Color mask for embedded contact lenses

A method of producing an embedded contact lens with an annular mask, the method comprising the steps of:

• obtaining a female mold half, a first male mold half, and a second male mold half, wherein the female mold half has a first molding surface defining an anterior surface of the embedded contact lens, wherein the first male mold half has a second molding surface defining a back surface of the insert to be molded, wherein the second male mold half has a third molding surface defining a posterior surface of the contact lens to be molded, wherein the first male mold half and the female mold half are configured to receive each other such that an insert-molding cavity is formed between the second molding surface and a central portion of the first molding surface when the female mold half is closed with the first male mold half, wherein the second male mold half and the female mold half are configured to receive each other such that a lens-molding cavity is formed between the first and third molding surfaces when the female mold half is closed with the second male mold half;
• dispensing an amount of an insert-forming composition on the central portion of the first molding surface of the female mold half;
• placing the first male mold half on top of the insert-forming composition in the female mold half and closing the first male mold half and the female mold half to form a first molding assembly comprising the insert-forming composition within the insert-molding cavity;
• curing the insert-forming composition in the insert-molding cavity of the first molding assembly to form a molded insert;
• separating the first molding assembly into the first male mold half and the female mold half with the molded insert that is adhered onto the central area of the first molding surface;
• dispensing a lens-forming composition in the female mold half with the molded insert adhered thereon in an amount sufficient for filling the lens-molding cavity;
• placing the second male mold half on top of the lens-forming composition in the female mold half and closing the second male mold half and the female mold half to form a second molding assembly comprising the lens-forming composition and the molded insert immersed therein in the lens-molding cavity;
• curing the lens-forming composition in the lens-molding cavity of the second molding assembly to form an embedded contact lens precursor that comprises a bulk hydrogel material formed from the lens-forming composition and the insert embedded in the bulk hydrogel material;
• separating the second molding assembly into the second male mold half and the female mold half with the embedded contact lens precursor adhered on a lens-adhered mold half which is one of the female and second male mold halves;
• applying an ink to form the annular mask on an exposed surface of the embedded contact lens precursor adhered on the lens-adhered mold half, wherein the annular mask is an opaque colored area that covers or overlaps the peripheral edge of the insert so as to minimize or eliminate optical disturbances induced by the peripheral edge of the insert;
• removing the embedded contact lens precursor from the lens-adhered mold half;
• and
• subjecting the embedded 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.

A method of producing an embedded contact lens with an annular mask, the method comprising the steps of:

• obtaining a first female mold half, a male mold half, and a second female mold half, wherein the first female mold half has a first molding surface defining a front surface of an insert to be molded, wherein the male mold half has a second molding surface defining a posterior surface of a contact lens to be molded, wherein the second female mold half has a third molding surface defining an anterior surface of the contact lens to be molded, wherein the first female mold half and the male mold half are configured to receive each other such that an insert-molding cavity is formed between the first molding surface and a central portion of the second molding surface when the first female mold half is closed with the male mold half, wherein the second female mold half and the male mold half are configured to receive each other such that a lens-molding cavity is formed between the second and third molding surfaces when the second female mold half is closed with the male mold half;
• dispensing an amount of an insert-forming composition on the first molding surface of the first female mold half;
• placing the male mold half on top of the insert-forming composition in the first female mold half and closing the first female mold half and the male mold half to form a first molding assembly comprising the insert-forming composition within the insert-molding cavity;
• curing the insert-forming composition in the insert-molding cavity of the first molding assembly to form a molded insert;
• separating the first molding assembly into the first female mold half and the male mold half with the molded insert that is adhered onto the central portion of the second molding surface;
• dispensing a lens-forming composition in the second female mold half in an amount sufficient for filling the lens-molding cavity;
• placing the male mold half with the molded insert adhered thereon on top of the lens-forming composition in the second female mold half and closing the second female mold half and the male mold half to form a second molding assembly comprising the lens-forming composition and the molded insert immersed therein in the lens-molding cavity;
• curing the lens-forming composition in the lens-molding cavity of the second molding assembly to form an embedded contact lens precursor that comprises a bulk hydrogel material formed from the lens-forming composition and the insert completely or partially embedded in the bulk hydrogel material;
• separating the second molding assembly into the second female mold half and the male mold half with the embedded contact lens precursor adhered on a lens-adhered mold half which is one of the male and second female mold halves;
• applying an ink to form the mask on an exposed surface of the embedded contact lens precursor adhered on the lens-adhered mold half, wherein the annular mask is an opaque colored area that covers or overlaps the peripheral edge of the insert so as to minimize or eliminate optical disturbances induced by the peripheral edge of the insert;
• removing the embedded contact lens precursor from the lens-adhered mold half;
• and
• subjecting the embedded 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 obtain an embedded contact lens of the invention.