Production line for the production of ophthalmic lenses

An automated production line for the production of soft contact lenses, the production line comprising:

• a production line front end (1) comprising:
• a first injection-molding machine (10) arranged in the production line and configured to concurrently produce a scalable plurality of front curve plastic lens molds (FCM) within a predetermined cycle time of less than ten seconds;
• a second injection-molding machine (12) arranged in the production line and configured to concurrently produce a scalable plurality of base curve plastic lens molds (BCM) corresponding to the scalable plurality of front curve plastic lens molds within the same predetermined cycle time of less than ten seconds;
• a casting module (14) comprising
• a filling station (144) configured to dose a predetermined amount of lens-forming material into a scalable predetermined number of the front curve plastic lens molds (FCM),
• a capping station (145) configured to place a corresponding scalable predetermined number of the base curve plastic lens molds (BCM) having the same age as the scalable predetermined number of front curve plastic lens molds (FCM) on the scalable predetermined number of front curve plastic lens molds (FCM) containing the predetermined amount of lens-forming material, to form a corresponding scalable predetermined number of closed plastic lens molds (BCM/FCM) containing the lens-forming material;
• a first transfer robot (1470) configured to transfer the corresponding scalable predetermined number of closed plastic lens molds (BCM/FCM) containing the lens-forming material from the casting module (14) to
• a stacking module (15) comprising
• a plurality of lens mold trays (150), each lens mold tray (150) configured for being loaded with a multiple of the corresponding scalable predetermined number of closed plastic lens molds (BCM/FCM) transferred by the first transfer robot (1470) and containing the lens-forming material,
• a stacking robot for stacking a scalable plurality of lens mold trays (150) loaded with the closed plastic lens molds containing the lens-forming material to form a scalable stack (151) of lens mold trays (150);
• a curing module (16) comprising
• a scalable plurality of ovens (160),
• a stack handling robot (162),
• wherein each individual oven (160) of the scalable plurality of ovens comprises a heatable chamber (161) sized to accommodate said scalable stack (151) of lens mold trays (150) carrying the closed plastic lens molds (BCM/FCM) as well as a door for opening and closing the chamber (161), to allow the stack handling robot (162) to load said scalable stack (151) of lens mold trays (150) loaded with the closed plastic lens molds (BCM/FCM) containing the lens-forming material into the heatable chamber (161) when the door is open, to allow the heatable chamber (161) to be heated to a predetermined temperature to effect curing of the lens-forming material to form cured lenses (CL) in the closed plastic lens molds on the individual lens mold trays (150) of the scalable stack (151) when the door is closed, and to allow the stack handling robot (162) to remove said scalable stack (151) of lens mold trays (150) loaded with the closed plastic lens molds (BCM/FCM) containing the cured lenses (CL) from the chamber (161) when the door is open again, and;
• a destacking module (17) comprising a destacking robot configured to destack the individual lens mold trays (150) from the scalable stack (151) of lens mold trays (150) removed from the chamber (161) of said oven (160) for allowing access to the closed plastic molds (BCM/FCM) of each individual lens mold tray (150);
• a second transfer robot (180) configured to transfer a predetermined number of the closed plastic lens molds (BCM/FCM) containing the cured lenses (CL) from said individual lens mold tray (150) to
• a demolding and delensing module (18) comprising
• a demolding station (1813, 1820) configured to open the predetermined number of closed plastic lens molds (BCM/FCM) by separating the base curve plastic lens molds (BCM) and the front curve plastic lens molds (FCM) from each other, with the cured lenses adhering either to the base curve plastic lens molds (BCM) or to the front curve plastic lens molds (FCM),
• a delensing station (1817, 1827) configured to release the cured lenses (CL) from the base curve plastic lens molds (BCM) or from the front curve plastic lens molds (FCM),
• a transfer gripper (TG2) configured to transfer the cured lenses (CL) released from the delensing station to a treatment carrier tray (200);
• a production line back end (2) comprising:
• a scalable treatment module (20) comprising a number of liquid baths for a liquid bath treatment of the cured lenses (CL) carried by the treatment carrier tray (200) to obtain the ophthalmic lenses, wherein the number of liquid baths are reduced or increased depending on the number of ophthalmic lenses concurrently produced by the production line;
• an inspection module (21) for the inspection of the ophthalmic lenses;
• and
• a primary packaging module (22) for packaging those ophthalmic lenses that have successfully passed the inspection in primary packaging containers,
• wherein the first injection-molding machine (10) comprises a first tool half (101) and a second tool half (102), the first tool half (101) and the second tool half (102) being movably arranged relative to one another between a closed position for injection-molding of the front curve plastic molds (FCM) and an open position for removal of the molded front curve plastic molds (FCM),
• wherein the first tool half (101) comprises a first tooling plate (1013) to which a scalable plurality of individual first sleeves (1014) are pre-mounted, each of the individual first sleeves (1014) having an individual optical tool insert (1015) mounted thereto that determines the shape of a concave optical front surface of the front curve plastic lens mold (FCM) formed by the individual optical tool insert (1015),
• and wherein the second tool half (102) comprises a second tooling plate (1023) to which a scalable plurality of individual second sleeves (1024) are pre-mounted, the scalable plurality of individual second sleeves (1024) corresponding to the scalable plurality of individual first sleeves (1014) of the first tool half (101), each of the individual second sleeves (1024) having an individual back piece insert (1025) mounted thereto that determines the shape of a convex back surface of the front curve plastic lens mold (FCM) formed by the individual back piece insert (1025),
• wherein the first tool half (101) further comprises a first slot (1012) accommodating the first tooling plate (1013), the first slot (1012) allowing to mount the first tooling plate (1013) by sliding the first tooling plate (1013) into the first slot (1012) and then fixing the first tooling plate (1013), and allowing to demount the first tooling plate (1013) by unfixing the first tooling plate (1013) and then pulling the first tooling plate (1013) out of the first slot (1012),
• and wherein the second tool half (102) further comprises a second slot (1022) accommodating the second tooling plate (1023), the second slot (1022) allowing to mount the second tooling plate (1022) by sliding the second tooling plate (1023) into the second slot (1022) and then fixing the second tooling plate (1023), and allowing to demount the second tooling plate (1023) by unfixing the second tooling plate (1023) and then pulling the second tooling plate (1023) out of the second slot (1022);
• and wherein the second injection-molding machine (12) comprises a third tool half (121) and a fourth tool half (122), the third tool half (121) and the fourth tool half (122) being movably arranged relative to one another between a closed position for injection-molding of the base curve plastic lens molds (BCM) and an open position for removal of the molded base curve plastic lens molds (BCM),
• wherein the third tool half (121) comprises a third tooling plate to which a scalable plurality of individual third sleeves are pre-mounted, each of the individual third sleeves having an individual optical tool insert mounted thereto that determines the shape of a convex optical front surface of the base curve plastic lens mold formed by the individual optical tool insert,
• and wherein the fourth tool half (122) comprises a fourth tooling plate to which a scalable plurality of individual fourth sleeves are pre-mounted, the scalable plurality of individual fourth sleeves corresponding to the scalable plurality of individual third sleeves of the third tool half (121), each of the individual fourth sleeves having an individual back piece insert mounted thereto that determines the shape of the concave back surface of the base curve plastic lens mold formed by the individual back piece insert,
• wherein the third tool half further (121) comprises a third slot accommodating the third tooling plate, the third slot allowing to mount the third tooling plate by sliding the third tooling plate into the third slot and then fixing the third tooling plate, and allowing to demount the third tooling plate by unfixing the third tooling plate and then pulling the third tooling plate out of the third slot,
• and wherein the fourth tool half (122) further comprises a fourth slot accommodating the fourth tooling plate, the fourth slot allowing to mount the fourth tooling plate by sliding the fourth tooling plate into the fourth slot and then fixing the fourth tooling plate, and allowing to demount the fourth tooling plate by unfixing the fourth tooling plate and then pulling the fourth tooling plate out of the fourth slot,
• wherein the first tool half (101) comprises
• a first fixed block (1010) comprising the first slot (1012) accommodating the first tooling plate (1013) to which the scalable plurality of individual first sleeves (1014) are pre-mounted,
• a first alignment plate (1011) releasably mounted to the first fixed block (1010), the first alignment plate (1011) being provided with a scalable plurality of separate first through-openings (1016) corresponding to the scalable plurality of individual first sleeves (1014), with each separate first through-opening (1016) of the first alignment plate (1011) accommodating therein one individual first sleeve (1014) of the scalable plurality of individual first sleeves (1014) for aligning the one individual first sleeve (1014), the first alignment plate (1011) being movable away from the first fixed block (1010) when being unmounted from the first fixed block (1010) to allow for sliding the first tooling plate (1013) into the first slot (1012) or pulling the first tooling plate (1013) out of the first slot (1012);
• and wherein the second tool (102) half comprises
• a second fixed block (1020) comprising a scalable plurality of hot runner pipes (1026) arranged therein for the injection of a thermoplastic material, the hot runner pipes (1026) extending out of the second fixed block (1020) towards the first tool half (101),
• a mounting plate (1021) releasably mounted to the second fixed block (1020), the mounting plate (1021) comprising the second slot (1022) accommodating the second tooling plate (1023) with the pre-mounted scalable plurality of individual second sleeves (1024), the mounting plate (1021), the second tooling plate (1023) and the individual second sleeves (1024) each comprising hot runner through-holes accommodating therein the hot runner pipes extending out of the second fixed block (1020), the mounting plate (1021) being movable away from the second fixed block (1020) when being unmounted from the second fixed block (1020) to allow for sliding the second tooling plate (1023) into the second slot (1022) or pulling the second tooling plate (1023) out of the second slot (1022),
• a second alignment plate (1027) movably mounted towards and away from the mounting plate (1021), the second alignment plate (1027) being provided with a scalable plurality of separate second through-openings (1028) corresponding to the scalable plurality of individual second sleeves (1024), with each separate second through-opening (1028) accommodating therein one individual second sleeve (1024) of the scalable plurality of individual second sleeves (1024) for aligning the one individual second sleeve (1024).