Formulation dosing device for contact lens fabrication

Abstract

A dispensing system and method for delivering contact lens formulations into a contact lens molding die. The system includes a carrier portion configured to hold the contact lens mold and an alignment mandrel configured to hold a lens formulation delivery device. The lens formulation delivery device is held in a specific position relative to the contact lens mold for precise delivery of the lens formulation into the mold. A first lens formulation can be dispensed to a central position within the mold, and different second lens formulations can be dispensed in an annular pattern around the central position to form contact lenses with different center and edge characteristics.

Description

Technical Field

[0001] This invention relates generally to the field of manufacturing products including ophthalmic contact lenses, and more specifically to apparatus, equipment, methods, and systems for dispensing or delivering lens formulations into molds or other molding devices in the manufacture or production of contact lenses or other products. Prior Technology

[0002] Various products are manufactured or produced by molding or casting processes. For example, optical contact lenses and other products can be manufactured by: delivering or dispensing a lens formulation (also known as a polymerizable composition or reaction mixture for forming contact lenses or other products) comprising one or more lens molding materials (such as uncured monomeric lens precursor materials) into a mold or other molding apparatus or structure; curing the lens molding material to form a polymeric contact lens or other product; and demolding the lens or other product for further processing or use.

[0003] In certain specific examples, separate dispensing of different lens formulations can be performed, for instance, to produce contact lenses consisting of a first type of lens formulation at the center of the lens and a different second type of lens formulation around the lens edge. Manually dispensing or pouring the center and edge lens formulations using a pipette can result in inconsistent dispensing, inaccurate alignment, and deformation of the dispensed lens formulations, potentially leading to inconsistent products, visual distortion, and other undesirable outcomes.

[0004] Therefore, it can be seen that there is a need for improved apparatus, devices, methods, and systems for dispensing or delivering lens formulations to molds or other molding devices in the manufacture or production of contact lenses or other products. This invention is primarily directed to providing improved apparatus, devices, methods, and systems that meet these and other needs. Summary of the Invention

[0005] In exemplary embodiments, the present invention provides improved apparatus, devices, methods, and systems for dispensing or delivering lens formulation materials to molds or other molding devices in the manufacture or production of contact lenses or other products. In a particular example, a lens formulation dispensing or delivery apparatus is provided for manufacturing gradient contact lenses with improved dispensing accuracy and consistency.

[0006] In a further example, an apparatus or configuration for dispensing central lens formulations can be provided, and another apparatus or configuration for dispensing peripheral lens formulations can be provided. The central dispensing apparatus holds a syringe or other central lens formulation delivery device on the very top and center of anterior curved (FC) lens mold, such that the central lens formulation is precisely centered and consistently controlled in a generally circular dot pattern. The peripheral dispensing apparatus holds a syringe or other peripheral lens formulation delivery device on the very top of and centered above the FC mold, and dispenses the peripheral lens formulation in a ring or annular pattern, thus the formulation is centered and consistently controlled in a ring pattern surrounding the central lens formulation.

[0007] The apparatus and equipment according to the exemplary embodiments can be provided as a complete, stand-alone product manufacturing system, or alternatively as a retrofit component for integration with existing manufacturing systems. While primarily described in relation to the manufacture of eye contact lenses, the invention is also applicable to the manufacture of other optical lenses and a variety of other products, as well as other patterning and printing applications.

[0008] In one aspect, the present invention relates to a dispensing system and method for delivering contact lens formulations into a contact lens molding die. The system preferably includes a carrier portion configured to hold the contact lens mold and an alignment mandrel configured to hold the lens formulation delivery device. The lens formulation delivery device is held in a specific position relative to the contact lens mold for precise delivery of the lens formulation into the contact lens mold.

[0009] The first lens formulation can be dispensed into the center of the mold, and different second lens formulations can be dispensed into a ring pattern around the center to form contact lenses with different center and edge characteristics.

[0010] In another aspect, the present invention relates to a dispensing system for delivering contact lens formulations to a contact lens molding die. Preferably, the dispensing system includes a carrier portion configured to hold the contact lens mold. Preferably, the dispensing system also includes a center dispensing alignment mandrel configured to hold a center lens formulation delivery device in a substantially fixed position relative to the carrier portion during delivery of the center lens formulation to the central portion of the contact lens mold. Preferably, the dispensing system also includes an edge dispensing alignment mandrel configured to hold an edge lens formulation delivery device in a substantially fixed position relative to the carrier portion during delivery of the edge lens formulation to the edge portion of the contact lens mold.

[0011] In another aspect, the present invention relates to a method for forming a contact lens from a central lens formulation and an edge lens formulation. The method preferably includes: holding a front-curved mold portion of the contact lens in a carrier; engaging a center-fitting alignment mandrel with the carrier over the front-curved mold portion of the contact lens; delivering the central lens formulation from a first delivery device held in a first delivery position by the center-fitting alignment mandrel to a central position within the front-curved mold portion of the contact lens; disengaging the center-fitting alignment mandrel from the carrier; engaging an edge-fitting alignment mandrel with the carrier over the front-curved mold portion of the contact lens; and delivering the edge lens formulation from a second delivery device held in a second delivery position by the center-fitting alignment mandrel in an annular pattern surrounding the central position within the front-curved mold portion of the contact lens.

[0012] These and other aspects, features, and advantages of the present invention will be understood with reference to the accompanying drawings and detailed description herein, and will be realized by means of the various elements and combinations specifically pointed out in the appended claims. It should be understood that the foregoing general description and the following brief description of the drawings and detailed description of exemplary embodiments are explanations of exemplary embodiments of the invention, and not limitations on the claimed invention. Simple Explanation of the Diagram

[0013] [Figure 1] is a perspective view of a central lens preparation dispensing or delivery device or system according to an exemplary embodiment of the present invention. []

[0014] [Figure 2] is a cross-sectional view of the dispensing device in Figure 1. []

[0015] [Figure 3] is a perspective view of an edge lens preparation dispensing or delivery device or system according to an exemplary embodiment of the present invention. []

[0016] [Figure 4] is a cross-sectional view of the dispensing device in Figure 3. []

[0017] [Figures 5A, 5B and 5C] illustrate the steps of the fitting and molding manufacturing process according to an exemplary form of the present invention, and the resulting lens product.

[0018] [Figure 6] is a perspective view of an edge lens preparation dispensing or delivery device or system according to another exemplary embodiment of the present invention. []

[0019] [Figure 7] is a cross-sectional view of the edge lens preparation dispensing or delivery device or system of Figure 6. Implementation

[0020] The invention can be more readily understood from the following detailed description of exemplary embodiments taken in conjunction with the accompanying drawings, which form part of this disclosure. It should be understood that the invention is not limited to the specific apparatus, methods, conditions, or parameters described and / or shown herein, and the terminology used herein is for the purpose of describing embodiments by way of example only and is not intended to limit the claimed invention. Any and all patents and other publications identified in this specification are incorporated herein by reference as if fully stated herein.

[0021] Furthermore, unless the context clearly indicates otherwise, the singular forms "a" and "the" as used in this specification (including the appended claims) include the plural, and references to a particular numerical value include at least that particular value. A range herein may be expressed as from "about" or "approximately" one specific value and / or to "about" or "approximately" another specific value. When such a range is expressed, another embodiment includes from that one specific value and / or to the other specific value. Similarly, when a value is expressed as an approximation by using the antecedent "about," it should be understood that the specific value constitutes another embodiment.

[0022] Referring now to the accompanying drawings, in which similar reference numerals denote corresponding parts in several views, Figures 1 and 2 illustrate a central lens formulation dispensing or delivery apparatus or system 10 according to an exemplary embodiment of the invention. The apparatus or system 10 generally includes a base or mold carrier portion 20, a mold portion 30, a central dispensing alignment mandrel or fixing portion 40, and a central lens formulation delivery device 60.

[0023] The mold carrier portion 20 includes a generally annular structure having a lower or bottom side or surface 22, a planar upper or top side or surface 24, an annular outer surface 26, and an internal recess or opening 28 configured to receive and releasably engage a front-curved (FC) or back (concave) mold portion 30 for manufacturing contact lenses or other products. The surface of the internal recess or opening 28 is preferably configured to have a size and / or shape and / or include one or more engagement features that are closely conformally adapted to and / or actively engage with the corresponding surface and / or features of the mold portion 30, so as to maintain a consistent relative positioning of the mold portion within and relative to the mold carrier portion 20 during the manufacturing of the central portion of the contact lens or other product. For example, in the depicted embodiment, an annular flange 25 projects upward from the top surface 24 of the mold carrier portion 20 and has a height, thickness, and diameter configured to substantially correspond to and engaged within a co-configured annular channel or receiver portion formed in the lower inner surface of the collar 32 of the mold portion 30. In a further example embodiment, one or more mold carrier portions 20 may be attached or secured to a belt or other carrier portion of an automated manufacturing system, or alternatively may be integrally formed with such belt or other carrier portion.

[0024] A center-dispensing alignment mandrel or fixing portion 40 is configured to be positioned on and releasably coupled to the mold carrier portion 20, and to detachably engage and hold the syringe or other center lens formulation delivery device 60 in a fixed position for precise alignment on the anterior curved mold portion 30. In an example embodiment, the center-dispensing alignment mandrel portion 40 includes a base portion 42, at least one upright wall portion 44, and a top plate portion 46 having a generally central opening or receiver 48 for receiving and engaging with the delivery device 60. In the depicted embodiment, the center-dispensing alignment mandrel portion 40 is a generally tubular or cylindrical body. In the depicted embodiment, the base portion 42 includes an annular ring having a planar base surface surrounding an opening, the size and shape of which are closely conformable to the outer surface of the collar 32 of the mold 30, wherein the annular flange 25 of the mold carrier portion 20 engages within an internal annular channel or receiver of the mold collar 32, for example by a tight fit or slight interference fit. In certain example embodiments, the mold collar 32 may be generally circular, with an outer diameter between approximately 20 mm and approximately 25 mm, for example, approximately 23.72 mm; however, in alternative embodiments, the mold collar may be configured in other ways and / or may be larger or smaller to suit the desired mold configuration. The upright wall portion 44 is preferably configured to have a height corresponding to the longitudinal dimension of the syringe or central lens formulation delivery device 60, so as to maintain the tip of the syringe or delivery opening at the desired height above the mold receiver. In a particular example embodiment, the height of the upright wall portion 44 may be configured to maintain a distance of approximately 1.0 mm to approximately 3.0 mm, for example, approximately 2.0 mm, between the dispensing tip 66 of the central lens formulation delivery device 60 and the receiving seat of the mold 30, but larger or smaller intervals may be provided in alternative embodiments. The upright wall portion 44 may comprise a continuous cylindrical wall or one or more wall segments that, as needed, provide one or more openings therebetween for accessing or observing syringe tip positioning and formulation delivery. In the depicted embodiment, the top plate portion 46 is a generally circular or annular disc, and the opening or receiver 48 is positioned centrally for aligning the delivery device 60 above the center of the mold receiving seat of the front curved mold portion 30. The size and shape of the opening 48 are determined to fit closely to the corresponding cylindrical portion of the delivery device 60 to receive and engage the delivery device, for example, by a tight fit or slight interference fit. In a particular example embodiment, the diameter of the opening 48 may be between about 0.4 mm and about 0.6 mm, for example about 0.48 mm, but in alternative embodiments it may be larger or smaller to accommodate a delivery device intended for a particular application.

[0025] In an example process or method for delivering or dispensing a central lens formulation CF (or a central polymerizable composition or central reaction mixture) comprising one or more lens forming materials (such as an uncured monomeric lens center precursor material or other liquid or gel product formulation material), a front-curved mold portion 30 is mounted onto a mold carrier portion 20, wherein the annular channel of a mold collar 32 is engaged over an upwardly projecting annular flange 25 of the carrier. A central dispensing alignment mandrel portion 40 is positioned over the carrier 20 and the mold 30, wherein the base 42 of the mandrel is engaged over the mold collar 32 and the flange 25 of the carrier. A syringe or central lens formulation delivery device 60 is positioned within an opening 48 of the mandrel 40. The delivery device 60 is actuated, for example, by advancing a syringe plunger 62 within a syringe barrel 64 to dispense the central lens formulation CF from the syringe tip 66 into the center of the mold receiving seat of the front-curved mold portion 30. For example, controlling the advance of the plunger 62 using an air pump, pneumatic or hydraulic actuator allows for control of the amount of central lens formulation delivered. The configuration and positioning of the central lens formulation dispensing or delivery device or system 10 ensures that the central lens formulation CF is delivered precisely to the top and center of the front-curved (FC) lens mold, such that the central lens formulation is precisely centered within the mold receiving seat and continuously controlled in the form of a generally circular dot or formulation. In an example embodiment, the mold 30 includes a mold-carrier-engagement portion (e.g., an internal annular channel in the underside of the mold collar 32) configured to directly and actively engage with the carrier-mold-engagement portion of the carrier 20 (e.g., with the annular flange 25 of the carrier), such that the position of the mold relative to the carrier is stable and fixed during dispensing operations, thereby helping to maintain precise control over the delivery or dispensing position of the central lens formulation CF. In a further exemplary embodiment, the mold 30 includes a mold-mandrel-engagement portion (e.g., the annular outer surface of the mold collar 32) configured to directly and actively engage with a mandrel-mold-engagement portion of the dispensing alignment mandrel 40 (e.g., with an inner annular opening in the base 42 of the mandrel), such that the position of the mandrel relative to the mold is fixed during dispensing operations, thereby also contributing to maintaining precise control over the delivery or dispensing position of the central lens formulation CF. Furthermore, in the exemplary embodiment, the mold-carrier-engagement portion of the mold may be fixed in place relative to the mold-mandrel-engagement portion of the mold, have a single construction with the mold-mandrel-engagement portion of the mold, or be the same component as the mold-mandrel-engagement portion of the mold (e.g., the inner and outer portions of the same mold collar 32), thereby minimizing or eliminating any clearance or tolerance overlap between components that might adversely affect position control of lens formulation delivery.

[0026] Figures 3 and 4 illustrate an edge lens formulation dispensing or delivery apparatus or system 110 according to an exemplary embodiment of the present invention. The apparatus or system 110 typically includes a base or mold carrier portion 120, a mold portion 130, an edge dispensing alignment and dispensing mandrel or fixing portion 140, and an edge lens formulation delivery device 160. If the edge lens formulation dispensing system 110 is used in conjunction with a central lens formulation dispensing system (e.g., system 10 described above), the mold carrier 120 and mold 130 of the edge lens formulation dispensing system may be the same component as the mold carrier 20 and mold 30 of the central lens formulation dispensing system.

[0027] The mold carrier portion 120 includes a generally annular structure having a lower or bottom side or surface 122, a generally planar upper or top side or surface 124, an annular outer surface 126, and an internal recess or opening 128 configured to receive and releasably engage a front-curved (FC) mold portion 130 for manufacturing contact lenses or other products. The surface of the internal recess or opening 128 is preferably configured to have a size and / or shape and / or include one or more engagement features that are closely conformally adapted to and / or actively engage with corresponding surfaces and / or features of the mold portion 130, so as to maintain a consistent relative positioning of the mold portion within and relative to the mold carrier portion 120 during use in the manufacturing of edge portions of contact lenses or other products. For example, in the depicted embodiment, an annular flange 125 projects upward from the top surface 124 of the mold carrier portion 120 and has an annular channel or receiver portion configured to substantially correspond to and engage within the collar 132 of the mold 130, with a height, thickness, and diameter thereof. In a further example embodiment, one or more mold carrier portions 120 may be attached or secured to a belt or other carrier portion of an automated manufacturing system, or alternatively may be integrally formed with such belt or other carrier portion.

[0028] An edge-dispensing alignment and fixing portion 140 is configured to be positioned over and releasably coupled to a mold carrier portion 120, and to engage and detachably retain a syringe or other edge formulation delivery device 160 in a fixed position for precise alignment over the front-curved mold portion 130. In an example embodiment, the edge-dispensing alignment mandrel and dispensing portion 140 includes a base portion 142, at least one upright wall portion 144, a top plate portion 146, and an edge-lens formulation dispensing portion 150 having a generally central opening or receiver 148 for receiving and engaging the delivery device 160. In a particular example embodiment, the diameter of the opening 148 may be between approximately 1.0 mm and approximately 1.5 mm, for example, approximately 1.25 mm, but in alternative embodiments it may be larger or smaller to accommodate a delivery device intended for a particular application. In the depicted embodiment, the edge-dispensing alignment mandrel portion 140 is a generally tubular or cylindrical body. In the depicted embodiment, the base portion 142 includes an annular ring having a planar base surface surrounding an opening, the size and shape of which are closely conformable to the collar 132 of the mold 130, wherein the annular flange 125 of the carrier 120 engages in the collar, for example by a tight fit or slight interference fit. The upright wall portion 144 is preferably configured to have a height corresponding to the longitudinal dimension of the syringe or edge lens formulation delivery device 160, so as to maintain the syringe tip or delivery opening at a desired height above the mold receiving seat. The upright wall portion 144 may include a continuous cylindrical wall or one or more wall segments, which may, as needed, provide one or more openings therebetween for accessing or observing syringe tip positioning and edge formulation delivery. In the depicted embodiment, the top plate portion 146 is a generally circular or annular disc, and the opening or receiver 148 is positioned centrally for aligning the delivery device 160 above the center of the mold receiving seat of the front curved mold portion 130. The size and shape of the opening 148 are determined to fit closely to the corresponding cylindrical portion of the delivery device 160 in order to receive and engage the delivery device, for example by a tight fit or a slight interference fit.

[0029] The peripheral lens formulation dispensing portion 150 is positioned generally vertically between the base portion 142 and the top plate portion 146, for example, on a support flange or shelf 152 extending through the internal chamber of the alignment mandrel and the dispensing portion 140. In the depicted embodiment, the peripheral lens formulation dispensing portion 150 includes a generally circular or polygonal array of holes or openings 154 surrounding generally tapered or symmetrically inclined protrusions or peaks 156 projecting upward from the support shelf 152. The openings 154 are preferably evenly spaced and symmetrically arranged around the tapered protrusions 156, and the peaks of the protrusions are preferably coaxially aligned with the central axis of the array of openings and centrally positioned on the shelf 152, directly below the center of the opening 148 in the top plate 146. In the depicted embodiment, the array of openings 154 includes ten openings, but fewer or more openings may be provided within the scope of the invention. Furthermore, while the openings 154 are depicted as circular holes, various other shapes and configurations of openings are also within the scope of the invention.

[0030] In an example process or method for delivering or dispensing an edge lens formulation EF (or an edge polymerizable composition or edge reaction mixture) comprising one or more lens molding materials (such as uncured monomeric lens edge precursor materials or other liquid or gel product formulation materials), a front-curved mold portion 130 is mounted onto a mold carrier portion 120, wherein the annular channel of a mold collar 132 is engaged over an upwardly projecting annular flange 125 of the carrier. As described above, the carrier portion and the mold portion may be the same components for both center dispensing and edge dispensing. An edge dispensing alignment mandrel and dispensing portion 140 is positioned over the carrier 120 and the mold 130, wherein the base 142 of the mandrel is engaged over the mold collar 132 and the carrier flange 125. A syringe or edge lens formulation delivery device 160 is positioned within an opening 148 of the mandrel 140. The delivery device 160 is actuated, for example, by advancing the syringe plunger 162 within a syringe barrel 164 to dispense the edge lens formulation EF from the syringe tip 166. The peripheral lens formulation EF is preferably delivered onto the peak or end of the protrusion 156 and flows down the slope of the protrusion in a substantially uniform pattern by gravity, through the opening 154, and is delivered in an annular pattern distributed around the center of the mold receiving seat of the front curved mold portion 130. If the central lens formulation CF has been previously delivered to the mold 130, the peripheral lens formulation EF is preferably uniformly distributed in a symmetrical ring surrounding the central lens formulation. The amount of lens formulation delivered can be controlled, for example, by using an air pump, pneumatic or hydraulic actuator to control the advance of the plunger 162. The configuration and positioning of the peripheral lens formulation dispensing or delivery device or system 110 ensures controlled, precise and consistent delivery of the peripheral lens formulation EF within the mold receiving seat. In an example embodiment, mold 130 includes a mold-carrier-engagement portion (e.g., an internal annular channel in the underside of mold collar 132) configured to directly and actively engage with a carrier-mold-engagement portion of carrier 120 (e.g., with an annular flange 125 of the carrier), such that the position of the mold relative to the carrier is stable and fixed during dispensing operations, thereby helping to maintain precise control over the delivery or dispensing position of the rim lens formulation EF. In a further example embodiment, mold 130 includes a mold-mandrel-engagement portion (e.g., the annular outer surface of mold collar 132) configured to directly and actively engage with a mandrel-mold-engagement portion of dispensing alignment mandrel 140 (e.g., with an internal annular opening in the base 142 of the mandrel), such that the position of the mandrel relative to the mold is fixed during dispensing operations, thereby also helping to maintain precise control over the delivery or dispensing position of the rim lens formulation EF.Furthermore, in the example embodiment, the mold-carrier-joint portion of the mold can be fixed in place relative to the mold-mandrel-joint portion of the mold, have a single construction with the mold-mandrel-joint portion of the mold, or be the same component as the mold-mandrel-joint portion of the mold (e.g., the inner and outer portions of the same mold collar 32), thereby minimizing or eliminating any clearance or tolerance overlap between components that may adversely affect the position control of lens formulation delivery.

[0031] The central lens formulation dispensing or delivery system 10 and the edge lens formulation dispensing or delivery system 110 can be used independently of each other, or they can be used together in a sequential lens formulation delivery process. In an example embodiment, the central lens formulation CF is first delivered to the center of the mold receiving seat, and then the edge lens formulation EF is delivered in an annular pattern surrounding the central lens formulation CF within the mold receiving seat. Alternatively, the annular pattern of the edge lens formulation EF can be delivered into the mold first, and then the central lens formulation CF can be delivered or dispensed into the inner ring of the edge lens formulation EF. The characteristics of the lens formulation, such as viscosity and surface adhesion, can be taken into account when determining the delivery or dispensing procedure. As shown in the example forms in Figures 5A, 5B, and 5C, the central lens formulation CF and the edge lens formulation EF can be delivered or dispensed into the mold receiving seat of the negative or front-curved (FC) lens mold half 30 according to the dispensing instructions for the specific lens or other product to be formed (Figure 5A). The positive or base-curved (BC) lens mold half 80 is then advanced to engage with the negative or front-curved (FC) lens mold half 30 (Figure 5B). Edge and center lens formulations are cured for a specific time, for example, by delivering light, heat, chemical catalysts, and / or other curing mechanisms, to form lenses or other products. In the depicted embodiment, the lens formulation is cured by light from a light source projected through the open or transparent bottom of the carrier 20 and through the light-transmitting portion of the mold 30. The lens halves are then separated, and the cured lens or other product 90 is removed from the lens for further processing, packaging, or use (Figure 5C).

[0032] Lenses produced according to the systems and methods disclosed herein can be, for example, photochromic lenses, ultraviolet (UVA and / or UVB) light-blocking lenses, high-energy visible light (HEVL) blocking lenses, colorblindness correcting lenses, diffraction multifocal lenses, and / or other contact lens applications. In a particular example embodiment, lens 90 can be a photochromic lens, wherein the darkening transition material is in the central region (CF) and the transparent material faces the edge (EF). In other examples, the central lens formulation (CF) can be a high UV and / or visible light blocking material, wherein the transparent material faces the edge (EF). In further examples, the central lens formulation (CF) can be a high-viscosity precursor material, while the edge formulation material (EF) can be a low-viscosity precursor material, or vice versa. In a particular application, the central lens formulation (CF) and the edge lens formulation material (EF) can be, for example, silicone hydrogels and / or other types of contact lens formulations.

[0033] Figures 6 and 7 show a perspective view and a cross-sectional view, respectively, of another exemplary embodiment of the edge lens formulation dispensing or delivery system 310, which is substantially similar to the embodiments described above, with the differences as indicated. System 310 similarly generally includes a base or mold carrier portion 320, a mold portion 330, an edge dispensing alignment mandrel and dispensing portion 340, and an edge lens formulation delivery device 360. An inclined edge lens formulation dispensing feature 350 is arranged generally centrally on a shelf 352 extending through the internal chamber of the alignment mandrel and dispensing portion 340, and is located below the material discharge end 366 of the delivery device 360 ​​during use. An opening 354 surrounds the edge lens formulation dispensing feature 350. If desired, the opening 354 is in fluid communication with a downwardly extending tube or channel 356 through which the edge lens formulation EF is delivered in an annular pattern in the mold receiving seat below. In the illustrated example embodiment, the tube or channel 356 extends downward and inward to form an obliquely inclined delivery conduit through which the peripheral lens formulation EF is delivered in an annular pattern that generally circumferentially surrounds and is concentric with the central lens formulation CF in the underlying mold receiving seat.

[0034] The lens formulation dispensing apparatus or system according to the example embodiments can be an accessory to existing dispensing equipment to enable better precision and greater consistency in the manufacture of gradient contact lenses, or it can be a standalone system. In the example form, there is one apparatus or system for center dispensing and another for edge dispensing. In an alternative form, a single apparatus or system can be reconfigured for both center and edge dispensing. Advantages of the example embodiments may include consistent dispensing volume, consistent dispensing shape (circle for the center and ring for the edge), and / or consistent centering of the center and edge formulations. For example, an embodiment of the center lens formulation dispensing apparatus allows for the connection of a syringe to a top cavity and a front-curved (FC) mold to a bottom cavity. Dispensing a measured amount of center lens formulation, it will drip precisely into the center of the FC mold. The center dispensing apparatus holds the syringe on the very top and center of the FC mold, so that each dose is precisely centered and controlled in a point-like manner. In an example embodiment of the edge lens formulation dispensing apparatus, the syringe is connected to the top cavity and the FC mold is connected to the bottom cavity. The dispensing of a measured amount of edge lens formulation will cause the edge lens formulation to be dispensed into a ring around the central droplet of the central lens formulation in the FC mold. The exemplary system and method of the present invention can be used to manufacture a variety of lenses with different central and edge structural compositions. Examples include photochromic lenses, high HEVL blocking lenses, and colorblindness corrective lenses.

[0035] Although the invention has been described with reference to exemplary embodiments, those skilled in the art will understand that various modifications, additions, and deletions are within the scope of the invention as defined by the following claims.

[0036] 10. Central lens preparation dispensing or delivery device or system 20. Base or mold support component 22. Below, or on the side, or on the surface 24. The top or top side or surface of a plane. 25. Annular flange 26. Annular outer surface 28. Internal recess or opening 30 Mold Section 32 rings 40 Center-fitting alignment mandrel or fixed part 42. Base section 44. Vertical wall section 46. ​​Top Slab Section 48. An opening or receiver roughly in the center. 60 syringes or other central lens preparation delivery devices 62 Syringe plunger 64 Syringe cartridges 66 Syringe tip 90% cured lenses or other products 110. Edge lens formulation dispensing or delivery device or system 120 Base or mold support component 122 Below or bottom side or surface 124. The upper or top side or surface of a roughly flat plane. 125 Annular Flange 126 Annular outer surface 128 Internal recess or opening 130 Mold Section 132 rings 140 Edge fitting alignment and distribution mandrel or fixed part 142 Base section 144 Vertical wall section 146 Top Slab Section 148. An opening or receiver roughly in the center. 150 Edge Lens Formulation Dispensing Section 152 Support flange or shelf 154 holes or openings 156. Roughly conical or symmetrically tilted protrusions or peaks 160 syringes or other peripheral formulation delivery devices 162 Syringe plunger 164 Syringe cartridges 166 Syringe tip 310 Edge lens formulation dispensing or delivery system 320 Base or mold support component 330 Mold Section 340 Edge-fitting Alignment Mandrel and Dispensing Section 350-degree tilted edge lens formulation dispensing characteristics 352 Shelves 354 Opening 356 pipe or channel 360° Edge Lens Formulation Delivery Device 366 Material Discharge Terminal

[0037] none

Claims

1. A dispensing system for delivering lens formulations to a contact lens forming mold, the dispensing system comprising: The carrier component is configured to hold the contact lens mold. Lens formulation delivery device; The device includes an alignment mandrel configured to hold the lens formulation delivery device in a designated position relative to the contact lens mold for precise delivery of the lens formulation into the contact lens mold. The carrier portion includes a carrier-mold-engagement portion for holding the mold in a fixed position relative to the carrier portion. The carrier-mold-engagement portion includes a flange configured to engage within a channel of the contact lens mold. The flange includes an annular flange projecting upward from the top surface of the carrier portion. The alignment mandrel includes an annular base configured to engage around the annular flange of the carrier portion. The annular flange of the carrier portion has an outer diameter between approximately 20 mm and approximately 25 mm. The alignment mandrel system includes an edge-feeding alignment mandrel configured to hold the lens preparation delivery device in the designated position for delivering the lens preparation in an annular pattern around the center position of the contact lens mold. The edge-feeding alignment mandrel includes an edge lens preparation dispensing portion for receiving the lens preparation from the lens preparation delivery device. The edge lens preparation dispensing portion includes a generally circular array of openings for dispensing the lens preparation into the annular pattern.

2. The distribution system as described in claim 1, wherein, The lens preparation delivery device is a syringe having a syringe barrel and a syringe plunger, wherein the alignment mandrel includes a top plate having an opening configured to securely engage the syringe barrel.

3. The distribution system as described in claim 1, wherein, The alignment mandrel is centrally engaged and configured to hold the lens formulation delivery device in the designated position for delivering the lens formulation at the center position in the contact lens mold.

4. The distribution system as described in claim 2, wherein, The alignment mandrel is centrally engaged and configured to hold the lens formulation delivery device in the designated position for delivering the lens formulation at the center position in the contact lens mold.

5. The dispensing system as described in any one of claims 1 to 4, further comprising a second alignment mandrel for delivering a second lens formulation in an annular pattern around the central location in the contact lens mold.

6. The distribution system as described in claim 5, wherein, The edge lens formulation dispensing portion further includes protrusions having peaks that are typically centered within the circular array of openings.

7. The distribution system as described in claim 5, wherein, The edge lens formulation dispensing portion further includes a downwardly extending tube in fluid communication with the openings.

8. The distribution system as described in any one of claims 1 to 4, wherein, The edge lens formulation dispensing portion further includes protrusions having peaks that are typically centered within the circular array of openings.

9. The distribution system as described in any one of claims 1 to 4, wherein, The edge lens formulation dispensing portion further includes a downwardly extending tube in fluid communication with the openings.

10. The distribution system as described in any one of claims 1 to 4, wherein, The alignment mandrel is configured for detachable connection with the carrier portion.

11. The dispensing system as described in claim 5, wherein, The alignment mandrel is configured for detachable connection with the carrier portion.

12. The distribution system as described in claim 6, wherein, The alignment mandrel is configured for detachable connection with the carrier portion.

13. The dispensing system as described in claim 7, wherein, The alignment mandrel is configured for detachable connection with the carrier portion.

14. The dispensing system as described in claim 8, wherein, The alignment mandrel is configured for detachable connection with the carrier portion.

15. The dispensing system as described in claim 9, wherein, The alignment mandrel is configured for detachable connection with the carrier portion.

16. A dispensing system for delivering lens formulation material to a contact lens molding die, the dispensing system comprising: The carrier component is configured to hold the contact lens mold. A center dispensing alignment mandrel configured to hold a center lens preparation delivery device in a substantially fixed position relative to the carrier portion during delivery of a center lens preparation to the center portion of the contact lens mold; and an edge dispensing alignment mandrel configured to hold an edge lens preparation delivery device in a substantially fixed position relative to the carrier portion during delivery of an edge lens preparation to the edge portion of the contact lens mold.

17. The dispensing system as described in claim 16, wherein, The carrier portion includes an annular flange configured to engage with the contact lens mold.

18. The dispensing system as described in claim 16 or 17, wherein, The center dosing alignment mandrel and the edge dosing alignment mandrel are configured to be interchangeably mounted on the carrier portion for delivering the center lens formulation and the edge lens formulation, respectively.

19. A method for forming a contact lens from a central lens formulation and a peripheral lens formulation, the method comprising: The contact lens anterior surface mold portion is held in a carrier; a center fitting alignment mandrel is engaged with the carrier on the contact lens anterior surface mold portion; the center lens preparation is delivered from a first delivery device held in a first delivery position by the center fitting alignment mandrel to the center position within the contact lens anterior surface mold portion; the center fitting alignment mandrel is disengaged from the carrier; an edge fitting alignment mandrel is engaged with the carrier on the contact lens anterior surface mold portion; and the edge lens preparation is delivered from a second delivery device held in a second delivery position by the center fitting alignment mandrel in an annular pattern around the center position within the contact lens anterior surface mold portion.

20. The method as described in claim 19, further comprising joining the base surface mold portion of the contact lens to the front surface mold portion of the contact lens.

21. The method as described in claim 19 or 20, further comprising curing the central lens formulation and the peripheral lens formulation to form a contact lens.

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