Deformable molds and methods for their use in the manufacture of ophthalmic lenses

Abstract

The present provides deformable molds and methods for manufacturing ophthalmic lenses using deformable molds. The molds of the invention may be used in the custom manufacture of ophthalmic lenses.

1 . A process for manufacturing an ophthalmic lens, comprising the steps of:
 a.) providing a casting cup comprising:
 (i) a non-molding surface and a molding surface, wherein at least a portion of the molding surface is capable of being reversibly deformed and 
 (ii.) adjustment means for reversibly deforming the deformable portion of the molding surface; and 
   b.) deforming the deformable portion of the molding surface to a shape suitable for imparting one or more optical characteristics onto a lens surface.   
     
     
         2 . The process of claim  24 , further comprising the steps of:
 c.) depositing a lens-forming material on the molding surface; and   d.) curing the lens-forming material under conditions suitable to form the ophthalmic lens.   
     
     
         3 . The process of claim  24 , further comprising:
 c.) measuring a wavefront shape for the molding surface;   d.) using the adjustment means to change the shape of the molding surface;   e.) depositing a lens-forming material on the molding surface mold; and   f.) curing the lens-forming material under conditions suitable to form the ophthalmic lens.   
     
     
         4 . The process of claim  25 , wherein the lens-forming material is selected from the group consisting of acquafilcon, etafilcon, genfilcon, lenefilcon, senefilcon, balafilcon, lotrafilcon, and galyfilcon. 
     
     
         5 . The process of claim  26 , wherein the lens-forming material is selected from the group consisting of acquafilcon, etafilcon, genfilcon, lenefilcon, senefilcon, balafilcon, lotrafilcon, and galyfilcon. 
     
     
         6 . The process of claim  24 , further comprising the step of attaching a plurality of pusher pins to the non-molding surface. 
     
     
         7 . The process of claim  24 , further comprising attaching a plurality of pusher pads to the non-molding surface. 
     
     
         8 . The process of claim  29 , further comprising attaching a plurality of pusher pads to the non-molding surface. 
     
     
         9 . A process for manufacturing a contact lens, comprising the steps of:
 a.) providing a casting cup comprising:
 (i) a non-molding surface and a molding surface, wherein at least a portion of the molding surface is capable of being reversibly deformed and 
 (ii.) adjustment means for reversibly deforming the deformable portion of the molding surface; 
   b.) deforming the deformable portion of the molding surface to a shape suitable for imparting one or more optical characteristics onto a lens surface   c.) measuring a wavefront shape for the molding surface;   d.) using the adjustment means to change the shape of the molding surface;   e.) depositing a lens-forming material on the molding surface mold; and   f) curing the lens-forming material under conditions suitable to form the ophthalmic lens.   
     
     
         10 . A process for manufacturing a contact lens, comprising the steps of:
 a.) providing a casting cup comprising:
 (i) a non-molding surface and a molding surface, wherein at least a portion of the molding surface is capable of being reversibly deformed and 
 (ii.) adjustment means for reversibly deforming the deformable portion of the molding surface; 
   b.) deforming the deformable portion of the molding surface to a shape suitable for imparting one or more optical characteristics onto a lens surface   c.) depositing a lens-forming material on the molding surface; and   d.) curing the lens-forming material under conditions suitable to form the ophthalmic lens.