Photochromic contact lenses and methods of manufacturing

A method for producing a contact lens comprising a photochromic pupillary region comprising:

• a) adding a volume of a first polymerizable monomer composition to a concave member of a casting mold comprising a concave member having a pupillary region and a convex member, said volume being sufficient to produce a pupillary region in an at least essentially cured contact lens;
• b) adding a photochromic amount of at least one photochromic material to the first polymerizable monomer composition in the concave member of the casting mold while at least partially curing said first polymerizable monomer composition during the addition of photochromic material;
• c) adding a volume of a second polymerizable monomer composition to the concave member of the casting mold of b), the total volume of the first and second polymerizable monomer compositions being sufficient to produce an at least essentially cured contact lens;
• d) affixing the convex member to the concave member of the casting mold of c);
• e) at least essentially curing the polymerizable composition in the casting mold of d);
• and
• f) removing the at least essentially cured contact lens from said casting mold.

A method for producing a contact lens having a photochromic pupillary region comprising:

• a) adding a volume of a first polymerizable monomer composition comprising a photochromic amount of at least one photochromic material to the concave member of a casting mold comprising a concave member having a pupillary region and a convex member, said volume being sufficient to form the pupillary region of an at least essentially cured contact lens;
• b) adding a volume of a second polymerizable monomer composition to the concave member of the casting mold using a dispensing means that avoids mixing of said second polymerizable monomer composition with the first polymerizable monomer composition, the total volume of the first and second polymerizable compositions added to said casting mold being sufficient to produce an at least essentially cured contact lens;
• c) affixing the convex member to the concave member of the casting mold of b);
• d) at least essentially curing the polymerizable composition in the casting mold of c).

A method for producing a contact lens having a photochromic pupillary region comprising:

• a) adding a first polymerizable monomer composition to the concave member of a casting mold comprising a concave member having a pupillary region and a convex member;
• b) adding a second polymerizable monomer composition comprising a photochromic amount of at least one photochromic material to the concave member of a), said second polymerizable monomer composition having a viscosity of at least 300 centipoise greater than the first polymerizable monomer composition;
• c) affixing the convex member to the concave member of the casting mold of b);
• d) at least essentially curing polymerizable composition in the casting mold of c);
• and
• e) removing the at least essentially cured contact lens from said casting mold.

A contact lens comprising a non-photochromic polymeric lens body and a photochromic pupillary region located within said lens body by:

• a) adding a volume of a first polymerizable monomer composition comprising a first viscosity and a photochromic amount of at least one photochromic material to a concave member of a casting mold comprising a concave member having a pupillary region and a convex member, said volume being sufficient to produce a photochromic pupillary region in an at least essentially cured contact lens;
• b) adding a volume of a second polymerizable monomer composition comprising a viscosity at least 300 centipoise less than said first polymerizable monomer composition to the concave member of the casting mold of a), the total volume of the first and second polymerizable monomer composition being sufficient to produce an at least essentially cured contact lens;
• c) affixing the convex member to the concave member of the casting mold of b);
• and
• d) at least essentially curing the polymerizable composition in the casting mold of c).

A contact lens comprising a non-photochromic polymeric lens body and a photochromic pupillary region located within said lens body by:

• a) adding a volume of a first polymerizable monomer composition to a concave member of a casting mold comprising a concave member having a pupillary region and a convex member, said volume being sufficient to produce a pupillary region in an at least essentially cured contact lens;
• b) adding a photochromic amount of at least one photochromic material to the first polymerizable monomer composition in the concave member of the casting mold while at least partially curing said first polymerizable monomer composition during the addition of photochromic material;
• c) adding a volume of a second polymerizable monomer composition to the concave member of the casting mold of b), the total volume of the first and second polymerizable monomer compositions being sufficient to produce an at least essentially cured contact lens;
• d) affixing the convex member to the concave member of the casting mold of c);
• e) at least essentially curing the polymerizable composition in the casting mold of d);
• and
• f) removing the at least essentially cured contact lens from said casting mold.

A contact lens comprising a non-photochromic polymeric lens body and a photochromic pupillary region located within said lens body by:

• a) adding a volume of a first polymerizable monomer composition comprising a photochromic amount of at least one photochromic material to the concave member of a casting mold comprising a concave member having a pupillary region and a convex member, said volume being sufficient to form the pupillary region of an at least essentially cured contact lens;
• b) adding a volume of a second polymerizable monomer composition to the concave member of the casting mold using a dispensing means that avoids mixing of said second polymerizable monomer composition with the first polymerizable monomer composition, the total volume of the first and second polymerizable compositions added to said casting mold being sufficient to produce an at least essentially cured contact lens;
• c) affixing the convex member to the concave member of the casting mold of b);
• d) at least essentially curing the polymerizable composition in the casting mold of c).

A contact lens comprising a non-photochromic polymeric lens body and a photochromic pupillary region located within said lens body by:

• a) adding a first polymerizable monomer composition to the concave member of a casting mold comprising a concave member having a pupillary region and a convex member;
• b) adding a second polymerizable monomer composition comprising a photochromic amount of at least one photochromic material to the concave member of a), said second polymerizable monomer composition having a viscosity of at least 300 centipoise greater than the first polymerizable monomer composition;
• c) affixing the convex member to the concave member of the casting mold of b);
• d) at least essentially curing polymerizable composition in the casting mold of c);
• and
• e) removing the at least essentially cured contact lens from said casting mold.