Polymer gel contact masks and methods and molds for making same

Abstract

The present invention relates to elastomeric contact masks, and methods of making these contact masks by complementary molding using complementary molds. The contact masks are made of polymer gels, including hydrogel materials. The complementary molds of the present invention include at least one elastomeric half mold. Also disclosed are methods of continuous complementary molding.

1 - 31 . (Canceled)  
     
     
         32 . A method of complementary molding comprising the steps of 
 a) providing a complementary mold including first and second half molds each having molding surfaces, wherein the molding surfaces define a void when the first and second half molds are closed and wherein at least one of the first or second half molds is an elastomer,    b) introducing a polymerizable precursor,    c) closing the half molds, and    d) polymerizing the molding precursor.    
     
     
         33 . The method of  claim 32  further comprising the step of separating the first and second half molds.  
     
     
         34 . The method of  claim 33  further comprising the step of removing the molded polymerized precursor from the half molds.  
     
     
         35 . The method of  claim 32  wherein one of the half molds is elastomeric.  
     
     
         36 . The method of  claim 32  further wherein one of the half molds has a release layer adjacent thereto.  
     
     
         37 . The method of  claim 32  wherein one of the half molds is made from a material selected from the group consisting of polydimethylsiloxane (PDMS), silicones, polyurethanes, polyphosphazenes, and latex rubber.  
     
     
         38 . The method of  claim 32  wherein one the half molds is made from a material selected from the group consisting of polyethylene, polypropylene, and Teflon.  
     
     
         39 . The method of  claim 32  further comprising the step of applying pressure to the closed mold.  
     
     
         40 . A method of complementary molding comprising the steps of 
 a) providing a complementary mold including first and second half molds each having a molding surface, the molding surfaces defining a void there between, wherein the half molds close to form a void, and wherein at least one of the first or second components is an elastomer,    b) closing the half molds to form a void,    c) introducing a polymerizable precursor into the void after the mold surfaces form the void, and    d) polymerizing the molding precursor.    
     
     
         41 . A method of continuous complementary molding comprising the steps of 
 a) providing a first half mold including a plurality of first molding surfaces adapted and arranged for moving the molding surfaces from an unprocessed position to a processed position,    b) providing a second half mold having a second molding surface, wherein the first and second molding surfaces form a void there between when closed    c) applying polymerizable polymer precursor to one of the molding surfaces in the unprocessed position,    d) closing the half molds,    e) polymerizing the polymer precursor, and    f) moving the molded polymer tot he processed position.    
     
     
         42 . The method of  claim 41  wherein at least one of the half molds is made from a material selected from the group consisting of polydimethylsiloxane (PDMS), silicones, polyurethanes, polyphosphazenes, and latex rubber.  
     
     
         43 . The method of  claim 41  wherein the one of the half molds is made from a material selected from the group consisting of polyethylene, polypropylene, and Teflon.  
     
     
         44 . The method of  claim 41  wherein a carrier film is disposed between the first and second half molds.  
     
     
         45 . The method of  claim 41  further comprising the step of applying pressure to the first and second half molds after forming the void.  
     
     
         46 - 52 . (Canceled)