700 mm. In other embodiments, the inner diameter or width of the window can be between about 0.050 mm to about 0.300 mm. In different embodiments, the window can have a greater or lesser width.

[0039] In Figure 1 and Figure 2 In the embodiment shown, the window 103 is located within the second lens section 102. In alternative embodiments, the window 103 can be located within other sections of the lens. For example, in some embodiments, the window 103 can be located only on the first lens section 101. In other embodiments, the window 103 can be located on other lens sections not presently described. In further embodiments, the window can be located on multiple sections of the lens 100.

[0040] FIG. 3 illustrates the steps of a method of producing a contact lens having one or more windows extending through the lens, such as a high speed double sided molding process, in accordance with example embodiments of the present application, in which the window is formed in situ in the lens as part of the molding process, without the need for a separate milling or drilling process to form the window. As shown in the cross-sectional view of FIG. 3, a second mold section or half 330 of the lens forming mold system is provided with one or more second raised or protruding portions 331 that extend or protrude outwardly from the concave front curve side lens forming surface 332 of the second mold section 310 by a distance. As shown in the cross-sectional view of FIG. 3, a dose of liquid lens forming material 360 is then deposited within the second mold section 330. The lens forming material 360 partially conforms to the shape of the second mold section 330, and also partially conforms around the second protruding portions 331. As shown in the cross-sectional view of FIG. 3, the lens forming material 360 is then cured to form a lens 100 having a window 103 extending through the lens 100. Figure 3A Figure 3B Figure 3C ​​As shown, a first mold section or half 310 of the lens forming mold system is then inserted into the second mold section 330 to form a lens forming mold cavity between the lens forming surface of the first mold section or half and the lens forming surface of the second mold section or half, which is substantially filled with the lens forming material 300. The first mold section 310 includes one or more first protrusions or projections 311 that extend or protrude outwardly from a convex front curve side lens forming surface 312 of the first mold section 310 a distance in the direction of the second mold section 330 and the second projections 331. The first mold section 310 and the second mold section 330 are configured and positioned such that one or more pairs of cooperating first and second projections 311, 331 are aligned with each other, and wherein the facing contact surfaces of the corresponding first and second projections are in abutment or contact with each other when the mold halves are engaged with each other. The lens forming material within the mold cavity can then be cured, for example, by light, heat, chemical, or other polymer curing processes, to form a solid or gel state lens 100. As Figure 3D As shown, once the lens material 360 has been cured to form the lens 300, the first mold section 310 is removed, leaving first windowed sections 304 of the windows 303 formed within the lens 300 and extending into the base curve side of the formed lens 300. The formed lens 300 is then demolded from the second mold half 330. Alternatively, the second mold section 330 is first removed, leaving second windowed sections 305 of the windows 303 formed within the lens 300 and extending into the front curve side of the formed lens 300. The formed lens 300 is then demolded from the first mold half 310. As Figure 3E As shown, once the lens 300 is removed from the second mold 330, the resulting lens includes windows 303 that extend through the thickness of the lens and form channels for fluid transport between the base curve side and the front curve side. The windows include first windowed sections 304 that are produced by the first projections 311 in the molding process and second windowed sections 305 that are produced by the second projections 331 in the molding process. In this way, the windows 303 are formed in situ in the lens as part of the lens forming or molding process, and do not require a separate milling or drilling process to form the windows after the lens is formed.

[0041] Moreover, in the exemplary embodiment, when the lens is formed, the first raised portion 311 and the second raised portion 331 meet and abut within or within the thickness of the lens molding material 360 and the lens 300 in the mold cavity, so that any burrs that may form due to the material pinching-off and demolding process are likely to be located within the fenestration 303, at or around the intersection of the first fenestration section 304 and the second fenestration section 305, and within the body of the lens 300, rather than on the inner surface 308 or the outer surface 309 of the lens exterior. This minimizes or eliminates the risk of any potential burrs or other surface irregularities contacting the patient's or wearer's eye and causing discomfort when the lens is in use.

[0042] In alternative embodiments, the steps previously described may be performed in a different order, and it should be understood that the methods and processes according to various example embodiments of the present invention are not limited to a particular sequence or order of steps. For example, the mold halves may be joined first, and then the liquid lens forming material may be inserted into the gap between the mold halves. In other examples, the liquid lens forming material may be added first to the mold halves used to form the base curve side of the lens, and then the mold halves used to form the front curve side of the lens may be joined. It should be understood by those skilled in the art that variations of the above steps are contemplated by this disclosure.

[0043] In some embodiments, the window is formed by at least one raised portion on either the first mold section or the second mold section, the at least one raised portion extending through the thickness of the resulting lens and extending between the two mold sections. In a specific embodiment, the window can be formed by a combination of two types of raised portions: one is an abutting raised portion (such as the raised portion in the embodiment shown in FIG3 ); the other is a raised portion extending through the thickness of the resulting lens and extending between the two mold sections (as described below with reference to FIG3 ). Figure 14 and Figure 15 described).

[0044] Figure 4 A close-up cross-sectional view of a first mold half 410 and a second mold half 430 is shown according to an example embodiment of the present invention. The first mold 410 includes at least one first raised portion 411, which further includes a recessed contact surface or disk 415, a peripheral edge 416, and a first sidewall 417. The second mold 430 includes a second raised portion 431, which further includes an intersection surface 435 and a second wall 437. Figure 4In the example embodiment shown, the first mold 410 forms the base curve side or back surface of the lens, i.e., the surface of the lens that contacts or faces the eye when worn in the intended manner, and the second mold 430 forms the front curve side or front surface of the lens that is farthest from the user's eye in use. When the mold halves are joined, the first protrusion 411 extends outward from the surface of the first mold half 410 toward the second mold half 430 and the second protrusion 431 within the lens forming cavity. When the mold halves are joined, the second protrusion 431 extends outward from the second mold half 430 toward the first mold half 410 and the first protrusion 411 within the lens forming cavity. The mold and protrusions are designed so that when the first mold half 410 and the second mold half 430 are pressed together or joined, the contact surface or edge of the first protrusion 411 contacts and abuts the intersection surface 437 of the second protrusion 431. The location of the abutment of the first protrusion 411 and the second protrusion 431 is between the first mold 410 and the second mold 430, within the interior region of the lens forming cavity formed between the mold halves, and thus, within the lens body and between the inner and outer surfaces of the resulting lens.

[0045] In Figure 4 In the embodiment shown, the diameter and / or width of the first protrusion 411 at the edge 416 is less than the diameter and / or width of the second protrusion 431 at the intersection surface 435. When the first mold 410 and the second mold 430 are pressed together, the difference in size helps to compensate for any translational movement between the first protrusion 411 and the second protrusion 430. For example, the first mold 410 can experience a slight rightward translation relative to the second mold 430, and the edge 416 of the first protrusion 411 can still abut and be surrounded by the intersection surface 435 of the second protrusion 431. The difference in size also helps to compensate for dimensional casting errors in forming the molds.

[0046] When the first protrusion 410 is inserted into the lens material, such as during the process shown in FIG. 3, the disc 415 of the first protrusion 411 on the first mold 410 captures the crushed material. The walls 417 of the disc 415 are angled relative to the plane formed by the intersection surface 435. In some embodiments, the angle may be between about 0° and about 50°. In other embodiments, the angle may be between about 10° and about 40°. A larger disc angle allows for greater edge resistance of the first protrusion 411 and greater positional mismatch between the first protrusion 411 and the second protrusion 431.

[0047] ​In an exemplary embodiment, the window molding protrusions are generally symmetrical about a central axis that is parallel to the path of engagement of the first and second mold halves during the lens molding process to allow for parallel engagement and release of the protrusions as the mold halves move into and out of engagement. Figure 4 In the embodiment shown, the first and second projections 411, 431 are formed and aligned generally about a vertical axis 420 that is parallel to the joint axis, and the intersection surface 435 is generally horizontal, and the edge 416 is also generally horizontal. In other embodiments, the projections can be oriented about a line that forms an oblique angle with the vertical axis or the joint axis or with respect to the vertical axis or the joint axis. For example, in Figure 5 In the embodiment shown, the first raised portion 511 and the second raised portion 531 are formed and aligned about the local normal 525. The intersection plane 535 and the edge 516 are perpendicular to the local normal 525, but in other embodiments, they can be at an oblique angle to the local normal. Figure 5 In the illustrated embodiment, local normal 525 is the local normal of second raised portion 530 forming the front curve side of the lens. In other embodiments, the raised portion may be formed around the local normal of the first mold forming the base curve side of the lens, or around another line at an oblique angle to the vertical.

[0048] In example embodiments with at least one raised portion on each side of the mold, the raised portions may have complementary heights so that when the raised portions abut, they span the thickness of the contact lens. For example, first raised portion 411 may have a first height H1, and second raised portion 431 may have a second height H2. The sum of first and second heights H1, H2, equals the mold cavity depth to which first and second raised portions 411, 431 abut. First height H1 is preferably between approximately 5% and 95% of the mold cavity depth or lens thickness, while second height H2 is the remaining portion. In some embodiments, first height H1 is between approximately 30% and 70% of the mold cavity depth or lens thickness, while H2 is the remaining portion. For example, H1 may be approximately 50% of the mold cavity depth or lens thickness, and H2 may be the remaining approximately 50% of the mold cavity depth or lens thickness. The exact height of the raised portion depends on several factors, such as the angle of the raised portion relative to the mold and the total thickness of the lens. In example embodiments, the raised portions may have a height ranging from about 0.01 mm to about 0.3 mm. In other embodiments, the raised portion height may range from about 0.02 mm to about 0.2 mm. In embodiments where the raised portions are oriented about a vertical axis, the relative thickness of the lens corresponding to the raised portions will be thicker. Thus, when the mold is oriented about a vertical axis, the overall apparent height of the mold will be greater than when the mold is oriented about a local normal or other axis.

[0049] exist Figure 4 In the exemplary embodiment of , the first wall 417 of the first protrusion 411 and the second wall 437 of the second protrusion 431 are substantially parallel to an axis 420 extending normal to the intersection surface 435 and parallel to the joining path of the first and second mold halves during the lens molding process, thereby forming a substantially cylindrical protrusion body. In alternative embodiments, the walls and the axis may not be parallel. For example, in Figure 5 In the illustrated embodiment, first wall 517 of first projection 511 can be angled relative to intersection surface 535 and local normal 525 such that first projection 511 is tapered and wider at its base where it intersects first mold half 510 than at edge 516 where it intersects intersection surface 535, thereby forming a generally frusto-conical projection body. Similarly, second wall 537 of second projection 531 can be angled such that the width of second projection 531 is tapered and greater at its base where it intersects second mold half 530 than at intersection surface 535. The increased relative widths at the bases of first and second projections 511, 531, and the resulting angles of first and second walls 517, 537, can help minimize any thin areas around the fenestrations in the resulting lens. If the lens forming material shrinks during curing, the draft taper of angled walls 517 and 537 can also help prevent the lens from locking onto molds 510 and 530 and / or raised portions 511 and 531, thereby facilitating separation of the lens from molds 510 and 530. In some embodiments, the angle between the wall and axis 520 can be between about 0 degrees and about 20 degrees. In a particular embodiment, the angle can be about 10 degrees.

[0050] exist Figure 4 and Figure 5 In the embodiment shown, the disc or recessed surface is located on a raised portion that projects from the mold half that forms the base curve side of the lens, which is the portion of the lens closest to the user's eye. When the disc is on a raised portion formed on the base curve side, the feature size of the fenestration on the base curve side of the lens can be minimized, thereby reducing the feature size that contacts the user's eye. In other embodiments, the raised portion that forms the surface of the lens farthest from the user's eye can have the disc, and another raised portion can have the receiving surface. For example, in Figure 6 In the embodiment shown, the first mold 610 also forms the base curve side and the second mold 630 forms the outermost surface of the lens, but the first raised portion 611 of the first mold 610 has an intersection surface 635, while the second raised portion 631 on the second mold 630 has a dish or recess 615 with a peripheral edge 616. Figure 6In an embodiment, the diameter or lateral dimension of the first protrusion 611 is greater than the diameter or lateral dimension of the second protrusion 631, so that even if there is some lateral or rotational movement or misalignment between the two half-molds during the lens molding process, the dome-shaped second protrusion 615 is surrounded by the intersection surface 635 on the first protrusion 611.

[0051] In some embodiments, similar to edges 416, 516, and 616, the peripheral edge of the dished raised portion or the concave raised portion can be sharp and / or pointed. Figure 7 In the example of , the peripheral edge 716 of the contact surface of the protrusion can be rounded, radiused, or chamfered. Additionally, the inner corner formed at the intersection of the protrusion and the base of the mold section can be rounded or radiused, such as Figure 7 The corner formed between the protrusion and the mold section can have a radius between about 0 mm and about 0.150 mm. In certain embodiments, the corner can have a radius between about 0.005 mm and 0.050 mm.

[0052] In some embodiments, one or both mold sections may include grooves instead of or in addition to the protrusions. Figure 8A In the embodiment of , the second mold half or mold section 830 has a groove 840 forming a ridge that forms an indentation on the resulting lens. Figure 8A In a particular embodiment, the first protrusion 811 intersects the groove to form a window that is visible from the outer surface of the lens (e.g., Figure 1 and Figure 2 The surface 107 in the lens extends until the window intersects with the indentation left by the groove 840 in the thickness of the resulting lens. In other embodiments, the groove can be on the base curve side of the lens. Figure 8B In the embodiment of the present invention, the first mold half or mold section 810 has a groove 840. The second protrusion 831 intersects the groove to form a window that is visible from the outer surface of the lens (e.g., Figure 1 and Figure 2 109) until the window intersects the indentation left by the groove 840 in the thickness of the resulting lens. Figure 9 In the embodiment shown, the groove 940 may also have a raised portion 911 extending from the groove. In embodiments where the raised portion extends from the groove, the smaller raised portion may be on either the first raised portion or the second mold section, as long as the other raised portion is wider. In some embodiments, both mold sections may include grooves and raised portions, such that a groove is formed on either side of the lens, with the fenestration extending across the groove.

[0053] In some embodiments, one of the bosses can be generally dome-shaped or hemispherical, while the other boss can have a generally smaller size. For example, in Figure 10 In the illustrated embodiment, the first mold 1010 has a dome-shaped boss 1050 that protrudes outward from the first mold 1010 toward the second mold 1030 and the second boss 1031. The second boss 1031 on the second mold 1030 includes a disc or recess 1035 with a peripheral edge 1036 and a wall 1037. In alternative embodiments, the dome-shaped boss can be on the mold that forms the outer surface of the resulting lens, and the smaller boss can be on the mold that forms the base curve side of the lens. The present disclosure also includes example embodiments in which the windowing forming boss(es) or protuberance is disposed on only one or the other of the first and second lens halves, and is configured to extend through the entire thickness of the mold cavity to abut or contact the lens forming surface of the other mold half, thereby forming a window through the lens in the molding process. In such embodiments, the boss or protuberance can optionally be shaped or otherwise configured to minimize or eliminate any surface irregularities on the outer surface of the lens, or the lens can be further processed to remove any surface irregularities, in order to improve the comfort of the wearer.

[0054] In some example embodiments, one or both of the bosses has a generally circular shape in plan view. For example, Figure 11 A top view of an embodiment in which the second boss 1131 has a circular planar intersection surface 1135 is shown. When the mold halves are joined, the smaller circular footprint formed by the peripheral edge 1116 of the smaller first boss (not shown) is circumscribed within and configured to be generally coaxially aligned with the circular intersection surface 1135 of the larger boss. In other embodiments, the larger boss can have an elliptical shape in plan view. For example, Figure 12 A top view of an embodiment in which the second boss 1231 has an elliptical intersection surface 1235 is shown. In this embodiment, the edge 1216 of the smaller first boss (not shown) forms a smaller circular footprint within the elliptical intersection surface 1235. In yet other embodiments, the larger boss can have a square, rectangular, or other shape in plan view. For example, Figure 13A top plan view of an embodiment in which a second raised portion 1331 has a rectangular intersection surface 1335 is shown. In this embodiment, edge 1316 of a smaller first raised portion (not shown) forms a smaller circular footprint within rectangular intersection surface 1335. In other embodiments, the smaller raised portion may alternatively or additionally have an elliptical or rectangular shape. In some examples, either or both raised portions may have a shape other than elliptical, rectangular, or circular, as long as the dimensions of one raised portion are sufficiently smaller than the dimensions of the other to allow for and compensate for translational or tolerance errors in the alignment or relative positioning between the two molds. In an example embodiment, the larger raised portion may have an arcuate configuration in plan view, defining an annular segment at a radial position corresponding to the radial position of the smaller raised portion. This allows the smaller raised portion to rest on the contact surface of the larger raised portion even if the mold halves are slightly rotationally misaligned during engagement during the lens molding process.

[0055] In some embodiments, either the first raised portion or the second raised portion may extend the entire distance between the two mold halves, such that the window is formed by only a single mold raised portion. Figure 14 In the embodiment shown, the raised portion 1411 extends from the base arc side 1410 about the local normal 1425 toward the second mold half 1430. When the mold halves 1410 and 1430 are engaged, the raised portion 1411 traverses the distance between the two mold halves 1410 and 1430 so that the edge 1416 of the raised portion 1410 abuts the second mold half 1430. In other embodiments, such as Figure 15 In the embodiment shown, the raised portion 1535 may extend from the second mold half 1530 such that an edge 1536 of the raised portion 1535 abuts the first mold half 1510 when the mold halves 1510 and 1530 are engaged. Figure 14 and Figure 15 In both embodiments shown, the projections are oriented about the local normal, but in other embodiments where a single projection is used to form the fenestration, the projections may be oriented about the vertical.

[0056] Additionally, it should be understood that aspects of the various embodiments of the invention may be interchanged in whole or in part or may be combined and / or used together in any manner.

[0057] Although the present invention has been described with reference to exemplary embodiments, those skilled in the art will appreciate that various modifications, additions and deletions are possible, within the scope of the invention as defined by the accompanying claims.

Claims

1. A system for molding a fenestrated contact lens, the system comprising: a first mold section having a first lens-forming mold surface; a second mold section having a second lens-forming mold surface; as well as at least one window-forming protrusion, the at least one window-forming protrusion protruding outwardly from either the first mold section or the second mold section by a certain distance and having a first contact surface, wherein the first mold section and the second mold section are joined to form a lens molding cavity, wherein when the first mold section and the second mold section are joined, the at least one window molding protrusion extends between the first lens molding mold surface and the second lens molding mold surface.

2. The system of claim 1, wherein: The at least one window molding protrusion includes a first window molding protrusion and a second window molding protrusion, wherein the first window molding protrusion protrudes outward from the first mold section and has a first contact surface having a first contact surface, and the second window molding protrusion protrudes outward from the second mold section and has a second contact surface, and wherein the first window molding protrusion and the second window molding protrusion are configured to align and abut each other when the first mold section and the second mold section are joined.

3. The system of claim 1 or 2, wherein: The first lens molding surface further includes a generally convex lens base curve side molding mold surface, and Wherein, the second lens molding surface further includes a roughly concave lens front arc side molding mold surface.

4. The system of claim 2 or 3, wherein: A transverse dimension of the first contact surface of the first window-forming protrusion is smaller than a transverse dimension of the second contact surface of the second window-forming protrusion.

5. The system according to any one of claims 1 to 4, wherein: The first contact surface of the first fenestration protrusion defines a disc-shaped recess surrounded by a peripheral edge.

6. The system of claim 5, wherein: The peripheral edge of the first contact surface is rounded.

7. The system according to any one of claims 1 to 6, wherein: At least one of the first mold section and the second mold section further includes a groove-forming ridge that protrudes a distance outward from a lens-forming mold surface thereof.

8. The system of claim 7, wherein: The groove-forming ridge has a further raised section within the groove-forming ridge.

9. The system according to any one of claims 1 to 8, wherein: The fenestration molding boss includes a generally cylindrical body having a sidewall extending generally parallel to a joining axis of the first and second mold sections.

10. The system according to any one of claims 1 to 8, wherein: At least one of the fenestration-forming projections includes a generally frusto-conical body having sidewalls angled obliquely relative to a longitudinal axis.

11. The system of any one of claims 2 to 8, wherein: At least one of the first fenestration-forming raised portion and the second fenestration-forming raised portion includes a straight sidewall.

12. The system of any one of claims 2 to 8, wherein: The first window molding protrusion and the second window molding protrusion both include angled side walls, whereby each protrusion is wider proximal to its corresponding lens curvature side molding mold surface and narrower distal to the corresponding lens curvature side molding mold surface.

13. The system of any one of claims 2 to 8, wherein: At least one of the first fenestration-forming protrusion or the second fenestration-forming protrusion is dome-shaped.

14. A method of cast molding a contact lens, the method comprising: Obtaining a system according to any one of claims 1 to 13; obtaining lens molding materials; dispensing a specified amount of the lens forming material onto the surface of the first lens forming mold or the surface of the second lens forming mold; joining the first mold section and the second mold section together to form the lens-forming cavity containing the lens-forming material therein, and ensuring that the at least one fenestration-forming projection extends between the first lens-forming mold surface and the second lens-forming mold surface; as well as The lens forming material is cured within the lens forming cavity to form a windowed contact lens.

15. A cast-molded contact lens comprising: a first surface; a second surface; as well as at least one fenestration extending through a thickness of the lens between the first surface and the second surface, the fenestration further comprising: The first windowed section, and The second window section, The first window section has a first lateral dimension and the second window section has a second lateral dimension, wherein a transition portion between the first window section and the second window section is located at an inner portion of the lens between the first surface and the second surface.

16. The contact lens of claim 15, wherein The first surface and the second surface further include an outer segment and an inner segment, wherein the outer segment surrounds the inner segment, and wherein the at least one fenestration is located within the inner segment of the first surface and the second surface.

17. The contact lens of claim 15, wherein: The first surface and the second surface further include an outer section and an inner section, wherein the at least one fenestration is located within the outer section of the first surface and the second surface.

18. The contact lens of claim 15, wherein: The first surface and the second surface further include an outer section and an inner section, wherein a first window of the at least one window is located within the inner section of the first surface and the second surface, and a second window of the at least one window is located within the outer section of the first surface and the second surface.

19. The contact lens of any one of claims 15 to 18, wherein The first and second surfaces of the lens are free of any significant surface irregularities resulting from the formation of the at least one fenestration.

20. The contact lens of any one of claims 15 to 18, wherein The first lateral dimension is smaller than the second lateral dimension.

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