An optical lens for protecting against light pollution after eye surgery and a process for manufacturing same

Abstract

This invention discloses an optical lens for postoperative light pollution protection of the eye and its manufacturing process. It includes an ultralight, high-transparency optical resin substrate and a multifunctional optical film layer formed on the surface of the ultralight, high-transparency optical resin substrate through a combined coating process. The edges of the ultralight, high-transparency optical resin substrate are rounded and polished. The multifunctional optical film layer consists of a bottom anti-reflection film, a middle precision filter film, and an outer diffuse reflection film. The bottom anti-reflection film is used to improve visible light transmittance; the middle precision filter film is used to selectively absorb or reflect harmful light of specific wavelengths; and the outer diffuse reflection film contains diffuse reflection material, which is used to convert strong direct light transmitted through the film layer into soft diffuse light. This invention relates to the field of optical lens technology, specifically an optical lens for postoperative light pollution protection of the eye and its manufacturing process, aiming to solve the problems of existing lenses' inaccurate protection of sensitive wavelengths of the eye after surgery, strong direct light stimulation, uncomfortable wearing, and lack of sterility assurance.

Description

Technical Field

[0001] This invention belongs to the field of optical lens technology, specifically an optical lens for postoperative protection against light pollution in the eye and its manufacturing process. Background Technology

[0002] Patients who have undergone eye surgeries such as phacoemulsification, laser-assisted corneal refractive surgery, and vitrectomy are in the repair phase of their eye structure. The tolerance of retinal photoreceptor cells and corneal nerve endings to external light, especially short-wavelength blue light (400-450nm), ultraviolet light (UVA / UVB), and stray light, is significantly reduced. Premature or prolonged exposure to such light pollution after surgery can easily lead to photophobia, tearing, glare, and eye strain, and may even increase the risk of macular light damage and prolonged postoperative inflammation. Currently available blue light blocking or UV protection lenses are mainly designed for daily protection by the general population and have the following technical shortcomings:

[0003] Ordinary lenses have a low blocking rate for harmful blue light (usually only 20%-40%), and are not designed with precise, high-intensity cutoff for the 400-450nm wavelength range, which is most sensitive to the eyes after surgery. Ordinary lenses can only absorb or reflect some light, and the transmitted light is still direct light, which cannot avoid the direct stimulation of the retina by bright light sources (such as sunlight and indoor lighting) after surgery. In pursuit of protective effects, some lenses use thick materials, which increases the burden on the easily fatigued eyes after surgery. Moreover, the edges of the lenses are prone to reflection, forming a secondary source of light pollution. The manufacturing process of ordinary lenses usually does not include aseptic processing. After surgery, patients' eyes have low resistance, and the microorganisms that may be carried on the lens surface may pose a risk of cross-infection.

[0004] Therefore, developing a multifunctional optical lens that specifically addresses the postoperative rehabilitation needs of the eye, integrating precise harmful light shielding, gentle light intensity conversion, lightweight and comfortable wear, and sterility protection, has significant clinical and market value. Summary of the Invention

[0005] In view of the above situation and to overcome the existing defects, the present invention provides an optical lens for postoperative light pollution protection of the eye and its manufacturing process, aiming to solve the technical problems of existing lenses being inaccurate in protecting sensitive wavelengths of the eye after surgery, having strong direct light stimulation, being uncomfortable to wear, and lacking sterility.

[0006] This invention provides the following technical solution: This invention discloses an optical lens for postoperative light pollution protection of the eye, comprising an ultralight and high-transparency optical resin substrate and a multifunctional optical film layer formed on the surface of the ultralight and high-transparency optical resin substrate by a combined coating process. The edges of the ultralight and high-transparency optical resin substrate are rounded and polished. The multifunctional optical film layer consists of a bottom antireflection film, a middle precision filter film, and an outer diffuse reflection film. The bottom antireflection film is used to improve visible light transmittance; the middle precision filter film is used to selectively absorb or reflect harmful light of specific wavelengths; and the outer diffuse reflection film contains diffuse reflection material, which is used to convert strong direct light transmitted through the film layer into soft diffuse light.

[0007] Furthermore, the ultralight high-transmittance optical resin substrate is composed of polycarbonate (PC) and polymethyl methacrylate (PMMA), and the lens made from the ultralight high-transmittance optical resin substrate has a center thickness ≤1.2mm and a density ≤1.2g / cm³. 3 .

[0008] Furthermore, the intermediate precision filter film contains nano-iron oxide, nano-cerium oxide and ultraviolet absorber, which can achieve 100% blocking of UVA / UVB (200-400nm) band, ≥95% blocking rate of harmful blue light in 400-450nm band, and at the same time ensure ≥80% transmittance in 500-760nm visible light band.

[0009] Furthermore, the diffuse reflective material in the outer diffuse reflective film is nano-sized spherical silicon dioxide (SiO2) with a particle size of 50-150 nm and a mass percentage of 0.5%-2% in the film layer. The spherical silicon dioxide, through physical scattering, transforms transmitted direct light into uniform and soft diffused light, avoiding the direct impact of peak light intensity on the retina.

[0010] Furthermore, the lens made of the ultra-lightweight, high-transmittance optical resin substrate has a chamfer radius of 0.2-0.5mm and a surface roughness Ra≤0.05μm, which is used to eliminate stray light reflection caused by edge corners.

[0011] Meanwhile, this invention also discloses a manufacturing process for an optical lens for postoperative protection against light pollution in the eye, characterized by comprising the following steps:

[0012] Step 1: Substrate preparation and edge treatment: Ultra-lightweight, high-transmittance optical resin substrate is prepared by injection molding, and the lens edge is rounded and polished by CNC precision grinding, then cleaned and dried for later use.

[0013] Step 2, Substrate Cleaning and Activation: The treated substrate undergoes ultrasonic cleaning and plasma surface activation treatment.

[0014] Step 3, Combined Coating:

[0015] 1. Vacuum ion plating technology is used to deposit an underlayer antireflective film and an intermediate precision filter film on the surface of the activated substrate;

[0016] 2. An outer diffuse reflection film is coated on the surface of the intermediate filter film using the sol-gel method, and then thermosetting to form a uniform film layer.

[0017] Step 4, In-situ Aseptic Treatment: In Step 1, the mold for lens injection is subjected to plasma sterilization; after Step 3, the entire lens is subjected to ultraviolet aseptic curing to ensure that the lens surface reaches a sterile state.

[0018] Step 5, Testing and Packaging: The lens is tested for optical performance, coating adhesion and sterility in a sterile environment. If it passes the test, it is aseptically packaged.

[0019] Furthermore, the combined vacuum ion plating and sol-gel coating process results in an interlayer bonding force of ≥5N for the multilayer films, and uniform thickness of each layer with an error of ≤±0.05μm.

[0020] Furthermore, in step (4), the ultraviolet sterile curing uses ultraviolet light with a wavelength of 254 nm and an irradiation intensity of 1000-2000 mJ / cm². 2 This process not only completes the final curing of the outer diffuse reflection film but also achieves thorough sterilization of the lens surface.

[0021] The beneficial effects achieved by the present invention using the above structure are as follows:

[0022] 1. Through the precise design of materials and thickness of the intermediate precision filter film, it achieves a high-intensity blockage of over 95% of the most harmful UVA / UVB and 400-450nm short-wave blue light to the eyes after surgery, while ensuring high transmittance of the main visible light, avoiding pupil dilation and accommodation burden caused by excessive light, and achieving precise protection that "harmful light cannot enter and beneficial light is not lost".

[0023] 2. An outer diffuse reflection film is introduced, utilizing the physical scattering properties of nano-sized spherical SiO2 to convert strong direct light (such as direct sunlight, car headlights, and indoor lighting) passing through the lens into uniform and soft diffuse light. This function greatly reduces the direct stimulation of the sensitive retina by the peak intensity of light after surgery, effectively alleviating photophobia, glare, and visual fatigue.

[0024] 3. The lens is made of a composite of polycarbonate (PC) and polymethyl methacrylate (PMMA) to form an ultra-lightweight and highly transparent resin substrate. The thickness of the lens center is controlled to less than 1.2mm, which significantly reduces the weight of the lens. Combined with the rounded chamfering and polishing treatment of the lens edge, it eliminates secondary light pollution caused by edge reflection and avoids pressure on the bridge of the nose and auricle from the sharp corners. It is suitable for postoperative patients who need to wear the lens for a long time and whose eyes are prone to fatigue.

[0025] 4. By combining vacuum ion plating with sol-gel coating, a multilayer optical film with strong adhesion (≥5N) and uniform thickness (error ≤ ±0.05μm) was obtained, which effectively solved the problems of easy peeling and unstable filtering band of traditional coatings, and ensured the stability of the protective effect of the lens in long-term use.

[0026] 5. An in-situ aseptic treatment step is introduced into the optical lens manufacturing process, namely, plasma sterilization of the mold + UV aseptic curing of the finished product, which provides hygiene protection for postoperative patients with low eye resistance and reduces the risk of secondary eye infections caused by wearing lenses from the source. Attached Figure Description

[0027] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0028] Figure 1 This is a cross-sectional view of the overall structure of the postoperative protective optical lens for the eye according to the present invention;

[0029] Figure 2 This is a schematic diagram illustrating the multifunctional optical film structure and function of the present invention;

[0030] Figure 3 This is a flowchart illustrating the manufacturing process of the postoperative protective optical lens for the eye according to the present invention.

[0031] Figure 4 This is a comparison diagram of the optical protection performance of the lenses of the present invention;

[0032] Figure 5 This is a schematic diagram of the band protection of the precision filter film of the present invention. Detailed Implementation

[0033] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example 1

[0034] This embodiment provides an optical lens for postoperative light pollution protection of the eye.

[0035] Lens composition and structure: The lens of this embodiment includes an ultra-lightweight and high-transmittance optical resin substrate and a multifunctional optical film layer formed on the surface of the substrate by a combined coating process, wherein the edges of the ultra-lightweight and high-transmittance optical resin substrate are rounded and polished.

[0036] Ultra-lightweight, high-transparency optical resin substrate: composed of polycarbonate (PC) and polymethyl methacrylate (PMMA) in a weight ratio of 70:30. After injection molding, the lens center thickness is 1.0 mm and the density is 1.19 g / cm³. 3 (≤1.2 g / cm) 3 This achieves an ultra-lightweight design, effectively reducing the burden on the eyes and bridge of the nose when worn by postoperative patients.

[0037] Edge rounding and polishing: The chamfer radius of the lens edge is 0.3mm (within the range of 0.2-0.5mm), and the surface roughness Ra is 0.04μm (≤0.05μm). This design eliminates stray light reflection that may be generated by the edge corners, avoids secondary light pollution, and improves the smoothness and comfort of wearing.

[0038] Multifunctional optical coating: composed of a bottom antireflection film, a middle precision filter film, and an outer diffuse reflection film.

[0039] The bottom antireflective coating is a multilayer film composed of alternating SiO2 and TiO2 layers, with a total thickness of 0.2 μm. Its function is to maximize the transmittance of visible light, providing a good optical substrate for subsequent functional layers.

[0040] The intermediate precision filter film, with a thickness of 0.15μm, contains nano-iron oxide (0.8wt%), nano-cerium oxide (0.5wt%), and UV-327 (2wt%), an ultraviolet absorber. This film selectively absorbs harmful light, achieving 100% blocking of UVA / UVB (200-400nm) and a 96.5% (≥95%) blocking rate of harmful blue light in the 400-450nm band, which is most sensitive to the eyes post-surgery. Simultaneously, it ensures a light transmittance of 82.3% (≥80%) in the beneficial visible light band of 500-760nm.

[0041] Outer diffuse reflection film: 0.1 μm thick, containing diffuse reflection material—spherical silicon dioxide (SiO2) with a particle size of 100 nm (within the range of 50-150 nm), accounting for 1% by mass (within the range of 0.5%-2%) of the film. This layer, through the physical scattering effect of the nanospherical particles, transforms transmitted strong direct light (such as sunlight, car headlights) into uniform, soft diffuse light. Tests have shown that the peak light intensity is reduced by 35%, effectively avoiding direct impact of direct light on the sensitive retina after surgery. Example 2

[0042] This embodiment provides a manufacturing process for optical lenses used for postoperative light pollution protection of the eye.

[0043] Step 1: Substrate preparation and edge treatment

[0044] Mold sterilization: First, the mold used for lens injection molding is placed in a plasma sterilizer and treated for 5 minutes at a frequency of 40kHz and a power of 200W to achieve in-situ sterilization of the mold surface.

[0045] Injection molding: Using the sterilized mold described above, PC / PMMA composite resin particles are injection molded to prepare an ultra-lightweight, high-transparency optical resin substrate.

[0046] Edge polishing: The molded substrate is fixed on a five-axis CNC engraving machine, and the edges of the lens are polished with a diamond grinding head to achieve a rounded chamfer. The chamfer radius is set to 0.3mm, resulting in a smooth edge with a surface roughness Ra of 0.04μm. Subsequently, it is ultrasonically cleaned with deionized water and anhydrous ethanol for 15 minutes in sequence, and then dried with nitrogen before use.

[0047] Step 2: Substrate cleaning and activation

[0048] The dried substrate is placed in a plasma surface treatment machine and activated for 3 minutes in an oxygen atmosphere at 100W power. This step aims to remove minute surface contaminants and introduce active groups to enhance the adhesion between the subsequent film layer and the substrate.

[0049] Step 3: Combined Coating

[0050] Vacuum ion plating: The activated substrate is placed in a vacuum coating machine. A vacuum of 1.0 × 10⁻⁶ is applied. -3 After Pa, SiO2 and TiO2 materials are alternately deposited using electron beam evaporation to form the bottom antireflection film. Subsequently, in the same vacuum chamber, the deposition continues using a target containing nano-iron oxide, nano-cerium oxide, and ultraviolet absorbers to form the intermediate precision filter film. This process ensures high density and adhesion between the bottom and intermediate film layers.

[0051] Sol-gel coating: Using a spin coating method, an organosilicon sol containing 1 wt% spherical SiO2 with a particle size of 100 nm is spin-coated at 800 rpm for 30 seconds to uniformly cover the surface of the intermediate filter film. Subsequently, it is pre-cured at 80°C for 10 minutes to form the outer diffuse reflection film.

[0052] Step 4: In-situ aseptic treatment

[0053] After completing all coating steps, the entire lens is sterilely cured with ultraviolet light using a dominant wavelength of 254nm and an irradiation intensity set at 1500 mJ / cm². 2 (in 1000-2000 mJ / cm) 2 Within the specified range, this step achieves thorough sterilization of the lens surface while completing the final cross-linking and curing of the outer diffuse reflection film.

[0054] Step 5: Testing and Packaging

[0055] Multiple tests were performed on the lenses in a Class 100 clean bench:

[0056] Optical performance testing: Using a spectrophotometer, it was confirmed that the ultraviolet light blocking rate was 100%, the blue light blocking rate of 400-450nm was 96.5%, and the transmittance of 500-760nm was 82.3%.

[0057] Film adhesion test: According to the cross-cut adhesion test in GB / T 9286-2021, the adhesion strength reached 5.2N (≥5N). Using a film thickness gauge, the thickness error of each film layer was ≤±0.03μm (better than ±0.05μm).

[0058] Sterility testing: According to the sterility test method 1101 of Part IV of the 2020 edition of the Chinese Pharmacopoeia, all results were negative.

[0059] After passing the inspection, the lenses are vacuum-sealed in a sterile environment to obtain the finished product.

[0060] Comparative Example 1

[0061] This comparative example provides a commercially available high-end blue light blocking lens (not for post-operative use) from a certain brand for performance comparison.

[0062] Its technical features are as follows:

[0063] Substrate: Ordinary CR-39 resin, center thickness 1.8mm.

[0064] Edge treatment: standard right-angle cut, no rounded chamfering or polishing.

[0065] Functional film layer: There is only one organic blue light absorption film prepared by dip coating, and no diffuse reflection layer.

[0066] Preparation process: No molds or finished product sterilization steps are required.

[0067] Comparative Example 2

[0068] This comparative example provides a lens whose structure is basically the same as that of Example 1, except that the outer diffuse reflection film is omitted, that is, it only includes a substrate, a bottom antireflection film and an intermediate precision filter film.

[0069] Performance testing and effect comparison

[0070] The lenses prepared in Example 1, Comparative Example 1, and Comparative Example 2 were subjected to key performance tests, and the results are shown in Table 1:

[0071]

[0072] Results Analysis

[0073] The comparison results between Example 1 and Comparative Examples 1 and 2 show that the present invention achieves significant synergistic technical effects through the technical solutions of ultra-light substrate, rounded edge, precision filter film, diffuse reflection film, combined coating and in-situ sterile treatment. It realizes precise and high-intensity shielding of harmful light to the eyes after surgery, and solves the problem of direct light stimulation through diffuse reflection function. At the same time, it achieves comprehensive improvement in wearing comfort, product durability and medical-grade hygiene and safety.

[0074] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, material, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, material, or apparatus.

[0075] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An optical lens for postoperative light pollution protection of the eye, comprising an ultralight, high-transparency optical resin substrate and a multifunctional optical film layer formed on the surface of the ultralight, high-transparency optical resin substrate by a combined coating process, characterized in that: The edges of the ultra-lightweight, high-transmittance optical resin substrate are polished with rounded chamfers; the multifunctional optical film layer consists of a bottom antireflection film, a middle precision filter film, and an outer diffuse reflection film. The bottom antireflection film is used to improve visible light transmittance, the middle precision filter film is used to selectively absorb or reflect harmful light of a specific wavelength, and the outer diffuse reflection film contains diffuse reflection material to convert strong direct light transmitted through the film layer into soft diffuse light.

2. The optical lens for postoperative light pollution protection of the eye as described in claim 1, characterized in that: The ultralight, high-transmittance optical resin substrate is composed of polycarbonate and polymethyl methacrylate, and the center thickness of the lens is ≤1.2mm, with a density ≤1.2 g / cm³. 3 .

3. The optical lens for postoperative light pollution protection of the eye as described in claim 1, characterized in that: The intermediate precision filter film contains nano iron oxide, nano cerium oxide and ultraviolet absorber, achieving 100% blocking of UVA / UVB band 200-400nm, blocking rate of ≥95% of harmful blue light in 400-450nm band, while ensuring light transmittance of ≥80% in 500-760nm visible light band.

4. The optical lens for postoperative light pollution protection of the eye as described in claim 1, characterized in that: The diffuse reflective material in the outer diffuse reflective film is nano-sized spherical silicon dioxide with a particle size of 50-150 nm and a mass percentage of 0.5%-2% in the film.

5. The optical lens for postoperative light pollution protection of the eye as described in claim 1, characterized in that: The chamfer radius of the lens edge made of the ultra-lightweight, high-transmittance optical resin substrate is 0.2-0.5mm, and the surface roughness Ra≤0.05μm.

6. The manufacturing process of the optical lens for postoperative ocular light pollution protection according to any one of claims 1 to 5, characterized in that: Specifically, the following steps are included: Step 1: Substrate preparation and edge treatment: Ultralight and high-transmittance optical resin substrate is prepared by injection molding, and the lens edge is rounded and polished by CNC precision grinding, then cleaned and dried for later use. Step 2, Substrate Cleaning and Activation: The treated substrate is subjected to ultrasonic cleaning and plasma surface activation treatment; Step 3, Combined Coating: Vacuum ion plating technology is used to deposit an underlayer antireflection film and an intermediate precision filter film on the surface of the activated substrate. Then, an outer diffuse reflection film is coated on the surface of the intermediate filter film using the sol-gel method, and a uniform film layer is formed by thermal curing. Step 4, In-situ Aseptic Treatment: In Step 1, the mold for lens injection molding is subjected to plasma sterilization; after Step 3, the entire lens is subjected to ultraviolet aseptic curing to ensure that the lens surface reaches a sterile state; Step 5, Testing and Packaging: The lens is tested for optical performance, coating adhesion and sterility in a sterile environment. If it passes the test, it is aseptically packaged.

7. The manufacturing process of the optical lens for postoperative light pollution protection of the eye according to claim 6, characterized in that: The combined vacuum ion plating and sol-gel coating process ensures that the bonding force between the multilayer films is ≥5N, and that the thickness of each film layer is uniform with an error of ≤±0.05μm.

8. The manufacturing process of the optical lens for postoperative light pollution protection of the eye according to claim 6, characterized in that: The ultraviolet sterile curing in step four uses ultraviolet light with a wavelength of 254 nm and an irradiation intensity of 1000-2000 mJ / cm². 2 It is used to complete the final curing of the outer diffuse reflection film and to achieve thorough sterilization of the lens surface.

9. The manufacturing process of the optical lens for postoperative light pollution protection of the eye according to claim 6, characterized in that: In the arc chamfering and polishing process in step one, the chamfer radius is 0.2-0.5mm and the surface roughness Ra≤0.05μm.

10. The manufacturing process of the optical lens for postoperative light pollution protection of the eye according to claim 6, characterized in that: In step three, the bottom antireflection film deposited by vacuum ion plating is composed of alternating SiO2 and TiO2, the thickness of the middle precision filter film is 0.15μm, and the thickness of the outer diffuse reflection film is 0.1μm.

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