Apparatus and method for handling lens carriers

Abstract

Novel methods and apparatus are disclosed for handling carriers for soft contact lenses in a lens manufacturing system. In accordance with a first aspect of the invention, article handling devices are located beneath a pre-cure station and a curing station of the system to move lens carriers within those stations. Pursuant to a second aspect of the invention, in a preferred embodiment multiple sets of assemblies are provided for moving a multitude of lens carriers into, through, and out from the pre-cure station and the curing station. In accordance with a third aspect of the invention, the curing station is provided with an intelligent buffer.

Description

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] This invention generally relates to the manufacture of soft contact lenses using a polymerizable monomer or monomer mixture. More specifically, the invention relates to methods and apparatus for moving lens carriers in such a manufacturing process. Even more specifically, the invention relates to such methods and apparatus that are particularly well suited for moving the lens carriers through pre-curing and curing stations.

[0004] 2. Prior Art

[0005] Over the last several years, systems have been successfully developed for the automated, mass production of soft contact lenses using a direct molding process. One such system is disclosed in U.S. Pat. No. 6,220,845, the entire disclosure of which is hereby incorporated herein in its entirety by reference.

[0006] Generally, in the system disclosed in U.S. Pat. No. 6,220,845, each lens is formed by sandwiching a monomer between back and front mold halves. The monomer is polymerized, thus forming a lens that is then removed from the mold halves, further treated, and packaged for consumer use. In order to polymerize the monomer, it has been found advantageous to pass the monomer through both a pre-cure and a curing step.

[0007] In the pre-cure step, the mold halves are held together under pressure while the polymerization is begun. Typically, the monomer composition includes initiators that work upon exposure to ultraviolet or visible radiation; and, in the pre-cure step, while the mold halves are held together, the composition is exposed to such radiation of an intensity and duration effective to initiate polymerization. After the pre-cure step, the monomer is again exposed to ultraviolet or visible radiation in a cure step in which the polymerization is permitted to proceed to completion.

[0008] More than one lens can be cured at a time, and the throughput of the lens manufacturing process can be increased by increasing the number of lenses being cured at the same time. Simply increasing the number of lenses being cured at one time is complicated, however, by several factors. For example, as this number increases, the size of the area or areas needed for the pre-cure and curing also tends to increase, and other design constraints or considerations may limit the size of this area or areas. In addition, as the number of lenses that are in the pre-cure and cure areas increases, the design and operation of the article handling apparatus used to move all of these lenses into, through, and out of these areas may become excessively complicated.

SUMMARY OF THE INVENTION

[0009] An object of this invention is to provide pre-cure and curing stations, in a system for molding soft contact lenses, that are compact and yet can also handle a large volume of lenses.

[0010] Another object of the present invention is to improve methods and apparatus for handling lens carriers in pre-cure and curing station of a lens manufacturing system.

[0011] A further object of the invention is to locate article handling equipment beneath the floors of pre-cure and curing stations of a contact lens manufacturing system, and thereby to reduce the required size of the footprint of the floors while still being able to move the lenses through the stations in a highly effective and efficient manner.

[0012] Another object of the invention is to provide a curing station, in a system for molding soft contact lenses, with an intelligent buffer.

[0013] A still another object of this invention is to hold a variable number of contact lenses in a curing station of a soft contact lens manufacturing system, to help the system accommodate temporary interruptions, or other changes, in the operation of other stations or subsystems of the system.

[0014] These and other objectives are attained with novel methods and apparatus for handling carriers for soft contact lenses in a lens manufacturing system. In accordance with a first aspect of the invention, article handling devices are located beneath a pre-cure station and a curing station of the system to move lens carriers within those stations. As a result of locating these devices beneath these stations, the desired movement of the carriers can be achieved without increasing the footprint of the station. Pursuant to a second aspect of the invention, a complete set of assemblies is provided for moving a multitude of lens carriers into, through and out from the pre-cure station and the curing station. This set of assemblies accomplishes this movement in a completely automated, high speed, mass production basis. In accordance with a third aspect of the invention, the curing station is provided with an intelligent buffer. This buffer allows the lens carriers to accumulate in the curing station, and then discharges the carriers from the station in an ordered manner at the appropriate time. This enables the output or throughput of the curing station to be controlled or adjusted to accommodate changing conditions or circumstances occurring in the manufacturing system downstream of the curing station.

[0015] Further benefits and advantages of the invention will become apparent from a consideration of the following detailed description, given with reference to the accompanying drawings, which specify and show preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a schematic view of a lens molding system embodying this invention.

[0017] FIG. 2 is a plan view of the pre-cure and curing stations of the lens molding system.

[0018] FIG. 3 is a side view of the pre-cure and curing stations.

[0019] FIGS. 4, 5 and 6 show assemblies for grouping lens carriers and moving groups of carriers into the pre-cure station.

[0020] FIG. 7 illustrates assemblies for moving the carriers across the pre-cure station, for discharging the carriers from that station, and for assembling a row of carriers in the curing station.

[0021] FIGS. 8 and 9 illustrate details of the assembly for moving the carriers across the pre-cure station.

[0022] FIGS. 10, 11 and 12 also show the assemblies for moving carriers from pre-cure to cure station and forming a row of carriers in the cure station. moving a row of carriers across the cure station.

[0023] FIGS. 13, 14 and 15 show an assembly for moving a row of carriers to an end position in the curing station.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] FIG. 1 generally illustrates a system 100 for manufacturing soft contact lenses from a polymerizable monomer or monomer mixture. The soft contact lenses are formed in a mold assembly having a first concave mold and a second, convex mold half. The mold halves themselves are molded in an injection molding machine, schematically represented at 102, and formed of polystyrene transparent to visible and ultraviolet light. The mold is thin enough to transmit heat rapidly and has sufficient rigidity to withstand prying forces applied to separate the mold halves during demolding.

[0025] From the injection molding machine 102, the mold halves are deposited in pallets or carriers 104. In particular, the front mold halves are placed in a first group of carriers, and the second mold halves are placed in a second group of carriers. Each carrier is designed to receive a number, such as eight, of these mold halves; and after receiving the mold halves, these carriers are conveyed from the injection mold area. At a dosing area 106, a polymerizable mixture is then dosed, onto the front curve mold halves; and subsequently, at deposition area 108, the front mold halves are covered with the base mold halves.

[0026] The carriers are then conveyed to a pre-cure area 110. The mold halves are clamped together, and the monomer or monomer mixture is then exposed to actinic light, preferably from a UV lamp. At the completion of the pre-cure step, the monomer or monomer mixture has formed a partially polymerized gel, with polymerization initiated throughout the mixture.

[0027] Following the pre-cure step, the lens carriers are moved to a UV oven 112 where the monomer/diluent mixture is cured whereby polymerization of the monomer is completed. This irradiation with actinic, visible or ultraviolet radiation and heat produces a polymer diluent mixture in the shape of the final desired hydrogel lens. After the polymerization process is completed, the lens carriers are conveyed to a demolding station 114, where the mold halves are separated, typically leaving the contact lens on the first, or front, mold half, from which it is subsequently removed. The front and base curve mold halves are used for a single lens molding and then discarded or disposed of. After the demolding step, the solvent is displaced with water to produce a hydrated lens. The lenses may be further treated, and are packaged for consumer use.

[0028] The present invention provides novel apparatus and methods for moving the lens carriers into, through and from the pre-cure and the curing stations 110 and 112. In its preferred form, the invention comprises first and second sets of article handling devices. The first set 116 of devices is used to form a first array 120 of lens carriers in, and to move that array of carriers through, the pre-cure area 110. The second set 122 of devices is used to form a second array 124 of carriers in, and to move this array of carriers through, the curing area 112.

[0029] The first set 116 of article handling devices includes assemblies 126, 130, 132 (shown in FIGS. 7-9) and 134; and the second set 122 of article handling devices includes assemblies 136, 140, 212, 234, 334 and 142. Generally, assembly 126 is provided for assembling a group of lens carriers into a row in a first position 144, with neighboring carriers in the row contiguous to each other; and assembly 130 is used to move this row of lens carriers from that first position and into the pre-cure area 110. Assembly 132 is provided for moving and preferably providing spacing between the row of carriers across the pre-cure area and into a final row position therein, and assembly 134 is used to move the row of lens carriers from that final position and out of the pre-cure area. Assembly 136 is provided for forming a row of lens carriers in a first position 194 in the curing area 112, with neighboring carriers in this row contiguous to each other; assembly 140 is preferably used to move this row of carriers through a sequence of positions in the curing area by repeatedly pushing the first row of carriers in position 194 into the position adjacent to position 194. When the array is full or the control means directs assembly 212 to move the row furthest to the right into position 211, then assemblies 334 and 142 are provided for moving the carriers in row 211 to row 196 and out of the curing area.

[0030] Preferably, assembly 140 pushes the carriers in row 194 over one row and then assembly 140 returns to its original position until row 194 again has carriers moved into it by assembly 136. Preferably when there are six carriers present in row 194, assembly 140 will push the carriers in row 194 again, and in this way row-by-row, assembly 140 will push first one row, then two rows, then three rows to form an array 124, and when fully operational multiple rows (up to eleven as shown) in the array. The row of carriers pushed furthest to the right in array 124 preferably to position 199 or position 210 or to any of the positions between positions 199 and 210. Alternatively in a different embodiment assembly 140 could be used to push the carriers in the row furthest to the right to row 196. Ccontrol means, schematically represented at 150, may be provided to control and to coordinate operation of the above-identified assemblies. Control means is preferably a programmable logic controller.

[0031] Assembly 126 is shown in greater detail in FIGS. 4 and 5, and with reference thereto, this assembly comprises arm 162, horizontal moving means 164, and vertical moving means 166. Generally, arm 162 is supported for horizontal and vertical movement. Mechanism 164 is used to move that arm between first and second positions to engage lens carriers 104 and to form a group of contiguous lens carriers, and vertical moving means 166 is used to move that arm vertically and then via mechanism 164 back to its starting position out of the way of the carriers being pushed by upstream mechanisms into positions 4 and 5.

[0032] With the embodiment of the invention illustrated in the drawings, assembly 126 is used to form groups of three lens carriers, and each group of three is assembled in a two-step process. In a first step, as lens carriers are moved down toward the pre-cure area, arm 162 is located just behind (to the top as viewed in FIG. 1) carrier position 5. At this point, two carriers are ahead of the arm, in locations 4 and 5. The arm moves downward, engages the carrier in position 5 and pushes this carrier downward to the carrier position 2. As the arm does this, this lens carrier pushes the carrier ahead of it to carrier position 1. After this is done, the arm 162 returns to a location just behind carrier position 5. The arm is moved to push this lens carrier to position 4. As this occurs, this carrier pushes the lens carrier ahead of it to position 3, abutting against the carrier in position 2, which in turn abuts against the carrier in position 1.

[0033] Assembly 130 is used to push this group of carriers 144 into the pre-cure area 110 in the direction shown by arrow 145 in FIG. 4. Assembly 130 is also shown in greater detail in FIGS. 4-6; and as shown therein, the assembly includes support member 160, pusher 168, and moving means 170. Generally, pusher 168 is supported by support member 160 for movement toward and away from the support member, and moving means 170 is provided to move the pusher, relative to the support member, to engage the group of lens carriers, and to push that row of carriers into the pre-cure area. Pusher 168 is shown in the extended 168E and the retracted positions 168R in FIG. 6. Preferably, the lens carriers are pushed into the pre-cure area as a group, while maintaining the alignment of the carriers and the abutting contact of neighboring carriers.

[0034] As will be understood by those skilled in the art, any suitable devices may be used as support member 160, arm 162, pusher 168, and moving means 164 and 170. Also, these devices may be operated in any suitable specific manner. Moving means 164 is preferably a servo drive. Moving means 166 is preferably a linear cylinder. Moving means 170 is preferably a rotary cylinder.

[0035] Once the lens carriers are in the pre-cure area, assembly 132 is used to move the carriers across that area. Assembly 132 is illustrated in detail in FIGS. 7, 8 and 9; and with reference thereto, this assembly comprises support member 172, arm subassembly 174, and moving means 176 and 178. Generally, support member 172 is located below the pre-cure area, and arm subassembly 174 is supported by the support member for horizontal and vertical movement. Also, moving means 176 is operated to move the arm subassembly vertically from a position beneath the pre-cure area, to a position extending above the floor of that area. The moving means 178 is operated to move arm subassembly 174 horizontally, to engage the rows of lens carriers in the pre-cure area and to move those rows across that area and into a final row position therein.

[0036] In order to accommodate the above-described movement of subassembly 174, the floor of pre-cure area is provided with slots 180 (shown in FIG. 2) that allow the subassembly to move from beneath that floor, upward through that floor, then forward, and then back downward, to a position beneath the floor.

[0037] Preferably, pre-cure area 110 holds three rows of lens carriers, and assembly 130 is used to move the carriers across into the pre-cure area one step at a time into the first row postion, from the first row position to the second row position and then to the third row position. In the preferred embodiment assembly 132 works with assembly 130 to provide the necessary spacing between the rows of carriers to accommodate the weight station 188. Assembly 132 can also work independently of assembly 130 to move rows of pallets through the precure area 110, particularly if no additional pallets have been pushed to assembly 130 by upstream processes. Preferably, assembly 130 moves carriers into the first row at the same time that the assembly 132 moves carriers from the first row to the second row to the third row. In an alternative embodiment if spacing were not required assembly 130 could be used without assembly 132 to move pallets through the precure area 110.

[0038] To achieve the proper spacing, arm subassembly 174 may comprise a pair of spaced apart arms or projections 182. These arms 182 are positioned and operated so that these arms move upward together, with one arm moved upward just behind the first row of carriers, and the other arm moved upward just behind the second row of carriers. These arms are then moved horizontally together, with one arm moving one row of carriers from the first row position to the second row position, and the other arm moving one row of carriers from the second row position to the third row position.

[0039] Any suitable support member 172, arm subassembly 174 and moving means 176 may be employed in the practice of this invention, and these devices may be operated in any suitable specific manner. In the preferred embodiment, moving means 176 is a vertical linear cylinder and moving means 178 is a rotary cylinder.

[0040] Assembly 134 is provided to move the lens carriers out of the pre-cure area from the final row position. Preferably, with particular reference to FIGS. 10 and 11, this assembly 134 includes first and second engagement means 184 and 186. First engagement means 184 is used to engage the row of lens carriers in the final row position in the pre-cure area, and to move this line of carriers in a first direction so that the carriers in that final row are located, one at a time, in a discharge position 190. With the specific arrangement shown in FIG. 1, this discharge position is the position of the bottom right carrier in the pre-cure area. Second engagement means 186 is used to engage each of the lens carriers in the final row of carriers, one carrier at a time, and to move the carrier from the discharge position and out of the pre-cure area to position 192 in the cure area 112.

[0041] Any suitable means may be used as the first and second engagement means 184 and 186. For example, these engagement means may be pneumatic cylinders that are operated to push the carriers in the desired manner. Alternatively, electrically operated pushing or pulling mechanism may also be employed to move the lens carriers in the appropriate way. Engagement means 184 is preferably a linear and rotary cylinder working together. Engagement means 186 comprises vertical and horizontal moving means operating on a pusher arm similar to assembly 130.

[0042] Assembly 136 is provided to move the carriers discharged from the pre-cure area into the cure area 112. More specifically, with reference to FIGS. 1 and 10, assembly 136 engages these carriers, one at a time, at a carrier receiving position 192, and moves these carriers in a first direction to form a row of lens carriers in a first row position 194 in the cure area, with neighboring carriers in the row contiguous to each other.

[0043] Any suitable specific means may be used to do this. For example, assembly 136 may comprise a pneumatic cylinder, preferably a rotary cylinder, positioned just below the receiving position 192. As carriers are moved from the pre-cure area and into that receiving position, this cylinder may engage these carriers, one at a time, and pushes the carriers upward, into the cure area, to form a row in position 194. After the first carrier is pushed into the row, then, as each subsequent carrier is pushed upward, that subsequent carrier abuts against the previous carrier and pushes that carrier further upward. This process continues until the row of carriers is formed.

[0044] As will be appreciated by those of ordinary skill in the art, other specific means may be used to form the carrier rows in the cure area. For instance, electrically operated pushing or pulling devices may be used to form these rows in the cure station.

[0045] Assembly 140 shown in FIG. 1 is used to push the rows of carriers across the cure station. Assembly 140 comprises a pusher, movement means and a support, similar to assembly 130. Assembly 140 is used to move each row of carriers across the curing station 112, from left to right as viewed in FIG. 1, from the first row position to a final row position 210. As this occurs, the rows form array 124, with neighboring rows in the array abutting each other. Assembly 140 pushes the row of lens carriers that is formed in row position 194 to the row position adjacent to position 194, which pushes the row adjacent to it. As each row is pushed forward, the row abuts against the row ahead of it and pushes that row forward one step. Assembly 140, then retracts and assembly 136 assembles a row of carriers in position 194 again and then assembly 140 pushes row 194 again. These steps are repeated, and in this way the rows of carriers are exposed to the conditions of the cure station for the required exposure times.

[0046] With the preferred embodiment of the invention, the process steps of forming a row of carriers in position 194 (a first row position) and pushing the row 194 to a second row position adjacent to row 194 via assembly 140, assembly 140 retracting, and forming another row of carriers in position 194 may continue until the row furthest to the right reaches one of the last row positions 199 to 210 of the array as described earlier. FIG. 1 shows the maximum number of pallets that the cure area 112 can accommodate; however, as described earlier the cure station 112 provides a buffer 200. Buffer 200 comprises three rows. One or more of the rows of the buffer 200 are only used when needed if the downstream processes are not in working condition to receive pallets. Assembly 140 continues in its step by step fashion to fill buffer 200 if the downstream process is not working.

[0047] If the downstream process is functioning properly, the buffer is not used, and assembly 212 is used to move the row of carriers in position 199 away from array 124. When the carriers reach position 199, they have received sufficient exposure to the curing conditions in the cure station. Under regular operations, assembly 212 is used to move the row of carriers furthermost to the right in positions 199 to 210 to position 211 for removal from the cure station.

[0048] Assembly 212 is supported for movement toward and away from that last row position of array 124 and in the preferred embodiment to position 211, and is used to engage the lens carriers in that last row position and to move that row of carriers away from the array into position 211.

[0049] Preferably, with particular reference to FIGS. 13-14, and 15 assembly 212 includes a series of engagement members 216 and moving means 220. Engagement members 216 are supported for horizontal movement beneath the curing area and for vertical movement. Moving means 220 comprise horizontal moving means 221 and vertical moving means 223. The horizontal moving means moves the engagement members 216 horizontally, preferably by a servo drive driven by motor 171, beneath the cure area, to positions below the last row of carriers in array 124, then vertical moving means 223, preferably by a linear cylinder moves the engagement members vertically to engage that row of carriers. With engagement members contacting the carrier, the horizontal movement means 221 moves the engagement members horizontally to move the carriers of that last row from the array 124 and into a final row position 211. Once the lens carriers are in the final row position, engagement members 216 are lowered, freeing the lens carriers from the engagement members. Engagement members 216 are shown in FIG. 14 by dashed lines in the extended 216 E and retracted positions 216R. Preferably, a respective two engagement members are provided for each carrier that is being moved away from the array 124. Preferably the two engagement members contact or otherwise engage each lens carrier in two places on the side of the carrier opposite the direction that the carrier is to be pushed. FIG. 15 shows that engagement members 216 in contact with one pallet 104. In operation the engagement members 216 shown in FIG. 15 would contact six pallets, the six pallets would preferably contact each other end-to-end in a row. Preferably the assembly 212 only moves one row of carriers and preferably that row is the last row of carriers in the array, preferably that last row is in any of the positions from 199 to 210; however, the assembly 212 is capable of moving any row of carriers from any position in the array 124, particularly if there is a reason for rejecting all the pallets in the cure area 112. Alternatively, the assembly 212 and other downstream assemblies for movement in the cure area 112 could be modified so that assembly 212 could empty the cure area 112 by simultaneously pushing multiple rows of carriers out of the cure area 112. If there were total reject situation, presently assembly 212 moves a single row of carriers in the right furthermost row to position 211, and then repeats the process until the cure station is cleared. The movement of the carriers to position 211 is coordinated by control means 150. Presently, assembly 140 is designed to be able to push any number of rows of carriers in the array 124 incrementally row-by-row; however, if desired assembly 140 could be modified so that it would be capable of pushing any number of rows of pallets across any number of row positions or across the entire array 124 so that the row furthest to the right in the array 124 is located in position 210.

[0050] In order to accommodate the above-describe movement of engagement members 216, the floor 66 of cure station 112 is provided with a series of elongated through slots 222 (shown in FIG. 2) that allow the engagement members to move from beneath that floor, and upward through the floor 66 and into engagement with carriers in the curing station. These slots also allow the engagement members to then move forward, and then back downward, beneath the floor. With the preferred embodiment of the invention, where a respective two engagement members 216 are provided for each lens carrier in a row of the carriers, the floor of the curing station is provided with a respective two of these elongated slots 222 for each carrier in the row. Thus, for instance, if there are six carriers in a row, preferably, the floor of the curing station is provided with twelve slots. Moreover, preferably, a respective pair of the slots extend directly below each line of carriers in the array 124.

[0051] Any suitable engagement members 216 and moving means 220 may be used in the practice of this invention. For example, the engagement members may be threaded rods mounted on carriers that, in turn, are mounted on rails. The carriers are moved along these rails to move the rods in the horizontal direction, and the rods are rotated to move the rods upwards and downwards. Any suitable means may be used to move the carriers along the rails, and for example, stepper motors may be used to do this. Preferably vertical moving means 223 is a cylinder and horizontal moving means 221 is a servo.

[0052] Preferably, assembly 212 is able to pull lens carriers from any row position in array 124 to the final row position 221 in the curing station 112. This allows the number of rows in that station to be varied or adjusted over time. This feature and the extra rows provided as buffer 200, is the intelligent buffer, enables the output of the curing station to be controlled and adjusted to accommodate conditions or circumstances occurring in the manufacturing system 100 downstream of the curing station. For example, if it is appropriate to interrupt the manufacturing system at some point downstream of the curing station, lens carriers can be allowed to accumulate in the curing station in buffer 200. In this way, the processes occurring at and upstream of the curing station can continue uninterrupted and are not affected by the downstream interruption, and then when the downstream processes are functioning again assembly 212 will proceed to move the row of carriers furthest to the right and put it in row 211 for exiting the cure station 112.

[0053] In order to achieve this ability, elongated slots 222 extend completely across array 124, preferably all the way to and underneath the first row position 194. Also, elongated members 216 are supported for movement completely across array 124, and can be used to engage lens carriers in any row of the array and to pull that engaged row of carriers to the final row position 196. In addition, with this preferred embodiment, a shield is provided to shield the rows of buffer 200 from the ultraviolet or visible light source in the curing station. With this shield, system 100 has the option of holding lens carriers in those last several rows without overexposing the contact lenses in those carriers to the light source.

[0054] In the preferred embodiment, the lens carriers are moved out of the cure station 112 in the same order as they were introduced into the cure oven; therefore, assembly 334 is provided similar to assembly 134 to remove the carriers from the cure oven 112. The first carrier in row 211 is moved to the right to position 196 and then the remaining carriers in row 211 are indexed up, and this process is repeated until there are no more carriers in 211. Then assembly 212 moves a row of carries into position 211 and the process is repeated again.

[0055] With reference again to FIG. 1, once lens carriers are located in the final row position 196, assembly 142 is used to move those carriers out of the curing station. Preferably, assembly 142 includes subassembly 230, receiver 232, and pushing means 234. Receiver 232 is located adjacent the final row position 196, preferably aligned with that row. Subassembly 230 is provided for engaging the lens carriers in that final row position and moving the lens carriers, one at a time, onto the receiver 232. Pushing means 234 is then used to push the lens carrier off the receiver and out of the curing station.

[0056] With the embodiment of subassembly 230 shown in the Figures, this subassembly includes a series of beams 236 and moving means 240. Beams 236, referred to as walking beams, are supported for movement along row position 196, to a location adjacent or above receiver 232; and means 240 is provided to move this series of beams across the final row position, to engage the lens carriers therein and to push those lens carriers onto the carrier receiver 232. For example, every other lens carrier may be engaged by one of the beams 236, and that one beam may be used to push two lens carriers onto receiver. Other arrangements may be used, however, in the practice of this invention.

[0057] Preferably, receiver 232 forms a defined area 242 for receiving carriers 104. The carriers are pushed into this area by subassembly 230, and then pushed out from this area by pushing means 234. In addition, preferably, receiver 232 is rotatable, and this defined area 242 has the shape of a cross, with each segment of the cross being adapted to receive two lens carriers.

[0058] In use, one of these segments is aligned with row position 196, then two lens carriers are pushed onto this segment, the receiver 232 is rotated ninety degrees, and pushing means 234 pushes these two lens carriers off the receiver. As the receiver rotates ninety degrees, the second cross segment becomes aligned with row 196, and subassembly 230 then pushes two more lens carriers onto this segment of the receiver. The receiver rotates another ninety degrees, and pushing means 234 now pushes the two additional carriers off the receiver. This process continues, with the receiver rotating ninety degrees each time two lens carriers are pushed onto the receiver. In this way, the receiver 232 changes the direction of the path of travel of lens carriers by ninety degrees. The carriers that are pushed off the receiver may be pushed onto a conveyer belt or other suitable means for transporting the carriers away from the curing station.

[0059] Any suitable beams 236, moving means 240 and receiver 242 may be used in the practice of this invention. For instance, beams 236 may be mounted on an endless conveyor belt that carries the beams through the desired path. Also, a pneumatic cylinder may be used as pushing means 234, although electrically operated pushing or pulling mechanisms may also be used to move the lens carriers from receiver 232.

[0060] Control means 150, as mentioned above, are provided to control and to coordinate the operation of the above-discussed article handling devices, and these assemblies may be controlled and operated in any suitable specific manner. For instance, these control means may be used to operate the article handling assemblies according to a defined timing sequence, or sensors may be used to identify when certain events occur or are to occur. Also, a combination of sensors and a defined timing sequence may be used to coordinate operation of the assemblies. For example, in order to facilitate operation of the above-discussed intelligent buffer feature of the curing station, preferably control means is provided with a signal or other information identifying where the last row of lens carriers is located in array 124. With this information, the control means is able to direct assembly 212 to the proper location the next time that assembly is activated to move a row of lens carriers from the array 124 and into the final row position.

[0061] While it is apparent that the invention herein disclosed is well calculated to fulfill the objects previously stated, it will be appreciated that numerous modifications and embodiments may be devised by those skilled in the art, and it is intended that the appended claims cover all such modifications and embodiments as fall within the true spirit and scope of the present invention.

Claims

1. A curing station for polymerizing contact lenses, comprising: a floor for supporting a plurality of carriers holding polymerizable contact lenses; a light source for directing light to the lenses to cure said lenses; and a plurality of article handling devices supported beneath the floor for engaging the lens carriers and moving the lens carriers around the floor.

2. A curing station according to claim 1, wherein: each of the devices has a retracted position and an extended position; in the retracted position, the device is entirely below the floor to facilitate moving the device beneath the floor; and in the extended position, the device extends above the floor to engage the lens carriers and to move the lens carriers across the floor.

3. A curing station according to claim 2, wherein: the floor forms a plurality of openings; and as the devices change from the retracted positions to the expended positions, the devices move upward through said openings.

4. A method of moving contact lens carriers around a defined area, comprising: positioning a plurality of lens carriers in the area; supporting a plurality of article handling devices beneath the area, wherein each of said devices has an engaged state, in which the device engages one of the lens carriers, and a disengaged state, in which the device is disengaged from the lens carriers; maintaining each device beneath said area when the device is in the disengaged state to facilitate moving the device; changing each device from the disengaged state to the engaged state to engage the lens carriers; and using the devices, when the devices are in the engaged states, to move the lens carriers across the area.

5. A method according to claim 4, wherein the defined area is on a floor, and the changing step includes the step of extending each device upward, through the floor, as the device changes from the disengaged state to the engaged state.

6. A method according to claim 5, wherein the floor defines a series of openings, and the extending step includes the step of extending each device upward, through one of said openings, as the device changes from the disengaged state to the engaged state.

7. Article handling apparatus for moving contact lens carriers, around a defined area, comprising: a first set of article handling devices for receiving a multitude of contact lens carriers, for forming a first array of lens carriers in a first section of said area, and for moving said lens carriers through said first section; and a second set of article handling devices for receiving contact lens carriers from said first section, for forming a second array of lens carriers in a second section of said area, and for moving the lens carriers of said second array through said second section.

8. Apparatus according to claim 7, wherein the first set of devices includes: a first assembly for assembling a group of lens carriers in a row in a first position, with neighboring carriers in the row contiguous to each other; a second assembly for moving said row of lens carriers from the first position and into the first section of the area; a third assembly for moving said row of lens carriers, across the first section and into a final position therein; and a fourth assembly for moving said row of lens carriers from the final position and out the first section.

9. Apparatus according to claim 8, wherein the first assembly includes: a support member; an arm mounted on the support member for movement therealong; and means to move the first arm between first and second positions to engage lens carriers and to assemble said group of lens carriers in said row.

10. Apparatus according to claim 2, wherein the second assembly includes: a support member; an arm supported by the support member for movement toward and away from the support member; and means to move the arm, relative to the support member, to engage said row of lens carriers in the first position and to push said row of lens carriers from the first position and into the first section.

11. Apparatus according to claim 8, wherein the third assembly includes: a support member located below the first section; an arm subassembly supported by the support member for horizontal and vertical movement; and means to move the arm subassembly vertically from a position beneath the first section, to a position extending above the first section, and to move the arm subassembly horizontally to engage said row of lens carriers in the first section and to move the row of lens carriers across the first section and into said final position therein.

12. Apparatus according to claim 2, wherein the fourth assembly includes: means to engage the row of lens carriers in said final position, and to push the lens carriers of said row in a first direction, wherein the lens carriers of said row are located, one carrier at a time, in a discharge position; and means to engage each of the lens carriers of said row, one carrier at a time, when the lens carrier is in the discharge position and to move the lens carrier out of the first section.

13. Apparatus according to claim 7, wherein the second set of devices includes: a first assembly for forming a row of lens carriers in a first position in said second section, wherein neighboring carriers in the row are contiguous to each other; a second assembly for moving said row of lens carriers through a sequence of positions in the second section and to a final position therein; and a third assembly for moving said row of lens carriers out of the second area.

14. Apparatus according to claim 7, wherein the first assembly includes means to engage a plurality of lens carriers, one at a time, in a carrier receiving position, and to move the lens carriers in a first direction to form said row of lens carriers.

15. Apparatus according to claim 13, wherein the second assembly includes: support means; a pusher subassembly supported by the support means for movement toward and away from the support means; and means to move the pusher subassembly to engage a plurality of rows of lens carriers, one row at a time, when each of said rows is in the first position in the second section, and to push the rows across the second section to form said second array of lens carriers in the second section, wherein said second array includes a plurality of rows of lens carriers, with neighboring rows in the second array contiguous to each other.

16. Apparatus according to claim 15, wherein: the second array of lens carriers in the second section includes a last row of lens carriers in a last row position; and the second assembly includes an engaging subassembly supported for movement toward and away from said last row position, and to engage a row of lens carriers in said last row position and to move said last row of lens carriers away from the second array.

17. Apparatus according to claim 16, wherein the engaging subassembly includes: a series of engagement members supported for horizontal movement beneath the second section and for vertical movement; and means to move the engagement members vertically from a position beneath the second section, to a position engaging the lens carriers in said last row, and to move the engagement members horizontally to move the lens carriers of said last row away from the array and into said final position.

18. Apparatus according to claim 13, wherein the third assembly includes: a carrier receiver located adjacent the final row position; a subassembly for engaging the lens carriers in the final row position and moving the lens carriers, one at a time, onto the carrier receiver; and means to push the lens carriers off the carrier receiver and out of the second section.

19. Apparatus according to claim 18, wherein said subassembly includes: a series of beams; and means to move said series of beams across the final row position to engage the lens carriers therein and to push the lens carriers onto the carrier receiver.

20. A contact lens holding station having an adjustable buffer, comprising: means defining an area for holding lens carriers; a first assembly for receiving contact lens carriers and forming the carriers into an array in said area, said array including an adjustable number of rows; a second assembly for engaging the lens carriers in any one of a defined group of said rows to pull the carriers in the engaged row away from the array and to move the carriers of the engaged row to a given location; and a third assembly for conveying lens carriers from the given location out of the station.

21. A station according to claim 20, wherein the second assembly includes: a plurality of engagement members supported for horizontal movement beneath said array and for vertical movement; means to move the engagement members vertically from a position beneath said array, to a position engaging the lens carriers in one of said defined group of rows, and to move the engagement members horizontally to move the lens carriers in the engaged row away from the array.

22. A station according to claim 20, wherein said array includes a last row having a varying position, and the station further comprises control means holding data identifying the location of said last row.

23. A station according to claim 20, wherein the second assembly is adapted to engage the lens carriers in any row of the array.

24. A method for holding contact lens carriers in a station, comprising; moving the lens carriers into the station; forming the lens carriers into an array, said array having an adjustable number of rows; engaging the lens carriers in any one of a defined group of the rows of the array to move the carriers in said one row away from the array; and moving the carriers of said one row out of the station.

25. A method according to claim 24, wherein the engaging step includes the step of engaging the lens carriers in any one row of the array.

26. A method according to claim 24, wherein the array includes a last row having a variable position, the method further comprises the step of keeping track of the position of said last row, and wherein the engaging step includes the step of engaging the lens carrier in said last row to move the carriers of the last row away from the array.