Method for making embedded hydrogel contact lenses

A method for producing embedded hydrogel contact lenses, comprising the steps of:

• (1) obtaining an female insert mold half having a first molding surface, an male insert mold half having a second molding surface, a female lens mold half having a third molding surface, and a male lens mold half having a fourth molding surface, wherein the first and second molding surfaces defines respectively the front and back surfaces of a to-be-molded insert, wherein the third and fourth molding surfaces defines respectively the anterior and posterior surfaces of a to be-molded contact lens, wherein the female and male insert mold halves are configured to receive each other such that an insert molding cavity is formed between the first and second molding surfaces when the female and male insert mold halves are closed securely, wherein the female and male lens mold halves are configured to receive each other such that a lens molding cavity is formed between the third and fourth molding surfaces when the female and male lens mold halves are closed securely, wherein the male lens mold and the female insert mold are configured to mate in a nested fashion with a close or interference fit;
• (2) dispensing an amount of an insert-forming composition on the first molding surface of the female insert mold half;
• (3) placing the male insert mold half on top of the insert-forming composition in the female insert mold half and closing the male and female insert mold halves to form a first molding assembly comprising the insert-forming composition therein;
• (4) curing the insert-forming composition in the first molding assembly to form the molded insert;
• (5) separating the first molding assembly obtained in step (4) into the male insert mold half and the female insert mold half with the molded insert adhered onto the first molding surface;
• (6) dosing a first amount of a lens-forming composition in the center of the back surface of the molded insert adhered on the first molding surface of the female insert mold half, wherein the first amount is sufficient to cover the back surface of the insert;
• (7) placing the male lens mold half on top of the lens-forming composition and closing the male lens mold half and the female insert mold half to form a second molding assembly in which the lens-forming composition is located in a gap between the back surface of the insert and the fourth molding surface of the male lens mold half;
• (8) actinically irradiating the lens-forming composition in specific locations in the second molding assembly so as to form spots of adhesion of the molded insert to the fourth molding surface of the male lens mold half;
• (9) removing the female insert mold half, leaving the molded insert adhered onto the fourth molding surface of the male lens mold half;
• (10) dispensing a second amount of the lens-forming composition on the third molding surface of the female lens mold half;
• (11) placing the male lens mold half with the molded insert adhered thereon and obtained in step (9) on top of the female lens mold half and closing the male and female lens mold halves to form a third molding assembly comprising the lens-forming composition and the insert adhered onto the male lens mold half and suspended in the lens-forming composition;
• (12) actinically curing the lens-forming composition in the third molding assembly to form an embedded hydrogel contact lens precursor that comprises the molded insert embedded within a hydrogel material formed from the lens-forming composition;
• (13) separating the third molding assembly obtained in step (12) into the male and female lens mold halves, with the embedded hydrogel contact lens precursor adhered on one of the male and female lens mold halves;
• (14) removing the embedded hydrogel contact lens precursor from the lens-adhered mold half;
• and
• (15) subjecting the embedded hydrogel contact lens precursor to post-molding processes including a hydration process and one or more other processes selected from the group consisting of extraction, surface treatment, packaging, sterilization, and combinations thereof to form an embedded hydrogel contact lens.