A method of producing an intraocular lens

Abstract

The application discloses a production method of an artificial lens, which comprises the following steps: (1) raw material filtering; (2) mold preparation; (3) raw material filling; (4) polymerization; (5) centrifugal cleaning; (6) extraction; (7) vacuum drying; and (8) detection and packaging. The production method of the artificial lens has the advantages that the lens produced is smooth in surface, the lens surface is not adhered, the lens has no glass transition temperature, the lens is not hardened at -40 DEG C, the requirement for transportation conditions is relatively low, the production efficiency is high, and the cost is low.

Description

Technical Field

[0001] This invention relates to the field of intraocular lens manufacturing technology, and in particular to a method for manufacturing an intraocular lens. Background Technology

[0002] Intraocular lenses (IOLs) are playing an increasingly important role in improving postoperative visual quality for patients with cataracts, presbyopia, and myopia. Current IOL manufacturing methods generally employ a turning process, where raw materials are first frozen at low temperatures (-10 to -15°C) to harden, and then ground into the desired lens shape using a grinding machine. This method is inefficient, costly, and results in numerous scratches on the lens surface. Furthermore, the lens has a glass transition temperature, hardening at -10 to -15°C, which places relatively high demands on transportation conditions. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the existing technology, solve the problems existing in the existing technology, and provide a method for producing an artificial lens. The artificial lens produced by this method has a smooth surface, does not stick together, has no glass transition temperature, does not harden at -40°C, and has relatively low requirements for transportation conditions.

[0004] The technical solution of this invention is as follows: A method for manufacturing an intraocular lens, comprising the following steps: (1) Raw material filtration; (2) Preparation of molds; (3) Raw material filling; (4) Aggregation; (5) Centrifugal washing; (6) Extraction; (7) Vacuum drying; (8) Inspect the packaging.

[0005] As a further improvement to this scheme, in the first step of raw material filtration, the following equipment is prepared: a suction flask, a vacuum pump, a water bath, and beakers. The raw materials were placed in a beaker, heated in a water bath, and stirred. Rinse the suction flask: Place filter paper in the flask and rinse along the wall of the upper flask with a small amount of acetone until the acetone has been completely filtered out. Vacuum filtration: Turn on the vacuum pump, open the valve, and after checking that the filtration flask is normal, pour in the raw material and begin filtration. Repeat the first filtration step, for a total of two filtrations; De-airing: Cover the filtration flask, vacuum the raw material to remove air bubbles, and then place the raw material into the raw material packer for later use.

[0006] As a further improvement to this solution, in the second step of mold preparation, a) Mold selection: Choose the appropriate upper and lower molds based on the required coke density. b. Silicone oil wiping: Apply silicone oil to the mold with a cotton ball, then wipe with a cotton ball soaked in acetone until no silicone oil is visible. Allow it to air dry. c. Wipe with acetone: Use cotton balls soaked in acetone to wipe the mold clean, and then let it air dry.

[0007] As a further improvement to this solution, step 3, raw material filling, includes several steps: mold cleaning, raw material filling, and microscopic inspection. The specific steps are as follows: a. Clean the matching upper and lower molds with acetone under a microscope and set aside; b. Place the matching upper mold into the mold sleeve, use tweezers to place the gasket on the surface of the upper mold, rotate the raw material filler to extrude the raw material onto the upper mold, and then close the matching lower mold. c. Put the mold cover on and tighten it. d. Microscopic examination: Place the mold filled with raw materials under a stereo microscope to observe whether there is center displacement, air bubbles, or impurities. Adjust the mold with center displacement to make it symmetrical; place the mold with air bubbles on its side and wait for the air bubbles to disappear; discard the mold with impurities.

[0008] As a further improvement to this solution, in the fourth polymerization step, the mold filled with raw materials is placed in the polymerization equipment, the run button is pressed, and after the run is completed, the mold is removed and passed to the next process.

[0009] As a further improvement to this solution, in step 5, the centrifugal cleaning process, the upper and lower molds are separated, the intraocular lens is placed on the lower mold, and the lower mold is placed in the centrifuge's spinner for centrifugal cleaning. After centrifugation and cleaning, the semi-finished artificial lens is observed under a microscope. Any unqualified lenses are discarded, while qualified lenses are wiped with a cotton swab dipped in an appropriate amount of acetone to ensure that the surface is free of lint, acetone residue, and obvious scratches in the center of the optical surface. An appropriate amount of isopropanol is applied to the mold to moisten it, and then the lens haptic is gently held with tweezers and gently peeled off to separate the lens from the mold.

[0010] As a further improvement to this scheme, in the extraction step 6, the lens is placed one by one on a stainless steel frame, and then the stainless steel frame is placed in a Soxhlet extractor for Soxhlet extraction.

[0011] As a further improvement to this solution, in step 7, the vacuum drying step, the intraocular lens after Soxhlet extraction is taken out, placed in a vacuum drying oven, the equipment is turned on, and after the time is up, the equipment is turned off, and the lens is placed in the vacuum drying oven for use. As a further improvement to this solution, in step 8 of the inspection and packaging process, the dried intraocular lens is removed from the stainless steel frame, observed and cleaned under a microscope to ensure that the intraocular lens is intact and its surface is clean and meets the requirements. Then, it is placed face up in a focimeter for optical power testing. After completion, the lens is placed on the corresponding carrier device, a serial number label is printed and affixed.

[0012] Advantages of this invention: The method for producing artificial lenses disclosed in this invention involves steps such as raw material filtration, mold preparation, raw material filling, polymerization, extraction, drying, testing and packaging. The resulting lens has a smooth surface, does not adhere to the surface, has no glass transition temperature, and does not harden even at -40°C. It also has relatively low requirements for transportation conditions. Detailed Implementation

[0013] The technical solution of the present invention will be described in detail below with reference to preferred embodiments.

[0014] This invention discloses a method for producing an intraocular lens, comprising the following steps: (1) raw material filtration; (2) mold preparation; (3) raw material filling; (4) polymerization; (5) centrifugal cleaning; (6) extraction; (7) vacuum drying; and (8) inspection and packaging. The method for producing an intraocular lens disclosed in this invention, through steps such as raw material filtration, mold preparation, raw material filling, polymerization, extraction, drying, and inspection, produces a lens with a smooth surface, non-adhesive surface, no glass transition temperature, and does not harden even at -40°C, thus having relatively low requirements for transportation conditions. In a preferred embodiment, polymerization is performed using UV polymerization, that is, curing and molding using UV light. UV light is also ultraviolet light. In the polymerization step, the mold containing the raw material is fixed in a mold sleeve and placed on top of a UV lamp for curing and molding. Molding typically takes three to five minutes, resulting in high production efficiency, low cost, and a smooth, non-adhesive lens surface.

[0015] As a further improvement to this method, in the first step of raw material filtration, the following equipment is prepared: a filtration flask, a vacuum pump, a water bath, and a beaker. The raw material is placed in the beaker, heated and stirred in the water bath. The filtration flask is rinsed: filter paper is placed inside, and a small amount of acetone is used to rinse along the upper wall of the flask. After the acetone has been completely filtered out, filtration is performed: the vacuum pump is turned on, the valve is opened, and after checking that the filtration flask is normal, the raw material is poured in for filtration. The first filtration action is repeated, for a total of two filtrations. For degassing: the filtration flask is capped, and a vacuum is applied to remove air bubbles from the raw material. After completion, the raw material is placed in a raw material packer for later use. This filtration method ensures that the lens is free of impurities and air bubbles, resulting in a clearer lens.

[0016] As a further improvement to this solution, in the second step of mold preparation, a) Mold selection: Choose the appropriate upper and lower molds based on the required coke density. b. Wipe with silicone oil: Apply silicone oil to the mold with a cotton ball, then wipe with a cotton ball soaked in acetone until there is no obvious silicone oil left, and then let it dry. c. Wipe with acetone: Use cotton balls soaked in acetone to wipe the mold clean, and then let it air dry.

[0017] This method of preparing molds helps produce lenses that meet quality and hygiene standards. The lenses are easy to peel off, and the lenses produced by matching them with the molds conform to the optical principles of the human eye.

[0018] As a further improvement to this solution, the third step, raw material filling, includes several steps: mold cleaning, raw material filling, and microscopic inspection. The specific steps are as follows: a. Clean the matching upper and lower molds with acetone under a microscope and set aside; b. Place the matching upper mold into the mold sleeve, use tweezers to place the gasket on the surface of the upper mold, rotate the raw material filler to extrude the raw material onto the upper mold, cover with the matching lower mold, and tighten the mold sleeve cover. c. Microscopic inspection: Place the mold filled with raw materials under a stereo microscope to observe for center displacement, air bubbles, and impurities. Adjust any displaced molds to ensure symmetry; place molds with air bubbles on their side until the bubbles disappear; discard any molds containing impurities. This ensures the quality of the lens products.

[0019] As a further improvement to this solution, in the fourth polymerization step, the mold filled with raw materials is placed in the polymerization equipment, the run button is pressed, and after the run is completed, the mold is removed and passed to the next process. In this process, the polymerization time is short, the production efficiency is high, and the produced lens has suitable hardness and a smooth, non-sticky surface.

[0020] As a further improvement to this solution, in step 5, the centrifugal cleaning process, the upper and lower molds are separated, the intraocular lens is placed on the lower mold, and the lower mold is placed in the centrifuge's spinner for centrifugal cleaning. After centrifugation and cleaning, the semi-finished artificial lens is observed under a microscope. Substandard lenses are discarded, while qualified lenses are wiped with a cotton swab dipped in acetone to ensure the surface is free of lint, acetone residue, and obvious scratches on the optical surface. A suitable amount of isopropanol is applied to the mold to moisten it, and then the lens haptic is gently held with tweezers and carefully peeled off to separate the lens from the mold. Lenses produced in this way are free of foreign matter and meet the high requirements of the eye for lenses.

[0021] As a further improvement to this method, in step 6, the lens is placed individually on a stainless steel frame, and then the frame is placed in a Soxhlet extractor for Soxhlet extraction. This produces lens lenses with optimal purity, are comfortable to use, and are less likely to cause rejection reactions.

[0022] As a further improvement to this method, in step 7, the vacuum drying process, the intraocular lens after Soxhlet extraction is removed and placed in a vacuum drying oven. The equipment is turned on, and after the set time, it is turned off, leaving the lens in the vacuum drying oven for later use. Vacuum drying ensures uniform drying of the lens, guarantees its quality, and better protects the patient's eyes.

[0023] As a further improvement to this solution, in step 8 of the inspection and packaging process, the dried intraocular lens is removed from the stainless steel frame, observed and cleaned under a microscope to ensure that the intraocular lens is intact and its surface is clean and meets the requirements. Then, it is placed face up in a focimeter for optical power testing. After completion, the lens is placed on the corresponding carrier device, a serial number label is printed and affixed. In the testing process, the following steps are involved: cleaning the intraocular lens (IOL) and determining its suitability: a) Gently and slowly remove the IOL from the stainless steel holder using tweezers; b) Adjust the microscope by observing the removed IOL under a microscope and adjusting the focus knob as needed to ensure a clear field of view; c) Observe the morphology of the IOL under a microscope to check for protrusions or depressions on the optical surface edges and the integrity of the haptic edges. If any defects are found, the IOL should be discarded directly into a waste bottle without further inspection; d) Clean the lens by gently wiping it with a cotton swab dipped in acetone in a clockwise or counterclockwise direction for 3 to 5 circles under a microscope. The haptic edges should also be cleaned. Avoid applying excessive force to prevent damage to the IOL. Repeat the same cleaning process on the other side.

[0024] After production, further packaging involves first preparing the inner packaging, setting the temperature, pressure, and heat-sealing time. Once the heat-sealing machine reaches the set temperature, the product can be heat-sealed. This further packaging ensures the quality and hygiene of the lens during transportation and use.

[0025] This invention has been described through preferred embodiments. Those skilled in the art will understand that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. This invention is not limited to the specific embodiments disclosed herein; other embodiments falling within the scope of the claims of this application are also within the protection scope of this invention. This invention has many other embodiments, and all technical solutions formed by equivalent transformations or equivalent modifications fall within the protection scope of this invention.

Claims

1. A method for producing an intraocular lens, characterized in that: It includes the following steps: (1) Raw material filtration; (2) Preparation of molds: The operators cleaned the upper and lower molds under a microscope, then matched them one by one according to the required soot level. The appropriate upper and lower molds were selected based on the desired soot level. Apply silicone oil to the upper mold with a cotton ball, then wipe it with a cotton ball soaked in acetone until there is no visible silicone oil left. Let it dry. Wipe the lower mold with a cotton ball soaked in acetone, and let it dry. (3) Raw material filling: a. Clean the matching upper and lower molds with acetone under a microscope and set aside; b. Place the matching upper mold into the mold sleeve, use tweezers to place the gasket on the surface of the upper mold, rotate the raw material filler to squeeze the raw material onto the upper mold, and cover it with the matching lower mold. c. Cover the mold with the lid and tighten it; d. Place the mold filled with raw materials under a stereo microscope to observe whether there is center displacement, air bubbles, or impurities. Adjust the mold with center displacement to make it symmetrical; place the mold with air bubbles on its side and wait for the air bubbles to disappear; discard the mold with impurities. (4) Polymerization: The mold with the raw material dripped on it is placed on the UV light for curing and shaping; (5) Centrifugal cleaning: Separate the upper mold and the lower mold, place the intraocular lens on the lower mold, place the lower mold in the centrifuge hole for centrifugal cleaning, observe the semi-finished intraocular lens under a microscope after centrifugal cleaning, discard any unqualified lenses, and wipe qualified lenses with a cotton swab dipped in an appropriate amount of acetone to ensure that there is no cotton wool, no acetone residue on the surface, and no obvious scratches in the center of the optical surface; dip an appropriate amount of isopropanol onto the mold to moisten it, and then use tweezers to gently hold the lens loop and peel it off to separate the lens from the mold; (6) Extraction; (7) Vacuum drying; (8) Inspect the packaging.

2. The method for producing an intraocular lens according to claim 1, characterized in that: In the first step of raw material filtration, prepare the following equipment: a suction flask, a vacuum pump, a water bath, and beakers. Place the raw materials in a beaker and heat and stir in a water bath; Rinse the filtration flask: Place filter paper in the flask and rinse along the wall of the upper flask with a small amount of acetone until the acetone has been completely filtered out. Vacuum filtration: Turn on the vacuum pump, open the valve, check that the filtration flask is normal, pour in the raw material and perform vacuum filtration. Repeat the first vacuum filtration action for a total of two filtrations. De-airing: Cover the filtration flask, vacuum the raw material to remove air bubbles, and then place the raw material into the raw material packer for later use.

3. The method for producing an intraocular lens according to claim 1, characterized in that: In step 4, place the mold filled with raw materials into the polymerization equipment, click the run button, and after the process is completed, remove the mold and pass it to the next process.

4. The method for producing an intraocular lens according to claim 1, characterized in that: In step 6, the lens is placed one by one on a stainless steel frame, and then the stainless steel frame is placed in a Soxhlet extractor for Soxhlet extraction.

5. The method for producing an intraocular lens according to claim 1, characterized in that: In step 7, the vacuum drying process, the intraocular lens after Soxhlet extraction is removed and placed in a vacuum drying oven. The equipment is turned on, and after the time is up, the equipment is turned off. The lens is then placed in the vacuum drying oven for use.

6. The method for producing an intraocular lens according to claim 1, characterized in that: In step 8, the dried intraocular lens is removed from the stainless steel frame, observed and cleaned under a microscope to ensure that the intraocular lens is intact and its surface is clean and meets the requirements. Then, it is placed face up in a focimeter for optical power testing. After completion, the lens is placed on the corresponding carrier device, a serial number label is printed and affixed.