EP4676726A1

EP4676726A1 - Fenestrated contact lens

Info

Publication number: EP4676726A1
Application number: EP24713570.0A
Authority: EP
Inventors: David Andrew Icenogle; Cornelius Daniel Niculas
Original assignee: Alcon Inc
Current assignee: Alcon Inc
Priority date: 2023-03-09
Filing date: 2024-03-07
Publication date: 2026-01-14
Also published as: WO2024184852A1; JP2026506959A; CN120769797A

Abstract

An apparatus, system, process, and method for fabricating fenestrated contact lenses, and contact lenses produced thereby. A first mold with a first protruding boss and a second mold with a second protruding boss are engaged with lens-forming material contained in a mold cavity between the first and second molds. The first and second bosses abut one another in the mold cavity between the first and second molds to form a fenestration through the lens as the lens material is cured. The interface between the first and second bosses may be located at an intermediate position in the mold cavity between the first and second molds, such that any surface irregularities are located within the interior of the lens rather than on an exterior lens surface.

Description

FENESTRATED CONTACT LENS

[0001] The present invention relates generally to the field of contact lenses, and more particularly to apparatus, systems, processes, and methods for creating fenestrations within contact lenses, and fenestrated contact lenses formed thereby,

BACKGROUND

[0002] Contact lenses with fenestrations or openings forming passages through the lens between the base curve or back side and the front curve or front side of the lens allow fluid to transfer through the lens and between the sides of the lenses. Fluid transfer may help to prevent the deformation of the lens and/or prevent suction between the lens and the eye that may cause discomfort to the users and hinder or prevent the removal of the lens from the eye.

[0003] Previously, contact lenses with fenestrations have been produced by milling or drilling fenestrations into the lens after the lenses were molded, lathed, or otherwise formed. Adding fenestrations after the lenses are formed may be impractical for production at high volumes or otherwise slower than desired. It has also been found that in some instances, the formation of fenestrations through a lens may leave excess material or burrs forming surface irregularities on the lens, which may result in discomfort to the lens wearer due to contact with the surface irregularities on the cornea or the inner surface of the eyelid.

[0004] Accordingly, it can be seen that the need exists for improved apparatus, systems, processes, and methods for creating fenestrations within contact lenses, and improved contact lenses formed thereby.

[0005] It is to the provision of improved apparatus, systems, processes, and methods for creating fenestrations within contact lenses, and contact lenses formed thereby, meeting these and other needs that the present invention is primarily directed.

SUMMARY

[0006] In example embodiments, the present invention provides improved systems and methods for manufacturing contact lenses with fenestrations. In further example embodiments, the invention provides improved contact lenses with fenestrations. Some example applications of the present invention may enable high-speed or high-volume manufacturing of fenestrated lenses, for example by forming the fenestrations as part of the process of molding of the lens rather than a separate step of milling or drilling fenestrations in a previously formed lens. Additionally, example embodiments provide fenestrated lenses without burrs or other significant lens surface irregularities at or around the fenestrations. [0007] Example contact lenses are formed by molding within a lens mold having a first mold section with a first boss and a second mold section with a second boss. When the first mold section and the second mold section are pressed together, the first and second bosses abut, forming a fenestration within and through the lens. In example embodiments, the bosses have different widths or contact surface areas, such that the width or contact surface area of one of the bosses is substantially larger than that of the other. The disparity in size allows the two bosses to abut one another even if there is relative translation, rotation, or other misalignment or variation in position between two molds. Additionally, because the two bosses each project outwardly from the lens forming surfaces of their respective mold sections into the mold cavity, the contact surfaces of the bosses abut one another during the molding process at a location within the interior of the lens (i.e., within the passage of the fenestration, inside the lens thickness) rather than on or around the lens forming surfaces, any excess material or burrs resulting from material pinch-off at the contact surfaces of the bosses will be inside the lens and not on the surface where it might cause discomfort to a wearer of the lens. In some example embodiments, a dish or recess on at least one of the bosses may aid in pinching off material cleanly during the molding process and help to account for positional mismatches between the two bosses. In some example embodiments, one or more of the mold sections may also have a channel section in addition to, or instead of, its respective boss such that a channel is formed within the lens.

[0008] In one aspect, the present invention relates to a system for molding fenestrated contact lenses. The system preferably includes a first mold section having a first lens forming mold surface, a second mold section having a second lens forming mold surface, and at least one fenestration-forming boss projecting outwardly from either the first or second mold sections. The system is configured such that when the two halve of the mold are engaged, they form a mold cavity that shapes a contact lens.

[0009] In another aspect, the invention relates to a contact lens including a first surface, a second surface, and at least one fenestration that extends through a thickness of the lens between the first and second surfaces. The fenestration preferably includes a first fenestration section, and a second fenestration section. The first fenestration section preferably has a first crosswise dimension and the second fenestration section has a second crosswise dimension, and a transition between the first fenestration section and the second fenestration section is preferably located at an interior portion of the lens between the first and second surfaces.

[0010] In still another aspect, the invention relates to a lens having at least one fenestration formed by the process including providing a first mold section comprising at least one first raised protuberance, providing a second mold section, delivering a lens-forming material to at least one of the first and second mold sections, and engaging the first and second mold sections together to define a lens-forming cavity between the first and second mold sections. The lens-forming material is preferably cured therein to form the lens, with the first raised protuberance extending through a thickness of the lens to form a fenestration extending through the lens.

[0011] In yet another aspect of the invention, the invention relates to a method of manufacturing a contact lens. The method preferably includes providing a first mold section with at least a first raised protuberance, providing a second mold section, delivering a lens material between the first and second mold sections, and engaging the first and second mold sections together while the lens material is between them such that the first raised protuberance forms a fenestration in a contact lens formed therein.

[0012] These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of example embodiments are explanatory of example embodiments of the invention, and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a front perspective view of a contact lens with fenestrations according to an example embodiment of the present invention.

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

[0015] Figures 3A-3E (collectively, Figure 3) show a sequence of forming a fenestrated contact lens according to an example embodiment of the invention, wherein:

[0016] Figure 3A shows a first step in an example process for creating a contact lens with fenestrations.

[0017] Figure 3B shows a second step in an example process for a creating contact lens with fenestrations.

[0018] Figure 3C shows a third step in an example process for creating a contact lens with fenestrations.

[0019] Figure 3D shows a fourth step in an example process for creating a contact lens with fenestrations. [0020] Figure 3E shows a fifth step in an example process for creating a contact lens with fenestrations.

[0021] Figure 4 is a close-up sectional view of a boss interface portion of a mold set used for creating a contact lens with fenestrations, according to an example embodiment of the present invention.

[0022] Figure 5 is a close-up sectional view of another boss interface portion of a mold set used for creating a contact lens with fenestrations, according to an example embodiment of the present invention.

[0023] Figure 6 is a close-up sectional view of yet another boss interface portion of a mold set used for creating a contact lens with fenestrations, according to an example embodiment of the present invention.

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

[0025] Figure 8A is a close-up sectional view of a further boss interface portion of a mold set used for creating a contact lens with fenestrations, according to an example embodiment of the present invention.

[0026] Figure 8B is a close-up sectional view of a further boss interface portion of a mold set used for creating a contact lens with fenestrations, according to an example embodiment of the present invention.

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

[0028] Figure 10 is a close-up sectional view of a further boss interface portion of a mold set used for creating a contact lens with fenestrations, according to an example embodiment of the present invention.

[0029] Figure 11 is a top-down plan view of the meeting area of the bosses of two mold halves used to create a contact lens with fenestrations, according to an example embodiment of the present invention.

[0030] Figure 12 is a top-down plan view of the meeting area of the bosses of another set of two mold halves used to create a contact lens with fenestrations, according to an example embodiment of the present invention. [0031] Figure 13 is a top-down plan view of the meeting area of the bosses of another set of two mold halves used to create a contact lens with fenestrations, according to an example embodiment of the present invention.

[0032] Figure 14 is a close-up sectional view of a boss interface portion of a mold set used for creating a contact lens with fenestrations, according to an example embodiment of the present invention.

[0033] Figure 15 is a close-up sectional view of another boss interface portion of a mold set used for creating a contact lens with fenestrations, according to an example embodiment of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0034] The present invention may be understood more readily by reference to the following detailed description of example embodiments taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.

[0035] Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. Also, any use of the terms “about,” “approximately,” “substantially,” and/or “generally” are intended to mean the exact value or characteristic indicated, as well as close approximations that are understood by persons of ordinary skill in the art to be sufficiently close to the exact value or characteristic based on the context of the intended use and application. In addition, any methods described herein are not intended to be limited to the sequence of steps described but can be carried out in other sequences, unless expressly stated otherwise herein.

[0036] With reference now to the drawing figures, wherein like reference numbers represent corresponding parts throughout the several views, Figure 1 and Figure 2 show an example fenestrated contact lens 100 produced by a molding process according to an example embodiment of the present invention. The lens 100 comprises a first lens section 101 , a second lens section 102, and fenestrations 103 in the form of openings forming fluid- transmissive channels or passages through the thickness of the lens body and extending from one surface of the lens to another. The first lens section 101 is generally hemispherical and has a first lens section inner surface 108 and a first lens section outer surface 109. The second lens section 102 is also generally hemispherical and has a second lens section inner surface 106 and a second lens section outer surface 107. The second lens section 102 is formed integrally with the first lens section 101 such that the first lens section 101 generally encompasses and surrounds the periphery of the second lens section 102. The first lens section 101 has a first curvature, and the second lens section has a second curvature that is generally steeper than the first curvature. In other embodiments, the first and second lens sections may have the same curvature. In further embodiments, the lens may or may not have multiple distinct lens sections or multiple curvatures. In yet further embodiments, the lens may have more than two sections or distinct curvatures.

[0037] A concave back or rear surface of the lens 100 that contacts or faces the surface of the eye when the lens is worn in the intended manner by a human or animal user may be referred to as the base curve of the lens, and may include inner surfaces 106, 108. An opposite convex front surface of the lens that faces away from the eye and may be contacted by the inner surface of the user’s eyelid when blinking or when the eyes are closed may be referred to as the front curve of the lens, and may include outer surfaces 107, 109. The fenestrations 103 within lens 100 allow fluid (e.g., tear liquid, air, eyedrops, etc.) to flow between the outer surface 107 and the inner surface 106 of lens 100. Fluid transfer from one surface of the lens to the other may help prevent the lens from deforming or locking down due to suction on the eye of the user. Further, the fluid transfer allows for the lenses to be in more than one state and may also allow for modification to the tear film of the user, better oxygen permeability, and improved comfort to the wearer.

[0038] In the example embodiment shown in Figure 1 and Figure 2, the fenestrations 103 extend between the outer surface 107 and the inner surface 106 of the second lens section 102 of the lens 100. The fenestrations 103 of the depicted embodiment 100 have a first fenestration section 104 and a second fenestration section 105. In this depicted embodiment, the first fenestration section 104 has a smaller cross-wise dimension or diameter than that of the second fenestration section 105. In other embodiments, the first fenestration section 104 may have a larger diameter than the second fenestration section 105. In other embodiments, the fenestration sections 104 and 105 may be the same size or approximately the same size. In yet further embodiments, there may be only one fenestration section, or there may be more than two fenestration sections. In some particular example embodiments, the fenestrations may have an inner diameter or width of between about 0.010 mm to about 0.700 mm. In other embodiments, the fenestrations may have an inner diameter or width of between about 0.050-0.300 mm. In different embodiments, the fenestrations may have greater or lesser widths.

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

[0040] Figure 3 shows steps of a method of creating a contact lens with one or more fenestrations extending through the lens according to an example embodiment of the invention, for example a high-speed, double-side molding process wherein fenestrations are formed in the lens in situ as part of the molding process, and not requiring a separate milling or drilling process to form the fenestrations. As shown in sectional view in Figure 3A, a second mold section or mold half 330 of a lens-forming mold system is provided with one or more second protuberances or bosses 331 extending or projecting outwardly a distance from a concave front curve lens-forming surface 332 of the second mold section 310. As shown in Figure 3B, a dose of liquid lens-forming material 360 is then deposited within the second mold section 330. The lens-forming material 360 conforms in part to the shape of the second mold section 330, and also conforms in part around the second bosses 331 . As shown in Figure 3C, a first mold section or mold half 310 of the lens-forming mold system is then inserted into the second mold section 330 to form a lens-forming mold cavity between the lens forming surfaces of the first and second mold sections or mold halves, which is substantially filled with the lens-forming material 300. The first mold section 310 comprises one or more first protuberances or bosses 31 1 that extend or projecting outwardly a distance from a convex front curve lens-forming surface 312 of the first mold section 310 in the direction of the second mold section 330 and second bosses 331. The first mold section 310 and the second mold section 330 are configured and positioned such that one or more cooperating pairs of a first boss 311 and a second boss 331 come into alignment with one another and wherein the confronting contact surfaces of the corresponding first and second bosses abut or contact one another when the mold halves are engaged with one another. The lens-forming material within the mold cavity may then be cured, for example by light, heat, chemical or other polymer curing process, to form a solid or gel lens 100. As shown in Figure 3D, once the lens material 360 has cured to form lens 300, the first mold section 310 is removed, leaving the first fenestration sections 304 of fenestrations 303 formed within the lens 300 and extending into the base curve of the formed lens 300. The formed lens 300 is then demolded from the second mold half 330. Alternatively, the second mold section 330 is removed first, leaving the second fenestration sections 305 of fenestrations 303 formed within the lens 300 and extending into the front curve of the formed lens 300. The formed lens 300 is then demolded from the first mold half 310. As shown in Figure 3E, once the lens 300 is removed from the second mold 330, the resulting lens comprises fenestrations 303 extending through the thickness of the lens and forming a channel for fluid transmission between the base curve and front curve sides. The fenestrations are comprised of first fenestration section 304 resulting from the first bosses 311 in the molding process and second fenestration section 305 resulting from the second bosses 331 in the molding process. In this manner, the fenestrations 303 are formed in the lens in situ as part of the lens-forming or molding process, and do not necessitate a separate milling or drilling process to form the fenestrations after the lens is formed.

[0041] Also, in example embodiments the first boss 311 and the second boss 331 meet and abut within or inside of the thickness of the lens-forming material 360 and the lens 300 in the mold cavity as the lens is formed, such that any burrs that might form due to the material pinch-off and demolding processes are likely to be located inside the fenestration 303 at or around the intersection of the first fenestration section 304 and the second fenestration section 305, inside the body of the lens 300, rather than on the inner surface 308 or the outer surface 309 of the lens exterior. This minimizes or eliminates the risk of any potential burrs or other surface irregularities contacting the eye of the patient or wearer and causing discomfort when the lens is in use.

[0042] In alternate embodiments, the steps previously described may be performed in a different order, and it will be understood that methods and processes according to various example embodiments of the invention are not limited to a particular sequence or order of steps. For example, the mold halves may be engaged before liquid forming lens material is inserted into the void between the mold halves. In other examples, the liquid forming lens material may be added first to the mold half forming the base curve of the lens, and then the mold half forming the front curve of the lens may be engaged. It will be understood by those of ordinary skill in the art that variations of the above steps are contemplated by this disclosure.

[0043] In some embodiments, the fenestrations are formed by at least one boss on eitherthe first orsecond mold sections that extends through the thickness of the resulting lens and between the two mold sections. In specific embodiments, the fenestrations may be formed by a combination of abutting bosses, such as those in the embodiment shown in Figure 3, and bosses that extend through the thickness of the resulting lens and between the two mold sections as described below with reference to Figures 14 and 15.

[0044] Figure 4 shows a close-up sectional view of a first mold half 410 and a second mold half 430 according to an example embodiment of the present invention. The first mold 410 comprises at least one first boss 411 , which is further comprised of recessed contact surface or dish 415, a peripheral edge 416, and a first side wall 417. The second mold 430 is comprised of a second boss 431 , which is further comprised of meeting surface 435 and second wall 437. In the example embodiment of Figure 4, the first mold 410 forms the base curve or back surface of a lens, that is, the surface of the lens that is in contact with or facing the eye when worn in the intended manner, and the second mold 430 forms the front curve or front surface of the lens that is furthest from a user’s eye in use. The first boss 411 extends outwardly from the surface of first mold half 410, towards the second mold half 430 and the second boss 431 within the lens-forming cavity when the mold halves are engaged. The second boss 431 extends outwards from the second mold half 430 towards first mold half 410 and first boss 411 within the lens-forming cavity when the mold halves are engaged. The molds and bosses are designed such that as the first mold half 410 and the second mold half 430 are pressed together or engaged, a contact surface or edge of the first boss 411 contacts and abuts the meeting surface 437 of the second boss 431 . The location at which the first boss 411 and the second boss 431 abut is between the first mold 410 and the second mold 430, within an interior region of the lens-forming cavity formed between the mold halves, and therefore inside the lens body and between the inner and outer surfaces of the resulting lens.

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

[0046] Dish 415 of first boss 411 on first mold 410 traps crushed material as first boss 410 is inserted into lens material, such as during the process shown in Figure 3. The walls of the dish 415 are at an angle 0 relative the plane formed by meeting surface 435. In some embodiments, the angle 0 may be between about 0° and about 50°. In other embodiments, the angle 0 may be between about 10° and about 40°. Larger dish angles allow for greater edge crush by the first boss 411 and greater positional mismatch between the first boss 41 1 and the second boss 431 .

[0047] In example embodiments, the fenestration forming bosses are generally symmetrical about a central axis that is parallel to the path of engagement of the first and second mold halves in the lens forming process, to allow parallel engagement and release of the bosses as the mold halves are moved into and out of engagement. For example, in the embodiment shown in Figures 4, the first boss 411 and second boss 431 are generally formed and aligned about the vertical axis 420 which is parallel to the axis of engagement, and the meeting surface 435 is approximately horizontal, as is the edge 416. In other embodiments the bosses may be oriented about a line forming an oblique angle with or relative to the vertical or the engagement axis. For example, in the embodiment shown in Figure 5, the first boss 51 1 and the second boss 531 are formed and aligned about the local normal 525. The meeting plane 535 and the edges 516 perpendicular to the local normal 525, but in other embodiments, they may lie at an oblique angle from the local normal. In the embodiment shown in Figure 5, the local normal 525 is the local normal to the second boss 530 which forms the front curve of the lens. In other embodiments, the boss may be formed about the local normal of the first mold which forms the base curve of the lens or another line at an oblique angle to the vertical.

[0048] In example embodiments having at least one boss on each side of the mold, the bosses may have complementary heights such that the bosses span the thickness of the contact lens when they abut. For example, first boss 411 may have a first height Hi, and second boss 431 may have a second height H₂. First height Hi and second height H₂ add together to equal the mold cavity depth where the first boss 411 and the second boss 431 abut. The first height Hi is preferably about 5% to about 95% of the mold cavity depth or lens thickness, with second height H₂ being remainder of the mold cavity depth or lens thickness. In some embodiments, the first height Hi is between about 30% to about 70% of the mold cavity depth or lens thickness, while H₂ is the remainder of the mold cavity depth or lens thickness. For example, Hi may be about 50% of the mold cavity depth or lens thickness, and H₂ may be the remaining about 50% of the mold cavity depth or lens thickness. The exact height of the bosses depends on several factors, such as the angle of the bosses relative to the mold and the overall thickness of the lens. In an example embodiment, the bosses may have a range of heights between about 0.01 mm to about 0.3 mm. In other embodiments, the range of boss heights may be between about 0.02 mm to about 0.2 mm. In embodiments where the bosses are oriented about the vertical, the relative thickness of the lens seen by the bosses will be thicker. As such, the total apparent height of molds will be larger when the molds are oriented about the vertical as compared to when the molds are oriented about a local normal or other axis. [0049] In the example embodiment of Figure 4, the first wall 417 of the first boss 411 and the second wall 437 of the second boss 431 are generally parallel to axis 420 running normal to the meeting surface 435 and parallel with the path of engagement of the first and second mold halves in the lens forming process, forming a generally cylindrical boss body. In alternate embodiments, the walls and the axis may not be parallel. For example, in the embodiment shown in Figure 5, the first wall 517 of the first boss 511 may be obliquely angled relative to the meeting surface 535 and local normal 525, such that first boss 511 is tapered and wider at its base where it meets the first mold half 510 than it is at the edge 516 where it meets the meeting surface 535, forming a generally frustoconical boss body. Similarly, the second wall 537 of the second boss 531 may be angled such that the width of the second boss 531 is tapered larger at its base where it meets the second mold 530 than it is at the meeting surface 535. The added relative width at the bases of the first boss 511 and the second boss 531 , and the resulting angles of the first wall 517 and the second wall 537 may help to minimize any thin spots around the fenestrations in the resulting lenses. The draft of the angled walls 517 and 537 may also help to prevent the lens from locking onto the molds 510 and 530 and/orthe bosses 511 and 531 if the lens-forming material shrinks during curing, thereby aiding in the separation of the lens from the molds 510 and 530. In some embodiments, the angles between the walls and axis 520 may be between about 0 degrees and about 20 degrees. In particular embodiments, the angle may be about 10 degrees.

[0050] In the embodiments shown in Figures 4 and 5, the dish or recessed face is on the boss protruding from the mold half that forms the base curve of the lens, which is the portion of the lens nearest the user’s eye. When the dish is on the boss formed on the base curve, the feature size of the fenestration on the base curve of the lens may be minimized, which reduces the feature sizes that touch a user’s eye. In other embodiments, the boss forming the surface of the lens furthest from a user’s eye may have a dish, and the other boss may have a receiving surface. For example, in the embodiment shown in Figure 6, the first mold 610 again forms the base curve and the second mold 630 forms the outer most surface of the lens, but the first boss 611 of the first mold 610 has a meeting surface 635 while the second boss 631 on the second mold 630 has a dish or recess 615 with a peripheral edge 616. In the embodiment of Figure 6, the first boss 611 is larger in diameter or crosswise dimension than the second boss 631 , such that the domed second boss 615 is encompassed by the meeting surface 635 on the first boss 611 , even if there is some lateral or rotational movement or misalignment between the two mold halves during the lens-forming process.

[0051] In some embodiments, the peripheral edge of the dished or recessed boss face may be sharp and or pointed, similar to edge 416, 516, and 616. In other examples, such as that of Figure 7, the peripheral edge 716 of the contact face of a boss may be radiused, rounded, or chamfered. Additionally, the inside corners formed where the bosses meet the base of the mold sections may be radiused or rounded, as seen in Figure 7. The corners formed between the bosses and the mold sections may have a radius between about 0 mm and about 0.150 mm. In particular embodiments, the corners may have a radius between about 0.005 to 0.050 mm.

[0052] In some embodiments, one or both of the mold sections may comprise a channel instead of or in addition to a boss. For example, in the embodiment of Figure 8A, the second mold half or section 830 has a channel forming protrusion 840 that forms an indentation on the resulting lens. In the particular embodiment of Figure 8A, the first boss 811 meets the channel to create a fenestration that extends from the exterior surface of the lens (e.g., surface 107 in Figure 1 and Figure 2) until it meets the indentation left by channel 840 within the thickness of the resulting lens. In other embodiments, the channel may be on the base curve of the lens. In the embodiment of Figure 8B, the first mold half or section 810 has a channel 840. The second boss 831 meets the channel to create a fenestration that extends from the exterior surface of the lens (e.g., surface 109 in Figure 1 and Figure 2) until it meets the indentation left by channel 840 within the thickness of the resulting lens. In other embodiments, such as the one shown in Figure 9, the channel 940 may also have a boss 911 extending from the channel. In embodiments where a boss extends from a channel, the smaller boss may be on either the first boss or the second mold section, so long as the so long as the other boss is wider. In some embodiments, both mold sections may comprise channels and bosses, such that a channel is formed on either side of the lens, and a fenestration traverses the channels.

[0053] In some embodiments, one of the bosses may be generally dome shaped or hemispherical, while the other boss may be of a generally smaller dimension. For example, in the embodiment shown in Figure 10, the first mold 1010 has a domed shaped boss 1050 that protrudes outwardly from the first mold 1010 towards the second mold 1030 and the second boss 1031. The second boss 1031 on second mold 103 comprises a dish or recess 1035 with a peripheral edge 1036 and a wall 1037. In alternate embodiments, the domed boss may be on the mold forming the outer surface of the resulting lens and the smaller boss may be on the mold forming the base curve of the lens. The invention also includes example embodiments wherein the fenestration-forming boss(es) or protuberance(s) is/are provided on only one or the other of the first and second lens halves, and is/are configured to extend through the entire thickness of the mold cavity to abut or contact with the lens forming surface of the other mold half to form a fenestration through the lens in the molding process. In such embodiments, the bosses or protuberances may optionally be shaped or otherwise configured to minimize or eliminate any surface irregularities on exterior lens surfaces, or the lens may be further treated to remove any surface irregularities, for improved wearer comfort.

[0054] In some example embodiments, one or both of the bosses have a generally circular shape in plan view. For example, Figure 11 shows a top-down view of an embodiment where the second boss 1131 has a circular flat meeting surface 1135. The peripheral edge 1116 of the smaller first boss (not pictured) forms a smaller circular footprint circumscribed within, and configured to align generally coaxially with, the circular meeting surface 1135 of the larger boss when the mold halves are engaged. In other embodiments, the larger boss may have an ellipsoidal shape in plan view. For example, Figure 12 shows a top-down view of an embodiment wherein the second boss 1231 has an ellipsoidal meeting surface 1235. In this embodiment, the edge 1216 of the smaller first boss (not pictured) forms a smaller circular footprint within the ellipsoidal meeting surface1235. In yet further embodiments, the larger boss may have a square, rectangular or other shape in plan view. For example, Figure 13 shows a top-down plan view of an embodiment wherein the second boss 1331 has a rectangular meeting surface 1335. In this embodiment, the edge 1316 of the smaller first boss (not pictured) forms a smaller circular footprint within the rectangular meeting surface 1335. In other embodiments, the smaller boss may alternatively or additionally. In other embodiments, the smaller boss may alternatively or additionally have an ellipsoidal or rectangular shape. In some examples, the shape of either or both bosses may be something other than ellipsoidal, rectangular, or circular, so long as the dimension of one of the bosses is sufficiently smaller than that of the other so as to allow and compensate for translation or tolerance errors in alignment or relative positioning between the two molds. In example embodiments, the larger boss may have an arcuate configuration in plan view, defining an annular segment, at a radial position corresponding to that of the smaller boss, whereby the smaller boss will still land on the contact face of the larger boss in the event that the mold halves may be slightly rotationally misaligned when brought into engagement in the lensforming process.

[0055] In some embodiments, either of the first or second bosses may extend the entire distance between two mold halves, such that a fenestration is formed by just a single mold boss. For example, in the embodiment shown in Figure 14, the boss 1411 extends from the base curve 1410 about a local normal 1425 towards the second mold half 1430. When the mold halves 1410 and 1430 are engaged, the boss 1411 traverses the distance between the distance between the two molds halves 1410 and 1430 such that the edges 1416 of the boss 1410 abut the second mold half 1430. In other embodiments, such as the embodiment shown in Figure 15, the boss 1535 may extend from the second mold half 1530 such that the edges 1536 of the boss 1535 abut the first mold half 1510 when the mold halves 1510 and 1530 are engaged. Although in both the embodiments show in Figures 14 and 15 the bosses are oriented about a local normal, in other embodiments using a single boss to form a fenestration, the boss may be oriented about the vertical.

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

[0057] While the invention has been described with reference to example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.

Claims

What is Claimed is:

1 . A system for molding fenestrated contact lenses, the system comprising: a first mold section having a first lens forming mold surface; a second mold section having a second lens forming mold surface; and at least one fenestration-forming boss projecting a distance outwardly from either the first mold section or the second mold section and having a first contact face, wherein the first and second mold sections engage to form a lens forming cavity, with the at least one fenestration-forming boss extending between the first lens forming mold surface and the second lens forming mold surface, when the first and second mold sections are engaged.

2. The system of Claim 1 , wherein the at least one fenestration-forming boss comprises a first fenestration-forming boss and a second fenestration-forming boss, the first fenestrationforming boss projecting outwardly from the first mold section and having a first contact face having a first contact surface, the second fenestration-forming boss projecting outwardly from the second mold section and having a second contact face, and wherein the first and second fenestration-forming bosses are configured to align with and abut one another when the first and second mold sections are engaged.

3. The system of Claim 1 or 2, wherein the first lens forming surface further comprises a generally convex lens base curve forming mold surface, and wherein the second lens forming surface further comprises a generally concave lens front curve forming mold surface.

4. The system of Claim 2 or 3, wherein the first contact face of the first fenestrationforming boss has a smaller crosswise dimension than the second contact face of the second fenestration-forming boss.

5. The system of any one of Claims 1 to 4, wherein the first contact face of the first fenestration-forming boss defines a dished recess surrounded by a peripheral edge.

6. The system of Claim 5, wherein the peripheral edge of the first contact face is radiused.

7. The system of any one of Claims 1 to 6, wherein at least one of the first and second mold sections further comprises a channel-forming protrusion projecting a distance outwardly from its lens forming mold surface.

8. The system of Claim 7, wherein the channel forming protrusion has a further raised section within the channel forming protrusion.

9. The system of any one of Claims 1 to 8, wherein the fenestration-forming boss comprises a generally cylindrical body having a sidewall extending generally parallel to an axis of engagement of the first and second mold sections.

10. The system of any one of Claims 1 to 8, wherein at least one ofthe fenestration-forming bosses comprises a generally frustoconical body having a sidewall obliquely angled relative to a longitudinal axis

11 . The system of any one of Claims 2 to 8, wherein at least one of the first and second fenestration-forming bosses comprises a straight sidewall.

12. The system of any one of Claims 2 to 8, wherein both the first and second fenestrationforming bosses comprise angled sidewalls whereby each boss is wider proximal its respective lens curve forming mold surface and narrower distal the respective lens curve forming mold surfaces.

13. The system of any one of Claims 2 to 8, wherein at least one of the first or second fenestration-forming bosses is dome shaped.

14. A method of cast-molding a contact lens, the method comprising: obtaining a system of any one of claims 1 to 13; obtaining a lens-forming material; dispensing a specified amount of the lens-forming material on the first or second lens forming mold surface; engaging the first and second mold sections together to form the lens forming cavity containing the lens-forming material therewithin and to ensure that the at least one fenestration-forming boss extends between the first lens forming mold surface and the second lens forming mold surface; and curing the lens-forming material within the lens forming cavity to form a fenestrated contact lens.

15. A cast-molded contact lens comprising: a first surface; a second surface; and at least one fenestration that extends through a thickness of the lens between the first and second surfaces, the fenestration further comprising a first fenestration section, and a second fenestration section, wherein the first fenestration section has a first crosswise dimension and the second fenestration section has a second crosswise dimension, with a transition between the first fenestration section and the second fenestration section being located at an interior portion of the lens between the first and second surfaces.

16. The contact lens of claim 15, wherein the first and second surfaces further comprise an outer section and an inner section, wherein the outer section circumscribes the inner section, wherein the at least one fenestration is located within the inner sections of the first and second surfaces.

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

18. The contact lens of Claim 15, wherein the first and second surfaces further comprise an outer section and an inner section, wherein a first fenestration of the at least one fenestrations is located within the inner sections of the first and second surfaces and a second fenestration of the at least one fenestrations is located within the outer sections of the first and second surfaces.

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

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