Apparatus, systems, and methods of forming ophthalmic lens components with soluble cores and molds

A system for manufacturing a lens component, comprising:

• a first mold component comprising a first molding surface defined by a first partial component cavity;
• a second mold component comprising a second molding surface defined by a second partial component cavity;
• and
• a soluble core component configured to be placed on either the first molding surface or the second molding surface,
• wherein the first mold component is configured to be mated to the second mold component to form an assembled mold,
• wherein a segment of the soluble core component is configured to be disposed within a mold cavity formed by the first partial component cavity and the second partial component cavity when the first mold component is mated to the second mold component,
• wherein the mold cavity within the assembled mold is configured to receive a lens component material for curing into a molded lens component, and
• wherein the soluble core component is configured to be dissolved in a solvent when the molded lens component is immersed in the solvent.

A method of manufacturing a lens component, comprising:

• providing a first mold component comprising a first molding surface defined by a first partial component cavity, wherein the first mold component is made of a soluble material;
• providing a second mold component comprising a second molding surface defined by a second partial component cavity, wherein the second mold component is made of the soluble material;
• placing at least part of a soluble core component on the first molding surface or the second molding surface, wherein the soluble core component is made of the soluble material;
• mating the second mold component to the first mold component to form an assembled mold, wherein a segment of the soluble core component is disposed within a mold cavity formed by the first partial component cavity and the second partial component cavity;
• introducing a lens component material into the mold cavity;
• curing the lens component material within the assembled mold to form a molded lens component;
• and
• immersing the assembled mold including the molded lens component in a solvent to dissolve the soluble core component, the first mold component, and the second mold component.

A system for manufacturing a lens component, comprising:

• a first mold component comprising a first molding surface defined by a first partial component cavity, wherein the first mold component is made of a soluble material;
• a second mold component comprising a second molding surface defined by a second partial component cavity, wherein the second mold component is made of the soluble material;
• and
• a soluble core component configured to be placed on either the first molding surface or the second molding surface,
• wherein the first mold component is configured to be mated to the second mold component to form an assembled mold,
• wherein a segment of the soluble core component is configured to be disposed within a mold cavity formed by the first partial component cavity and the second partial component cavity when the first mold component is mated to the second mold component,
• wherein the mold cavity within the assembled mold is configured to receive a lens component material for curing into a molded lens component, and
• wherein the soluble core component, the first mold component, and the second mold component are configured to be dissolved in a solvent when the assembled mold is immersed in the solvent.

A method of manufacturing a lens component, comprising:

• providing a first mold component comprising a first molding surface defined by a first partial component cavity, wherein the first mold component is made of a soluble material;
• providing a second mold component comprising a second molding surface defined by a second partial component cavity;
• placing at least part of a soluble core component on the first molding surface or the second molding surface, wherein the soluble core component is made of the soluble material;
• mating a second mold component to the first mold component to form an assembled mold, wherein a segment of the soluble core component is disposed within a mold cavity formed by the first partial component cavity and the second partial component cavity;
• introducing a lens component material into the mold cavity;
• curing the lens component material within the assembled mold to form a molded lens component;
• and
• immersing the first mold component and the molded lens component in a solvent to dissolve the first mold component and the soluble core component.

A system for manufacturing a lens component, comprising:

• a first mold component comprising a first molding surface defined by a first partial component cavity, wherein the first mold component is made of a soluble material;
• a second mold component comprising a second molding surface defined by a second partial component cavity;
• and
• a soluble core component configured to be placed on the first molding surface or the second molding surface,
• wherein the first mold component is configured to be mated to the second mold component to form an assembled mold,
• wherein a segment of the soluble core component is configured to be disposed within a mold cavity formed by the first partial component cavity and the second partial component cavity when the first mold component is mated to the second mold component,
• wherein the mold cavity within the assembled mold is configured to receive a lens component material for curing into a molded lens component, and
• wherein the soluble core component and the first mold component are configured to be dissolved in a solvent when the first mold component and the molded lens component are immersed in the solvent.