Supervised machine learning curing systems

Abstract

Disclosed herein are methods and systems for manufacturing a contact lens. An example method may comprise causing a mold containing a reactive mixture to be irradiated with curing energy in a curing area, measuring an intensity of the curing energy at one or more sites in the curing area, generating an intensity profile indicative of an intensity of the curing energy at one or more of the sites as a function of the electrical settings driving the curing energy, and determining target electrical settings for a source of the curing energy based on the intensity profile. Also disclosed herein is a method for calibrating a plurality of lights in a curing tunnel that includes recording measured intensity data, on a sensor device, from a plurality of lights, calculating error data using the measured intensity data and target intensity data, making a determination that the error data surpasses an error threshold, and based on the determination adjusting a light, of the plurality of lights using the error data.

Description

SUPERVISED MACHINE LEARNING CURING SYSTEMSRELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 515,890, filed July 27, 2023, which is incorporated herein by reference in its entirety.FIELD

[0002] This disclosure relates to energy systems such as curing systems used in the manufacture of contact lenses. More specifically, this disclosure relates to curing systems with improved control of exposure to curing energy.BACKGROUND

[0003] Manufacture of contact lenses may include exposing a reactive monomer mixture to a curing process to initiate polymerization. Generally, curing processes may include irradiating curable materials with light or thermal energy. Sources of curing light may include light emitting diodes (LEDs) or ultraviolet (UV) lamps. Other processes and systems may incorporate an energy system such as a lighting system.

[0004] In the commercial manufacture of contact lenses, the curing area may be designed to cure hundreds or even thousands of lenses at one time. The energy source may include multiple UV lamps or LED clusters positioned at various locations within the apparatus, each with an individual intensity output that will vary over time as the light sources age. As such, the curing intensity applied to each lens can vary. Curing intensity affects the propagation of polymerization and the properties of the resultant polymerized articles. Thus, variation in curing intensity is problematic in the manufacture of contact lenses because lenses are subject to numerous exacting criteria with respect to structural integrity, clarity, finish, transparency, and freedom from defects, and lenses with even very minor flaws are considered unwearable.

[0005] There is a need for improvements to conventional curing processes, and particularly improvements in the ability to control curing energy and uniformity in such processes.SUMMARY

[0006] Lighting systems such as those used for curing materials may be controlled based on an intensity profile to direct a prescribed amount of energy to any given surface.

[0007] As an illustrative example, manufacture of contact lenses (e.g., on a commercial manufacturing line) may use radiation (e.g., light) photopolymerization or other energy (e.g., thermal) to form one or more contact lenses. Various materials such as reactive mixtures, reactive compositions, photopolymers, and / or the like may be used. Various curing energies may be used. Where radiant energy is used, various wavelengths may be used. As described herein, various materials and sources of curing energy may be used to provide cured contact lenses.

[0008] One general aspect includes a method for manufacturing a contact lens. The method also includes providing at least one mold having a cavity formed therein, the cavity containing a reactive mixture, and exposing the reactive mixture to curing energy thereby at least partially curing the reactive mixture to form the contact lens, where the curing energy is directed at one or more sites on the mold and controlled based on a curing energy control model. The curing energy control model may include: calculating an intensity profile indicative of an intensity of curing energy at one or more sites of the mold as a function of the electrical settings driving the curing energy, and determining target electrical settings for a source of the curing energy based on the calculated intensity profile. The method may also include providing a plurality of molds each with a single cavity. The plurality of molds may also be arranged on trays or pallets configured to move the molds through the manufacturing line. The method may include computer systems, hardware, and computer programs or software recorded on one or more computer storage devices, each configured to perform the actions of the methods.

[0009] Implementations may include one or more of the following features. The method where each of the cavities may include a base curve and a front curve associated with a contact lens. The target electrical settings may be configured to minimize deviation of curing of the reactive mixture between the plurality of sites of the molds. The calculating an intensity profile may include measuring an intensity of curing energy (e.g., incident energy, radiant energy, etc.) at one or more sites of the mold as a function of the electrical settings driving the curing energy. The calculating an intensity profile may include predicting, using a learning model, an intensity of the energy at one or more of the sites of the mold as a function of the electrical settings driving the output energy. The calculating an intensity profile may include generating a representational model such as a k matrix, as described herein. The source of the curing energy may include a thermal energy source. The source of the curing energy may include one or more light sources. The source of the curing energy may include one or more light emitting diodes. The source of the curing energy may includea plurality of light sources and the calculating an intensity profile may include estimating an intensity of radiation at each of the sites as a function of the electrical settings driving each of the light sources. Determining the target electrical settings for a source of the curing energy based on the calculated intensity profile may include determining target electrical settings for each of the light sources to minimize deviation of curing of the reactive mixture between the plurality of sites on the mold. The reactive mixture may include at least one polymerizable monomer.

[0010] One general aspect includes causing output of a radiant energy; measuring an intensity of the radiant energy at one or more sites of incident radiant energy; generating, based on the measuring an intensity of the radiant energy, an intensity profile indicative of an intensity of the radiant energy at the one or more of sites as a function of the electrical settings driving the radiant energy; determining target electrical settings for a source of the radiant energy based on the intensity profile.BRIEF DESCRIPTION OF DRAWINGS

[0011] These drawings illustrate certain aspects of some examples of the present disclosure and should not be used to limit or define the disclosure.

[0012] FIG. 1 illustrates a schematic diagram of a two-zone curing tunnel in accordance with an aspect of the present disclosure.

[0013] FIG. 2 illustrates an example method in accordance with an aspect of the present disclosure.

[0014] FIG. 3 illustrates a schematic diagram of an example curing tunnel in accordance with an aspect of the present disclosure.

[0015] FIG. 4 illustrates a schematic diagram of an example curing tunnel showing irradiation of a plurality of molds by a curing energy source in accordance with an aspect of the present disclosure.

[0016] FIG. 5 illustrates a schematic diagram of an example curing tunnel showing a component irradiation of a plurality of molds by a select curing energy source in accordance with an aspect of the present disclosure.

[0017] FIG. 6 illustrates a schematic diagram of an example curing tunnel showing a component irradiation of a select cavity of a mold by a plurality of curing energy sources in accordance with an aspect of the present disclosure.

[0018] FIG. 7 illustrates a schematic diagram of an example curing tunnel showing selection of a cavity of a plurality of molds in accordance with an aspect of the present disclosure.

[0019] FIG. 8 illustrates an example model in accordance with an aspect of the present disclosure.

[0020] FIG. 9 illustrates an example model for determining an intensity profile in accordance with an aspect of the present disclosure.

[0021] FIG. 10 illustrates an example method in accordance with an aspect of the present disclosure.

[0022] FIG. 11 illustrates an example method in accordance with an aspect of the present disclosure.

[0023] FIG. 12 illustrates an example method in accordance with an aspect of the present disclosure.

[0024] FIG. 13 is a diagram of an example computing environment.

[0025] FIG. 14A is a diagram of an example calibration system.

[0026] FIG. 14B is a diagram of an example portion of a curing tunnel.

[0027] FIG. 14C is a diagram of example measured intensity data and measured intensity analysis data.

[0028] FIG. 15 is a flowchart of the overall process of using a calibration system.

[0029] FIG. 16 is a flowchart of a process of using a calibration system in a production line.DETAILED DESCRIPTION— Overview and Advantages —

[0030] In an aspect, manufacture of contact lenses (e.g., on a commercial manufacturing line) may use radiation (e.g., light) photopolymerization, other energy (e.g., thermal) or a combination thereof to form one or more contact lenses. Various materials such as reactive mixtures, reactive compositions, photopolymers, and / or the like may be used. Various curing energies may be used. Where radiant energy is used, various wavelengths may be used. Although examples are provided herein that relate to curing materials for contact lenses, other energy systems such as multiple light systems may benefit from the same principles, system configurations, and methods of operation discussed herein. The present systems and methods are not limited to contact lens curing and manufacturing.

[0031] As an illustrative example, a mold may comprise one or more cavities configured to hold a reactive mixture (e.g., reactive composition), which may be cured to form a contact lens. Multiplemolds may be disposed in a tray or pallet to convey the molds through the curing area to be irradiated by a plurality of curing energy sources (e.g., light sources, light emitting diodes, etc.) from one or both sides of the mold. As a result, there are several intensity locations or sites affecting the polymerization conditions. The intensity at these locations may be controlled by the output of the source(s) of curing energy, wherein the individual intensity output is controlled independently by changing the electrical settings (e.g., voltage, current, driving energy, etc.) through each of the respective curing energy source(s). In accordance with the present disclosure, an intensity profile may be determined that provides uniform irradiation and curing profiles for all lenses (or sites on the mold), which may also vary over time as the sources of curing energy age and are replaced. When the reactive monomer mixture contains a visible light absorbing compound, the intensity profiles within the mold may be more variable and require more process controls to reliably manufacture the target contact lens. Various light absorbing compounds may be used such as photochromic, static, or other dynamic or responsive dyes.

[0032] The intensity profile of the source(s) of curing energy may be configured to maximize the yield of contact lenses within the specification. Additionally or alternatively, a model -based (e.g., supervised machine learning) approach can be adopted to provide an intensity profile. As an example, the present disclosure relates to a model (e.g., supervised machine learning) process employing bounded least squares methodology as a primary engine used to minimize variations of intensity from target values. In this way, a commercial manufacturing line for contact lenses can be configured for maximum output and quality and equipment / process bias can be removed or controlled. Moreover, a base model may be generated using the methods herein and the base model may be applied across various machines or system setups without having to re-generate the full model (for example, by using a flashing routine and building a new k matrix). Instead, the base model may be adjusted using bias correction methods to reduce error when moving from machine or system to another machine or system.

[0033] It is to be understood that the invention is not limited to the details of construction or process steps set forth in the following description. The invention is capable of other embodiments and of being practiced or being carried out in various ways using the teaching herein.

[0034] With respect to the terms used in this disclosure, the following definitions are provided. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. Thepolymer definitions are consistent with those disclosed in the Compendium of Polymer Terminology and Nomenclature, IUPAC Recommendations 2008, edited by: Richard G. Jones, Jaroslav Kahovec, Robert Stepto, Edward S. Wilks, Michael Hess, Tatsuki Kitayama, and W. Vai Metanomski. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference.

[0035] As used herein, the term "(meth)" designates optional methyl substitution. Thus, a term such as "(meth)acrylates" denotes both methacrylates and acrylates.

[0036] Wherever chemical structures are given, it should be appreciated that alternatives disclosed for the substituents on the structure may be combined in any combination. Thus, if a structure contained substituents R* and R**, each of which contained three lists of potential groups, 9 combinations are disclosed. The same applies for combinations of properties.

[0037] When a subscript, such as "n" in the generic formula [***]n, is used to depict the number of repeating units in a polymer's chemical formula, the formula should be interpreted to represent the number average molecular weight of the macromolecule.

[0038] The term "individual" includes humans and vertebrates, where applicable.

[0039] The term "biomedical device" refers to any article that is designed to be used while either in or on mammalian tissues or fluids, and preferably in or on human tissue or fluids. Examples of these devices include but are not limited to wound dressings, sealants, tissue fillers, drug delivery systems, coatings, adhesion prevention barriers, catheters, implants, stents, and ophthalmic devices such as intraocular lenses and contact lenses. The biomedical devices may be ophthalmic devices, particularly contact lenses, most particularly contact lenses made from silicone hydrogels or conventional hydrogels.

[0040] The term "ocular surface" includes the surface and glandular epithelia of the cornea, conjunctiva, lacrimal gland, accessory lacrimal glands, nasolacrimal duct and meibomian gland, and their apical and basal matrices, puncta and adjacent or related structures, including eyelids linked as a functional system by both continuity of epithelia, by innervation, and the endocrine and immune systems.

[0041] The term "ophthalmic device" refers to any optical device relating to the eye and includes devices which resides in or on the eye or any part of the eye, including the ocular surface. These devices can provide optical correction, cosmetic enhancement, vision enhancement, therapeutic benefit (for example as bandages) or delivery of active components such as pharmaceutical andnutraceutical components, or a combination of any of the foregoing. Examples of ophthalmic devices include but are not limited to lenses, optical and ocular inserts, including but not limited to punctal plugs, and the like. "Lenses" include spectacle lenses, sunglass lenses, soft contact lenses, hard contact lenses, hybrid contact lenses, intraocular lenses, and overlay lenses. The ophthalmic device may comprise a contact lens.

[0042] The term "contact lens" refers to an ophthalmic device that can be placed on the cornea of an individual's eye. The contact lens may provide corrective, cosmetic, or therapeutic benefit, including wound healing, the delivery of drugs or nutraceuticals, diagnostic evaluation or monitoring, ultraviolet light absorbing, visible light or glare reduction, or any combination thereof. A contact lens can be of any appropriate material known in the art and can be a soft lens, a hard lens, or a hybrid lens containing at least two distinct portions with different physical, mechanical, or optical properties, such as modulus, water content, light transmission, or combinations thereof.

[0043] Spectacle lenses or sunglasses may be comprised of mineral material, for example based on silicate, or made from an organic material, such as polycarbonate; polyamide; polyimide; polysulfones; polyethylene terephthalate / polycarbonate copolymers; and various other materials known in the art.

[0044] The biomedical devices, ophthalmic devices, and lenses of the present invention may be comprised of silicone hydrogels or conventional hydrogels. Silicone hydrogels typically contain at least one hydrophilic monomer and at least one silicone-containing component that are covalently bound to one another in the cured device.

[0045] "Target macromolecule" means the macromolecule being synthesized from the reactive monomer mixture comprising monomers, macromers, prepolymers, cross-linkers, initiators, additives, diluents, and the like.

[0046] The term "polymerizable compound" means a compound containing one or more polymerizable groups. The term encompasses, for instance, monomers, macromers, oligomers, prepolymers, cross-linkers, and the like.

[0047] "Polymerizable groups" are groups that can undergo chain growth polymerization, such as free radical and / or cationic polymerization, preferably free radical polymerization, for example a carbon-carbon double bond which can polymerize when subjected to radical polymerization initiation conditions. Non-limiting examples of polymerizable groups include (meth)acrylates, styryls, (meth)acrylamides, and vinyl groups. Preferably, the polymerizable group is selected from(meth)acrylate, (meth)acrylamide, N-vinyl lactam, N-vinylamide, vinyl carbonate, vinyl ether, vinyl carbamate, and styryl functional groups. More preferably, the polymerizable group is selected from (meth)acrylates and (meth)acrylamides. The polymerizable group may be unsubstituted or substituted. For instance, the nitrogen atom in (meth)acrylamide may be bonded to a hydrogen, or the hydrogen may be replaced with alkyl or cycloalkyl (which themselves may be further substituted).

[0048] Any type of free radical polymerization may be used including but not limited to bulk, solution, suspension, and emulsion as well as any of the controlled radical polymerization methods such as stable free radical polymerization, nitroxide-mediated living polymerization, atom transfer radical polymerization, reversible addition fragmentation chain transfer polymerization, organotellurium mediated living radical polymerization, and the like.

[0049] A "monomer" is a mono-functional molecule which can undergo chain growth polymerization and, in particular, free radical polymerization, thereby creating a repeating unit in the chemical structure of the target macromolecule. Some monomers have di-functional impurities that can act as cross-linking agents. A "hydrophilic monomer" is also a monomer which yields a clear single phase solution when mixed with deionized water at 25°C at a concentration of 5 weight percent. A "hydrophilic component" is a monomer, macromer, prepolymer, initiator, cross-linker, additive, or polymer which yields a clear single-phase solution when mixed with deionized water at 25°C at a concentration of 5 weight percent. A "hydrophobic component" is a monomer, macromer, prepolymer, initiator, cross-linker, additive, or polymer which is slightly soluble or insoluble in deionized water at 25°C.

[0050] A "macromolecule" is an organic compound having a number average molecular weight of greater than 1500, and may be reactive or non-reactive.

[0051] A "macromonomer" or "macromer" is a macromolecule that has one group that can undergo chain growth polymerization and, in particular, free radical polymerization, thereby creating a repeating unit in the chemical structure of the target macromolecule. Typically, the chemical structure of the macromer is different than the chemical structure of the target macromolecule, that is, the repeating unit of the macromer's pendent group is different than the repeating unit of the target macromolecule or its mainchain. The difference between a monomer and a macromer is merely one of chemical structure, molecular weight, and molecular weight distribution of the pendent group. As a result, and as used herein, the patent literature occasionallydefines monomers as polymerizable compounds having relatively low molecular weights of about 1,500 Daltons or less, which inherently includes some macromers. In particular, monomethacryloxypropyl terminated mono-n-butyl terminated polydimethylsiloxane (molecular weight = 500-1500 g / mol) (mPDMS) and mono-(2-hydroxy-3-methacryloxypropyl)-propyl ether terminated mono-n-butyl terminated polydimethylsiloxane (molecular weight = 500-1500 g / mol) (OH-mPDMS) may be referred to as monomers or macromers. Furthermore, the patent literature occasionally defines macromers as having one or more polymerizable groups, essentially broadening the common definition of macromer to include prepolymers. As a result and as used herein, di-functional and multi-functional macromers, prepolymers, and crosslinkers may be used interchangeably.

[0052] A "silicone-containing component" is a monomer, macromer, prepolymer, cross-linker, initiator, additive, or polymer in the reactive mixture with at least one silicon-oxygen bond, typically in the form of siloxy groups, siloxane groups, carbosiloxane groups, and mixtures thereof.

[0053] Examples of silicone-containing components which are useful in this invention may be found in U.S. Patent Nos. 3,808,178, 4,120,570, 4,136,250, 4,153,641, 4,740,533, 5,034,461,5,070,215, 5,244,981, 5,314,960, 5,331,067, 5,371,147, 5,760,100, 5,849,811, 5,962, 5485,965,631, 5,998,498, 6,367,929, 6,822,016, 6,943,203, 6,951,894, 7,052,131, 7,247,6927,396,890, 7,461,937, 7,468,398, 7,538,146, 7,553,880, 7,572,841, 7,666,921, 7,691,916,7,786,185, 7,825,170, 7,915,323, 7,994,356, 8,022,158, 8,163,206, 8,273,802, 8,399,538,8,415,404, 8,420,711, 8,450,387, 8,487,058, 8,568,626, 8,937,110, 8,937,111, 8,940,812,8,980,972, 9,056,878, 9,125,808, 9,140,825, 9,156,934, 9,170,349, 9,217,813, 9,244,196,9,244,197, 9,260,544, 9,297,928, 9,297,929, and European Patent No. 080539. These patents are hereby incorporated by reference in their entireties.

[0054] A "polymer" is a target macromolecule composed of the repeating units of the monomers used during polymerization.

[0055] A "homopolymer" is a polymer made from one monomer; a "copolymer" is a polymer made from two or more monomers; a "terpolymer" is a polymer made from three monomers. A "block copolymer" is composed of compositionally different blocks or segments. Diblock copolymers have two blocks. Triblock copolymers have three blocks. "Comb or graft copolymers" are made from at least one macromer.

[0056] A "repeating unit" is the smallest group of atoms in a polymer that corresponds to the polymerization of a specific monomer or macromer.

[0057] An "initiator" is a molecule that can decompose into radicals which can subsequently react with a monomer to initiate a free radical polymerization reaction. A thermal initiator decomposes at a certain rate depending on the temperature; typical examples are azo compounds such as 1,1'azobisisobutyronitrile and 4,4'-azobis(4-cyanovaleric acid), peroxides such as benzoyl peroxide, tert-butyl peroxide, tert-butyl hydroperoxide, tert-butyl peroxybenzoate, dicumyl peroxide, and lauroyl peroxide, peracids such as peracetic acid and potassium persulfate as well as various redox systems. A photo-initiator decomposes by a photochemical process; typical examples are derivatives of benzil, benzoin, acetophenone, benzophenone, camphorquinone, acylphosphine oxides, bisacylphosphine oxides and mixtures thereof as well as various monoacyl and bisacyl phosphine oxides and combinations thereof.

[0058] A "cross-linking agent" is a di-functional or multi-functional monomer or macromer which can undergo free radical polymerization at two or more locations on the molecule, thereby creating branch points and a polymeric network. Common examples are ethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, trimethylolpropane trimethacrylate, methylene bisacrylamide, triallyl cyanurate, and the like. Silicone-containing monomers and crosslinkers can also be used.

[0059] A "prepolymer" is a reaction product of monomers which contains remaining polymerizable groups capable of undergoing further reaction to form a polymer.

[0060] A "polymeric network" is a cross-linked macromolecule that may swell but cannot dissolve in solvents. "Hydrogels" are polymeric networks that swell in water or aqueous solutions, typically absorbing at least 10 weight percent water. "Silicone hydrogels" are hydrogels that are made from at least one silicone-containing component with at least one hydrophilic component. Hydrophilic components may also include non-reactive polymers.

[0061] " Conventional hydrogels" refer to polymeric networks made from components without any siloxy, siloxane or carbosiloxane groups. Conventional hydrogels are prepared from reactive mixtures comprising hydrophilic monomers. Examples include 2-hydroxyethyl methacrylate ("HEMA"), N-vinyl pyrrolidone ("NVP"), N, N-dimethylacrylamide ("DMA") or vinyl acetate.

[0062] U.S. Patent Nos. 4,436,887, 4,495,313, 4,889,664, 5,006,622, 5,039459, 5,236,969, 5,270,418, 5,298,533, 5,824,719, 6,420,453, 6,423,761, 6,767,979, 7,934,830, 8,138,290, and 8,389,597 disclose the formation of conventional hydrogels. Commercially available conventionalhydrogels include, but are not limited to, etafilcon, genfilcon, hilafilcon, lenefilcon, nesofilcon, omafilcon, polymacon, and vifilcon, including all of their variants.

[0063] " Silicone hydrogels" refer to polymeric networks made from at least one hydrophilic component and at least one silicone-containing component. Examples of suitable families of hydrophilic components that may be present in the reactive mixture include (meth)acrylates, styrenes, vinyl ethers, (meth)acrylamides, N-vinyl lactams, N-vinyl amides, N-vinyl imides, Nvinyl ureas, O-vinyl carbamates, O-vinyl carbonates, other hydrophilic vinyl compounds, and mixtures thereof. Silicone-containing components are well known and have been extensively described in the patent literature. For instance, the silicone-containing component may comprise at least one polymerizable group (e.g., a (meth)acrylate, a styryl, a vinyl ether, a (meth)acrylamide, an N-vinyl lactam, an N-vinylamide, an O-vinylcarbamate, an O-vinylcarbonate, a vinyl group, or mixtures of the foregoing), at least one siloxane group, and one or more linking groups (which may be a bond) connecting the polymerizable group(s) to the siloxane group(s). The siliconecontaining components may, for instance, contain from 1 to 220 siloxane repeat units. The silicone-containing component may also contain at least one fluorine atom. Silicone hydrogel lenses may contain a coating, and the coating may be the same or different material from the substrate.

[0064] Examples of silicone hydrogels include acquafilcon, asmofilcon, balafilcon, comfilcon, delefilcon, enfilcon, fanfilcon, formofilcon, galyfilcon, lotrafilcon, narafilcon, riofilcon, samfilcon, senofilcon, somofilcon, and stenfilcon, including all of their variants, as well as silicone hydrogels as prepared in US Patent Nos. 4,659,782, 4,659,783, 5,244,981, 5,314,960, 5,331,067, 5,371,147, 5,998,498, 6,087,415, 5,760,100, 5,776,999, 5,789,461, 5,849,811, 5,965,631,6,367,929, 6,822,016, 6,867,245, 6,943,203, 7,247,692, 7,249,848, 7,553,880, 7,666,921,7,786,185, 7,1456,131, 8,022,158, 8,273,802, 8,399,538, 8,470,906, 8,450,387, 8,487,058, 8,507,577, 8,637,621, 8,703,891, 8,937,110, 8,937,111, 8,940,812, 9,056,878, 9,057,821,9,125,808, 9,140,825, 9156,934, 9,170,349, 9,244,196, 9,244,197, 9,260,544, 9,297,928,9,297,929 as well as WO 03 / 22321, WO 2008 / 061992, and US 2010 / 0048847. These patents are hereby incorporated by reference in their entireties.

[0065] An "interpenetrating polymeric network" comprises two or more networks which are at least partially interlaced on the molecular scale but not covalently bonded to each other and which cannot be separated without braking chemical bonds. A "semi-interpenetrating polymericnetwork" comprises one or more networks and one or more polymers characterized by some mixing on the molecular level between at least one network and at least one polymer. A mixture of different polymers is a "polymer blend." A semi-interpenetrating network is technically a polymer blend, but in some cases, the polymers are so entangled that they cannot be readily removed.

[0066] "Reactive components" are the polymerizable compounds (such as monomers, macromers, oligomers, prepolymers, and cross-linkers) in the reactive mixture (defined below), as well as any other components in the reactive mixture which are intended to substantially remain in the resultant polymeric network after polymerization and all work-up steps (such as extraction steps) and packaging steps have been completed. Reactive components may be retained in the polymeric network by covalent bonding, hydrogen bonding, electrostatic interactions, the formation of interpenetrating polymeric networks, or any other means. Components that are intended to release from the polymeric network once it is in use are still considered "reactive components." For example, pharmaceutical or nutraceutical components in a contact lens which are intended to be released during wear are considered "reactive components." Components that are intended to be removed from the polymeric network during the manufacturing process (e.g., by extraction), such as diluents, are not "reactive components."

[0067] The terms "reactive mixture" and "reactive monomer mixture" refer to the mixture of components which are mixed together and, when subjected to polymerization conditions, result in formation of a polymeric network (such as conventional or silicone hydrogels) as well as biomedical devices, ophthalmic devices, and contact lenses made therefrom. The reactive mixture may comprise reactive components such as monomers, macromers, prepolymers, cross-linkers, and initiators, additives such as wetting agents, polymers, dyes, light absorbing compounds such as UV absorbers, pigments, photochromic compounds, pharmaceutical compounds, and / or nutraceutical compounds, any of which may be polymerizable or non-polymerizable but are capable of being retained within the resulting biomedical device (e.g., contact lens). The reactive mixture may also contain other components which are intended to be removed from the device prior to its use, such as diluents. It will be appreciated that a wide range of additives may be added based upon the contact lens which is made and its intended use. Concentrations of components of the reactive mixture are expressed as weight percentages of all reactive components in the reactive mixture, therefore excluding diluents. When diluents are used, their concentrations are expressedas weight percentages based upon the amount of all components in the reactive mixture (including the diluent).

[0068] The term "silicone hydrogel contact lens" refers to a hydrogel contact lens that is made from at least one silicone-containing compound. Silicone hydrogel contact lenses generally have increased oxygen permeability compared to conventional hydrogels. Silicone hydrogel contact lenses use both their water and polymer content to transmit oxygen to the eye.

[0069] The term "multi-functional" refers to a component having two or more polymerizable groups. The term "mono-functional" refers to a component having one polymerizable group.

[0070] The terms "halogen" or "halo" indicate fluorine, chlorine, bromine, and iodine.

[0071] "Alkyl" refers to an optionally substituted linear or branched alkyl group containing the indicated number of carbon atoms. If no number is indicated, then alkyl (including any optional substituents on alkyl) may contain 1 to 16 carbon atoms. Preferably, the alkyl group contains 1 to 10 carbon atoms, alternatively 1 to 8 carbon atoms, alternatively 1 to 6 carbon atoms, or alternatively 1 to 4 carbon atoms. Examples of alkyl include methyl, ethyl, propyl, isopropyl, butyl, iso-, sec- and tert-butyl, pentyl, hexyl, heptyl, 3-ethylbutyl, and the like. Examples of substituents on alkyl include 1, 2, or 3 groups independently selected from hydroxy, amino, amido, oxa, carboxy, alkyl carboxy, carbonyl, alkoxy, thioalkyl, carbamate, carbonate, halogen, phenyl, benzyl, and combinations thereof. "Alkylene" means a divalent alkyl group, such as -CH2-, - CH2CH2-, -CH2CH2CH2-, -CH2CH(CH3)CH2-, and -CH2CH2CH2CH2-.

[0072] "Haloalkyl" refers to an alkyl group as defined above substituted with one or more halogen atoms, where each halogen is independently F, Cl, Br or I. A preferred halogen is F. Preferred haloalkyl groups contain 1-6 carbons, more preferably 1-4 carbons, and still more preferably 1-2 carbons. "Haloalkyl" includes perhaloalkyl groups, such as -CF3- or -CF2CF3-. "Haloalkylene" means a divalent haloalkyl group, such as -CH2CF2-.

[0073] "Cycloalkyl" refers to an optionally substituted cyclic hydrocarbon containing the indicated number of ring carbon atoms. If no number is indicated, then cycloalkyl may contain 3 to 12 ring carbon atoms. Preferred are G-G cycloalkyl groups, G-G cycloalkyl, more preferably C4-C7 cycloalkyl, and still more preferably G-G cycloalkyl. Examples of cycloalkyl include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and cyclooctyl. Examples of substituents on cycloalkyl include 1, 2, or 3 groups independently selected from alkyl, hydroxy, amino, amido, oxa, carbonyl, alkoxy, thioalkyl, amido, carbamate, carbonate, halo, phenyl, benzyl,and combinations thereof. "Cycloalkylene" means a divalent cycloalkyl group, such as l,2cyclohexylene, 1,3- cyclohexylene, or 1,4- cyclohexylene.

[0074] "Heterocycloalkyl" refers to a cycloalkyl ring or ring system as defined above in which at least one ring carbon has been replaced with a heteroatom selected from nitrogen, oxygen, and sulfur. The heterocycloalkyl ring is optionally fused to or otherwise attached to other heterocycloalkyl rings and / or non-aromatic hydrocarbon rings and / or phenyl rings. Preferred heterocycloalkyl groups have from 5 to 7 members. More preferred heterocycloalkyl groups have 5 or 6 members. Heterocycloalkylene means a divalent heterocycloalkyl group.

[0075] "Aryl" refers to an optionally substituted aromatic hydrocarbon ring system containing at least one aromatic ring. The aryl group contains the indicated number of ring carbon atoms. If no number is indicated, then aryl may contain 6 to 14 ring carbon atoms. The aromatic ring may optionally be fused or otherwise attached to other aromatic hydrocarbon rings or non-aromatic hydrocarbon rings. Examples of aryl groups include phenyl, naphthyl, and biphenyl. Preferred examples of aryl groups include phenyl. Examples of substituents on aryl include 1, 2, or 3 groups independently selected from alkyl, hydroxy, amino, amido, oxa, carboxy, alkyl carboxy, carbonyl, alkoxy, thioalkyl, carbamate, carbonate, halo, phenyl, benzyl, and combinations thereof. "Arylene" means a divalent aryl group, for example 1,2-phenylene, 1,3 -phenylene, or l,4phenylene.

[0076] "Heteroaryl" refers to an aryl ring or ring system, as defined above, in which at least one ring carbon atom has been replaced with a heteroatom selected from nitrogen, oxygen, and sulfur. The heteroaryl ring may be fused or otherwise attached to one or more heteroaryl rings, aromatic or nonaromatic hydrocarbon rings or heterocycloalkyl rings. Examples of heteroaryl groups include pyridyl, furyl, and thienyl. "Heteroarylene" means a divalent heteroaryl group.

[0077] "Alkoxy" refers to an alkyl group attached to the parent molecular moiety through an oxygen bridge. Examples of alkoxy groups include, for instance, methoxy, ethoxy, propoxy and isopropoxy. "Thioalkyl" means an alkyl group attached to the parent molecule through a sulfur bridge. Examples of thioalkyl groups include, for instance, methylthio, ethylthio, n-propylthio and iso-propylthio. "Aryloxy" refers to an aryl group attached to a parent molecular moiety through an oxygen bridge. Examples include phenoxy. "Cyclic alkoxy" means a cycloalkyl group attached to the parent moiety through an oxygen bridge.

[0078] "Alkylamine" refers to an alkyl group attached to the parent molecular moiety through an -NH bridge. Alkyleneamine means a divalent alkylamine group, such as -CH2CH2NH-.

[0079] "Siloxanyl" refers to a structure having at least one Si-O-Si bond. Thus, for example, siloxanyl group means a group having at least one Si-O-Si group (i.e. a siloxane group), and siloxanyl compound means a compound having at least one Si-O-Si group. "Siloxanyl" encompasses monomeric (e.g., Si-O-Si) as well as oligomeric / polymeric structures (e.g., -[Si-O]n, where n is 2 or more). Each silicon atom in the siloxanyl group is substituted with independently selected RAgroups (where RAis as defined in formula A options (b)-(i)) to complete their valence.

[0080] "Silyl" refers to a structure of formula RiSi- and "siloxy" refers to a structure of formula RiSi-O-, where each R in silyl or siloxy is independently selected from trimethylsiloxy, Ci-Cs alkyl (preferably C1-C3 alkyl, more preferably ethyl or methyl), and C3-C8 cycloalkyl.

[0081] "Alkyleneoxy" refers to groups of the general formula -(alkylene-O)p- or -(O-alkylene)p, wherein alkylene is as defined above, and p is from 1 to 200, or from 1 to 100, or from 1 to 50, or from 1 to 25, or from 1 to 20, or from 1 to 10, wherein each alkylene is independently optionally substituted with one or more groups independently selected from hydroxyl, halo (e.g., fluoro), amino, amido, ether, carbonyl, carboxyl, and combinations thereof. If p is greater than 1, then each alkylene may be the same or different and the alkyleneoxy may be in block or random configuration. When alkyleneoxy forms a terminal group in a molecule, the terminal end of the alkyleneoxy may, for instance, be a hydroxy or alkoxy (e.g., HO-fCFECFEO p- or CH3O[CH2CH2O]P-). Examples of alkyleneoxy include polyethyleneoxy, polypropyleneoxy, polybutyleneoxy, and poly(ethyleneoxy-co-propyleneoxy).

[0082] "Oxaalkylene" refers to an alkylene group as defined above where one or more non- adjacent CH2 groups have been substituted with an oxygen atom, such as - CH2CH2OCH(CH3)CH2-. "Thiaalkylene" refers to an alkylene group as defined above where one or more non-adjacent CH2 groups have been substituted with a sulfur atom, such as - CH2CH2SCH(CH3)CH2-.

[0083] The term "linking group" refers to a moiety that links a polymerizable group to the parent molecule. The linking group may be any moiety that is compatible with the compound of which it is a part, and that does not undesirably interfere with the polymerization of the compound, is stable under the polymerization conditions as well as the conditions for the processing and storage of the final product. For instance, the linking group may be a bond, or it may comprise one or more alkylene, haloalkylene, amide, amine, alkyleneamine, carbamate, ester (-CO2-), arylene, heteroarylene, cycloalkylene, heterocycloalkylene, alkyleneoxy, oxaalkylene, thiaalkylene,haloalkyleneoxy (alkyleneoxy substituted with one or more halo groups, e.g., -OCF2-, -OCF2CF2, -OCF2CH2-), siloxanyl, alkylenesiloxanyl, or combinations thereof. The linking group may optionally be substituted with 1 or more substituent groups. Suitable substituent groups may include those independently selected from alkyl, halo (e.g., fluoro), hydroxyl, HO-alkyleneoxy, MeO-alkyleneoxy, siloxanyl, siloxy, siloxy-alkyleneoxy-, siloxy-alkylene-alkyleneoxy- (where more than one alkyleneoxy groups may be present and wherein each methylene in alkylene and alkyleneoxy is independently optionally substituted with hydroxyl), ether, amine, carbonyl, carbamate, and combinations thereof. The linking group may also be substituted with a polymerizable group, such as (meth)acrylate (in addition to the polymerizable group to which the linking group is linked).

[0084] Preferred linking groups include Ci-Cs alkylene (preferably C2-C6 alkylene), Ci-Cs oxaalkylene (preferably C2-C6 oxaalkylene), Ci-Cs thiaalkylene, Ci-Cs alkylene-carboxylate-CiCs alkylene, Ci-Cs alkylene-amide-Ci-Cs alkylene, and Ci-Cs alkylene-amine-Ci-Cs alkylene, each of which is optionally substituted with 1 or 2 groups independently selected from hydroxyl and siloxy.

[0085] When the linking group is comprised of combinations of moieties as described above (e.g., alkylene and cycloalkylene), the moieties may be present in any order. For instance, if in Formula A below, L is indicated as being -alkylene-cycloalkylene-, then Rg-L may be either Rg- alkylenecycloalkylene-, or Rg-cycloalkylene-alkylene-. Notwithstanding this, the listing order represents the preferred order in which the moieties appear in the compound starting from the terminal polymerizable group (Rg or Pg) to which the linking group is attached. For example, if in Formula A, L is indicated as being alkylene-cycloalkylene, then Rg-L is preferably Rg- alkylenecycloalkylene-.

[0086] The terms "light absorbing compound" refers to a chemical material that absorbs light within the visible spectrum (e.g., in the 380 to 780 nm range). A "high energy radiation absorber," "UV / HEV absorber," or "high energy light absorbing compound" is a chemical material that absorbs various wavelengths of ultraviolet light, high energy visible light, or both. A material's ability to absorb certain wavelengths of light can be determined by measuring its UV / Vis transmission or absorbance spectrum.

[0087] When the compounds described herein contain olefinic double bonds or other centers of geometric asymmetry, and unless otherwise specified, it is intended that the compounds includethe cis, trans, Z- and E- configurations. Likewise, all tautomeric and salt forms are also intended to be included.

[0088] The term "optional substituent" means that a hydrogen atom in the underlying moiety is optionally replaced by a substituent. Any substituent may be used that is sterically practical at the substitution site and is synthetically feasible. Identification of a suitable optional substituent is well within the capabilities of an ordinarily skilled artisan. Examples of an "optional substituent" include, without limitation, Ci-Ce alkyl, Ci-Ce alkoxy, Ci-Ce thioalkyl, C3-C7 cycloalkyl, aryl, halo, hydroxy, amino, NR4R5, benzyl, SO3H, SChNa, or -Y-Pg, wherein R4and R5are independently H or Ci-Ce alkyl, Y is a linking group; and Pgis a polymerizable group. The foregoing substituents may be optionally substituted by an optional substituent (Ih, unless otherwise indicated, is preferably not further substituted). For instance, alkyl may be substituted by halo (resulting, for instance, in CF).

[0089] " Substructure" means the chemical structure of the compound and any compounds derived from that chemical structure via the replacement of one or more hydrogen atoms by any other atom (which atom may be bound to other atoms or groups). Replacement, for instance, may be of one or more, preferably 1, 2, or 3, more preferably 1 or 2, more preferably 1, hydrogen atoms with an independently selected optional substituent. Encompassed within the definition of "substructure" are materials wherein the substructure forms a fragment of a larger compound, such as a monomer (e.g., containing one or more polymerizable groups), a polymer, or a macromolecule.

[0090] " Visible light absorption maximum means a wavelength in the visible light wavelength range (380 to 760 nm) at which a light absorbance is a maximum. The definition encompasses materials that exhibit overall absorption maxima outside of the visible light range, such as within the UV region.

[0091] The terms "photostable," "photostability," or similar expressions mean that the compound (which may, when measured, be optionally embedded in an ophthalmic device, such as a hydrogel contact lens, and optionally measured either within or outside of a blister pack or a vial) exhibits a loss of absorbance at the visible light absorbance maximum of no more than 20 percent after exposure to light under conditions such as those of the International Conference on Harmonisation (ICH) of Technical Requirements for Registration of Pharmaceuticals for Human Use guideline,

[0092] Q1B Photostability Testing of New Drug Substances and Products, published on November 1996. Preferably, the exposure is conducted under the ICH Photostability Guidelineusing an Option 2 light source with an estimated illuminance exposure of 1.5192 x 106Lux hours (168.8 hours exposure time) and an estimated ultraviolet irradiation exposure of 259.4 Watt hours / m2(16.2 hours exposure time), preferably in a photostability chamber that is controlled at 25 °C / Amb RH. After exposure, the UV / Vis spectrum of the sample is collected and compared to a sample's spectrum prior to exposure. Changes are calculated relative to the visible light absorbance maximum of the lens as observed prior to exposure. By way of example, if the absorbance at the visible light absorbance maximum before exposure is 4 absorbance units, and is 2 absorbance units after exposure, then the loss of absorbance is 50 percent. In the invention, the loss of absorbance after photo exposure is preferably no more than 15 percent, or no more than 10 percent, or no more than 7 percent, or no more than 5 percent, or no more than 4 percent, or no more than 3 percent, or no more than 2 percent, or no more than 1 percent, or no more than 0.5 percent, or no more than 0.1 percent.

[0093] The term "more photostable than macular pigment" or similar expression means that the compound (which may, when tested, be optionally embedded in an ophthalmic device, such as a hydrogel contact lens, and optionally measured either within or outside of a blister pack) exhibits less loss of absorbance at the visible light absorbance maximum than observed with macular pigment, following exposure to light, for instance under the ICH Photostability Guideline as described above.

[0094] The term full width half maximum (FWHM) means the width of the absorbance peak at half its maximum intensity.

[0095] The terms "thermally stable," "thermal stability," or similar expressions mean that the compound (which may, when measured, be optionally embedded in an ophthalmic device, such as a hydrogel contact lens, and optionally measured either within or outside of a blister pack or a vial) exhibits a loss of absorbance at the visible light absorbance maximum of no more than 20 percent after exposure in a stability chamber at 89°C for one month as described in the examples below. After exposure, the UV / Vis spectrum of the sample is collected and compared to a sample's spectrum prior to exposure. Changes are calculated relative to the visible light absorbance maximum of the lens as observed prior to exposure. By way of example, if the absorbance at the visible light absorbance maximum before exposure is 4 absorbance units, and is 2 absorbance units after exposure, then the loss of absorbance is 50 percent. In the invention, the loss of absorbance after thermal exposure is preferably no more than 20 percent, or no more than 15 percent, or nomore than 12 percent, or no more than 10 percent, or no more than 5 percent, or no more than 4 percent, or no more than 3 percent, or no more than 2 percent, or no more than 1 percent, or no more than 0.5 percent, or no more than 0.1 percent.

[0096] The term "more thermally stable than macular pigment" or similar expression means that the compound (which may, when tested, be optionally embedded in an ophthalmic device, such as a hydrogel contact lens, and optionally measured either within or outside of a blister pack) exhibits less loss of absorbance at the visible light absorbance maximum than observed with macular pigment, following thermal exposure as described above.

[0097] Unless otherwise indicated, ratios, percentages, parts, and the like are by weight.

[0098] Unless otherwise indicated, numeric ranges, for instance as in "from 2 to 10" or "between 2 and 10" are inclusive of the numbers defining the range (e.g., 2 and 10).

[0099] The term "curing energy" as employed in this specification means an energy used to irradiate a material. In various examples, curing energy is used to at least partially effect a curing process. However, the term curing energy may include other transfer of energy from a source to a site or surface without being limited to a curing process. As an example, curing energy may comprise radiant energy, thermal energy, or other transfer of energy.

[0100] The term "radiant energy" as employed in this specification means the energy of the electromagnetic radiation. In the disclosure, the radiant energy may be controlled by the intensity, the wavelength, or both the intensity and the wavelength, of the radiation.

[0101] In certain aspects, the disclosure provides methods for manufacturing photoabsorbing contact lenses, for instance contact lenses that contain a photochromic compound and / or a high energy visible (HEV) light absorbing compound. The contact lenses are made from reactive mixtures that comprise at least one polymerizable monomer, a photoinitiator which absorbs at an activating wavelength, and a photoabsorbing compound which displays absorption at the activating wavelength.

[0102] The presence of both a photoinitiator and a photoabsorbing compound having overlapping light absorption properties in the same reactive mixture can make controlled activation of the photoinitiator problematic. Without wishing to be bound to any particular theory, it is believed that the absorption by the light absorbing compound in the same spectral region as the photoinitiator causes the photoabsorbing compound to at least partially "shield" the photoinitiator. Where the photoabsorbing compound is a photochromic compound, this absorption may occur when thephotochromic is at least partially activated. The incomplete activation of the initiator resulting from the absorption by the photoabsorbing compound is believed to prevent curing and / or results in a non-uniform or anisotropic cure that causes material defects and stresses to form within the lens. These defects negatively impact the mechanical and optical properties of the resulting contact lens. The disclosure addresses these problems by providing a differential cure process, as further described below.

[0103] The disclosure may be used to provide hard or soft contact lenses made of any known lens material, or material suitable for manufacturing such lenses. The lenses of the disclosure are soft contact lenses that may have water contents from about 0 to about 90 percent, or from about 20 and about 75% water. The contact lenses of the disclosure may have a water content of at least about 25%. The lenses of the disclosure may have other desirable properties, such as a tensile modulus of less than about 200 psi, or less than about 150 psi. The lenses may have oxygen permeabilities of greater than about 50 x 10'11(cm2 / sec) (ml Ch / ml x mmHg), or greater than about 75 x 10'11(cm2 / sec) (ml Ch / ml x mmHg). It should be understood that combinations of the foregoing properties are desirable, and the above referenced ranges may be combined in any combination.

[0104] The contact lenses of the disclosure may be conventional hydrogels. The contact lenses of the disclosure may be silicone hydrogels. The contact lenses may be made of hydrophilic monomers, silicone-containing components and mixtures thereof to form polymers such as siloxanes, hydrogels, silicone hydrogels, and combinations thereof. Material useful for forming the lenses of the disclosure may be made by reacting blends of macromers, monomers, polymers and combinations thereof along with additives such as polymerization initiators. Suitable materials include, without limitation, silicone hydrogels made from silicone macromers and hydrophilic monomers. A reactive mixture of different polymerizable monomers may also be used, resulting in the production of a co-polymer.

[0105] Reactive mixtures for making contact lenses are well known and the components of such mixtures are commercially available or may be readily prepared by those skilled in the art. Examples polymers suitable for forming contact lenses include but are not limited to etafilcon A, genfilcon A, lenefilcon A, polymacon, balafilcon, acquafilcon, comfilcon, galyfilcon, senofilcon, narafilcon and lotrafilcon. Contact lens formulations may include etafilcon, senofilcon, balafilcon, galyfilcon, lotrafilcon, comfilcon, filcon II 3, asmofilcon A, and silicone hydrogels, as prepared,for instance, in U.S. PatentNo. 5,998,498; U.S. Patent App. No. 09 / 532,943, a continuation-inpart of U.S. Patent App. No. 09 / 532,943, filed on August 30, 2000, and U.S. Patent No. 6,087,415, U.S. 6,087,415, U.S. 5,760,100, U.S. 5,776, 999, U.S. 5,789,461, U.S. 5,849,811, U.S. 5,965,631, US7,553,880, W02008 / 061992, US2010 / 048847. These patents are hereby incorporated by reference for the hydrogel compositions contained therein.

[0106] The reactive mixture of the disclosure may be a 2-hydroxyethyl methacrylate (HEMA) based hydrogel, such as etafilcon A. Etafilcon A, disclosed in U.S. Patent Nos. 4,680,336 and 4,495,313 incorporated herein in their entireties by reference, generally is a formulation primarily of HEMA and methacrylic acid (MAA), as well as various other additives such as crosslinkers and visibility tints.

[0107] The reactive mixture of the disclosure may be a silicone hydrogel made from at least one hydrophilic monomer and at least one silicone-containing component. Examples of silicone hydrogels include acquafilcon, asmofilcon, balafilcon, comfilcon, delefilcon, enfilcon, fanfilcon, formofilcon, galyfilcon, kalificlon lotrafilcon, narafilcon, riofilcon, samfilcon, senofilcon, serafdcon, somofilcon, stenfilcon, and verofilcon including all of their variants.

[0108] Reactive mixtures may comprise one or more hydrophilic monomer selected from N, Ndimethylacrylamide (DMA), N,N-vinylpyrrolidone (NVP), HEMA, and mixtures thereof; a silicone-containing component selected from 2-hydroxy-3-[3-methyl-3,3-

[0109] di(trimethylsiloxy)silylpropoxy]-propyl methacrylate (SiMAA), monomethacryloxypropyl terminated mono-n-butyl terminated polydimethylsiloxane (mPDMS), monomethacryloxypropyl terminated mono-n-methyl terminated poly dimethyl siloxane (methyl terminated mPDMS), mono-(2-hydroxy-3-methacryloxypropyl)-propyl ether terminated mono-n- butyl terminated poly dimethylsiloxane (OH-mPDMS), and mixtures thereof. For the hydrophilic monomer, DMA, NVP, HEMA and mixtures thereof are suitable. For the silicone containing component, of SiMAA, mPDMS, methyl terminated mPDMS, and mixtures thereof are suitable.

[0110] Reactive mixtures may be based on a hydrophilic monomer comprising a mixture of DMA and HEMA; a silicone-containing component comprising a mixture of mono-(2-hydroxy- 3methacryloxypropyloxy)-propyl terminated mono-n-butyl terminated polydimethylsiloxanes (OH-mPDMS) having from 2 to 20 repeat units (preferably a mixture of 4 and 15 repeat units).[OHl] The reactive mixture may contain additional components such as, but not limited to, diluents, initiators, UV absorbers, visible light absorbers, photochromic compounds,pharmaceuticals, nutraceuticals, antimicrobial substances, tints, pigments, copolymerizable dyes, nonpolymerizable dyes, release agents, visibility tints, and combinations thereof

[0112] Classes of suitable diluents for silicone hydrogel reactive mixtures include alcohols having 2 to 20 carbon atoms, amides having 10 to 20 carbon atoms derived from primary amines and carboxylic acids having 8 to 20 carbon atoms. The diluents may be primary, secondary, and tertiary alcohols.

[0113] Generally, the reactive components are mixed in a diluent to form a reactive mixture. Suitable diluents are known in the art. For silicone hydrogels, suitable diluents are disclosed in WO 03 / 022321 and US 6020445, the disclosure of which is incorporated herein by reference.

[0114] Classes of suitable diluents for silicone hydrogel reactive mixtures include alcohols having 2 to 20 carbons, amides having 10 to 20 carbon atoms derived from primary amines, and carboxylic acids having 8 to 20 carbon atoms. Primary and tertiary alcohols may be used. Preferred classes include alcohols having 5 to 20 carbons and carboxylic acids having 10 to 20 carbon atoms.

[0115] Specific diluents which may be used include l-ethoxy-2- propanol, diisopropylaminoethanol, isopropanol, 3,7-dimethyl-3-octanol, 1-decanol, 1-dodecanol, 1 octanol, 1 -pentanol, 2-pentanol, 1 -hexanol, 2-hexanol, 2-octanol, 3 -methyl-3 -pentanol, tert-amyl alcohol, tert-butanol, 2-butanol, 1 -butanol, 2-methyl-2-pentanol, 2-propanol, 1 -propanol, ethanol, 2-ethyl-l -butanol, (3-acetoxy-2-hydroxypropyloxy)-propylbis(trimethylsiloxy) methylsilane, ltert-butoxy-2-propanol, 3,3-dimethyl-2-butanol, tert-butoxyethanol, 2-octyl- 1-dodecanol, decanoic acid, octanoic acid, dodecanoic acid, 2-(diisopropylamino)ethanol mixtures thereof and the like. Examples of amide diluents include N,N-dimethyl propionamide and dimethyl acetamide.

[0116] Preferred diluents include 3,7-dimethyl-3-octanol, 1-dodecanol, 1-decanol, 1-octanol, Ipentanol, 1-hexanol, 2-hexanol, 2-octanol, 3-methyl-3-pentanol, 2-pentanol, t-amyl alcohol, tertbutanol, 2-butanol, 1-butanol, 2-methyl-2-pentanol, 2-ethyl-l -butanol, ethanol, 3,3-dimethyl- 2butanol, 2-octyl- 1-dodecanol, decanoic acid, octanoic acid, dodecanoic acid, mixtures thereof and the like.

[0117] More preferred diluents include 3,7-dimethyl-3-octanol, 1-dodecanol, 1-decanol, 1 octanol, 1 -pentanol, 1-hexanol, 2-hexanol, 2-octanol, 1-dodecanol, 3 -methyl-3 -pentanol, Ipentanol, 2-pentanol, t-amyl alcohol, tert-butanol, 2-butanol, 1-butanol, 2-methyl-2-pentanol, 2ethyl- 1-butanol, 3,3-dimethyl-2-butanol, 2-octyl- 1-dodecanol, mixtures thereof and the like. If a diluent is present, generally there are no particular restrictions with respect to the amount of diluentpresent. When diluent is used, the diluent may be present in an amount in the range of about 2 to about 70 weight percent, including in the range of about 5 to about 50 weight percent, and in the range of about 15 to about 40 weight percent, based on the total weight of the reactive mixtures (including reactive and nonreactive Formulas). Mixtures of diluents may be used.

[0118] A polymerization initiator may be used in the reactive mixture. The polymerization initiator may include, for instance, at least one of lauroyl peroxide, benzoyl peroxide, iso- propyl percarbonate, azobisisobutyronitrile, and the like, that generate free radicals at moderately elevated temperatures, and photoinitiator systems such as aromatic alpha-hydroxy ketones, alkoxyoxybenzoins, acetophenones, acylphosphine oxides, bisacylphosphine oxides, and a tertiary amine plus a diketone, mixtures thereof and the like. Illustrative examples of photoinitiators are 1 hydroxy cyclohexyl phenyl ketone, 2-hydroxy-2-methyl-l-phenyl-propan- 1-one, bis(2,6dimethoxybenzoyl)-2,4-4-trimethylpentyl phosphine oxide (DMBAPO), bis(2,4,6trimethylbenzoyl)-phenyl phosphine oxide (Irgacure 819), 2,4,6-trimethylbenzyldiphenyl phosphine oxide and 2,4,6-trimethylbenzoyl diphenylphosphine oxide, benzoin methyl ester and a combination of cam- phorquinone and ethyl 4-(N,N-dimethylamino)benzoate.

[0119] Commercially available (from IGM Resins B.V., The Netherlands) visible light initiator systems include Irgacure® 819, Irgacure® 1700, Irgacure® 1800, Irgacure® 819, Irgacure® 1850 and Lucrin® TPO initiator. Commercially available (from IGM Resins B.V.) UV photoinitiators include Darocur® 1173 and Darocur® 2959. These and other photoinitiators which may be used are disclosed in Volume III, Photoinitiators for Free Radical Cationic & Anionic Photopolymerization, 2nd Edition by J. V. Crivello & K. Dietliker; edited by G. Bradley; John Wiley and Sons; New York; 1998. The initiator is used in the reactive mixture in effective amounts to initiate photopolymerization of the reactive mixture, e.g., from about 0.1 to about 2 parts by weight per 100 parts of reactive monomer mixture. Polymerization of the reactive mixture can be initiated using the appropriate choice of heat or visible or ultraviolet light or other means depending on the polymerization initiator used. Alternatively, initiation can be conducted using e- beam without a photoinitiator. However, when a photoinitiator is used, the preferred initiators are bisacylphosphine oxides, such as bis(2,4,6-tri-methylbenzoyl)-phenyl phosphine oxide (Irgacure® 819) or a combination of 1 -hydroxy cyclohexyl phenyl ketone and bis(2,6dimethoxybenzoyl)-2,4- 4-trimethylpentyl phosphine oxide (DMBAPO).

[0120] The reactive mixture for making the ophthalmic devices of the invention may comprise, in addition to an invention compound, any of the polymerizable compounds and optional components described above.

[0121] In certain aspects, the reactive mixture used in the methods of the disclosure may contain a photoinitiator. The photoinitiator may absorb (and be activated by) various wavelengths of light, for instant UV wavelengths and / or visible wavelengths. Preferably, the photoinitiator of the methods of the disclosure may absorb within the visible range (about 380 nm to about 780 nm) of the electromagnetic spectrum. Suitable visible light photoinitiators are known in the art and include, but are not limited to, aromatic alpha-hydroxy ketones, alkoxyoxybenzoins, acetophenones, acylphosphine oxides, bisacylphosphine oxides, and a tertiary amine plus a diketone, mixtures thereof and the like. Illustrative examples of photoinitiators are 1 hydroxy cyclohexyl phenyl ketone, 2-hydroxy-2-methyl-l-phenyl-propan-l-one, bis(2,6dimethoxybenzoyl)-2,4-4-trimethylpentyl phosphine oxide (DMBAPO), bis(2,4,6trimethylbenzoyl)-phenyl phosphineoxide (Irgacure 819), 2,4,6-trimethylbenzyldiphenyl phosphine oxide and 2,4,6-trimethylbenzoyl diphenylphosphine oxide, benzoin methyl ester and a combination of camphorquinone and ethyl 4-(N,N-dimethylamino)benzoate. Commercially available visible light photoinitiator systems include Irgacure 819, Irgacure 1700, Irgacure 1800, Irgacure 819, Irgacure 1850 (all from Ciba Specialty Chemicals) and Lucirin TPO initiator (available from BASF). These and other photoinitiators which may be used are disclosed in Volume III, Photoinitiators for Free Radical Cationic & Anionic Photopolymerization, 2nd Edition by J.V. Crivello& K. Dietliker; edited by G. Bradley; John Wiley and Sons; New York; 1998. The initiator may be used in the reactive mixture in effective amounts to initiate photopolymerization of the reactive mixture, e.g., from about 0.1 to about 2 parts by weight per 100 parts of reactive monomer(s).

[0122] Visible light photoinitiators may include alpha-hydroxy ketones such as Irgacure® (e.g. Irgacure 1700 or 1800) available from CIBA; various organic phosphine oxides, '2, 2'-azo- bisisobutyro-nitrile; diethoxyacetophenone; 1 -hydroxy cyclohexyl phenyl ketone; 2,2-dimethoxy- 2phenylacetophenone; phenothiazine; diisopropyl xanthogen disulfide; benzoin or benzoin derivatives; and the like. The photoinitiator may be activated at wavelengths including ranges from 200 to 600 nm, or from 300 to 500 nm, or from 350 to 450 nm, or from 380 to 450 nm, or from 400 to 450 nm, or from 430 to 440 nm.

[0123] In certain aspects, the photoabsorbing compound present in the reactive mixture is generally a compound that absorbs at least some of the activating radiation. For example, such compounds may absorb UV and or visible light in wavelengths that at least partially overlap with the wavelengths of the activating radiation that are needed to initiate the photoinitiator. The photoabsorbing compound may be a static photoabsorbing compound, meaning that its absorption profile does not significantly change upon exposure to radiation. Static photoabsorbing compounds are used, for instance, in non-photochromic sunglasses. Examples include compounds that absorb UV and / or HEV light (e.g., blue light).

[0124] The photoabsorbing compound may be a photochromic dye. A photochromic dye is any compound that is capable of transforming between a first "clear," "bleached" or "unactivated" ground state and a second "colored", "darkened" or "activated" state in response to the absorption of certain wavelengths of electromagnetic radiation (or "actinic radiation"). In one embodiment, the photochromic dye, when in an activated state, absorbs within the visible range (380 nm to 780 nm) of the electromagnetic spectrum. Examples of suitable photochromic dyes are known in the art and include, without limitation, the following classes of materials: chromenes, such as naphthopyrans, benzopyrans, indenonaphthopyrans and phenanthropyrans; spiropyrans, such as spiro (benzindoline) naphthopyrans, spiro (indoline) benzopyrans, spiro (indoline) naphthopyrans, spiro (indoline) quinopyrans and spiro (indoline) pyrans; oxazines, such as spiro (indoline) naphthoxazines, spiro (indoline) pyridobenzoxazines, spiro (benzindoline) pyridobenzoxazines, spiro (benzindoline) naphthoxazines and spiro (indoline) benzoxazines; mercury dithizonates, fulgides, fulgimides and mixtures of such photochromic compounds.

[0125] Additional suitable photochromic dyes include, without limitation, organo-metal dithiozonates, such as (arylazo)-thioformic arylhydrazidates, e.g., mercury dithizonates; and fulgides and fulgimides, naphthoxazines, spirobenzopyrans; polymerizable spirobenzopyrans and spirobenzopyrans; polymerizable fulgides; polymerizable naphthacenediones; polymerizable spirooxazines; and polymerizable polyalkoxylated napthopyrans. The photochromic dyes may be used alone or in combination with one or more other photochromic dyes or static photoabsorbing compound.

[0126] Other suitable photochromic compounds are disclosed in US7,556,750, the disclosure of which is incorporated by reference. The dyes may include polymerizable functional groups such that they are copolymerized into the resulting contact lens. Examples of polymerizable functionalgroups include (meth)acrylates, (meth)acrylamides, vinyls and the like. In one embodiment, a photochromic dye is selected such that, when in an activated state, it absorbs across the visible spectrum but, when unactivated, absorbs below about 430 nm and less than about 10% across the visible spectrum.

[0127] Still other useful photochromic dyes include indeno-fused naphthopyrans chosen from an indeno[2',3':3,4]naphtho[l,2-b]pyran and an indeno[l',2':4,3]naphtho[2,l-b]pyran, which are more specifically disclosed in US2009 / 0072206 and US2006 / 0226401 and those cited in US7, 364,291, and combinations thereof.

[0128] The contact lens may contain a mixture of photoabsorbing compounds, for instance at least one photochromic compound in mixture with other static photoabsorbing compounds, including pigments, dyes and UV and / or HEV absorbing compounds.

[0129] The reactive mixture may contain various other additives, which may be reactive or nonreactive. Examples of such additives include, but are not limited to, crosslinkers, wetting agents, release agents, polymers, dyes, other light absorbing compounds such as UV absorbers, pigments, pharmaceutical compounds, nutraceutical compounds, diluents, or combinations of any of the foregoing.

[0130] According to the disclosure, reactive mixtures such as described above, are formed into contact lenses by dispensing the mixture into a mold and subsequently curing the mixture. The mold is comprised of a base curve, which is the mold half that contacts the posterior surface of the lens, and a front curve, which contacts the anterior surface. The front curve and base curve, when brought together, define and enclose a cavity between them which, according to the disclosure, contains the reactive mixture.

[0131] The mold components (front curve and base curve), from the which the mold used in the disclosure is comprised, may be made from various materials, including disposable or reusable materials. For instance, the mold may be a thermoplastic optical mold, made from any suitable material including, without limitation, polyethylene, polypropylene, other polyolefins including homopolymers, copolymers, and terpolymers, polystyrene, polystyrene copolymers, polyesters such as polyethylene terephathalate) and poly(butylene terephthalate), polyamides, poly(vinyl alcohol) and its derivatives, hydrogenated styrene butadiene block copolymers like Tuftec, cyclic olefin polymers such as Zeonor® and Topas resins, and combinations thereof. The mold may be selected to be transparent or mostly transparent to wavelengths that will activate the photoinitiator,thus permitting irradiation through the front and base curves. The material may be the same or difference between the front and base curves. A suitable material for the front curve of the mold is a 90: 10 (w / w) blend of cyclic olefin polymer and hydrogenated styrene butadiene block copolymer, respectively. A suitable material for the base curve of the mold is a 90: 10 (w / w) blend of cyclic olefin polymer and polypropylene. Other exemplary materials include a blend of Zeonor® and Tuftec for either or both of the base curve and the front curve. The thickness of the base curve or front curve molds may vary, but is typically between 100 and 1500 microns, preferably between 600 and 800 microns, as measured in the center of the optical zone of the target lens mold design.

[0132] Sources of activating radiation for initiating the photoinitiators include, for instance, lamps that transmit light at the appropriate wavelengths for such initiation. A preferred source of activating radiation is a light emitting diode (LED) lamp. Preferred are LED lamps that transmit at the desired intensity and at a range of wavelengths that include from 200 to 600 nm, more preferably from 300 to 500 nm, most preferably from 350 to 450 nm.

[0133] The curing step is carried out by exposing the reactive mixture to radiation that includes the activating wavelength (the wavelength required to activate the photoinitiator). In the disclosure, the radiation is directed at both the base curve and the front curve of the mold. In addition, the radiation has a radiant energy at the base curve that is greater than the radiation's radiant energy at the front curve.

[0134] The differential in radiant energy may be provided by using higher intensity radiation at the base curve than at the front curve. Radiation intensity may be measured by various instruments.

[0135] For instance, as demonstrated in the examples a preferred instrument is ILT-2400, obtained from International Light Technologies.

[0136] The intensity of the radiation may generally be in the range of from 0.1 to 25 mW / cm2, preferably from 1 to 15 mW / cm2. As noted, the intensity of the radiation at the base curve may be greater than its intensity at the front curve. The radiation may have an intensity at the base curve that is at least 1 percent, alternatively at least 5 percent, alternatively at least 10 percent, alternatively at least 15 percent, or alternatively at least 20 percent, greater than the radiation's intensity at the front curve. The radiation may have an intensity at the base curve that is less than 350 percent, alternatively up to 300 percent, alternatively up to 250 percent, alternatively up to 200 percent, alternatively up to 150 percent, alternatively up to 100 percent, alternatively up to 90percent, alternatively up to 80 percent, alternatively up to 70 percent, alternatively up to 60 percent, alternatively up to 50 percent, alternatively up to 45 percent, alternatively up to 40 percent, alternatively up to 35 percent, or alternatively up to 30 percent greater than the intensity at the front curve. For example, the radiation may have an intensity at the base that is greater than the radiation's intensity at the front curve by at least 1 percent and less than 350 percent, alternatively from 1 to 300 percent, alternatively from 1 to 250 percent, alternatively from 1 to 250 percent alternatively from 1 to 200 percent, alternatively from 1 to 150 percent, alternatively from 1 to 100 percent, alternatively from 5 to 300 percent alternatively from 5 to 250 percent, alternatively from 5 to 200 percent, alternatively from 5 to 150 percent, alternatively from 5 to 100 percent, alternatively from 10 to 300 percent, alternatively from 10 to 200 percent, alternatively from 10 to 150 percent, alternatively from 10 to 100 percent, alternatively from 20 to 300 percent, alternatively from 20 to 250 percent, alternatively from 20 to 200 percent, alternatively from 20 to 150 percent, or alternatively from 20 to 100 percent. By way of further example, the radiation may have an intensity at the base that is greater than the radiation's intensity at the front curve by at least 5 percent and up to 100 percent, alternatively from 5 to 80 percent, alternatively from 10 to 66.7 percent. As illustration, if the intensity at the base curve is 10 percent greater than at the front curve, then if the intensity at the base curve is about 3.3 mW / cm2, the radiation's intensity at the front curve would be about 3.0 mW / cm2. For further illustration, if the intensity at the base curve is 66.7 percent greater than at the front curve, then if the intensity at the base curve is about 4.17 mW / cm2, the radiation's intensity at the front curve would be about 2.5 mW / cm2.

[0137] When the radiation's intensity is used to provide the differential in radiant energy at the front and base curves, it is preferable that the wavelength at the front and base curves be the same. For instance, the wavelength may range from 350 nm to 450 nm, or from 380 nm to 450 nm, or from 400 nm to 450 nm, or from 430 nm to 440 nm.

[0138] The differential in radiant energy in the method of the disclosure may be provided by using different wavelengths of radiation at the base curve and the front curve. More specifically, the wavelength at the base curve may be shorter than the wavelength at the front curve. For example, the wavelength at the base curve may be at least 5 nm, or at least 10 nm, or at least 20 nm shorter than the wavelength at the front curve. Both wavelengths are capable of activating the photoinitiator. Both wavelengths may have the same intensity.

[0139] The differential in radiant energy in the method of the disclosure may be provided by using both different wavelengths and intensities of radiation at the base curve and the front curve. For example, the differential may be provided by using shorter wavelength and higher intensity radiation at the base curve than at the front curve.

[0140] There are several ways in which to create curing energy such as the radiant energy differential across the mold. One method is to use two separate light sources having different intensities, wavelengths, or both intensity and wavelength. Another method is to use a single light source directed to the base curve with a series of mirrors or reflective pallet features to redirect and / or reflect a portion of the irradiation light, now having a reduced intensity, towards the front curve.

[0141] After curing, the lens may be subjected to extraction to remove unreacted components and release the lens from the lens mold. The extraction may be done using conventional extraction fluids, such as organic solvents, such as alcohols, or may be extracted using aqueous solutions.

[0142] Aqueous solutions are solutions which comprise water. The aqueous solutions of the present disclosure may comprise at least about 20 weight percent water, or at least about 50 weight percent water, or at least about 70 weight percent water, or at least about 95 weight percent water. Aqueous solutions may also include additional water-soluble compounds such as inorganic salts or release agents, wetting agents, slip agents, pharmaceutical and nutraceutical compounds, combinations thereof and the like. Release agents are compounds or mixtures of compounds which, when combined with water, decrease the time required to release a contact lens from a mold, as compared to the time required to release such a lens using an aqueous solution that does not comprise the release agent.

[0143] Extraction may be accomplished, for example, via immersion of the lens in an extraction fluid or exposing the lens to a flow of an extraction fluid. The extraction fluid may be an aqueous solution. Extraction may also include, for example, one or more of (i) heating the extraction fluid; (ii) stirring the extraction fluid; (iii) increasing the level of release aid in the extraction fluid to a level sufficient to cause release of the lens; (iv) mechanical or ultrasonic agitation of the lens; and (v) incorporating at least one leaching or extraction aid in the extraction fluid to a level sufficient to facilitate adequate removal of unreacted components from the lens. The foregoing may be conducted in batch or continuous processes, with or without the addition of heat, agitation, or both.

[0144] Application of physical agitation may be desired to facilitate leach and release. For example, the lens mold part to which a lens is adhered can be vibrated or caused to move back and forth within an aqueous solution. Other methods may include ultrasonic waves through the aqueous solution.

[0145] Lenses prepared as described above may exhibit the following quality properties. The lens may have a root mean squared optical path wavefront deviation from lens design target with spherical and cylindrical power as well as coma removed as measured using a 6.5 millimeter aperture that has been reduced as compared to an otherwise identical lens made under conditions of equal radiant energy at the base and front curves. The lens may have a root mean squared optical path wavefront deviation from lens design target with spherical and cylindrical power as well as coma removed as measured using a 6.5 millimeter aperture that has been reduced by at least 3% as compared to an otherwise identical lens made under conditions of equal radiant energy at the base and front curves. The lens may have a root mean squared optical path wavefront deviation from lens design target with spherical and cylindrical power as well as coma removed as measured using a 6.5 millimeter aperture that has been reduced by at least 0.0020 microns as compared to an otherwise identical lens made under conditions of equal radiant energy at the base and front curves.— Curing and Manufacture of Lens —

[0146] The reactive mixtures may be formed by any of the methods known in the art, such as shaking or stirring, and used to form polymeric articles or devices by known methods. The reactive components are mixed together either with or without a diluent to form the reactive mixture.

[0147] For example, ophthalmic devices may be prepared by mixing reactive components and optionally diluent(s) with a polymerization initiator and curing by appropriate conditions to form a product that can be subsequently formed into the appropriate shape by lathing, cutting, and the like. Alternatively, the reactive mixture may be placed in a mold and subsequently cured into the appropriate article.

[0148] A method of making a molded ophthalmic device, such as a silicone hydrogel contact lens, may comprise (i) preparing a reactive monomer mixture; (ii) transferring the reactive monomer mixture onto a first mold; (iii) placing a second mold on top the first mold filled with the reactive monomer mixture; and (iv) curing the reactive monomer mixture by free radical copolymerization to form the silicone hydrogel in the shape of a contact lens.

[0149] The reactive mixture may be cured via any known process for molding the reactive mixture in the production of contact lenses, including spin casting and static casting. Spin casting methods are disclosed in U.S. Patents Nos. 3,408,429 and 3,660,545, and static casting methods are disclosed in U.S. Patents Nos. 4,113,224 and 4,197,266. The contact lenses of this invention may be formed by the direct molding of the silicone hydrogels, which is economical, and enables precise control over the final shape of the hydrated lens. For this method, the reactive mixture is placed in a mold having the shape of the final desired silicone hydrogel and the reactive mixture is subjected to conditions whereby the monomers polymerize, thereby producing a polymer in the approximate shape of the final desired product.

[0150] The lenses may be sterilized by known means such as, but not limited to, autoclaving.— FIGs. 1-4 —

[0151] As an illustrative example, contact lenses may be prepared on a line comprising a curing tunnel having one or more irradiation zones in which irradiation may occur from one or more of the top and the bottom of the tunnel. As a non-limiting example, the curing tunnel of FIG. 1 is shown as a two-zone tunnel having a low intensity cure zone and a high intensity cure zone. Any number of zones may be used, including a single zone. The example curing tunnel is shown irradiating from a top and bottom of the mold. However, any arrangement may be used. Other sources of curing energy (e.g., radiation) may be used. Various wavelengths of radiation energy may be used.

[0152] As described herein, curing intensity may be inconsistent across a curing tunnel or between molds disposed within the curing tunnel. Improvements in control of curing energy can provide more consistent curing between the lens materials in the molds, which can improve the quality of the cured products. As an illustrative example, FIG. 2 outlines a method flow 200 in accordance with an aspect of the present disclosure.

[0153] At step 202, each position intensity (e.g., associated with each cavity 302 in FIG. 3) may be measured with each curing energy source (306 in FIG.3) at a maximum linear setting. At step 204, a flash intensity data may be verified. At step 206, a representational matrix (e.g., K matrix) may be generated, such as described herein. At step 208, the matrix may be corrected for bias. At step 210, control settings for each of the curing energy sources may be generated based on target outcomes. At step 212, the control settings may be loaded into an irradiation controller and tested using one or more intensity sensors (step 214, such as radiometer). The control settings may beoptimized for a given target outcome (step 216) and may be verified using one or more intensity sensors (step 218). Each of the illustrative steps is described in further detail below.

[0154] FIG. 3 shows a schematic representation of a plurality of molds 300 of the present disclosure. One or more of the molds 300 may be configured with one or more cavities 302 configured to hold and / or contain a material for forming a contact lens. The molds 300 may be irradiated by curing energy. As a non-limiting example, the molds 300 are shown in a curing tunnel 304 comprising a plurality of curing energy sources 306. Any number of curing energy sources 306 may be used. In certain operations of the present disclosure there may be hundreds or even thousands of independently controlled curing energy sources 306. The curing energy sources 306 may comprise light sources or light emitting diodes configured to output curing energy. As shown, the curing tunnel 304 is configured to irradiate the molds 300 from the top and the bottom. Other arrangements may be used includes irradiating from the sides or a single side or angle.

[0155] With the potential of several curing energy sources 306, each of which may have a top and / or bottom intensity, there are a multiple of intensity measurement locations (e.g., sites on the molds 300) within the tunnel 304, as illustrated in FIG. 4. As an example, the intensity at a given site (e.g., front or back of a given cavity 302) is the summation of the intensity received at that location from each of the curing energy sources 306.— FIG. 5 —

[0156] As illustrated in FIG. 5, the component contribution of the curing energy sources 306 to a given site depends on the geometric relationship between them (distance, angle, etc.), the efficiency of each of the curing energy sources 306 (quantum yield, etc.), and the electric current flowing through each of the curing energy sources 306, for example. Other factors may be considered. The relationship between electric current and intensity may be nominally linear, and so can be defined using a linear equation:

[0157] Intensity = k * I (1)

[0158] where and I is the electric current flowing through the cluster, and k i s a slope, specific to the curing energy source / site pair (which accounts for the geometry, efficiency, and other factors impacting how much of a given curing energy source's output reaches the site of interest).

[0159] Since each site (e.g., front and / or back of each cavity 302) may receive curing energy (e.g., light) from a plurality of curing energy sources (e.g., LED clusters), the above equation can be expanded to account for all of the curing energy sources:

[0160] Intensity = kr* / + k2* I2+ ••• kt* / (2)

[0161] As an example, when there are 'n' number of sites, one may calculate (e.g., estimate, predict) 'n' number of unique intensity prediction equations, each of which has 'N' terms (one for each curing energy source 306), to completely define the intensity profile of the irradiation system(e.g., tunnel). This may be more succinctly stated using matrix equations. Below is the K matrix equation defining the predicted intensity at j sites site / ) for z curing energy sources (e.g., LED clusters)

[0163] There are n * N k values that may be determined to build the matrix above. This may be calculated by individually causing output from each curing energy source 306 (one at a time), with a known electric current, while simultaneously measuring the intensity at each of the sites using one or more intensity sensors. This generates an initial k-matrix.

[0164] For each site, the entire set of k-values may be measured using a single sensor, which subjects the entire k-matrix to sensor-to-sensor bias. Moreover, even at maximum electric current (max linear setting), curing energy sources 306 relatively far from a given site location contribute only a very small quantity of light to said site. In many cases, this non-zero quantity is less than the detection limit of the select sensor (e.g., 0.01 mW / cmA2), and thus cannot be measured during a curing energy source 306 flashing routine. As an illustrative example, a flashing routine may comprise a prescribed on / off energizing of one or more of the sources 306 (e.g., or all of the sources 306). As a further example a flashing routine may comprise energizing each of the light sources 306 for a set time in a given sequence. Other routines may be used. However, many curing energy sources 306 contributing a small fraction light add up to a significant contribution. While such individual contribution may be difficult to measure, a summation of such contribution may be measured. Various solutions may be implemented.— FIG. 6 —

[0165] As an illustration, all curing energy sources 306 may be caused to output simultaneously (FIG. 6), and the contribution of the previously immeasurable curing energy sources 306 is detected by first subtracting the contribution of the known individually measurable curing energy sources 306. The k-matrix is subsequently updated to account for the "missing energy" bymultiplying existing k-values accordingly. For example, if an additional 1% light is detected during this process, all existing k-values are multiplied by 1.01. Additional or alternative methods may be used to account for the missing light. Another element of a bias correction process may be attributed to the use of multiple sensors (e.g., 4 or more intensity sensors, radiometer, absorption spectrometer). When multiple sensors are used to measure a state when all of the curing energy sources 306 are caused to output, the total output may be averaged before k-values are adjusted. Since the standard error is inversely proportional to sqrt(n), the averaging process substantially reduces error (halving it in the case of 4 sensors). The output of this k-adjustment (which accounts for missing light and mitigates sensor-to-sensor bias) is the "bias-corrected k-matrix," which may be used for the subsequent steps and formula illustrations below.

[0166] As an illustrative example, one or more of the flashing routines described herein (e.g., each light source, all light sources, etc.) may be implemented to generate a representative model (e.g., k matrix) for the specific machine or set of light sources. The model may then be applied to a different machine and a bias correction may be applied to the model to adapt the model to the new machine. As such, the base model may be used from machine to machine without having to repeat a new flashing routine for each machine. Instead, the base model may be corrected using the bias correction processes to reduce error in the model as applied to the new machine.— FIGs. 7-9 —

[0167] As illustrated in FIG. 7, the above enables prediction of the intensity at each of the n sites (e.g., cavity 302 locations) as a function of the current flowing through each of the N curing energy sources 306. Additionally, one may determine the optimum electrical settings (e.g., current, voltage, driving energy, etc.) for a given intensity profile. This may be achieved, for example, by minimizing the predicted Sum of Squares Intensity Error as defined in the model shown in FIG. 8.

[0168] Setting the gradient V to zero gives a system of equations, which when solved, yields the N electrical settings predicted to minimize the deviation from target intensity. In certain situations, the actual intensities may not exactly match the predictions. To correct for this, the residual error at each cavity (Residual = Actual Intensity - Predicted Intensity) is subtracted from the target intensity in the Error prediction matrix, and the Sum of Squares Error Minimization is repeated.

[0169] This procedure is referred to as additive error correction.

[0171] Alternatively, a multiplicative error correction procedure may be used in which the target intensity is scaled according to the observed error.

[0173] The residual error correction can be repeatedly applied over time to correct for curing energy source aging, obstructions / shadows, dirty equipment, in-process spillage, etc., and may be applied in real-time to maintain intensities during manufacturing. In summary, the model presented in FIG. 9 may be used to calculate (e.g., estimate, predict) an intensity profile for one or more curing energy sources.— FIGs. 10-12 —

[0174] As further examples, FIGS. 10-12 depict example flowcharts for manufacturing a contact lens. A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. As an example, a contact lens manufacturer may have a manufacturing facility comprising one or more computing devices configured to manufacture a contact lens.

[0175] Turning to FIG. 10, at step 1002, a mold having a plurality of cavities formed therein may be provided. One or more of the cavities may contain a reactive composition such as a reactive mixture. The reactive mixture may comprise at least one polymerizable monomer. Other reactive mixtures as described herein may be used. One or more of the cavities may comprise a base curve and a front curve defining at least a portion of the respective cavity.

[0176] At step 1004, the reactive mixture may be caused to be exposed to curing energy thereby at least partially curing the reactive mixture to form the contact lens. The curing energy may be directed at various locations or sites of the mold. The curing energy may be controlled based on aRECTIFIED SHEET (RULE 91)curing energy control model. The curing energy control model may comprise calculating an intensity profile indicative of an intensity of curing energy at one or more of the cavities as a function of the electrical settings driving the curing energy. The curing energy control model may comprise determining target electrical settings for a source of the curing energy based on the calculated intensity profile. The target electrical settings may be configured to minimize deviation of curing of the reactive mixture between the plurality of cavities.

[0177] The calculating an intensity profile may comprise measuring an intensity of curing energy at one or more of the cavities as a function of the electrical settings driving the curing energy. The calculating an intensity profile may comprise predicting, using a learning model, an intensity of curing energy at one or more of the cavities as a function of the electrical settings driving the curing energy. The calculating an intensity profile may comprise generating a K matrix. The source of curing energy may comprise one or more light sources. The source of curing energy may comprise one or more light emitting diodes. The source of curing energy may comprise a plurality of light sources. The calculating an intensity profile may comprise estimating an intensity of curing energy at each of the cavities as a function of the electrical settings driving each of the light sources. Determining the target electrical settings for a source of the curing energy based on the calculated intensity profile may comprise determining target electrical settings for each of the light sources to minimize deviation of curing of the reactive mixture between the plurality of cavities. Other sources of curing energy may be used.

[0178] Turning to FIG. 11, at step 1102, a reactive mixture may be disposed in one or more cavities of a plurality of cavities formed in a mold. The reactive mixture may comprise at least one polymerizable monomer. Other reactive mixtures as described herein may be used. One or more of the cavities may comprise a base curve and a front curve defining at least a portion of the respective cavity.

[0179] At step 1104, the reactive mixture may be exposed to curing energy thereby curing the reactive mixture to form the contact lens. The curing energy may be directed at one or more of the base curve and the front curve of the mold. The curing energy may be controlled based on a curing energy control model. The curing energy control model may comprise calculating an intensity profile indicative of an intensity of curing energy at one or more of the cavities as a function of the electrical settings driving the curing energy. The curing energy control model may comprise determining target electrical settings for a source of the curing energy based on the calculatedintensity profile. The target electrical settings are configured to minimize deviation of curing of the reactive mixture between the plurality of cavities.

[0180] The calculating an intensity profile may comprise measuring an intensity of curing energy at one or more locations, such as at one or more of the cavities, as a function of the electrical settings driving the curing energy. The calculating an intensity profile may comprise predicting, using a learning model, an intensity of curing energy at one or more of the cavities as a function of the electrical settings driving the curing energy. The calculating an intensity profile may comprise generating a K matrix. The source of curing energy may comprise one or more light sources. The source of curing energy may comprise one or more light emitting diodes. The source of curing energy may comprise a plurality of light sources. The calculating an intensity profile may comprise estimating an intensity of curing energy at each of the cavities as a function of the electrical settings driving each of the light sources. Determining the target electrical settings for a source of the curing energy based on the calculated intensity profile may comprise determining target electrical settings for each of the light sources to minimize deviation of curing of the reactive mixture between the plurality of cavities.

[0181] Turning to FIG. 12, at step 1202, a mold comprising a plurality of cavities formed therein may be caused to be irradiated with curing energy. Each of the cavities may comprise a base curve and a front curve defining at least a portion of the respective cavity. The source of curing energy may comprise one or more light sources. The source of curing energy may comprise one or more light emitting diodes.

[0182] At step 1204, an intensity of the curing energy may be measured at one or more positions on the mold or pallet.

[0183] At step 1206, an intensity profile may be generated based on the measuring an intensity of the curing energy. The intensity profile may be indicative of an intensity of curing energy at one or more of the plurality of cavities as a function of the electrical settings driving the curing energy. The generating an intensity profile may comprise generating a K matrix. The source of curing energy may comprise a plurality of light sources. The calculating an intensity profile may comprise estimating an intensity of curing energy at each of the cavities as a function of the electrical settings driving each of the light sources.

[0184] At step 1208, target electrical settings may be determined for a source of the curing energy based on the calculated intensity profile. The target electrical settings may be configured tominimize deviation of curing of the reactive mixture between the plurality of cavities. Determining the target electrical settings for a source of the curing energy based on the calculated intensity profde may comprise determining target electrical settings for each of the light sources to minimize deviation of curing of the reactive mixture between the plurality of cavities.— FIG. 13 —

[0185] FIG. 13 is a diagram of an example computing environment. Computing environment 1300 may include one or more information handling system(s) 1301 connected via network 1312. Each of these components is described below.

[0186] Information handling system 1301 is a hardware computing device which may be utilized to perform various steps, methods, and techniques disclosed herein (e.g., via the execution of software). In any embodiment, information handling system 1301 may include one or more processor(s) 1302, cache 1304, memory 1306, storage 1308, and / or one or more peripheral device(s) 1309. Any two or more of these components may be operatively connected via a system bus (not shown) that provides a means for transferring data between those components. Although each component is depicted and disclosed as individual functional components, these individual components may be combined (or divided) into any combination or configuration of components.

[0187] A system bus is a system of hardware connections (e.g., sockets, ports, wiring, conductive tracings on a printed circuit board (PCB), etc.) used for sending (and receiving) data to (and from) each of the components connected thereto. In any embodiment, a system bus allows for communication via an interface and protocol (e.g., inter-integrated circuit (I2C), peripheral component interconnect (express) (PCI(e)) fabric, etc.) that may be commonly recognized by the components utilizing the system bus. In any embodiment, a basic input / output system (BIOS) may be configured to transfer information between the components using the system bus (e.g., during initialization of information handling system 1301).

[0188] In any embodiment, information handling system 1301 may additionally include internal physical interface(s) (e.g., serial advanced technology attachment (SATA) ports, peripheral component interconnect (PCI) ports, PCI express (PCIe) ports, next generation form factor (NGFF) ports, M.2 ports, etc.) and / or external physical interface(s) (e.g., universal serial bus (USB) ports, recommended standard (RS) serial ports, audio / visual ports, etc.). Internal physical interface(s) and external physical interface(s) may facilitate the operative connection to one or more peripheral device(s) 1309.

[0189] Non-limiting examples of information handling system 1301 include a general purpose computer (e.g., a personal computer, desktop, laptop, tablet, smart phone, etc.), a network device (e.g., switch, router, multi-layer switch, etc.), a server (e.g., a blade-server in a blade-server chassis, a rack server in a rack, etc.), a controller (e.g., a programmable logic controller (PLC)), and / or any other type of computing device with the aforementioned capabilities. Further, information handling system 1301 may be operatively connected to another information handling system 1301 via network 1312 in a distributed computing environment. As used herein, a "computing device" may be equivalent to an information handling system.

[0190] Processor 1302 is a hardware device which may take the form of an integrated circuit configured to process computer-executable instructions (e.g., software). Processor 1302 may execute (e.g., read and process) computer-executable instructions stored in cache 1304, memory 1306, and / or storage 1308. Processor 1302 may be a self-contained computing system, including a system bus, memory, cache, and / or any other components of a computing device. Processor 1302 may include multiple processors, such as a system having multiple, physically separate processors in different sockets, or a system having multiple processor cores on a single physical chip. A multicore processor may be symmetric or asymmetric. Multiple processors 1302, and / or processor cores thereof, may share resources (e.g., cache 1304, memory 1306) or may operate using independent resources.

[0191] Non-limiting examples of processor 1302 include general-purpose processor (e.g., a central processing unit (CPU)), an application specific integrated circuit (ASIC), a programmable gate array (PGA), a field programmable gate array (FPGA), a digital signal processor (DSP), and any digital or analog circuit configured to perform operations based on input data (e.g., execute program instructions).

[0192] Cache 1304 is one or more hardware device(s) capable of storing digital information (e.g., data) in a non-transitory medium. Cache 1304 expressly excludes transitory media (e.g., transitory waves, energy, carrier signals, electromagnetic waves, signals per se, etc.). Cache 1304 may be considered "high-speed", having comparatively faster read / write access than memory 1306 and storage 1308, and therefore utilized by processor 1302 to process data more quickly than data stored in memory 1306 or storage 1308. Accordingly, processor 1302 may copy needed data to cache 1304 (from memory 1306 and / or storage 1308) for comparatively speedier access when processing that data. In any embodiment, cache 1304 may be included in processor 1302 (e.g., asa subcomponent). In any embodiment, cache 1304 may be physically independent, but operatively connected to processor 1302.

[0193] Memory 1306 is one or more hardware device(s) capable of storing digital information (e.g., data) in a non-transitory medium. Memory 1306 expressly excludes transitory media (e.g., transitory waves, energy, carrier signals, electromagnetic waves, signals per se, etc.). In any embodiment, when accessing memory 1306, software (executed via processor 1302) may be capable of reading and writing data at the smallest units of data normally accessible (e.g., "bytes"). Specifically, memory 1306 may include a unique physical address for each byte stored thereon, thereby enabling the ability to access and manipulate (read and write) data by directing commands to a specific physical address associated with a byte of data (i.e., "random access"). Non-limiting examples of memory 1306 devices include flash memory, random access memory (RAM), dynamic RAM (DRAM), static RAM (SRAM), resistive RAM (ReRAM), read-only memory (ROM), and electrically erasable programmable ROM (EEPROM). In any embodiment, memory 1306 devices may be volatile or non-volatile.

[0194] Storage 1308 is one or more hardware device(s) capable of storing digital information (e.g., data) in a non-transitory medium. Storage 1308 expressly excludes transitory media (e.g., transitory waves, energy, carrier signals, electromagnetic waves, signals per se, etc.). In any embodiment, the smallest unit of data readable from storage 1308 may be a "block" (instead of a "byte"). Prior to reading and / or manipulating the data on storage 1308, one or more block(s) may be copied to an intermediary storage medium (e.g., cache 1304, memory 1306) where the data may then be accessed in "bytes" (e.g., via random access). In any embodiment, data on storage 1308 may be accessed in "bytes" (like memory 1306). Non-limiting examples of storage 1308 include integrated circuit storage devices (e.g., a solid-state drive (SSD), Non-Volatile Memory Express (NVMe), flash memory, etc.), magnetic storage devices (e.g., a hard disk drive (HDD), floppy disk, magnetic tape, diskette, cassettes, etc.), optical media (e.g., a compact disc (CD), digital versatile disc (DVD), etc.), and printed media (e.g., barcode, quick response (QR) code, punch card, etc.).

[0195] As used herein, "non-transitory computer readable medium" is cache 1304, memory 1306, storage 1308, and / or any other hardware device capable of non-transitorily storing and / or carrying data.

[0196] Peripheral device 1309 is a hardware device configured to send (and / or receive) data to (and / or from) information handling system 1301 via one or more internal and / or external physical interface(s). Any peripheral device 1309 may be categorized as one or more "types" of computing devices (e.g., an "input" device, "output" device, "communication" device, etc.). However, such categories are not comprehensive and are not mutually exclusive. Such categories are listed herein strictly to provide understandable groupings of the potential types of peripheral devices 1309. As such, peripheral device 1309 may be an input device, an output device, a communication device, and / or any other optional computing component.

[0197] An input device is a hardware device that receives data into information handling system 1301. In any embodiment, an input device may be a human interface device which facilitates user interaction by collecting data based on user inputs (e.g., a mouse, keyboard, camera, microphone, touchpad, touchscreen, fingerprint reader, joystick, gamepad, etc.). In any embodiment, an input device may collect data based on raw inputs, regardless of human interaction (e.g., any sensor, logging tool, audio / video capture card, etc.). In any embodiment, an input device may be a reader for accessing data on a non-transitory computer readable medium (e.g., a CD drive, floppy disk drive, tape drive, scanner, etc.).

[0198] An output device is a hardware device that sends data from information handling system 1301. In any embodiment, an output device may be a human interface device which facilitates providing data to a user (e.g., a visual display monitor, speakers, printer, status light, haptic feedback device, etc.). In any embodiment, an output device may be a writer for facilitating storage of data on a non-transitory computer readable medium (e.g., a CD drive, floppy disk drive, magnetic tape drive, printer, etc.).

[0199] A communication device is a hardware device capable of sending and / or receiving data with one or more other communication device(s) (e.g., connected to another information handling system 1301 via network 1312). A communication device may communicate via any suitable form of wired interface (e.g., Ethernet, fiber optic, serial communication etc.) and / or wireless interface (e.g., Wi-Fi® (Institute of Electrical and Electronics Engineers (IEEE) 802.11), Bluetooth® (IEEE 802.15.1), etc.) and utilize one or more protocol(s) for the transmission and receipt of data (e.g., transmission control protocol (TCP), user datagram protocol (UDP), internet protocol (IP), remote direct memory access (RDMA), etc ). Non-limiting examples of a communication device include a network interface card (NIC), a modem, an Ethernet card / adapter, and a Wi-Fi® card / adapter.

[0200] An optional computing component is any hardware device that operatively connects to information handling system 1301 and extends the capabilities of information handling system 1301. Non-limiting examples of an optional computing components include a graphics processing unit (GPU), a data processing unit (DPU), and a docking station.

[0201] As used herein, "software" (e.g., "code", "algorithm", "application", "routine") is data in the form of computer-executable instructions. Processor 1302 may execute (e.g., read and process) software to perform one or more function(s). Non-limiting examples of functions may include reading existing data, modifying existing data, generating new data, and using any capability of information handling system 1301 (e.g., reading existing data from memory 1306, generating new data from the existing data, sending the generated data to a GPU to be displayed on a monitor). Although software physically persists in cache 1304, memory 1306, and / or storage 1308, one or more software instances may be depicted, in the figures, as an external component of any information handling system 1301 that interacts with one or more information handling system(s) 1301.

[0202] Network 1312 is a collection of connected information handling systems (e.g., 1301, 1301N) that allows for the exchange of data and / or the sharing of computing resources therebetween. Non-limiting examples of network 1312 include a local area network (LAN), a wide area network (WAN) (e.g., the Internet), a mobile network, any combination thereof, and any other type of network that allows for the communication of data and sharing of resources among computing devices operatively connected thereto. A person of ordinary skill in the relevant art, having the benefit of this detailed description, would appreciate that a network is a collection of operatively connected computing devices that enables communication between those computing devices.— FIG. 14A —

[0203] FIG. 14A is a diagram of an example calibration system. Calibration system 1450 may include information handling system 1301, one or more top light(s) 1452, one or more bottom light(s) 1454, conveyor 1456, one or more sensor device(s) 1458, target intensity data 1460, and measured intensity data 1462. Each of these components is described below.

[0204] A light (e.g., top light 1452, bottom light 1454), generally, is an electrical device which may emit electromagnetic radiation (e.g., photons) when electrically coupled to a power source. One of ordinary skill in the art, provided the benefit of this detailed description, would understandwhat a light is and the various forms a light may take. Non-limiting examples of lights include a light emitting diode (LED), a panel of LEDs, an incandescent bulb, a halogen bulb, and a fluorescent bulb. Further, in one or more embodiments, a light may emit photons entirely, primarily, or mostly in a region of non-visible radiation (i.e., outside of the visible spectrum). Such radiation may be used to activate (or otherwise cause) a reaction in a nearby component (e.g., ultraviolet curing, infrared curing, etc.). The intensity of a light may be manipulated by information handling system 1301 by controlling the current (and / or voltage) supplied to the light from a power source. Accordingly, information handling system 1301 may control the intensity of the light (e.g., from "off1to the maximum brightness / intensity by the light).

[0205] Top light 1452 (e.g., top light A 1452A, top light B 1452B) is a light which may be disposed on a "top" side of conveyor 1456. In one or more embodiments, top light(s) 1452 are disposed opposite bottom light(s) 1454 to allow for radiation (emitted from top lights 1452) to contact a top side of any object (e.g., sensor device 1458, pallet 1466) disposed along conveyor 1456.

[0206] Bottom light 1454 (e.g., bottom light A 1454A, bottom light B 1454B) is a light which may be disposed on a "bottom" side of conveyor 1456. In one or more embodiments, bottom light(s) 1454 are disposed opposite top light(s) 1452 to allow for radiation (emitted from bottom lights 1454) to contact a bottom side of any object (e.g., sensor device 1458, pallet 1466) disposed along conveyor 1456.

[0207] Conveyor 1456 is an electromechanical system which may move along a track, belt, or other circulating path. The movement of conveyor 1456 (e.g., by a motor mechanically coupled to conveyor 1456) may be controlled by information handling system 1301 (e.g., toggling the movement, controlling the speed of the motor). Non-limiting examples of a conveyor 1456 include a belt conveyor, a roller conveyor, and a magnetic conveyor. One of ordinary skill in the art (having the benefit of this detailed description) would appreciate what a conveyor is and the varying forms a conveyor may take.

[0208] Sensor device 1458 is a peripheral device (e.g., peripheral device 1309) which may be configured to collect data about radiation emitted from top light(s) 1452 and bottom light(s) 1454 and store that data as measured intensity data 1462. In one or more embodiments, sensor device 1458 interlocks and engages with conveyor 1456 to provide transportation of sensor device 1458 through the production line. Sensor device 1458 may be operatively connected to informationhandling system 1301 via a direct wire connection (e.g., after transporting via conveyor 1456 and collecting measured intensity data 1462) and / or wirelessly via any suitable protocol. In one or more embodiments, sensor device 1458 may be configured to collect measured intensity data 1462 for a range of frequencies on the electromagnetic spectrum. In one or more embodiments, sensor device 1458 may include one or more individual sensors (light sensors) on a single unit "device". That is, sensor device 1458 may be a collection of two or more sensors disposed on one or more surface(s) thereof. As a non-limiting example, sensor device 1458 may include optical sensors on a "top" side (facing top lights 1452) and may additionally include optical sensors on a "bottom" side (facing bottom lights 1454).

[0209] Target intensity data 1460 is data corresponding to the ideal, optimal, default, or otherwise required intensity data for lights. As a non-limiting example, light intensity at one or more location(s) (e.g., sites 1468) along conveyor 1456 may be required to have light intensity above a minimum threshold (and / or below a maximum threshold). Target intensity data 1460 is the value or collection of values corresponding to those ideal values (or range of values).

[0210] Measured intensity data 1462 is data corresponding to the intensity data measured and recorded by one or more sensor device(s) 1458. That is, when sensor device 1458 is disposed along conveyor 1456 and moved between top light(s) 1452 and / or bottom light(s) 1454 (e.g., in curing tunnel 1451), intensity data is collected. In one or more embodiments, the values of measured intensity data 1462 is largely affected by the lights (top light(s) 1452 and / or bottom light(s) 1454) and the intensity at which those lights are controlled.— FIG. 14B —

[0211] FIG. 14B is a diagram of an example portion of a curing tunnel.

[0212] Curing tunnel 1451, in the example of FIG. 14B, includes low intensity top light(s) 1452L, high intensity top light(s) 1452H, low intensity bottom light(s) 1454L, high intensity bottom light(s) 1454H, disposed above and below conveyor 1456 along which pallet(s) 1466 and sensor device(s) 1458 movably ride. Curing tunnel 1451 may be a portion of a larger production line that uses lights (e.g., top lights 1452 and bottom lights 1454) to "cure" a product being manufactured (carried on pallets 1466 moving along conveyor 1456).

[0213] Low intensity top light 1452L is a top light 1452 which emits radiation at a lower intensity compared to high intensity top light(s) 1452H. Low intensity top light 1452L may be disposed above (opposite conveyor 1456) low intensity bottom light(s) 1454L. Accordingly, incombination, low intensity top light(s) 1452L and low intensity bottom light(s) 1454L may form a "low intensity" portion of curing tunnel 1451.

[0214] High intensity top light 1452H is a top light 1452 which emits radiation at a higher intensity compared to high intensity top light(s) 1452H. High intensity top light 1452H may be disposed below (opposite conveyor 1456) high intensity bottom light(s) 1454H. Accordingly, in combination, high intensity top light(s) 1452H and high intensity bottom light(s) 1454H may form a "high intensity" portion of curing tunnel 1451.

[0215] Low intensity bottom light 1454L is a bottom light 1454 which emits radiation at a lower intensity compared to high intensity bottom light(s) 1454H.

[0216] High intensity bottom light 1454H is a bottom light 1454 which emits radiation at a higher intensity compared to low intensity bottom light(s) 1454L.

[0217] As shown in FIG. 14B, sensor device 1458 may be disposed on conveyor 1456 among pallet(s) 1466 (e.g., in an active production line). Alternatively, sensor device 1458 may be disposed on conveyor 1456 alone or with other sensor devices 1458, where calibration (of lights) may occur independently of active production.

[0218] Pallet 1466 is a component which may be used to hold one or more product(s) (e g., contact lenses) during the manufacturing process. In one or more embodiments, pallet 1466 interlocks and engages with conveyor 1456 to provide transportation of pallet 1466 (and any product thereon) through the production line.

[0219] Site 1468 is a location (e.g., position) in curing tunnel 1451 where light intensity is of interest for analysis and comparison. In one or more embodiments, sites 1468 may be disposed at multiple locations where products are manufactured (disposed along the route of pallets' 1466 travel). In the example shown in FIG. 14B, each pallet 1466 may hold two products. Accordingly, there are two sites 1468 disposed on each pallet. In one or more embodiments, sites 1468 may remain fixed with respect to stationary components (e.g., lights) while pallets 1466 and sensor devices 1458 move along conveyor 1456.— FIG. 14C —

[0220] FIG. 14C is a diagram of example measured intensity data and measured intensity analysis data.

[0221] In one or more embodiments, measured intensity data 1462 may be divided (e.g., separated, categorized, tagged) into one or more logical classifications (i.e., "data groups"). As anon-limiting example, sensor device(s) 1458 may be configured to acquire measured intensity data 1462 on both a "top" and "bottom" side of conveyor 1456. Accordingly, measured intensity data 1462 may be logically separated into two mutually exclusive portions (i.e., measured top intensity data 1462T, measured bottom intensity data 1462B).

[0222] Additionally, as another non-limiting example, the curing section of the production line (e.g., curing tunnel 1451) may be divided into "high" intensity and "low" intensity sections. Consequently, sensor device(s) 1458 may be configured to acquire measured intensity data 1462 throughout both the "high" and "low" intensity portions of the curing tunnel. Accordingly, measured intensity data 1462 may be logically separated into two mutually exclusive portions (i.e., measured high intensity data 1462H, measured low intensity data 1462L).

[0223] Further, although some of portions of measured intensity data 1462 are mutually exclusive, other portions may not be mutually exclusive. As a non-limiting example, as shown in FIG. 14C, measured intensity data 1462 may be divided into four groups, each having two properties, where the properties — individually — may be mutually exclusive of other properties.

[0224] In one or more embodiments, measured intensity data 1462 may be divided (e.g., separated, categorized, tagged) into section relevant to each site 1468. That is, based on the time of the relevant data points (as well as an identification in the difference between "high" and "low" intensity lights), measured intensity data 1462 may be parsed to identify the light intensity at each of the location designated as sites 1468 in curing tunnel 1451. Further, this categorization may be combined with the categorization of location ("top", "bottom") and intensity ("high, "low") to identify nearest and proximate lights that most directly affect measured intensity data 1462.

[0225] Measured intensity analysis data 1463 is data which may be calculated using measured intensity data 1462. In one or more embodiments, measured intensity analysis data 1463 may be calculated after parsing (or otherwise grouping) measured intensity data 1462 into one or more sections relevant to the desired analysis. As shown in the example of FIG. 14C, multiple calculations are made (generating measured intensity analysis data 1463) including (i) average error, (ii) low percent deviation, (iii) high percent deviation, and (iv) quantity of sites 1468 out of range (beyond some intensity threshold).

[0226] Error data (calculated as part of measured intensity analysis data 1463) is data which provides a comparison between target intensity data 1460 and measured intensity data 1462. In one or more embodiments, error data may be the difference between measured intensity data 1462and target intensity data 1460 (e.g., via subtraction, equation (5)). In one or more embodiments, error data may be the ratio between measured intensity data 1462 and target intensity data 1460 (e.g., via division, equation (6)). Further, error data may be negative or positive (when calculated via subtraction) or above or below 1 (when calculated via division). When data exists for multiple "sites" along the path of conveyor 1456, an averaging of errors may be used to calculate a single value for error data (e.g., see "S", "Sum of Squares Error" in FIG. 9).— FIG. 15 —

[0227] FIG. 15 is a flowchart of the overall process of using a calibration system. All or a portion of the method shown may be performed by one or more components of information handling system 1301 (see description in FIG. 13), calibration system 1450 (see description in FIG. 14A), or a user thereof. While the various steps in this flowchart are presented and described sequentially, a person of ordinary skill in the relevant art (having the benefit of this detailed description) would appreciate that some or all steps may be executed in different orders, combined, or omitted, and some or all steps may be executed in parallel.

[0228] At Step 1502, target intensity data 1460 is loaded into calibration system 1450. In one or more embodiments, target intensity data 1460 may be loaded into information handling system 1301 by a user, automatically from existing data (e.g., from a stored file), or otherwise provided.

[0229] At Step 1504, the light intensity measurement process is initiated using one or more sensor device(s) 1458. In one or more embodiments, initiating the measurement process may include placing one or more sensor device(s) 1458 onto conveyor 1456. Additionally, initiating the intensity measurement process may further include initiating one or more programs on information handling system 1301 to collect measured intensity data 1462 (as it is later created). In one or more embodiments, where sensor device(s) 1458 are included in a production line, the light intensity measurement process may be initiated automatically by information handling system 1301 when any such sensor device 1458 begins traversing curing tunnel 1451.

[0230] At Step 1506, measured intensity data 1462 is received from one or more sensor device(s) 1458. In one or more embodiments, measured intensity data 1462 may be copied to information handling system 1301 after one or more sensor device(s) 1458 fully navigate conveyor 1456 (e.g., via direct wired connection between sensor device(s) 1458 and information handling system 1301). Further, one or more sensor device(s) 1458 may transmit measured intensity data 1462 toinformation handling system 1301 wirelessly during and / or after one or more sensor device(s) 1458 navigate through conveyor 1456 (or curing tunnel 1451).

[0231] At Step 1508, measured intensity analysis data 1463 is calculated. As described in FIG. 14C, error data is calculated using measured intensity data 1462 and target intensity data 1460. In one or more embodiments, error data may be the difference or ratio between measured intensity data 1462 and target intensity data 1460 and may be used to quantify the lack or abundance of light intensity from measured intensity data 1462.

[0232] At Step 1510, a determination is made as to whether one or more sensor device(s) 1458 are faulty. In one or more embodiments, measured intensity data 1462 (collected from one or more sensor device(s) 1458) may be missing, have null values, or otherwise fail to record (e.g., all zeros). Further, measured intensity data 1462 may be clearly erroneous (e.g., having spikes in values that do not correspond to the surrounding light, intermittent collection, saturated data, etc.). In such circumstances, information handling system 1301 and / or a user thereof may identify that measured intensity data 1462 is empty or otherwise erroneous and perform a corrective action. Specifically, if it is determined that one or more sensor device(s) 1458 are faulty (or believed to be faulty) (Step 1510- YES), the method proceeds to Step 1512. If it is determined that a sensor device 1458 is not faulty (or not believed to be faulty) (Step 1510-NO), the method proceeds to Step 1514.

[0233] At Step 1512, one or more sensor device(s) 1458 (identified as faulty) are replaced. In one or more embodiments, a user may remove the sensor device(s) 1458, from conveyor 1456, which have been identified as faulty and replace those faulty sensor device(s) 1458 with different sensor device(s) 1458. After replacing one or more sensor device(s) 1458, the user may restart the light intensity measurement process, and the method may return to Step 1504.

[0234] At Step 1514, a determination is made as to whether the error data surpasses an error threshold. In one or more embodiments, an error threshold allows for a comparison with error data to determine the sufficiency of measured intensity data 1462. Error data may be positive or negative (or centered around 1.0). Accordingly, an error threshold may be compared against an absolute value of the error data (i.e., considering the error data's magnitude, regardless of sign). Similarly, an error threshold may be compared against a deviation from a known point (e.g., 1.00 ± 0.15). Alternatively, an error threshold may account for the sign (direction) of the error data (e.g., where a required minimum intensity is specified in target intensity data 1460 without an upper bound). As a non-limiting example, consider a scenario where target intensity data 1460specifies a minimum light intensity of 1.0 mW / cm2, measured intensity data 1462 shows actual intensity to be at 1.3 mW / cm2, and the error threshold is -0.1 mW / cm2(indicating that measured intensity data 1462 at or below 0.9 mW / cm2is too low). In such an instance, error data is calculated as +0.3 mW / cm2, and therefore would not surpass the error threshold (requiring error data of -0.1 or less).

[0235] If it is determined that the error data surpasses the error threshold (Step 1514-YES), the method proceeds to Step 1516. If it is determined that the error data does not surpass the error threshold (Step 1514-NO), the process may end. In one or more embodiments, after the process ends, curing tunnel 1451 may proceed to be used in the manufacture and production of products (e.g., contact lenses).

[0236] At Step 1516, the light intensity of one or more lights is adjusted based on the error data. As a non-limiting example, if the error data identifies certain sites 1468 have too low light intensity, an increase in current would be supplied to the lights most nearly affecting the identified sites 1468 (e.g., nearest top light(s) 1452 and / or bottom light(s) 1454). Conversely, if the error data identifies that certain sites 1468 have too high intensity, an increase in current would be supplied to the lights most nearly affecting the identified sites 1468 (e.g., nearest top light(s) 1452 and / or bottom light(s) 1454). In one or more embodiments, any single site 1468 may be affected by multiple lights. Some lights may be adjusted to increase their light intensity while other lights are adjusted to decrease their light intensity. Accordingly, adjusting the light intensity of any single light is likely to affect the measured intensity data 1462 at every site 1468 (albeit to varying degrees). Accordingly, adjustments to light intensity may be made to minimize a single cumulative, averaged, or sum error (e.g., see "S" of FIG. 9).

[0237] As a non-limiting example, consider a scenario with three adjacent sites 1468 (site A, site B, and site C) with corresponding errors of -0.3 mW / cm2, 0.0 mW / cm2, and -0.4 mW / cm2, making the sum of the errors squared 0.25 (i.e., (-0.3)2+ (0.0)2+ (-0.4)2= 0.09 + 0.00 + 0.16 = 0.25). In turn, the current is increased to the light nearest site B (and adjacent to site A and site B) to account for the low intensity measured at site A and site C. In turn, when collecting measured intensity data 1462 and calculating updated error data, the errors change to 0.0 mW / cm2, 0.4 mW / cm2, and -0.1 mW / cm2, respectively, making the sum of the errors squared 0.17 (i.e., (0.0)2+ (0.4)2+ (-0.1)2= 0.00 + 0.16 + 0.01 = 0.17). Accordingly, although the error at site B increased (from 0.0 mW / cm2to 0.3 mW / cm2), the overall error (measured in sum of errors squared) decreased by 32% (from 0.25 to 0.17) due to the decrease in errors at site A and site C.— FIG. 16 —

[0238] FIG. 16 is a flowchart of a process of using a calibration system in a production line. All or a portion of the method shown may be performed by one or more components of information handling system 1301 (see description in FIG. 13), calibration system 1450 (see description in FIG. 14A), or a user thereof. While the various steps in this flowchart are presented and described sequentially, a person of ordinary skill in the relevant art (having the benefit of this detailed description) would appreciate that some or all steps may be executed in different orders, combined, or omitted, and some or all steps may be executed in parallel.

[0239] At Step 1602, one or more sensor device(s) 1458 are placed in a production line (i.e., on conveyor 1456 in calibration system 1450). In one or more embodiments, the production line may be active and manufacturing a product (e.g., contact lenses). Accordingly, one or more sensor device(s) 1458 may be disposed between adjacent pallets of contact lenses and navigate through curing tunnel 1451 on conveyor 1456 (e.g., as shown in FIG. 14B).

[0240] At Step 1604, measured intensity data 1462 is received from one or more sensor device(s) 1458. Step 1604 may be substantially similar to the process described for Step 1506.

[0241] At Step 1606, measured intensity analysis data 1463 is calculated. Step 1606 may be substantially similar to the process described for Step 1508.

[0242] At Step 1608, a determination is made as to whether the error data surpasses a high error threshold. In one or more embodiments, a high error threshold allows for a comparison with error data to determine large disparities between target intensity data 1460 and measured intensity data 1462. A high error threshold may be considered "high" (compared to a "low" error threshold) to identify scenarios where measured intensity data 1462 deviates sufficiently far from target intensity data 1460 such that integrity of the manufactured product (e.g., contact lenses) may be compromised. As a non-limiting example, a high error threshold may be set to 20% deviation from target intensity data 1460 (i.e., if error data shows any error data which is less than 0.8 or greater than 1.2, when using a ratio-calculated error). Similarly, a high error threshold may be fixed to a specific number, such that if error data exceeds that number (e.g., 1 mW / cm2) the high threshold is surpassed.

[0243] If it is determined that the error data surpasses the high error threshold (Step 1608-YES), the method proceeds to Step 1610. If it is determined that the error data does not surpass the high error threshold (Step 1608-NO), the method may proceed to Step 1612.

[0244] At Step 1610, the production line is stopped. In one or more embodiments, if the high error threshold is surpassed, measured intensity data 1462 deviated sufficiently from target intensity data 1460 that the product being manufactured likely does not conform to a standard (or other requirement) for the product. As a non-limiting example, one or more federal regulation(s) may require that the product be cured with a minimum light intensity of 5 mW / cm2and maximum light intensity of 7 mW / cm2. In turn, target intensity data 1460 is to cure the product with 6 mW / cm2. Accordingly, a low error threshold (see Step 1612) may be set to 5.8 mW / cm2and 6.2 mW / cm2. However, the high error threshold may be set to ±1 mW / cm2(i.e., <5 mW / cm2and >7 mW / cm2), such that if measured intensity data 1462 indicates light intensities below 5 mW / cm2or above 7 mW / cm2, the positive determination is made that the production line needs to be halted until the light intensity can be brought into compliance.

[0245] At Step 1612, a determination is made as to whether the error data surpasses a low error threshold. In one or more embodiments, the low error threshold is smaller, in magnitude, than the high error threshold (of Step 1608). That is, if the high error threshold of Step 1608 is surpassed, the low error threshold of Step 1612 is also necessarily surpassed. However, conversely, if the low error threshold is surpassed, the high error threshold is not necessarily surpassed. Step 1612 may be substantially similar to the process described for Step 1514 (i.e., the "low threshold" of FIG. 16 may correspond to the "error threshold" in Step 1514 of FIG. 15). If it is determined that the error data surpasses the low error threshold (Step 1612-YES), the method proceeds to Step 1614. If it is determined that the error data surpasses the low error threshold (Step 1612-NO), the method may end.

[0246] At Step 1614, the light intensity of one or more lights is adjusted based on the error data. Step 1614 may be substantially similar to the process described for Step 1516.— Aspects —

[0247] The systems and methods may comprise any of the various features disclosed herein, comprising one or more of the following statements.

[0248] Aspect 1. A method for manufacturing a contact lens, the method comprising: providing a mold having a plurality of cavities formed therein, one or more of the cavities containing a reactivemixture; and causing the reactive mixture to be exposed to curing energy thereby at least partially curing the reactive mixture to form the contact lens, wherein the curing energy is directed at one or more sites on the mold, wherein the curing energy is controlled based on a curing energy control model, and wherein the curing energy control model comprises: calculating an intensity profile indicative of an intensity of curing energy at one or more sites on the mold as a function of the electrical settings driving the curing energy, and determining target electrical settings for a source of the curing energy based on the calculated intensity profile.

[0249] Aspect 2. The method of aspect 1, wherein each of the cavities comprises a base curve and a front curve defining at least a portion of the respective cavity.

[0250] Aspect 3. The method of any one of aspects 1-2, wherein the target electrical settings are configured to minimize deviation of curing of the reactive mixture between a plurality of sites on the mold.

[0251] Aspect 4. The method of any one of aspects 1-3, wherein the calculating an intensity profile comprises measuring an intensity of curing energy at one or more of the sites as a function of the electrical settings driving the curing energy.

[0252] Aspect 5. The method of any one of aspects 1-4, wherein the calculating an intensity profile comprises predicting, using a learning model, an intensity of the curing energy at one or more of the sites as a function of the electrical settings driving the curing energy.

[0253] Aspect 6. The method of any one of aspects 1-5, wherein the calculating an intensity profile comprises generating a K matrix.

[0254] Aspect 7. The method of any one of aspects 1-6, wherein the source of the curing energy comprises one or more light sources.

[0255] Aspect 8. The method of any one of aspects 1-7, wherein the source of the curing energy comprises one or more light emitting diodes.

[0256] Aspect 9. The method of any one of aspects 1-6, wherein the source of the curing energy comprises a plurality of light sources and wherein the calculating an intensity profile comprises estimating an intensity of radiation at each of the one or more sites on the mold as a function of the electrical settings driving each of the light sources.

[0257] Aspect 10. The method of claim 9, wherein determining the target electrical settings for a source of the curing energy based on the calculated intensity profile comprises determining targetelectrical settings for each of the light sources to minimize deviation of curing of the reactive mixture between a plurality of sites on the mold.

[0258] Aspect 11. The method of any one of aspects 1-10, further comprising inputting the target electrical settings into an irradiation controller, evaluating one or more of the target electrical settings with an intensity sensor, and optionally changing one or more of the target electrical settings in response to that evaluation.

[0259] Aspect 12. The method of any one of aspects 1-11, wherein the curing energy control model

[0260] is developed based on a first system comprising the curing energy source, and further comprising applying the curing energy control model to a second system comprising a different curing energy source.

[0261] Aspect 13. The method of aspect 12, wherein at least one bias correction factor or error correction factor is used in applying the curing energy control model to the second system.

[0262] Aspect 14. The method of aspect 13, wherein applying the curing energy control model to the second system does not require calculating an intensity profile for the second system.

[0263] Aspect 15. The method of any one of aspects 1-14, wherein the reactive mixture comprises at least one polymerizable monomer.

[0264] Aspect 16. The method of any one of aspects 1-15, wherein the reactive mixture comprises a visible light absorbing compound.

[0265] Aspect 17. The method of any one of aspects 1-16, wherein the reactive mixture comprises at least one photochromic dye.

[0266] Aspect 18. The method of any one of aspects 1-17, wherein the reactive mixture comprises at least one static dye.

[0267] Aspect 19. A method comprising: causing output of a radiant energy; measuring an intensity of the radiant energy at one or more sites of incident radiant energy; generating, based on the measuring an intensity of the radiant energy, an intensity profile indicative of an intensity of the radiant energy at the one or more sites as a function of the electrical settings driving the radiant energy; determining target electrical settings for a source of the radiant energy based on the intensity profile.

[0268] Aspect 20. The method of aspect 19, wherein the target electrical settings are configured to minimize deviation of intensity between a plurality of sites of incident radiant energy.

[0269] Aspect 21. The method of any one of aspects 19-20, wherein the generating an intensity profile comprises generating a K matrix.

[0270] Aspect 22. The method of any one of aspects 19-21, wherein the source of the radiant energy comprises one or more light sources.

[0271] Aspect 23. The method of any one of aspects 19-22, wherein the source of the radiant energy comprises one or more light emitting diodes.

[0272] Aspect 24. The method of any one of aspects 19-23, wherein the source of the radiant energy comprises a plurality of light sources and wherein the generating an intensity profile comprises estimating an intensity of radiation at each of the one or more sites as a function of the electrical settings driving each of the light sources.

[0273] Aspect 25. The method of any one of aspects 19-24, wherein determining the target electrical settings for a source of the radiant energy based on the intensity profile comprises determining target electrical settings for each of the light sources to minimize deviation of intensity between a plurality of sites of incident radiant energy.

[0274] Aspect 26. The method of any one of aspects 19-25, wherein the source of radiant energy comprises a first system, and further comprising applying a bias correction function to the intensity profile based upon one or more characteristic of a second system, different from the first system.

[0275] Aspect 27. The method of any one of aspects 19-26, wherein the source of radiant energy comprises a first system, and further comprising applying an error correction function to the intensity profile based upon one or more characteristic of a second system, different from the first system.

[0276] Aspect 28. The method of any one of aspects 19-27, further comprising inputting the target electrical settings into an irradiation controller, evaluating one or more of the target electrical settings with an intensity sensor, and optionally changing one or more of the target electrical settings in response to that evaluation.

[0277] Aspect 29. A method for calibrating a light in a curing tunnel, comprising recording measured intensity data, on a sensor device, from the light calculating error data using the measured intensity data and target intensity data making a determination that the error data surpasses an error threshold; based on the determination adjusting current to the light using the error data.

[0278] Aspect 30. The method of aspect 29, wherein after adjusting current to the light, the method further comprises recording second measured intensity data, on the sensor device, the light calculating second error data using the second measured intensity data and the target intensity data making a second determination that the error data does not surpass the error threshold; based on the determination proceeding to use the curing tunnel for production.

[0279] Aspect 31. The method of aspects 29-30, wherein prior to making the determination, the method further comprises making a second determination that the sensor device is faulty.

[0280] Aspect 32. The method of aspect 31, wherein based on the second determination, the method further comprises replacing the sensor device with a second sensor device.

[0281] Aspect 33. The method of aspects 29-32, wherein prior to calculating the error data, the method further comprises parsing the measured intensity data into a plurality of data groups.

[0282] Aspect 34. The method of aspect 33, wherein calculating the error data comprises calculating a plurality of error data for the plurality of data groups, respectively.

[0283] Aspect 35. The method of aspect 34, wherein adjusting the light comprises minimizing a sum of the plurality of error data.

[0284] Aspect 36. The method of aspects 29-35, wherein prior to making the determination, the method further comprises making a second determination that the error data does not surpasses a high error threshold; based on the second determination continuing operation of the curing tunnel.

[0285] Aspect 37. The method of aspects 29-36, wherein the error data indicates that a light intensity is too low.

[0286] Aspect 38. The method of aspect 37, wherein adjusting current to the light comprises increasing current to the light.

[0287] Aspect 39. The method of aspects 29-38, wherein the error data indicates that a light intensity is too high.

[0288] Aspect 40. The method of aspect 39, wherein adjusting current to the light comprises decreasing current to the light.

[0289] Aspect 41. The method of aspects 29-40, wherein based on the determination, the method further comprises adjusting a second light using the error data.

[0290] Aspect 42. A calibration system, comprising a plurality of lights, a conveyor disposed along the plurality of lights a sensor device carried on the conveyor; an information handling system.

[0291] Aspect 43. The calibration system of aspect 42, wherein the plurality of lights comprises a plurality of top lights disposed above the conveyor; a plurality of bottom lights disposed below the conveyor.

[0292] Aspect 44. The calibration system of aspect 43, wherein the sensor device comprises a first light sensor configured to face the plurality of top lights; a second light sensor configured to face the plurality of bottom lights.

[0293] Aspect 45. The calibration system of aspect 44, wherein the sensor device is configured to collect measured intensity data from the first light sensor and the second light sensor.

[0294] Aspect 46. The calibration system of aspect 45, wherein the sensor device is configured to operatively connect to the information handling system and transfer the measured intensity data from the sensor device to the information handling system.

[0295] Aspect 47. The calibration system of aspects 42-46, wherein the information handling system is configured to perform a method for calibrating the plurality of lights, comprising receiving measured intensity data from the sensor device calculating error data using the measured intensity data and target intensity data making a determination that the error data surpasses an error threshold; based on the determination adjusting current to the plurality of lights using the error data.

[0296] Aspect 48. The calibration system of aspect 47, wherein prior to calculating the error data, the method further comprises parsing the measured intensity data into a plurality of data groups; calculating a plurality of error data for the plurality of data groups, respectively.— General Notes —

[0297] As it is impracticable to disclose every conceivable embodiment of the technology described herein, the figures, examples, and description provided herein disclose only a limited number of potential embodiments. A person of ordinary skill in the relevant art would appreciate that any number of potential variations or modifications may be made to the explicitly disclosed embodiments, and that such alternative embodiments remain within the scope of the broader technology. Accordingly, the scope should be limited only by the attached claims. Further, the compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods may also "consist essentially of or "consist of the various components and steps. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the elements that itintroduces. Certain technical details, known to those of ordinary skill in the relevant art, may be omitted for brevity and to avoid cluttering the description of the novel aspects.

[0298] For further brevity, descriptions of similarly named components may be omitted if a description of that similarly named component exists elsewhere in the application. Accordingly, any component described with respect to a specific figure may be equivalent to one or more similarly named components shown or described in any other figure, and each component incorporates the description of every similarly named component provided in the application (unless explicitly noted otherwise). A description of any component is to be interpreted as an optional embodiment — which may be implemented in addition to, in conjunction with, or in place of an embodiment of a similarly-named component described for any other figure.— Lexicographical Notes —

[0299] As used herein, adjective ordinal numbers (e.g., first, second, third, etc.) are used to distinguish between elements and do not create any ordering of the elements. As an example, a "first element" is distinct from a "second element", but the "first element" may come after (or before) the "second element" in an ordering of elements. Accordingly, an order of elements exists only if ordered terminology is expressly provided (e.g., "before", "between", "after", etc.) or a type of "order" is expressly provided (e.g., "chronological", "alphabetical", "by size", etc ). Further, use of ordinal numbers does not preclude the existence of other elements. As an example, a "table with a first leg and a second leg" is any table with two or more legs (e.g., two legs, five legs, thirteen legs, etc ). A maximum quantity of elements exists only if express language is used to limit the upper bound (e.g., "two or fewer", "exactly five", "nine to twenty", etc.). Similarly, singular use of an ordinal number does not imply the existence of another element. As an example, a "first threshold" may be the only threshold and therefore does not necessitate the existence of a "second threshold".

[0300] As used herein, the word "data" may be used as an "uncountable" singular noun — not as the plural form of the singular noun "datum". Accordingly, throughout the application, "data" is generally paired with a singular verb (e.g., "the data is modified"). However, "data" is not redefined to mean a single bit of digital information. Rather, as used herein, "data" means any one or more bit(s) of digital information that are grouped together (physically or logically). Further, "data" may be used as a plural noun if context provides the existence of multiple "data" (e.g., "the two data are combined").

[0301] As used herein, the term "operative connection" (or "operatively connected") means the direct or indirect connection between devices that allows for the transmission of data. For example, the phrase 'operatively connected' may refer to a direct connection (e.g., a direct wired or wireless connection between devices) or an indirect connection (e.g., multiple wired and / or wireless connections between any number of other devices connecting the operatively connected devices).

[0302] As used herein, indefinite articles "a" and "an" mean "one or more". That is, the explicit recitation of "an" element does not preclude the existence of a second element, a third element, etc. Further, definite articles (e.g., "the", "said") mean "any one of (the "one or more" elements) when referring to previously introduced element(s). As an example, there may exist "a processor", where such a recitation does not preclude the existence of any number of other processors. Further, "the processor receives data, and the processor processes data" means "any one of the one or more processors receives data" and "any one of the one or more processors processes data". It is not required that the same processor both (i) receive data and (ii) process data. Rather, each of the steps ("receive" and "process") may be performed by different processors.

Claims

CLAIMSWhat is claimed is:

1. A method for manufacturing a contact lens, the method comprising: providing a carrier comprising at least one mold disposed therein, the at least one mold having a cavity containing a reactive mixture; and causing the carrier to be exposed to curing energy in a curing area, thereby at least partially curing the reactive mixture to form the contact lens, wherein the curing energy is controlled based on a curing energy control model; and wherein the curing energy control model comprises: calculating an intensity profile indicative of an intensity of curing energy at one or more sites in the curing area as a function of electrical settings driving the curing energy, and determining target electrical settings for a source of the curing energy based on the calculated intensity profile.

2. The method of claim 1, wherein the cavity comprises a base curve and a front curve defining at least a portion of the respective cavity.

3. The method of claim 1, wherein the target electrical settings are configured to minimize deviation of curing of the reactive mixture between the one or more sites.

4. The method of claim 1, wherein the calculating an intensity profile comprises measuring an intensity of curing energy at one or more of the sites as a function of the electrical settings driving the curing energy.

5. The method of claim 1, wherein the calculating an intensity profile comprises predicting, using a learning model, an intensity of the curing energy at one or more of the sites as a function of the electrical settings driving the curing energy.

6. The method of claim 1, wherein the calculating an intensity profile comprises generating a K matrix.

7. The method of claim 1, wherein the source of the curing energy comprises one or more light sources.

8. The method of claim 1, wherein the source of the curing energy comprises one or more light emitting diodes.

9. The method of claim 1, wherein the source of the curing energy comprises a plurality of light sources and wherein the calculating an intensity profile comprises estimating an intensity of radiation at each of the one or more sites on the mold as a function of the electrical settings driving each of the light sources.

10. The method of claim 9, wherein determining the target electrical settings for a source of the curing energy based on the calculated intensity profile comprises determining target electrical settings for each of the light sources to minimize deviation of curing of the reactive mixture between the one or more sites.

11. The method of claim 1, further comprising inputting the target electrical settings into an irradiation controller, evaluating one or more of the target electrical settings with an intensity sensor, and optionally changing one or more of the target electrical settings in response to that evaluation.

12. The method of claim 1, wherein the curing energy control model is developed based on a first system comprising the curing energy source, and further comprising applying the curing energy control model to a second system comprising a different curing energy source.

13. The method of claim 12, wherein at least one bias correction factor is used in applying the curing energy control model to the second system.

14. The method of claim 12, wherein applying the curing energy control model to the second system does not require calculating an intensity profile for the second system.

15. The method of claim 1, wherein the reactive mixture comprises at least one polymerizable monomer.

16. The method of claim 1, wherein the reactive mixture comprises a visible light absorbing compound.

17. The method of claim 1, wherein the reactive mixture comprises at least one photochromic dye.

18. The method of claim 1, wherein the reactive mixture comprises at least one static dye.

19. A method comprising: causing output of a radiant energy; measuring an intensity of the radiant energy at one or more sites of incident radiant energy; generating, based on the measuring an intensity of the radiant energy, an intensity profile indicative of an intensity of the radiant energy at the one or more sites as a function of electrical settings driving the radiant energy; determining target electrical settings for a source of the radiant energy based on the intensity profile.

20. The method of claim 19, wherein the target electrical settings are configured to minimize deviation of intensity between a plurality of sites of incident radiant energy.

21. The method of claim 19, wherein the generating an intensity profile comprises generating a K matrix.

22. The method of claim 19, wherein the source of the radiant energy comprises one or more light sources.

23. The method of claim 19, wherein the source of the radiant energy comprises one or more light emitting diodes.

24. The method of claim 19, wherein the source of the radiant energy comprises a plurality of light sources and wherein the generating an intensity profile comprises estimating an intensity of radiation at each of the one or more sites as a function of the electrical settings driving each of the light sources.

25. The method of claim 24, wherein determining the target electrical settings for a source of the radiant energy based on the intensity profile comprises determining target electrical settings for each of the light sources to minimize deviation of intensity between a plurality of sites of incident radiant energy.

26. The method of claim 19, wherein the source of radiant energy comprises a first system, and further comprising applying at least one bias correction function or error correction function to the intensity profile based upon one or more characteristics of a second system, different from the first system.

27. The method of claim 19, further comprising inputting the target electrical settings into an irradiation controller, evaluating one or more of the target electrical settings with an intensity sensor, and optionally changing one or more of the target electrical settings in response to that evaluation.

28. A method for calibrating a light in a curing tunnel, comprising: recording measured intensity data, on a sensor device, from the light; calculating error data using the measured intensity data and target intensity data; making a determination that the error data surpasses an error threshold; and based on the determination: adjusting current to the light using the error data.

29. The method of claim 28, wherein after adjusting current to the light, the method further comprises: recording second measured intensity data, on the sensor device, the light; calculating second error data using the second measured intensity data and the target intensity data; making a second determination that the error data does not surpass the error threshold; and based on the determination: proceeding to use the curing tunnel for production.

30. The method of claim 28, wherein prior to making the determination, the method further comprises:making a second determination that the sensor device is faulty.

31. The method of claim 30, wherein based on the second determination, the method further comprises: replacing the sensor device with a second sensor device.

32. The method of claim 28, wherein prior to calculating the error data, the method further comprises: parsing the measured intensity data into a plurality of data groups.

33. The method of claim 32, wherein calculating the error data comprises: calculating a plurality of error data for the plurality of data groups, respectively.

34. The method of claim 33, wherein adjusting the light comprises: minimizing a sum of the plurality of error data.

35. The method of claim 28, wherein prior to making the determination, the method further comprises: making a second determination that the error data does not surpasses a high error threshold; and based on the second determination: continuing operation of the curing tunnel.

36. The method of claim 28, wherein the error data indicates that a light intensity is too low.

37. The method of claim 36, wherein adjusting current to the light comprises: increasing current to the light.

38. The method of claim 28, wherein the error data indicates that a light intensity is too high.

39. The method of claim 38, wherein adjusting current to the light comprises: decreasing current to the light.

40. The method of claim 28, wherein based on the determination, the method further comprises:adjusting a second light using the error data.

41. A calibration system, comprising: a plurality of lights; a conveyor disposed along the plurality of lights; a sensor device carried on the conveyor; and an information handling system.

42. The calibration system of claim 41, wherein the plurality of lights comprises: a plurality of top lights disposed above the conveyor; and a plurality of bottom lights disposed below the conveyor.

43. The calibration system of claim 42, wherein the sensor device comprises: a first light sensor configured to face the plurality of top lights; and a second light sensor configured to face the plurality of bottom lights.

44. The calibration system of claim 43, wherein the sensor device is configured to collect measured intensity data from the first light sensor and the second light sensor.

45. The calibration system of claim 44, wherein the sensor device is configured to operatively connect to the information handling system and transfer the measured intensity data from the sensor device to the information handling system.

46. The calibration system of claim 41, wherein the information handling system is configured to perform a method for calibrating the plurality of lights, comprising: receiving measured intensity data from the sensor device; calculating error data using the measured intensity data and target intensity data; making a determination that the error data surpasses an error threshold; and based on the determination: adjusting current to the plurality of lights using the error data.

47. The calibration system of claim 46, wherein prior to calculating the error data, the method further comprises:parsing the measured intensity data into a plurality of data groups; and calculating a plurality of error data for the plurality of data groups, respectively.

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