CA1322091C

CA1322091C - Method and apparatus for producing molded articles

Info

Publication number: CA1322091C
Application number: CA000580572A
Authority: CA
Inventors: Gordon P. Brown; Harry C. Morgan; Robert L. Merker
Original assignee: Ocutech Inc
Current assignee: Ocutech Inc
Priority date: 1987-11-09
Filing date: 1988-10-19
Publication date: 1993-09-14
Anticipated expiration: 2010-09-14
Also published as: US4840754A; SE8803920A; NL8802742A; JPH02501A; DE3836744A1; SE8803920D0; SE8803920A0; IN172162B; BE1001759A5; AU2430088A; GB8825248D0; KR890007860A; LU87374A1; IT1229824B; GB2212095A; IT8822431A0; FR2622835A1; FR2622835B1

Abstract

ABSTRACT OF THE DISCLOSURE
A method and apparatus for molding articles such as ophthalmic devices to provide high surface smoothness without the formation of flask anywhere on the molded articles. A predetermined quantity of moldable material is arranged between spaced apart molding surfaces, between which as an outer boundary, a meniscus is formed. The configuration of the meniscus is controlled as by moving the molding surfaces toward each other to produce convex rounding of the moldable material forming the meniscus. When thermo-curring material is used, heating of the molds is controlled to accelerate the polymerization of the moldable material. The molding surfaces are moved when the moldable material attains a predetermined gel state.

Description

METHOD AND APPARATUS FOR PRODUCING
MOLDED ART I CLES

1 Field of the Invention: The pre~ent .
invention relates to a method and apparatus for producing mold~d articles of manufacture comprised of thermo-curing materials including thermo-setting and thermo-plastic materials; and more particularly the present invention relates to the production of such articles wherein a meni~cus of such material at a boundary to molding surfaces of a mold assembly during the solidification process i8 controlled and/or adjusted to provide a de~ired shape to the molded article in a manner which preclude~ the formation of flash anywhere on the article during the molding process.

2. Description of the Prior Art: Standard designs of conventional reusable molds provide at lea~t one parting line established by the site of separation between top and bottom and/or inner and outer component mold parts. The parting line cannot be ~ealed again~t ingress of moldable material particularly liquids from the mold cavity. Therefore, the partlng line fills with moldable material during the actual molding operations whereby an unwanted thin web section usually called flash i~ formed as an integral part of the molded object. For certain applications the parting line flash is of no consequence and can be left in place. For many applications, however,/the flash must be removed. This can usually be accomplished by suitable machining operations. Alternative molding techniques and apparatus are needed when satisfactory machining operations cannot be accomplished as when, for example~ the molded article comprises elastomeric material.
While not 80 limited, the present invention 0 i8 particularly useful for producing molded articles useful in an as-molded-condition without surface modification to the molded article. Certain molded articles must comply with the requirement of a high surface smoothness throughout. A specific class of such molded articles is ophthalmic devices comprising intraocular, intracorneal and contact lenses. Such ophthalmic devices can be made from glass or clear pla~tic, e.g. polymethyl methacrylate, silicone rubber or hydrogel polymers. In this class of materials, silicone rubber, particularly hydrocarbon substituted polysiloxane offers desirable properties making this material well suited for ophthalmic ~
device~. One recent development in the intraocular lens art provides that a lens made of molded ~ilicone rubber can be folded for insertion through an unusually small incision at the limbal area of the eye.

In the manufacture of a silicone rubber intraocular lens, a two part liquid silicone polymer is thoroughly mixed and a de~ired quantity is introduced into one part of a mold cavity in a mold block that can be positioned in a cooperative relation with a second part of a mold cavity to form the lens.
In the known method, the amount of llquid silicone polymer introduced into the mold cavity waR always greater than the amount necessary to form the cured intraocular len~. In this way, it could be assured that the mold cavity is completely filled with ~ilicone material. The excess silicone material extrudes out from the mold cavity when the two mold block~ are forced together under pressure while the curing process is completed. The curing is carried out by heating the molds to a predetermined temp~rature, about 150 degrees C, for a period of time sufficient to cure the ~ilicone material. Curing i~
usually completed within about 15 minutes residence time in the mold at the curing temperature.
Thereafter, the mold blocks are separated, and the molded lens remaining in one of the mold halves must be separated from a flashing consisting of a thin web of cured silicone rubber protruding from the outer periphery of the intraocular lens. The flashing is removed by tearing the fla~hing from the lens. The lens is then removed from the mold cavity in the mold block. The edge surface of the intraocular lens from which the flashing has~been torn away is rough and irregular because the flashing is separated by applying ~ufficient force to shear the silicone material at the site where the flashing joins the intraocular lens. The site is a haptic part of the lens which functions to anchor, stabilize and poaition the lens after placement in the eye of the recipient.
The present invention seek~ to prevent pathology that may develop due to a rubbing or other trauma from contact over a period of time between the rough and irregular peripheral edge surface of the haptic which i8 the site where the flashing was torn away from the intraocular lens, and the ciliary ~ulcu8 or lens capsule.
In the pa~t, ophthalmic devices were also made from hard, non-elastic materiAls ~uch as glass or methylmethacrylate by first forming a lens blank and then shaping the blank by grinding and other machining - operations to impart a desired curvature and finlsh to the finished lens. Machining a lens blank in this manner was limited to a di3c-like hemispherical shape, ~ince the machining operation~ are performed by rotation of the lens blank. On the other hand, machining of elastomeric materials ~uch as silicone rubber to form an ophthalmic device could not be carried out in this manner because the ela~tomeric ~ 32209 1 material tears when machining or cutting is attempted.
One teaching to overcome this ~hortcoming can be found in U.S. Patent No. 3,874,124 wherein a lens blank made from elastomeric material is placed on a support 6urface and cooled to such an extent that hardnes~ of the elastomeric material i~ increa~ed ~o that a machining operation can be carried out in the presence of a liquid interface. However, such a machining of ela~tomeric material ha~ not met with commercial success and i8 limited to circular and hemispherical geometrical ~hapes. After completion of the machining operation on the elastomeric material, it was necessary to eliminate contamination by the liquid interface from the elastomeric material. It was also found that the machined surface of the elastomeric material was hydrophobic and thus re~isted wetting by tear fluid whereas the unmachined, molded surface of the lens exhibits good wetting properties.
SUMMARY OF THE PRESENT INVENTION
It i8 an object of the pre~ent invention to provide a method and apparatus for producing a molded article by loading a predetermined quantity of moldable material into a mold cavity formed by spaced apart mold parts and a meniscus where surface tension on the moldable material in the space between the mold BurfaCes acts to define a boundary of the molded article.

1 3220q l It iæ a further object of the present invention to provide a~method and apparatus for producing molded articlec comprised of a predetermined quantity of moldable material which i6 supplied to a mold cavity formed by two ~paced apart mold members which can undergo relative movement to impart a desired configuration to the ~urface of the moldable material at the ~pace between the mold parts.

More particularly~ according to the present invention there is provided a method for molding an article, the method including the steps of providing a mold having separable molding surface~; loading a predetermined quantity of moldable material in at least one molding ~urface of the mold, positioning the molding ~urfaces of the mold into a spaced apart relation to establi~h a meniscus of moldable material in the gap about the periphery of the moldable material, causing the meniscus to attain a convex curvature extending outwardly of the gap between the molding surface~, and finalizing the molding of the moldable material to form the article while maintaining the meni~cu~ with a convex curvature..
The method preferably provides that when the thermal curing material is used, ~he polymerization include~ dividing the reaction time into first and second time periods of which the fir~t time period corresponds to a fir~t degree of polymerization of the t 3220~ 1 thermal curing material up to the step of cau~ing the meni~cus to attain a ~onvex curvature, and the second time period correspond~ to ~ second degree of polymerization of the thermal curing material after the meniscus is ~ormed with a convex curvature. The second time period preferably extends to the complete cure of the thermal curing material. The apparatus of the present invention which iB u~eful to carry out the method thereof includes first and second molding surfaces which can be brought into a spaced apart relation to define a meniscus established by moldable thermal curing material in the mold cavity, means for supporting the molding surfaces at a first spaced apart relation~hip, means for allowing di~placement of one molding surface toward the other molding surface into a second ~paced apart relationship corresponding to the desired dimension of the molded ~rticle, and means for allowing solidifying a moldable material in the mold cavity.
The material selected for introduction into the mold cavity in the method and apparatus of the present invention can be thermo-setting or thermo-plastic. When thermo curing material is selected, time and temperature curing characteristics are used to determine the point of t$me when the mold part~ can be moved together without imparting stre~s and Rtrain to the molded article, i.e. before three ~ 3220q l dimensional cross-linking occur~. On the other hand, the gel state of the thermal curing material in the mold must be allowed to increase due to the polymeriæation proces~ so that material at the meniscus between the molding surfaces can undergo a profile change 80 a~ to form a desixed ~moothly rounded profile which is free of an unwanted sharp edge. When thermo-pla~tic material i~ selected, the material undsrgoe~ ~olidificatlon in ~he mold c~vity.
BRIEF DESCRIPTION OF THE DRAWINGS
These features and advantages of the present invention a~ well as others will be more fully under~tood when the following de3cription i8 read in light of the accompanying drawings in which:
Figure 1 i~ a side elevational view of a longitudinal section of a ~chematic representation of the human eye including a natural lens, Figure 2 i8 a plan view of one form of intraocular lens which has been made according to the method and apparatus of the pre~ent invention;
Figure 3 i8 a ~ide-elevational view of the lens ~hown in Figure 2;
Figure 4 is an isometric view of one mold part including a molding cavity therein for producing the intraocular lens shown in Fiqures 2 and 3;

I322n~l Figure 5 i~ an isometric view of a mold part including a mold cavity to cooperate with a mold cavity in Figure 4;
Figure 6 is a flow diagram of a preferred embodiment of the present invention;
Figure 7 is an enlarged elevational view in section of the mold parts at a first spaced apart posi~ion for carrying out the method of the present lnvention;
Figure 8 1~ a view ~imilar to Figure 7 and illustrating the mold parts at a second spaced apart po~ition;
Figure 9 i~ an elevational view in section of two mold parts in a ~paced apart relation for producing a contact lens; and Figure 10 is a view similar to Figure ~ and illustrating the mold parts in a ~econd spaced apart relation.
DETAILED DESCRIPTION OF THE PREFERRED ~MBODIMENTS
As described hereinbefore the pre~ent invention is not limited to but is particularly useful for producing ophthalmic devices. In Figure 1 there i8 a ~chematic illustration of the human eye which is identified generally by reference numeral 10, and includes a cornea 12, an iris 14, a lens 16, the ciliary 8ulcus 18 adjacent to the lens, the retina 20 and the macula 22. As is well known, light ray~ are 1 3220~ 1 focused directly on the macula 22 by the cornea 12 and the len~ 16. When the/light bending properties of the cornea and len~ fail to focus light ray~ clearly on the macula 22, the refractive propertie~ of the eye can be modified through the use of an ophthalmic device to again bring incident light into focus on the macula. The refractive properties of the eye can be modified by placing a contact lens on the cornea 12.
A contact lens iB one form of ophthalmic device which can be produced according to the method and apparatus of the present invention. The contact lens should have smooth surfaces blended together about the posterior and anterior qurfaces of the lens.
A unique characteri~tic of a contact lens when manufactured according to the pre~ent invention, is that the lens i8 entirely comprised of only molded surfaces and as ~uch there are no ~urface6 or axeas of the lens from which, for example, a flashing ha6 been cut, machined or otherwise removed. A contact lens can be made according to the present invention from a ' moldable material selected from the group con~isting of glas~, polymethyl methacrylate, silicone rubber and hydrogel polymers.
A second form of ophthalmic device which can be produced according to the pre~ent invention, is an intraocular len~ which may compri6e any of diverse configurations and con~truction~, one typical 1 3220q 1 construction being shown in Figure~ 2 and 3. An intraocular lens is uskd to replace ths lens 16 (Figure l) after the lens 16 i5 removed by surgery as commonly necessary because of a cataract. Shown in Figures 2 and 3, is an intraocular lens made up of two hemispheric like lens sections 26 and 28 facing in opposite directions from a centrally positioned haptic 3D having a planar web section 32 with a generally rectangular form and rounded corner~ 34. The haptic essentially includes a convexly rounded edge about the outer periphery of the planar web section 32 without fla~hing and sharp edges that might cau~e pathology.
In the past, an intraGcular lens of the type ~hown in Figures 2 and 3 was made, a8 described hereinbefore, by a molding process that resulted in the production of a flashing extending from an attachment ~ite around the entire outermost periphery of the outer edge of the haptic. When the flashing was torn away from the lens, the resulting face surface about the outer edge of the rib of the haptic was rough, lrregular and sometimes required additional cutting operations to remove parts of the fla~hing. ~he present invention provides for the manufacture of a molded intraocular lens wherein no flashing i~ produced anytime, ~5 including during the molding of the len~ material.
The lens i8 used in an as-molded condition without alteration including surface machining operation.

There may be, of cour~e, post molding treatment of the lens, for example, sterilization.
According to ~he pre~ent invention is an intracorneal lens that can be implanted in the cornea to adjust the refractive powers of the cornea. Such a lens resemble a contact lens but an intracorneal lens has a smaller diameter and a thinner wall thickness as compared with a contact lens. An intracorneal lens i~
produced in es~entially the same manner as will be described hereinafter by a method and apparatus for producing a contact lens.
Turnlng now to one embodiment of the present invention, in Fiqure 4 and 5 there i~ illustrated a mold assembly which includes mold halves 41 and 42 havi.ng general form of rectangular block~ of metal each provided with 6paced apart and generally parallel drilled openings 43 and 44 into which there are po~itioned cartridge type electrical heaters 45 controlled by controller~ 45A whereby the mold halves can be heated to a desired temperature and maintained at a desired temperature during thermal curing of the liquid silicon rubber in the mold cavitieR. The cartridge heater~ are retained in the opening~ by ~uitable means, such as a potting compound. The mold blocks include one, or more if desired, bored opening 46 wherein a thermocouple 47 is placed to pOBition the temperature responsive portion thereof clo~ely 1 3220q 1 adjacent to concave optic mold ~urfaces 48 u~ed to form the len~ portion~ of an intraocular lans.
Numerical read-out gauges 47A provide temperature mea6urement that can be used by an operator to operate controllers 45A. An automatic controller such as a microproces~or can be used to control the heaters 45 in re~ponse to output signals from the thermocoupleA
47. The thermocouples can be held in place by ~uitable means such as a potting compound.
Surrounding the concave optic mold$ng surfaces 48 in the molds are relatively shallow haptic molding surfaces 49 that can be defined in a ~eparable lnsert S0 removably secured to a mold block 41. The insert may, when desired, include an optic molding surface 48.
It should be under~tood that it is arbitrary to designate top and bottom mold halves becau6e a mold can be ~et on a support ~urface in a manner where either of the mold assembly halves can be a bottom or a top mold half. A raised pad 51 is provided at each of the four corners of the rectangularly shaped mold block 42. The pads have equal upstanding heights which extend as shown in Figure 5 equal d$stance~
above the insert 50 and the haptic molding surface 49.
Between the pad~ 51 at each of opposite end~ of the mold half, there is an upstanding elongated guide shaft 52 having a threaded end portion that can threadedly engage wi~h a fa~tener 52A ~uch as a nut member. Mold half 41,is provided with opening~ 53 at spaced apart loca~ions to guide and slidably receive the guide shafts which have a length sufficient to pass through mold half 42 and protrude from the surface of mold half which i8 opposite the surface where haptic molding surface of inser~ 50 is found.
Shown in Figure 5 are spacers 54 which are supported on the exposed face surface~ of the raised pads. It 0 i8 to be understood that the thickne~ of the four spacers is preselec~ed according to a desired amount of rounding to be imparted to the thermal curing material forming a meniscus between molding surface~
as will be explained in greater detail hereinafter.
The spacers 54 can be replaced by ~paced apart ~haft~
threadedly engaqed with threaded bores in one mold half and projecting into engagement with the other mold half 80 that by adjusting the shaft~ the spacing between the molding surfaces can be selectively adjusted. Identified by reference numeral 55 is a schematic illustration of a material discharge device ~n Figure 4 which operates to supply a predeterm~ned quantity of a moldable thermal curing material into one or, if desired, both halves of the mold parts.
One material for molding lenses, in accordance wlth the present invention is silicone rubber, particularly hydro-carbon ~ubstituted poly~iloxane. The material i8 a two-part ~ystem, which after mixing together in a prescr$bed ratio underqoes polymerization to a complete cure. Heating thi~ material above ambient temperature only accelerates the cure time. The di3penser 55 includes storage chambers 56 and 57 haviny cross sectional area~ corresponding to the pre~cribed ratio of the two components which reside in the respective chambers and which are discharged by ~eparate plungers 58 and 5~. A tie bar interconnects the plungers to move equal distances along graduation marks used to determine the preselected quantity of liquid ~ilicon rubber compQnents diacharged from conduit 61 into the mold cavity. A s~atic mixing chamber 62 receives the prescribed g~antities of liquid silicon rubber from passageways communicat~ng with chamber6 56 and 57 and delivers a thoroughly mixed flowstream to conduit 61.
As illustrated by the flow diagram of Figure 6, when the moldable material is comprised of a multi-component, the components are first mixed together and a measured quantity i8 introduced onto one of the mold cavities. The mold i8 then clo~ed by placing one mold half on the other whereby the guide shafts 5~
slide along to the openings of the mold half 41. A
~5 ~pacer 54 1~ located on each of the pads 51 between the mold parts ~o as to maintain a prescribed neparation between the molding nurface~ in the two 1 3220q l mold parts. Fa~teners 52A are u~ed to firmly ~ecure the two mold part~ togéther. When fa~tener~ are in the form of nut members they can be tightened on threaded ends of the ~haft members. The thickness of the spacers 54 are carefully pre~elected 80 that the molding surfaces will be Rpaced apart from one another to form a meniscus at the gap between the two molding eurface~. If not already initiated, this assembly of mold parts i~ partly ~hown in Figure 7. It can be seen that the mass of thermal curing moldable material 60 is comprised of a preselected quantity which is ~ufficient to wet all khe molding surfaces 48 and 49 and fill the space between the re~pective oppositely positioned corresponding molding ~urfaces. The volume of moldable material i8 such that when the spacer~ 54 are in place, the meni~cus 61 will assume a pre~crlbed shape, namely, concave (as shown in Figure 7);
generally planar or convex. The magnitude of the convex shape ~hould be small becau~e of the natural tendency of the liquid polymer to flow from the mold cavity. For this rea~on it i~ preferred to e~ablish a meni~cus having a concave configuration whereb~
~urface tension facilitates the maintaining of the meniRcus without breakouts or leakage of the liquid polymer. Surface wetability of the molding surfaces by the liquid polymer i~ also a factor affecting the meni~cus and can be used to control the shape of the meniscus. Cùrrent i8 applied to the cartri3ge ~ aters to 6peed the polymeriz~tion proceæs. Depending on the particular polymer, the moldq are heated to a predetermined temperature, such as, for example, 150 degrees C. At this temperature, the polymerization process is allowed to continue to the extent that the liquid polymerized in the mold Gavity approaches a gel state. At a selected time when the polymer material i~ between, for example 70 and 100 percent of a gelled state, the fasteners 52A are released so that the spacer 54 can be removed. After the spacer~ are removed, fasteners are again tightened 80 as to bring the molding surfaces in the two mold parts closer together whereby the gap between the molding surfaces is reduced. This relationship of part~ is shown in Figure 8 and causes the meniscus to undergo a rounding to form a desired convex profile in cros~ section.
The mold parts must be moved together sufficiently 80 that rounding does occur to an extent necessary to prevent the formation of sharp edges on the periphery of the haptic at the conclusion of the molding proce~s. Thereafker as shown in Figure 6, heati~g of the mold i9 continued for the prescribed perlod of time sufficient to cure the polymer. The cured polymer is notably characterized by the fact that polymerization has proceeded through cross linking of the polymer. At the end of the curing process, heating of the mold is terminated and, if de~ired, the mold can be artificial~y cooled to a temperature to permit safe handling. The mold can be opened by first removing the fastener6 52A and then separating the mold halves from one another. The molded article will reside in one of the mold halve~ and can be removed from the mold cavity thereof. The mold halves can then be prepared for the production of additional len~es. It is to be understood that the curing process for silicone rubber will proceed without heating the mold although the curinq time will be substantially lengthened. Thenmo-setting material i8 also responsive to time and temperature conditions.
In Figures 9 and 10 there is illustrated an arrangement of mold halve~ for producing a contact lens. Again it is preferred to produce the contact lens from sllicone rubber although polymethyl methacrylate and hydrogel polymers can be used. The mold halves 70 and 71 are constructed in a manner which ~8 ~imilar to that already described in Figures 4 and 5. However, the mold cavity 72 is generally hemispherical which define~ molding surface 73 with a concave hemispherical ~hape and mold surface 74 wlth a convex hemispherical shape. The mold cavity i8 esta~)lished by positioning the two mold surface in a spaced apart and inter-fitting relation. A meniscus i8 formed at the outer peripheral edge of the moldable material in the mold. After a predetermined quantity of liquid polymer is i,ntroduced onto surface 73, the other mold part 71 i~ positioned on expo~ed faces of spacer members 75 whereby the two mold part~ are spaced apart so that the mold surfaces 73 and 74 of the mold parts never form a closed mold cavity.
Cartridge heaters and thermocouples are introduced in the openings in the moldæ as shown and described hereinbefore to heat the mold and give measurements of the temperature to which the mold iB
heated. The thermocouples are important for establishing the duration of the polymerization process when the polymer has proceeded to a desired gel state. The mold parts are held together securely by threaded fasténers that engage anchor posts extending from one mold part through openings in the other mold part. After the fa~teners are secured in place, the mold is heated in a manner as described previously to a temperature until the polymer obtains a desired gel state. When this occurs, the fasteners are released ~ufficiently 80 tha~ the spacer members 75 can be removed and the mold parts moved toward one another by a distance corresponding to the distance defined by the thickness of ~he spacers. The fasteners are then used to secure the mold parts in the newly repo~itioned relationship and the polymerization process continues by continued heating of the mold. Before ~he mold parts are moved together, as ~hown ln Figure 9, the meni~cu~ that i6 e~tablished about the outer periphery of the lene i8 planar or ~lightly concave. The form of the meni~cus i8 reshaped by producing a bulging or roundlng when the spacers are removed and the mold part~ are moved closer together 80 that no sharp edge~ exist at the meniscus and at the demarcation ~ite between the meni6cu6 and len~ surface~ controlled by the molding surfaces of the mold halves. The polyme~ i8 then cured through continued heating of the mold. At the end of the curing proces~ the fasteners are removed and the mold part~ are separated. The molds are cooled and the molded contact len~ can be removed from the mold half in which the lens resldes. An intracorneal lens can be molded in essentially the same manner as just de~cribed for molding a contact lens .
It is an important feature of the present invention that there iB no flashing ever produced during the production of the molded article. The meni~cus that is established about the periphery of the molded article can be ~ituated at any desired position, but it is important, of course, to ensure that no sharp edgee occur. Also, the meniscu~ ic created by a formation of a spaced apart relation between molding ~urfaces and the moldable material which is placed in the mold cavity. If the moldable material is too liqui~, ~hen the surface tension may be inadequate to prevent leakage of the material and a meniscus will not form. When a desired profile of the meniscus can be established between molding surfaces without moving the mold halves toward each other during the curing process, then such relative movement of the mold halves can be eliminated from the proce~s.
While the present invention has been described in connection with the preferred embodiment ~hown in the variou~ figures, $t is understood that other similar embodiments may be u~ed or modifications and additions may be made to the described embodiment for performing the same functions of the present invention without deviating therefrom. Therefore, the pre~ent invention should not be limited to any s~ngle embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims.

Claims

1. A method for molding an article, the method including the steps of:
providing a mold having separable molding surfaces;
loading a predetermined quantity of moldable material on at least one molding surface of the mold;
positioning the molding surfaces of the mold into a spaced apart relation to establish a meniscus of moldable material in the gap about the periphery of the moldable material;
causing said meniscus to attain a convex curvature extending outwardly of the gap between the molding surfaces, and finalizing the molding of the moldable material to form the article while maintaining said meniscus with a convex curvature.

2. The method according to claim 1 wherein said step of causing includes moving the separable molding surfaces of said mold toward each other to cause convex rounding of said meniscus.

3. The method according to claim 1 wherein said step of positioning includes positioning said separable molding surfaces at a first predetermined spaced apart relation, said step of causing including adjusting the position of the separable molding surfaces relative to each other to form a second predetermined spaced apart relation.

4. The article of manufacture comprising a contact lens, intracorneal lens or intraocular lens produced according to the method of claim 3.

5. The article of manufacture according to claim 4 wherein said contact lens, intracorneal lens, or intraocular lens is comprised of silicone rubber.

6. The method according to claim 1 wherein said moldable material is thermal curing and said method includes the further step of dividing the time for thermal curing of the moldable material into first and second time periods of which the first time period corresponds to the attainment of a first degree of polymerization of the thermal curing material by said step of positioning the molding surfaces and the second time period corresponds to the attainment of a second degree of polymerization of the thermal curing material after said step of positioning the molding surfaces.

7. The method according to claim 6 wherein said second time period extends to the desired complete cure of the thermal curing material.

8. The method according to claim 6 wherein said first degree of polymerization of the thermal curing material corresponds to the attainment of a desired gel state of the thermal curing material.

9. The method according to claim 1 wherein said thermal curing moldable material comprises thermo-setting moldable material.

10. The method according to claim 1 wherein said moldable material comprises thermo-plastic material.

11. The method according to claim 1 wherein said moldable material is thermal curing and said method includes the further step of heating said mold for thermal curing of the moldable material for first and second time periods of which the first time period corresponds to the attainment of a first degree of polymerization of the thermal curing material before said step of causing the mensicus to attainn a convex curvature and the second time period corresponds to said step of finalizing.

12. The method according to claim 11 wherein said first degree of polymerization of the thermal curing material corresponds to the attainment of a desired gel state of the thermal curing material.

13. The article of manufacture comprising a contact lens intracorneal, or interocular lens produced according to the method of claim 12.

14. The article of manufacture according to claim 13 which said thermal curing material comprise silicone rubber.

15. The article of manufacture comprising a contact lens, intracorneal lens, or intraocular lens produced according to the method of claim 1.

16. The article of manufacture according to claim 15 which said thermal during material comprise silicone rubber.

17. The method according to claim 1 wherein said step of loading a quantity of thermal curing moldable material includes measuring a predetermined quantity of such material for introduction in a mold cavity of said mold.

18. Apparatus to mold an article, said apparatus including first and second separable molding surfaces for forming part of said article, means to position the separable molding surfaces into a spaced apart relation for forming a meniscus of moldable material defining with said molding surfaces the mold cavity for said article, means for allowing displacement of one molding surface toward the other molding surface to establish a convex curvature of said meniscus, and means for finalizing the molding of the moldable material in said mold cavity while maintaining the convex curvature to said meniscus.

19. The apparatus according to claim 18 further including means for loading a predetermined quantity of moldable material on at least one of said molding surfaces.

20. The apparatus according to claim 19 wherein said means for finalizing includes heater for heating the moldable material in the mold cavity.