Methods and systems for forming ophthalmic lens mold assemblies

A mold assembly comprising:

• a first mold section having a first cavity surface, and a first peripheral region extending outward of the first cavity surface, the first peripheral region having an open ended bore;
• and
• a second mold section having a second cavity surface and a second peripheral region extending outward of the second cavity surface, the second peripheral region having a closed end bore;
• the first and second mold sections are attached together so as to define a cavity therebetween;
• wherein the mold sections are attached by at least one spot weld located in the first and second peripheral regions at the location of the open ended bore and closed end bore.

A method of making an ophthalmic lens, the method comprising:

• providing a first mold section having a first cavity surface and a first peripheral region extending outward of the first cavity surface;
• providing a second mold section having a second cavity surface and a second peripheral region extending outward of the second cavity surface;
• attaching the first mold section and the second mold section together to define a cavity therebetween;
• providing an ophthalmic lens composition selected from the group consisting of ophthalmic lens compositions and ophthalmic lens precursor compositions on at least one of the first and second mold sections so that the cavity defined between the first and second mold sections includes the composition;
• subjecting the composition in the mold assembly to conditions effective to form an ophthalmic lens product from the composition;
• and
• wherein the first mold section and the second mold section are attached by at least one spot weld located in the first and second peripheral regions at a location of an open ended bore and a closed end bore.

A system useful in making ophthalmic lenses, the system comprising:

• a surface configured to carry a mold assembly in a substantially fixed location, the mold assembly comprising first and second mold sections placed together so as to define a cavity therebetween, the first and second mold sections having first and second peripheral regions, respectively, extending outward of the cavity;
• an elongated element having a distal tip and positioned and movable relative to the surface so that the distal tip passes through the first peripheral region and into the second peripheral region, and then out of the second peripheral region and the first peripheral region;
• and
• a source of energy operatively coupled to the elongated element to provide energy to the elongated element effective in allowing the distal end of the elongated element to pass through the first peripheral region and into the second peripheral region to form a spot weld between the first and second peripheral regions.