Abstract:
A method, device and trays for transferring ophthalmic lenses from one work station to another. The first tray supports the lenses after release from the mold. The second tray supports the lenses during further processing including surface treatment. The articles are precisely placed and inverted as they are transferred from the first tray unto the second tray. Additionally, both sides of the ophthalmic lenses may be plasma reacted while supported on the second tray.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a method of transferring ophthalmic lenses between treatment stations during manufacturing. Also disclosed and claimed are trays useful for transporting the lenses between stations. Included in this invention is a transfer tray for holding small, delicate articles such as contact lenses or intraocular lenses, a surface treatment support tray useful during gaseous processes, and a device for transferring the lenses from the transfer tray to the surface treatment support tray. In a preferred embodiment, contact lenses are transferred from a concave-side up position on the transfer tray to a concave-side down position on the surface treatment tray or vice-versa. The lenses are further subjected to a plasma reaction while on the surface treatment tray. The lenses may then be transferred using the inventive transfer tray for further processing such as polymer coating, extraction, hydration, or packaging, for example. 
     Those skilled in the art have long recognized the need for modifying the surface of hydrophobic contact lenses so that they are compatible with the eye. It is known that increased hydrophilicity of the contact lens surface improves the wettability of the contact lenses. This, in turn, is associated with improved wear comfort of contact lenses. Additionally, the surface of the lens can affect the lens susceptibility to deposition, particularly protein and lipid deposition from the tear fluid during lens wear. Accumulated deposition can cause eye discomfort or even inflammation. In the case of extended wear lenses, the surface is especially important since extended wear lenses must be designed for high standards of comfort over an extended period of time, without requiring daily removal of the lens before sleep. Thus, the regimen for the use of extended wear lenses would not provide a daily period of time for the eye to recover from any discomfort or other possible adverse effects of lens wear. 
     The patent literature has disclosed various surface treatments for rendering the surface of hydrophobic contact lenses, including those made with silicone materials, more hydrophilic and more wettable, including changing the chemistry of the surface layer, coating the surface, and compounding the polymer with additives that subsequently diffuse to the surface. 
     Silicone lenses, in particular, have been subjected to plasma surface reaction to improve their surface properties, e.g., surfaces have been rendered more hydrophilic, deposit resistant, scratch resistant, and the like. Examples of common plasma surface reactions include subjecting the contact-lens surfaces to plasma of an inert gas or oxygen (see, for example, U.S. Pat. Nos. 4,055,378; 4,122,942; and 4,214,014); various hydrocarbon monomers (see, for example, U.S. Pat. No. 4,143,949); and combinations of oxidizing agents and hydrocarbons, e.g., water and ethanol (see, for example, WO 95/04609 and U.S. Pat. No 4,632,844). Sequential plasma surface treatments are also known such as those comprising a first reaction with a plasma of an inert gas or oxygen, followed by a hydrocarbon plasma (see, for example, U.S. Pat. Nos. 4,312,575 and 5,326,584). 
     Another type of chemical surface modification that has been disclosed in the patent literature involves the introduction of functional groups absent in the parent polymer by the grafting or immobilization of molecules, oligomers, or polymers onto a surface. Grafting or immobilization typically involves, first, the formation of a grafting site which may comprise the formation of a radical by means of chemical reactions, UV irradiation, ionizing radiation, plasma reaction, or the like. The next step is the reaction of the species to be grafted or immobilized with the active site. Surface grafting typically involves the propagation of the reaction to form an anchored chain, wherein competing solution and interfacial reactions occur. Surface crosslinking may occur. 
     Non-plasma techniques for forming a coating have been disclosed. For example, U.S. Pat. No. 3,814,051 to Lewison discloses vacuum bonding a uniform hydrophilic quartz surface to a contact lens by vaporizing quartz, namely silicon dioxide, within a high vacuum chamber. The coating of contact lenses by dipping, swabbing, spraying or other mechanical means has been disclosed in U.S. Pat. Nos. 3,637,416 and 3,708,416 to Misch et al. The latter patents disclose a chemical process in which a coupling film-forming organic silicon compound, a vinyl trichlorosilane, is applied to a silicone surface, followed by a silica or silica gel deposit formed by contact with a silicon halide such as tetrachlorosilane or with a silicic ester, more particularly a tetraalkoxysilane. 
     In all of the above treatments, it is important that the surface area of the object being treated be uniformly coated. In particular, lenses that undergo coating or surface treatment need to be supported on a fixture or device which allows the entire lens surface to be coated evenly as possible. One such device is disclosed in U.S. Pat. No. 5,874,127 (Winterton et al). In Winterton et al., the contact lens is supported by a plurality of point-contact support locations. The support locations are sufficient to support the lens to be treated but do not prevent uniform coating of the lens. 
     Another such device capable of supporting lenses during surface treatment is disclosed in U.S. patent application Ser. No. 60/163,208 entitled “MESH TRAY” (assigned to Bausch &amp; Lomb Incorporated, the entire contents herewith incorporated by reference). This tray comprises a mesh insert which is supported by a rigid, preferably metal tray. Plasma or any gaseous atmosphere may circulate within the mesh insert to uniformly coat the lens. 
     Material handling devices are known in the field of contact lens manufacturing. For instance, as shown in FIGS. 1-3 (prior art), a perforated tray assembly is used to transport mold assemblies between stations after casting (tray assembly  1  holding mold assemblies  5  shown in FIG.  3 ). The tray assembly has top portion  2  and base portion  4 . Top portion  2  has a series of openings  2   a  which when assembled, rest on the lower portion  6   a  of upper mold  6 . Base portion  4  also has a series of openings  4   a  but the openings are smaller than openings  2   a  and have a counterbore area  4   b  to correspond to outer diameter  7   a  of lower mold  7 . Mold assembly  5  has upper mold portion  6  and lower mold portion  7 . When assembled, mold assembly  5  rests on lower tray portion  4  and is secured in place by top tray portion  2 . The upper mold portion  6  protrudes through opening  2   a  of top tray portion  2 . This perforated tray assembly  1  allows mold assembly  5  to remain coupled while mold assembly  5  is transferred between stations. 
     Lenses are removed from the mold and edged, if necessary. The lenses are now ready for additional processes such as coating or surface treatment. 
     As previously mentioned, plasma reaction is a common surface treatment and has typically been a two-staged process. 
     In one prior art method, contact lenses requiring surface treatment are dry-released from the anterior mold and edged polished, if necessary. The lenses are placed manually by a worker concave-side up into a transfer tray. The transfer tray contains a plurality of cylindrical cavities with flat bottoms and is typically made from white polystyrene having a matte finish. The lens diameter is typically smaller than the diameter of the cavity so that the lens is easily placed and retrieved from the tray. The lenses are taken to a different workstation for surface treatment. At the surface treatment station (e.g. using commercial Metroline Plasma Deposition Model Number 7100 Series Chamber), lenses are inverted onto a surface treatment tray such as the removable shelf supplied with the Metroline Plasma Chamber. The Metroline shelf has a plurality of small, spaced perforations located at predetermined intervals, each of the perforations having diameters substantially smaller than any one of the lenses. Each lens is placed on the shelf, concave-side down. The lenses are plasma reacted and inverted, e.g. using a manual method or using a semi-automated device such as an air knife as disclosed in U.S. Pat. No. 5,503,515 (Moorehead, assigned to Bausch &amp; Lomb Incorporated). Unfortunately, it has been found that when lenses are initially inverted from the transfer tray onto the Metroline shelf, placement of the lenses is random with the individual lens not necessarily over a perforation as intended. If an individual lens is not situated over a perforation, the lens will not invert. Instead, a worker must use tweezers to turn the lens over. The other side of the lens is then subjected to a plasma reaction. The surface treatment requires two cycles of plasma reaction. The lenses are then picked up by a worker using tweezers and transferred for other processing such as extraction. The worker is integral to this whole process, especially in making sure all the lenses invert over the air knife and transferring the surface treated lenses for extraction. 
     Small, delicate work pieces such as contact lenses are difficult to transfer. In the dry state, a contact lens is fragile and prone to scratching, cracking and breaking. Manipulating a contact lens into a desired orientation, such as having the concave side of the lens facing upward or toward a particular direction, can be difficult. The lens is extremely lightweight and can accumulate static charge. Usually, this lens is manually manipulated. A worker may have to turn the lens with a pair of tweezers. Inevitably, a few lenses are damaged by the tweezers or the worker is exposed to repetitive motions, contributing to injuries. It has therefore been desirable to automate as much of the contact lens manufacturing process as possible. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a method of handling and transferring small, delicate articles such as ophthalmic lenses between stations and during certain manufacturing process such as coating/plasma reaction processes. In particular, this invention provides a method of inverting lenses to place the lenses in correct position for surface treatment. The invention also discloses devices in the form of trays for supporting the lenses during processing and surface treatment. In particular, one device allows for a single cycle surface treatment when previously, two cycles were necessary. 
     In the first aspect, the present invention is directed to a transfer tray for containing lenses during movement from workstation to workstation. After the lenses are released from the mold assembly and if necessary, edged, they are placed onto a transfer tray concave-side up. The transfer tray is rigid and has numerous cavities formed for containing the lenses. 
     The transfer tray is then secured within a holding frame of an inverting device. The inverting device causes the transfer tray to rotate around an axis such that the tray, containing the lenses, is essentially inverted. The lenses are now concave-side down and resting on a surface treatment support tray, 
     The surface treatment support tray allows for unrestricted surface access in any gaseous type of surface treatment. 
     The surface treatment support tray is rigid and has a plurality of through-holes formed therein. On one surface of the tray is a shallow counterbore ring around each through-hole. The counterbore ring is slightly larger than the outer perimeter of a contact lens or intraocular lens while the through-hole is slightly smaller than the diameter of the lens. There is no masking of any portion of the lens surface. 
     In yet a further aspect of the invention, support trays may be affixed onto a larger tray such that multiple support trays are processed at one time. Examples of suitable larger trays include those used in plasma reaction chambers. 
     Advantages of the present invention include the reduced demand on a worker including less manipulation and handling of the lenses with tweezers which frequently destroy lenses which then must be scrapped. The inverting process is more precise, resulting in placement of the lenses in correct orientation and spacing into the next tray. The placement of the lenses is always precise and does not require the use of an air knife such as that disclosed in Moorehead. The surface treatment process can furthermore be performed in a single-cycle as opposed to a two-cycle process, reducing the time necessary for treating the lenses. Additionally, the lenses are directly transferred from a surface treatment tray into an apparatus for extraction. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     FIG. 1 is a top plan view of the base portion of a prior art tray assembly used to transport contact lenses; 
     FIG. 2 is a top plan view of the top portion of the tray assembly as seen in FIG. 1; 
     FIG. 3 is a cross-section elevational view of a prior art assembly containing contact lens molds and lenses therein; 
     FIG. 4 is a top plan view of a transfer tray having a plurality of cavities; 
     FIG. 5 is a cross-section elevational view taken along line  5 — 5  of FIG. 4; 
     FIG. 6 is a top plan view of an inverting device used to transfer lenses from a concave-side up position to a concave-side down position; 
     FIG. 7 is a side, elevational view of FIG. 6; 
     FIG. 8 is a top plan view of a surface treatment tray; 
     FIG. 9 is a cross-section elevational view taken along line  9 — 9  of FIG. 8; 
     FIG. 10 is a partial, enlarged view of FIG. 9 showing details of the placement of contact lenses on the surface treatment tray; 
     FIG. 11 is a perspective view of multiple transfer support trays secured within the holding frame of the inverting device with contact lenses concave-side up; 
     FIG. 12 is a perspective view of multiple surface treatment trays secured to a perforated tray; 
     FIG. 13 is a perspective view of the surface treatment trays/perforated tray assembly as it is placed over the transfer trays/holding frame assembly of the inverting device; 
     FIG. 14 is a perspective view of the inverting device as the holding frame is rotated about axis Y—Y; 
     FIG. 15 is a perspective view of the inverting device as rotation of the holding frame is completed onto the base plate; and 
     FIG. 16 is a perspective view of the rotation of the holding frame back to starting position after lenses have been transferred to the surface treatment trays in the concave-side down position. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As previously stated, small articles such as contact lenses or intraocular lenses may be difficult to process for various reasons. By automating or removing the need for individual manual lens handling, more lenses can be processed and treated without worker involvement. The present invention will be discussed in relation to contact lenses with the understanding that other ophthalmic lenses may be used with the present invention. In particular, intraocular lenses may be processed with the present invention. Other applications may include use of the deposition tray with spectacle lenses, especially if the spectacle lens requires a coating or deposition treatment. 
     While the following embodiments illustrate contact lenses, any ophthalmic lens may be transferred using this invention. 
     In the present invention, the dried contact lenses are removed from the mold in which they were cast (see, e.g., U.S. Pat. No. 5,969,793 to Dobner, assigned to Bausch &amp; Lomb Incorporated, the entire contents herewith incorporated by reference), edged (if desired) and placed on transfer tray  10  (tray shown in FIGS.  4  and  5 ). Up to 50 contact lenses fit onto transfer tray  10 , concave-side facing up, although the tray dimensions may be changed as desired to accommodate any number of lenses. Each cavity  12  holds a single contact lens. 
     Transfer tray  10  has fifty cavities  12  arranged in a predetermined array. As seen in the cross-sectional view, cavities  12  each have a spherical radius for holding the contact lens (contact lens not shown). The convex side of a contact lens, which faces down, is comprised of spherical radii. This allows the contact lens to sit in cavity  12 . 
     Transfer tray  10  has upper surface  14 , lower surface  16 , corners  26 , two attachment sides  18 ,  18 ′, two lateral sides  20 ,  20 ′ and alignment means  24  (which will be detailed later). Corners  26  and areas  22 ,  22 ′ (areas  22 ,  22 ′ adjacent to lateral sides  20 ,  20 ′, respectively) are positioned below upper surface  14 . 
     As shown in FIG. 5, attachment sides  18 ,  18 ′ have edges  19 ,  19 ′, respectively. 
     Adjacent to edge  19 ,  19 ′ are raised portions  30 ,  30 ′, respectively. Lateral sides  20 ,  20 ′ each have two raised portions  20   a ,  20   b ,  20 ′ a  and  20 ′ b , respectively ( 20   a ′ and  20   b ′ shown in FIG.  4 ). The height of  30 ,  30 ′,  20   a ,  20   b ,  20 ′ a  and  20 ′ b  are similar. Multiples of tray  10  may be stacked upon each other, with the lower surface  16  separated from upper surface  14  by raised portions  30 ,  30 ′,  20   a ,  20   b ,  20 ′ a  and  20 ′ b . This leaves sufficient space between upper surface  14  and bottom surface  16  so that any article contained in cavities  12  of first tray  10  does not contact any portion of the next tray  10  when multiple trays are stacked on top of each other. Transfer tray  10  may be made from any moldable material, metal or ceramic material. In particular, due to the ability of dry contact lenses to collect static charge, it is preferred that when transfer tray  10  is utilized for transferring contact lenses, a non-static material be used. Examples of suitable materials include polyethylenes including HDPE and UHDPE&#39;s, polypropylene, polybutylene, polystyrenes including styrene-butadienes, styrene-acrylonitriles, acrylonitrile-butadiene-styrenes, maleic annhydride-styrenes, polyvinylchlorides, acrylics such as polymethylmethacrylate, cellulosics including cellulose acetate, cellulose acetate butyrate, cellulose proprionate, acetals such as polyoxymethylenes, polyamides including polyamide-imides, polycarbonates, polyarylates, polyesters, polyetherimides, polyphenyleneoxides, silicon dioxide, silicon nitride, silicon carbide, silicon-aluminum-oxynitride, aluminum titanate, zirconia toughened aluminum, cermets-ceramic/metal composites, aluminum and aluminum alloys, silver and silver alloys, copper and copper alloys, magnesium and magnesium alloys, tin and tin alloys, nickel and nickel alloys, gold and gold alloys, and titanium and titanium alloys. In particular, a material such as white polystyrene contains sufficient moisture to retain the lenses on the tray. Use of a static-prone material may allow the dry contact lenses to “jump off” the tray due to static charge. 
     Multiples of transfer tray  10  may be stacked upon each other, thereby allowing the worker to transfer large amounts of lenses in a single move. 
     Inverting device  40  as shown in FIGS. 6 and 7 has two portions, holding frame  60  and base plate  80 . Holding frame  60  is connected to base plate  80  by rotating means  90  such that holding frame  60  pivotally rotates about axis Y—Y onto base plate  80 . 
     Holding frame  60  is comprised of an upper surface  62 , lower surface  66 , two lateral portions  70 , 70 ′, two frame portions  74 ,  74 ′ and clamps  75 . Lateral portions  70 ,  70 ′ have upper portions  71 ,  71 ′ and lower portions  72 ,  72 ′. The lower portions  72 ,  72 ′, along with upper portions  71 ,  71 ′ form a recessed area for holding transfer tray  10 . Lateral portion  70  is connected to frame portion  74 , which is connected to lateral portion  70 ′, which is connected to frame portion  74 ′, which is connected to lateral portion  70 ; this forms the rectangular frame of holding frame  60 . Interior area  78  is open. 
     Legs  76  on lower surface  66  support holding frame  60  when inverting device  40  is in an open position, when transfer tray  10  is being secured to holding frame  60  and when base plate  80  has been rotated over above holding frame  60 . 
     On lateral portions  70 ,  70 ′ there are attached clamping devices  75  which are used to secure transfer tray  10  to holding frame  60 . Lower surface  16  of transfer tray  10  rests on the recessed area formed by lower portions  72 ,  72 ′ (not shown). While any releasable clamping device may be used, especially preferred is a spring-ball plunger clamp which secures transfer tray  10  in place on holding frame  60 . It is preferred that transfer tray  10  be easily and smoothly secured into place on holding frame  60  so as to not jar the lenses held in cavities  12 . While any number of transfer trays  10  may be secured to holding frame  60 , it is preferred that at least two transfer trays be releasably attached to holding frame  60 . It is especially preferred that three transfer trays be attached to holding frame  60 . This would allow up to 150 lenses to be inverted from transfer tray  10 . FIG. 11 illustrates placement of three trays onto holding frame  60 . 
     Returning to FIGS. 6 and 7, base plate  80  has upper surface  84  and lower surface  86 . Base plate  80  has a similar shape to that of the holding frame (such as a rectangular shape). On upper surface  84  are located stops  82 , preferably on the outer perimeter of the rectangle. Stops  82  provide space between base plate  80  and holding frame  60  when holding frame  60  has been rotated over onto base plate  80 , sandwiching transfer trays  10 , surface treatment support trays  100  or similar devices therebetween. This can be seen in FIG.  15 . 
     Rotating means  90  provides means for rotating holding frame  60  about axis Y—Y. While any type of hinge or rotating device may be used, it is especially preferred that rotating means  90  has two portions, pivoting member  92  and stationary member  94 . Pivoting member  92  is attached to holding frame  60  and is attached to stationary member  94  located on base plate  80  by connecting means  98 . Connecting means  98  can be any device which extends through openings in both pivoting member  92  to stationary member  94 . A preferred means for connecting pivoting member  92  to stationary member  94  is a cylindrical bolt or a screw. In transferring articles such as contact lenses from a receptacle secured to holding frame  60  to a receptacle secured to base plate  80 , base plate  80  remains stationary on a surface while holding frame  60  pivots about axis Y—Y. 
     Additionally, holding frame  60  may have a means for manipulating the frame in the form of a handle. As shown in FIG. 6, there are located on portions  74  and  74 ′, two handles  73 ,  73 ′. While the location of handles is not critical, for ease of movement it is desired that handles be located such that they facilitate movement about axis Y—Y which is shown in FIG.  6 . 
     Also located on holding frame  60  are locking devices  65 ,  65 ′. In the preferred embodiment, locking devices  65 ,  65 ′ pivot, releasable holding any type of elongated tray placed over holding frame  60 . This is shown in FIG.  13 . 
     FIGS. 8-10 illustrate a surface treatment support tray having multiple through-holes for holding contact lenses. Ophthalmic lenses may be processed while being retained in trays. Such processes may involve surface treatment such as plasma reaction, including plasma oxidation, plasma polymerization or plasma deposition. 
     FIG. 8 illustrates surface treatment support tray  100  from a top plan view. The support tray  100  has multiple through-holes  112 . Each through-hole  112  is cylindrically shaped as shown in FIG. 8 but other shapes are possible. In the preferred embodiment, support tray  100  has five rows of ten through-holes. Additionally, tray  100  may have other sections removed such as opening  116  in order to optimize gas flow around the lenses. It is preferred that support tray  100  be made from a lightweight, non-ferrous material suitable for use with plasma oxidation, plasma polymerization or plasma deposition. Especially preferred is a material such as aluminum which is not anodized, and thus avoids any surface static charge. 
     As seen in FIGS. 9 and 10, support tray  100  has upper surface  120  and lower surface  130 . Each through-hole  112  has shallow counterbore  114  in the upper surface  120  portion. Counterbore  114  has a circular diameter and circumvents the outer perimeter of through-hole  1   12 . Counterbore  1   14  has width sufficient to allow lens  140  to be easily positioned in counterbore  114  with the lens edge  142  resting on counterbore surface  122 . It is important that lens edge  142  maintains continuous contact with surface  122  of counterbore  1   14  and does not contact any other portion of tray  100 . Preferably, lens  140  is centered over through-hole  112 . 
     Legs  132  are fixed on lower surface  130  of support tray  100 . In the preferred embodiment, there are four legs made of an electrically insulating material. Legs  132  keep tray  100  from contacting the interior plasma chamber or shelf. Legs  132  also provide spacing so that any gaseous or liquid coating may be able to freely reach both sides of lens  140  during processing. In the preferred embodiment, legs  132  are made from polycarbonate which insulates the tray from any shelf or plasma chamber surface. 
     As previously mentioned in the Background of the invention, plasma oxidation, plasma polymerization or plasma deposition can be accomplished in an apparatus such as the Metroline Plasma Deposition Chamber. Large planar support surfaces such as perforated shelves are used to support the articles being treated (Metroline shelf  88  seen in FIG.  12 ). Feet  132  of surface treatment tray  100  can be affixed to perforated shelf  88  by any attachment means such as screws or hooks. Preferably, legs  132  are hollow and have raised upper surface  134  (upper surface seen in FIGS.  9  and  10 ). In the preferred embodiment, upper surface.  134  of surface treatment tray  100  matingly engage with attachment means  24  of transfer tray  10 . The trays are now aligned such that when inversion occurs, the lenses are transferred from the cavities . 12  of transfer tray  10  directly into cavities  112  of surface treatment tray  100 . It is possible to position a multiple number of trays  100  onto perforated shelf  88 . In the preferred embodiment, at least support trays  100  are attached to the perforated shelf  88 . It is especially preferred that three support trays  100  are attached to perforated shelf  88 , thereby treating  150  lenses at once. 
     Since surface treatment support tray  100  allows the plasma to freely access both sides of the lens, it is necessary for the lenses to undergo only a single plasma cycle. The lenses do not have to be inverted or “flipped”, and the time required for the process is reduced. 
     As shown in FIG. 11, multiple transfer trays  10  are secured within the holding frame  60  of the inverting device  40 . Each cavity  12  of transfer tray  10  contains a contact lens (lenses not shown). Clamps  75  contact tray corner portion  26  such that trays  10  are smoothly inserted between clamps  75  without jarring contact lenses. Contact lenses are concave-side up as transfer tray  10  is secured to holding frame  60 . In the preferred embodiment, multiple transfer trays  10  are secured. It is preferred that at least two and especially preferred that three transfer trays are secured to the holding frame  60 . In the preferred embodiment, three transfer trays  10  are attached to the holding frame  60  thereby capable of inverting  150  lenses at once. 
     As seen in FIG. 12, surface treatment support tray  100  is secured to upper surface  88 a of perforated tray  88  by attachment means  89 . The number of surface treatment support trays  100  attached to shelf  88  depends on and should correspond to the number of transfer trays  10  attached to holding frame  60 . It is critical that both trays be aligned to ensure that the contact lenses are precisely transferred from one tray to the other. 
     FIG. 13 shows lower surface  88 b of perforated shelf  88 . Surface treatment tray  100  is attached to shelf  88  and is visible through the perforations of shelf  88 . Locking devices  65 ,  65 ′ secure shelf  88  such that upper surface  88 a is adjacent to upper surface  62  of holding frame  60 . Directly under surface treatment trays  100  are transfer trays  10  (not shown) such that upper portion  120  of surface treatment support tray  100  is directly over upper portion  14  of transfer tray  10 . As previously mentioned, it is necessary for surface treatment support trays  100  to be aligned with transfer trays  10  such that a contact lens in cavity  12  of transfer tray  10  is aligned with cavity  112  of surface treatment tray  100 . 
     In another embodiment, shelf  88  is secured to holding frame  60 . In this embodiment, lenses are inverted directly onto perforated shelf  88  and further processed. 
     FIG. 14 shows inverting device  40  as holding frame  60  is rotated about axis Y—Y. Lenses (not shown) are held between transfer tray  10  (not shown) and surface treatment support tray  100  (not shown) such that the lenses are secured and stay in place. A worker grasps handle  73 ′, lifting holding frame  60 . 
     FIG. 15 shows inverting device  40  as rotation of the holding frame  60  is completed onto base plate  80 . Lower surface  16  of transfer tray  10  is now facing upwards. Edges  142  of lenses  140  (not shown) are now resting within counterbore  114  of surface treatment tray  100  (not shown). After the rotation is complete, locking devices  65 ,  65 ′ are released, thereby releasing shelf  88  to remain on base plate  80  (shown in FIG.  16 ). 
     FIG. 16 shows the rotation of the holding frame back  60  about axis Y—Y to starting position. Lenses are now residing in surface treatment support tray  100  and in a concave-side down position. 
     After reaction, the perforated support tray  88  and trays  100  are removed from the plasma chamber. The lenses are concave-side down and ready for further processing. An example of further processing is extraction and hydration. In particular, perforated shelf  88  is replaced on base plate  80 . Mesh extraction inserts such as those disclosed in U.S. Ser. No. 60/163,208 are set over the lenses. Holding frame  60  is rotated over onto the mesh inserts and locked into place over shelf  88 . Holding frame  60  is rotated back over such that legs  76  contact the surface. This action transfers lenses into the mesh extraction wells. After placement of mesh top over the insert bottom, the insert assembly is placed into bottom supporting tray portion and covered with the top supporting tray portion. The lenses are now ready to be placed into a carrier and extracted as appropriate. Additional processing of the lenses may include dipping the mesh assembly into a polymer coating solution. 
     Any type of medical device including ophthalmic lenses may be transferred using the transfer tray, inverting device and surface treatment support tray. Ophthalmic lenses include intraocular lenses, rigid gas permeable and soft contact lenses and spectacle lenses. Preferred lenses are contact lenses which require a surface treatment, including lenses which are fluorosilicone, xerogels or silicone hydrogels. Especially preferred are silicone hydrogel lenses which are treated to render the surface more hydrophilic. 
     In the preferred embodiment, the lenses are surface treated by plasma oxidation, plasma polymerization or plasma deposition. Examples of plasma reaction methods are disclosed in the following: 
     U.S. Ser. No. 09/219,500 (Grobe and assigned to Bausch &amp; Lomb Incorporated, the entire disclosure herewith incorporated by reference) discloses treating a fluorinated contact lens with a hydrogen-containing plasma to reduce the fluorine content of the surface layer, followed by oxidation of the surface. 
     U.S. Ser. No. 09/315558 (Grobe et al and assigned to Bausch &amp; Lomb Incorporated, the entire disclosure herewith incorporated by reference) discloses modifying the surface of a silicone contact lens by plasma reacting the lens with a carbon-containing layer made from a diolefinic compound having 4 to 8 carbon atoms, followed by plasma or chemical treatment of the carbon layer to render it hydrophilic. 
     U.S. Ser. No. 09/315,306 (Valint et al and assigned to Bausch &amp; Lomb Incorporated, the entire disclosure herewith incorporated by reference) discloses plasma reacting the surface of a silicone contact lens with a carbon layer followed by attachment of hydrophilic polymer chains to the surface of the carbon layer. 
     U.S. Ser. Nos. 09/295,651 and 09/295,675 (both to Valint et al and assigned to Bausch &amp; Lomb Incorporated, the entire disclosures herewith incorporated by reference) disclose plasma reacting the surface of a silicone contact lens to form a silicatecontaining coating. The surface modified lens shows desirable coating characteristics even after extraction, hydration and sterilization. 
     Additionally, U.S. Ser. No. 09/315,912 (Grobe et al and assigned to Bausch &amp; Lomb Incorporated, the entire disclosure herewith incorporated by reference) discloses coating a silicone lens with plasma deposition of a carbon layer, functionalizing the carbon layer followed by graft polymerization of a hydrophilic polymer onto the carbon layer. In the preferred embodiment, a silicone contact lens surface is pretreated with an oxidizing plasma prior to deposition of the carbon layer, in order to improve adhesion of the carbon layer. 
     By using multiple transfer and surface treatment trays and the device for transferring contact lenses, the number of lenses processed can be increased dramatically. By using the above-described surface treatment tray, lenses can be plasma reacted in a single cycle whereas previous methods required two cycles.