# US 2013/0155372 A1 · Ophthalmic Lens Molds, Ophthalmic Lenses Molded Therein, And Related Methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0155372 A1 - Document ID: US20130155372A1 - Status: Published application - Kind: A1 - Application number: 13/805,524 - Filed: 2011-07-29 - Published: 2013-06-20 - Earliest claimed: 2010-07-30 - Assignees: CooperVision International Holding Company, LP - Inventors: A.K.M. Shahab Siddiqui; David Robert Morsley; Sarah L. Almond; Richard C. Rogers; Ian Bruce; Lee Darren Norris; Edyta S. Bialek; Benjamin S. Sheader - Web page: https://patentgrep.com/patent/US20130155372A1 ## CPC - B29D 11/00038: {Production of contact lenses} - B29D 11/0048: {Moulds for lenses (moulds for plastic articles in general B29C33/00)} - G02B 1/043: {Contact lenses} - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS ## Abstract Methods of manufacturing contact lenses using ophthalmic lens molds having a molding surface comprising a thermoplastic polymer, the molding surface having a percent polarity from 3% to 20% and a surface energy from about 25 mN/m to about 40 mN/m to cast mold a polymerizable composition having a surface tension from about 20 mN/m to about 25 mN/m, wherein a surface energy differential of the surface tension of the polymerizable composition less the surface energy of the molding surface less than or equal to zero (0); and silicone hydrogel contact lens bodies so manufactured are described. ## Claims ### Claim 1 A method of manufacturing a silicone hydrogel contact lens body, comprising: providing a first mold member and a second mold member, the first mold member comprising a concave molding surface configured to mold an anterior surface of a contact lens and the second mold member comprising a convex molding surface configured to mold a posterior surface of a contact lens, the first mold member and the second mold member being configured to form a lens-shaped cavity therebetween when combined as a mold assembly, the molding surface of at least one of the first mold member and the second mold member comprising a thermoplastic polymer, the molding surface having a percent polarity from 3% to 20% and a surface energy from about 25 mN/m to about 40 mN/m; placing a polymerizable composition comprising a) at least one silicon-containing monomer and b) at least one hydrophilic monomer in the first mold member, the polymerizable composition having a surface tension from about 20 mN/m to about 25 mN/m, and a surface energy differential of the surface tension of the polymerizable composition less the surface energy of the molding surface is less than or equal to zero (0); assembling the mold assembly by placing the second mold member in contact with the first mold member so as to form a lens-shaped cavity therebetween with the polymerizable composition contained in the lens-shaped cavity of the mold assembly; and curing the polymerizable composition in the mold assembly to form a cast-molded polymerized reaction product in the lens-shaped cavity of the mold assembly, the polymerized reaction product comprising a silicone hydrogel contact lens body. ### Claim 2 (depends on 1) The method of claim 1, wherein the molding surface of the at least one of the first mold member and the second mold member comprises a mixture of a thermoplastic polymer and an additive. ### Claim 3 (depends on 2) The method of claim 2, wherein the molding surface formed of the mixture of the thermoplastic polymer and the additive has a percent polarity at least 1% higher and a surface energy at least lmN/m lower than a molding surface formed under the same conditions but of the thermoplastic polymer alone. ### Claim 4 (depends on 2) The method of claim 2, wherein the additive comprises a non-ionic surfactant, a fatty acid amide, or a form of silicone oil, or any combination thereof. ### Claim 5 (depends on 2) The method of claim 2, wherein the additive comprises a fatty acid amide. ### Claim 6 (depends on 2) The method of claim 2, wherein the additive comprises a non-ionic surfactant. ### Claim 7 (depends on 6) The method of claim 6, wherein the non-ionic surfactant is a non-ionic surfactant having a structure including a linear hydrocarbon portion at least 8 carbons in length. ### Claim 8 (depends on 1) The method of claim 1, wherein the thermoplastic polymer comprises a form of polypropylene. ### Claim 9 (depends on 1) The method of claim 1, wherein the thermoplastic polymer comprises a cyclic olefin polymer. ### Claim 10 (depends on 1) The method of claim 1, wherein the thermoplastic polymer comprises polybutylene terephthalate (PBT), the at least one of the first mold member and the second mold member comprising the thermoplastic polymer molding surface is formed by injection molding, and the mold tool used to form the mold member is maintained at a temperature from about 30° C. to about 70° C. during the injection molding. ### Claim 11 (depends on 1) The method of claim 1, wherein the percent polarity of the molding surface is from about 3% to about 17%. ### Claim 12 (depends on 1) The method of claim 1, wherein a percent polarity of the polymerizable composition is from about 2% to about 10%. ### Claim 13 (depends on 1) The method of claim 1, wherein a polarity differential of a percent polarity of the polymerizable composition less a percent polarity of the molding surface is from about +6 to about −6. ### Claim 14 (depends on 1) The method of claim 1, wherein the polymerizable composition and the molding surface of at least one of the first mold member and the second mold member have a spreading coefficient greater than or equal to about 10 mN/m. ### Claim 15 (depends on 1) The method of claim 1, wherein the lens body has ophthalmically acceptably wettable anterior and posterior surfaces without application of a surface treatment to the lens body, or without the presence of an interpenetrating network (IPN) of a polymeric wetting agent in the lens body. ### Claim 16 (depends on 1) The method of claim 1, wherein method further comprises the steps of separating the mold assembly using a dry demolding method which does not involve application of a liquid to the mold assembly comprising the lens body, and of delensing the lens body using a dry delensing method which does not involve application of a liquid to the lens body. ### Claim 17 (depends on 1) The method of claim 1, wherein the hydrophilic monomer of the polymerizable composition comprises a hydrophilic monomer with an N-vinyl group. ### Claim 18 (depends on 1) The method of claim 1, wherein the a) at least one silicon-containing monomer comprises a silicon-containing monomer having a first reactivity ratio, and the b) at least one hydrophilic monomer comprises a hydrophilic monomer having a second reactivity ration, and the second reactivity ratio is less than the first reactivity ratio. ### Claim 19 (depends on 1) The method of claim 1, wherein the average adhesion energy between the molding surface and the polymerized lens body is from about 45 mJ/m2 to about 60 mJ/m2. ### Claim 20 A silicone hydrogel contact lens body, comprising: a cast-molded polymerized lens body comprising the reaction product of a polymerizable composition, the polymerizable composition comprising a) at least one silicon-containing monomer, and b) at least one hydrophilic monomer, the polymerizable composition having a surface tension from about 20 mN/m to about 25 mN/m; wherein the lens body is cast-molded in a mold assembly comprising a first mold member and a second mold member, at least one of the first mold member and the second mold member having a thermoplastic polymer molding surface, the molding surface having a polarity from 3% to 20% and a surface energy from about 25 mN/m to about 40 mN/m, wherein a surface energy differential between the surface tension of the polymerizable composition and the surface energy of the molding surface is less than or equal to zero (0); and the lens body has ophthalmically acceptably wettable anterior and posterior surfaces without application of a surface treatment to the lens body, or without the presence of an interpenetrating network (IPN) of a polymeric wetting agent in the lens body.