Contact lenses and methods for making contact lenses

Abstract

To provide a contact lens having enhanced durability, wettability, and / or oxygen permeability, and further including legible text thereon. One embodiment of a contact lens includes a lens body configured for direct contact with the surface of the eye and legible text disposed on the lens body. Another embodiment of the contact lens includes a lens body including a polymeric material and a lens reinforcing material (e.g., ink, silicone material, medicated material, etc.) encapsulated in the polymeric material. The lens reinforcing material may be in the form of isolated portions dispersed in the surrounding polymeric material. A method of making a contact lens includes forming a first lens layer including a first surface, forming a pattern on the first surface, and forming a second lens layer over the pattern.

Description

[Technical field]

[0001] The present invention relates to contact lenses and methods of making same. [Background technology]

[0002] Contact lenses have improved greatly over the last 20 years. They are now made of materials that provide better wettability and higher oxygen permeability. They can also be used to change the appearance of the wearer's eyes. For example, colored contacts can be used to change the appearance of the wearer's irises.

[0003] Even with these improvements, contact lenses still suffer from several shortcomings. For example, it would be beneficial to provide contact lenses that have increased durability, wettability, and / or oxygen permeability. Additionally, it would be beneficial to provide contact lenses that include legible text thereon. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent No. 6,731,408 [Patent Document 2] U.S. Patent No. 5,713,963 [Patent Document 3] U.S. Patent No. 7,354,959 Summary of the Invention

[0005] A number of representative embodiments are provided to illustrate various features, characteristics, and advantages of the disclosed subject matter, and it will be understood that features, characteristics, advantages, etc. described in connection with one embodiment may be used separately or in various combinations and subcombinations with other features described in connection with other embodiments.

[0006] Contact lenses include lens enhancement materials that modify one or more properties of the contact lens. The lens enhancement materials can modify properties such as the appearance of the lens, which in turn modifies the appearance of the eye. For example, the lens enhancement materials can include ink patterns that enhance the appearance of the iris, limbal ring, pupil, or other parts of the eye.

[0007] The lens reinforcement material can further enhance properties of the contact lens, such as wettability and oxygen permeability. For example, the lens reinforcement material can include a silicone material arranged in combination with a hydrogel material to provide enhanced wettability and oxygen permeability.

[0008] The lens reinforcement materials can also be used to deliver medicinal agents such as drugs, vitamins, etc. For example, the lens reinforcement materials can include antibiotic materials that are slowly released into the eye to eliminate infection. The lens reinforcement materials can be placed in the peripheral zone and / or the optic zone of the contact lens.

[0009] In one embodiment, a contact lens includes a lens body configured to be worn directly on the surface of the eye. The lens body includes a plurality of legible characters that are visible to a third party observer when the contact lens is on the eye. The plurality of legible characters are formed by ink included as part of the lens body. The legible characters may include written characters forming one or more words, such as "I Love You" or "Imagine Me". They may also include letters, numbers, symbols, and geometric figures. The legible characters may be disposed on and / or encapsulated in the lens body.

[0010] The text can be located in any suitable location, but is preferably printed in the peripheral zone of the contact lens so as not to affect the user's vision. The text may be in black and white, but is preferably in color. In one embodiment, the lens body includes a first layer and a second layer, with the legible text located between the two layers.

[0011] In another embodiment, the lens enhancing material forms a marking on the contact lens that has the appearance of an iris, limbus, pupil, or other part of the eye and / or that enhances the appearance of the iris, limbus, pupil, or other part of the eye (making it appear wider than normal). The ink can include a thickener to enhance its ability to adhere to polymeric materials.

[0012] In another embodiment, a contact lens comprises a lens body including a polymeric material and a lens reinforcement material encapsulated, encased, or surrounded by the polymeric material. The lens reinforcement material can include any of the materials described above, including inks, silicone materials (e.g., silicone polymers, silicone hydrogel materials, etc.), medicinal materials (e.g., drug delivery materials and vitamin delivery materials), and the like.

[0013] In another embodiment, a contact lens comprises a lens body including a polymeric material and an isolated portion of a lens reinforcement material encapsulated in a surrounding polymeric material, the lens reinforcement material being isolated as a physically separate portion to enhance the structural integrity of the contact lens. The lens reinforcement material may be any of the materials described above.

[0014] In one embodiment, the lens body comprises a polymeric material that includes a pattern of isolated portions of silicone material encapsulated in a surrounding polymeric material. The silicone material may include a silicone hydrogel material or silicone polymers. In one embodiment, the silicone material is at least substantially entirely silicone polymers (with little or no hydrogel polymers) to enhance the oxygen permeability of the contact lens.

[0015] The contact lenses can be made using any suitable process. In one embodiment, a method for making a contact lens includes: (1) forming a first lens layer including a first surface, (2) forming a pattern on the first surface of the first lens layer and / or depositing a lens enhancement material on the first surface of the first lens layer, and (3) forming a second lens layer over the pattern or the lens enhancement material.

[0016] The layers can be formed using contact lens manufacturing processes such as centrifugal spin casting, casting molding, and / or spin molding. The first lens layer is desirably formed by pouring a liquid polymeric material into a mold, spinning the polymeric material centrifugally, and partially curing it. The second lens layer can be formed in a similar manner, except that it is fully cured. A printing process, such as a tamp printing process or a liquid jet (e.g., inkjet) printing process, can be used to form the pattern and / or deposit the lens enhancement material.

[0017] The Summary is provided to introduce in a simplified form a selection of concepts that are further described below in the Detailed Description. The Summary and Background are not intended to identify key concepts or essential aspects of the disclosed subject matter, nor should they be used to constrain or limit the scope of the Claims. For example, the scope of the Claims should not be limited based on whether the described subject matter includes any or all aspects referred to in the Summary and / or whether the described subject matter addresses any of the problems referred to in the Background.

[0018] The preferred and alternative embodiments are disclosed in connection with the accompanying drawings, in which like reference numbers indicate similar, but not necessarily identical, elements throughout. The following is a description of the drawings: [Brief description of the drawings]

[0019] [Figure 1] FIG. 1 is a cross-sectional view of one embodiment of a contact lens having visible markings in the peripheral zone. [Diagram 2] 2 is an enlarged view of a portion of the contact lens shown in FIG. 1. [Diagram 3] FIG. 2 is a front view of one of various embodiments of a marking pattern that may be included in the peripheral zone of the contact lens shown in FIG. 1, designed to have the appearance of an iris and / or to enhance the appearance of an iris. [Figure 4] FIG. 2 is a front view of one of various embodiments of a marking pattern that may be included in the peripheral zone of the contact lens shown in FIG. 1, designed to have the appearance of an iris and / or to enhance the appearance of an iris. [Diagram 5] FIG. 2 is a front view of one of various embodiments of a marking pattern that may be included in the peripheral zone of the contact lens shown in FIG. 1, designed to have the appearance of an iris and / or to enhance the appearance of an iris. [Figure 6] FIG. 2 is a front view of one of various embodiments of a marking pattern that may be included in the peripheral zone of the contact lens shown in FIG. 1, designed to have the appearance of an iris and / or to enhance the appearance of an iris. [Figure 7] FIG. 2 is a front view of one of various embodiments of a marking pattern that may be included in the peripheral zone of the contact lens shown in FIG. 1. The markings are designed to enhance the appearance of the iris with Asian script markings. [Figure 8]FIG. 2 is a front view of one of various embodiments of a marking pattern that may be included in the peripheral zone of the contact lens shown in FIG. 1. The markings are designed to enhance the appearance of the iris with Asian script markings. [Figure 9] 2A-2C are front views of different embodiments of marking patterns that may be included in the peripheral zone of the contact lens shown in FIG. 1, including legible lettering disposed over a dark background. [Figure 10] 2A-2C are front views of different embodiments of marking patterns that may be included in the peripheral zone of the contact lens shown in FIG. 1, including legible lettering disposed over a dark background. [Figure 11] 2A-2C are front views of different embodiments of marking patterns that may be included in the peripheral zone of the contact lens shown in FIG. 1, including legible lettering disposed over a dark background. [Figure 12] 2A-2C are front views of different embodiments of marking patterns that may be included in the peripheral zone of the contact lens shown in FIG. 1, including legible lettering disposed over a dark background. [Figure 13] FIG. 2 is a cross-sectional view of one embodiment of a contact lens having a pattern of lens reinforcement material in the peripheral zone. [Figure 14] FIG. 14 is an enlarged view of a portion of the contact lens shown in FIG. 13. [Figure 15] 1 is a cross-sectional view of another embodiment of a contact lens having a pattern of lens reinforcing material in the peripheral zone. [Figure 16] FIG. 16 is an enlarged view of a portion of the contact lens shown in FIG. [Figure 17] FIG. 1 is a cross-sectional view of one embodiment of a contact lens having a pattern of lens reinforcement material in the optic zone. [Figure 18] FIG. 18 is an enlarged view of a portion of the contact lens shown in FIG. 17. [Figure 19]1 is a cross-sectional view of another embodiment of a contact lens having a pattern of lens reinforcement material in the optic zone. [Figure 20] FIG. 20 is an enlarged view of a portion of the contact lens shown in FIG. [Figure 21] 1 is a cross-sectional view of another embodiment of a contact lens having a pattern of lens reinforcement material in the optic zone. [Figure 22] FIG. 22 is an enlarged view of a portion of the contact lens shown in FIG. 21. [Figure 23] 23 is a flow chart of one embodiment of a method for making the contact lenses shown in FIGS. 1-22. [Figure 24] 2A-2C are front views of different embodiments of marking patterns that may be included in the peripheral zone of the contact lens shown in FIG. 1, including legible lettering disposed over a dark background. [Diagram 25] 2A-2C are front views of different embodiments of marking patterns that may be included in the peripheral zone of the contact lens shown in FIG. 1, including legible lettering disposed over a dark background. [Figure 26] 2A-2C are front views of different embodiments of marking patterns that may be included in the peripheral zone of the contact lens shown in FIG. 1, including legible lettering disposed over a dark background. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Contact lenses are disclosed that include various lens strengthening materials. The lens strengthening materials modify one or more properties of the contact lens in a desired manner. Examples of ways in which the lens strengthening materials can modify the contact lens include modifying the appearance of the contact lens and thus the appearance of the eye, modifying the wettability of the contact lens, modifying the oxygen permeability of the contact lens, etc.

[0021] 1 illustrates one embodiment of a contact lens 100 having visible markings 102 forming one or more patterns on the contact lens 100. The contact lens 100 includes a first lens layer 104 and a second lens layer 106, with the markings 102 disposed between layers 104 and 106. Although the markings 102 are shown as being disposed between layers 104 and 106, it should be appreciated that the markings 102 could also be disposed on the convex outer surface of the contact lens 100.

[0022] The combination of layers 104 and 106 and markings 102 form the lens body of contact lens 100. Layers 104 and 106 may be made of the same material or different materials. In one embodiment, layers 104 and 106 are made of the same material, so that contact lens 100 has no discernible boundary layer, either visually or physically. Layers 104 and 106 may be joined together using any suitable method. In one embodiment, layers 104 and 106 are covalently bonded to each other to provide greater internal structural strength to contact lens 100. For example, layers 104 and 106 may be polymerized together.

[0023] In another embodiment, layers 104, 106 are formed of different materials. Layers 104, 106 may still have no discernible boundary layer, either visually or in terms of physical properties. The different materials may provide layers 104, 106 with different properties, making it possible to customize the properties of each surface of contact lens 100.

[0024] Whether layers 104, 106 are made of the same or different materials, it is also feasible to form a discernible boundary layer between layers 104, 106. It is desirable that the boundary layer not interfere with the visual clarity of contact lens 100.

[0025] The first lens layer 104 and the second lens layer 106 can be made of any material suitable for use in contact lenses. For example, layers 104, 106 can be made of any silicone and / or hydrogel material. Layers 104, 106 can be made of any number of suitable polymers, including, but not limited to, low water content (<50% water), non-ionic hydrogel polymers such as tefilcon, tetrafilcon A, crofilcon, helfilcon A and B, mafilcon, polymacon, and hioxifilcon B. Low water content non-ionic silicone hydrogel polymers include lotrafilcon A, lotrafilcon B, galyfilcon A, senofilcon A, sifilcon A, comfilcon A, and enfilcon A. High water content (>50% water) non-ionic hydrogel polymers include lidofilcon B, surfilcon A, lidofilcon A, alfafilcon A, omafilcon A, vasurfilcon A, hyoxifilcon A, hyoxifilcon D, nelfilcon A, hilafilcon A, and acofilcon A. Low water content ionic hydrogel polymers include bufilcon A, deltafilcon A, and phemfilcon A. Low water content ionic silicone hydrogel polymers include balafilcon A.High water content ionic hydrogel polymers include bufilcon A, perfilcon, etafilcon A, focofilcon A, ocufilcon B, ocufilcon C, ocufilcon D, ocufilcon E, ocufilcon F, femfilcon A, methafilcon A, methafilcon B, and vilfilcon A.

[0026] These materials include various combinations of monomers, polymers, and other materials that form the final polymer. For example, common components of these materials include HEMA, HEMA-GMA, etc.

[0027] In one embodiment, layers 104, 106 are made at least substantially entirely of hydrogel polymers that do not include any silicone, which may be desirable to enhance the wettability of contact lens 100. In another embodiment, layers 104, 106 are made of a silicone hydrogel material.

[0028] In one embodiment, layers 104, 106 are configured such that the inner surface 108 and outer surface 110 of contact lens 100 are made mostly or completely of hydrogel polymers. In this configuration, the hydrophilic hydrogel polymers contact the surface of the eye and the back of the eyelid, rather than the hydrophobic silicone polymers. Although layers 104, 106 may still contain silicone polymers, silicone polymers are not present on surfaces 108, 110 of contact lens 100.

[0029] The first lens layer 104 and the second lens layer 106 can be shaped and sized based on various factors including the shape and size of the user's eye and various optical properties desired to be achieved by the contact lens. In some embodiments, the lens layer 104, the lens layer 106 each have a thickness of about 0.01 mm to about 0.09 mm. The total thickness of the contact lens 100 can be about 0.1 mm to about 0.14 mm. The thickness of the lens layer 104, the lens layer 106 may vary at different locations of the contact lens 100. For example, the second lens layer 106 may be thicker near the outer edge of the contact lens 100 than the optical zone, as shown in FIG. 1.

[0030] The layers 104, 106 may have different thicknesses such that one layer 104, 106 is thicker or thinner than the other layer 104, 106. For example, the first lens layer 104 in FIG. 1 is substantially thinner than the second lens layer 106. This allows the marking 102 to be positioned closer to the outer surface 110 of the contact lens 100. It should be appreciated that either layer 104, 106 can have any desired thickness or thickness profile.

[0031] The first lens layer 104 includes a first surface 112 (alternatively referred to as the first lens surface) disposed opposite a second surface, which is the exterior surface 110 of the contact lens 100. The first surface 112 may have a concave shape and generally serves as the surface on which the markings 102 of the first lens layer 104 are formed.

[0032] The second lens layer 106 includes a first surface 114 disposed opposite the second lens surface, which is the inner surface 108 of the contact lens 100. The first surface 114 may have a convex shape corresponding to the first surface 112 of the first lens layer 104, such that the markings 102 on the first surface 112 are encapsulated when the two layers 112 and 114 are brought together. The layers 112, 114 may be formed in a manner that eliminates any gaps or voids in the contact lens 100.

[0033] It should be appreciated that contact lens 100 can include additional layers. For example, one lens reinforcement material can be disposed between layers 104 and 106, and another lens reinforcement material can be disposed between lens 106 and a third lens layer (not shown). A first lens reinforcement material can be marking 102 and a second lens reinforcement material can be a medicinal material.

[0034] The markings 102 are configured to be visible to a third party observer when the contact lens 100 is in the user's eye. The markings 102 may modify and / or enhance the appearance of the user's eye. The markings 102 may be used to modify or enhance the appearance of the user's iris, limbus, pupil, etc. For example, the markings 102 may be used to change the color of the user's eyes.

[0035] 3-8 show various embodiments of the markings 102 that are configured to have the appearance of an iris and / or to enhance the appearance of an iris. The markings 102 may be black and white, but are preferably in color. For example, the markings 102 in FIG. 5 may have different shades of green, such that a user wearing the contact lens 100 has green eyes. Similarly, the markings 102 in FIG. 6 may be different shades of magenta, which can change the user's eye color to red.

[0036] 7-8 show one embodiment of a contact lens 100 configured to enhance the appearance of the iris with markings 102 that resemble Asian script characters that are placed over a solid background. The script characters extend beyond the area where the solid background ends toward the optical zone of the contact lens 100.

[0037] It should be noted that in some embodiments, the markings 102 are generally restricted to the peripheral zone of the contact lens 100 to avoid interfering with the vision of the wearer. For example, the markings 102 may be arranged circumferentially around the peripheral zone of the contact lens 100. This may be a desirable configuration when the lens reinforcement material is visible to a third party observer, whereas in other situations where the lens reinforcement material is transparent, it may be located in the peripheral zone or the optical zone, or both.

[0038] In one embodiment, the marking 102 forms a plurality of legible characters 116 on the contact lens 100. The legible characters 116 can include letters, numbers, symbols, and geometric shapes. The size, format, and orientation of the characters are virtually unlimited. The color of the characters is likewise unlimited, and in some embodiments, the legible characters 116 include multiple colors.

[0039] In one embodiment, the legible characters 116 are legible written characters in English, Japanese, Chinese, Korean, or any other language. The legible characters 116 may be configured to form at least one or more words. For example, the legible characters 116 may form at least a two word phrase, such as "I Love You," "See Me," or "Imagine Me."

[0040] The legible lettering 116 is visible to a third party observer when the contact lens 100 is in the eye of the user. The lettering 116 may be visible and legible to a third party observer with normal vision (20 / 20) at a distance of approximately 7 cm to approximately 120 cm. The lettering 116 may be visible and legible to a third party observer with normal vision at a distance of approximately 7 cm, approximately 15 cm, approximately 23 cm, approximately 30 cm, approximately 45 cm, approximately 2 feet (60.96 cm), approximately 60 cm, or approximately 120 cm.

[0041] 9-12 show various embodiments of a contact lens 100 having legible characters 116. The legible characters 116 form the words "I Love You" in Figs. 9-10 and the words "See me...Imagine me" in Figs. 11-12. The legible characters 116 are arranged circumferentially in the peripheral zone of the contact lens 100. The characters 116 are arranged over a color background that matches the color of the characters. Similarly, Figs. 24-26 depict various embodiments of a contact lens 100 having legible characters 116. The legible characters 116 form the words "Feel Me Imagine Me" in Fig. 24, the characters "I, RO, HA" and the word and pattern "magic" including a texture gradient that is arranged circumferentially in the peripheral zone of the contact lens 100. The characters 116 are arranged over a color background that matches the color of the characters.

[0042] The markings 102 may be made using any suitable technique. In one embodiment, the markings 102 are made by depositing ink on the first surface 112 of the first lens layer 104. Although the markings 102 are shown in Figures 1-2 as a continuous layer, it should be appreciated that the actual cross-sectional configuration of the markings 102 will depend on the desired design.

[0043] It should be appreciated that the markings 102 may be formed of any ink suitable for use with contact lenses. Suitable inks include, but are not limited to, those commercially available from Unicorn (Taiwan) Chemical Co. Ltd. Additional inks can be found in U.S. Patents 6,731,408 (Bensky et al.), 5,713,963 (Bensky), and 7,354,959 (Tucker et al.), which are incorporated herein by reference. In some embodiments, the ink is of a type that is incorporated into the material of the first lens layer 104 and / or the second lens layer 106.

[0044] A thickener may be added to the ink to modify the viscosity and to prevent the ink from running after it is formed on the first lens layer 104. Any thickener that is safe for use with contact lenses and improves the viscosity of the ink may be used. In one embodiment, the thickener may be polyethylene glycol and / or glycerol.

[0045] The ink may have any suitable viscosity that allows the ink to remain in place after being deposited on the first surface 112 of the first lens layer 104. In one embodiment where a pad or tamp printing method is used, the ink has a viscosity of about 1.0 Pa·s to about 1.8 Pa·s, preferably about 1.4 Pa·s. According to yet another exemplary embodiment, the ink may have a viscosity of less than 1.0 Pa·s if an inkjet or other printing methodology is used.

[0046] The thickness of the markings 102 formed on the first lens layer 104 may vary anywhere from approximately 2 microns to approximately 120 microns. According to one embodiment, the thickness of the markings 102 formed on the first lens layer 104 may vary anywhere from approximately 5 microns to approximately 20 microns. The thickness of the markings 102 may be uniform or variable across the contact lens 100.

[0047] 13 shows another embodiment of a contact lens 120 in which the lens enhancing material includes a silicone material 122 that forms a pattern on the contact lens 120. The presence of the silicone material means that the contact lens 120 may be considered a silicone hydrogel contact lens. The silicone material 122 increases the oxygen permeability of the contact lens 100, making it more comfortable for the user to wear for extended periods of time.

[0048] Contact lens 120 includes many of the components shown in connection with contact lens 100 of Figures 1-2. The same numbers are used to designate similar components. It should be recognized that components designated as similar in Figures 13-22 are not required to be the same as components in Figures 1-2, although they can be.

[0049] The combination of layers 104, 106 and silicone material 122 form the lens body of contact lens 120. Silicone material 122 may be any suitable material. In one embodiment, silicone material 122 is at least substantially entirely composed of silicone polymers without any hydrogel polymers. This configuration maximizes the oxygen permeability of contact lens 120. It should be appreciated that silicone material 122 may further include a combination of silicone polymers and hydrogel polymers in varying amounts.

[0050] Layers 104, 106 may be made of any of the materials described above, although it should be noted that exterior surface 110 and interior surface 108 are preferably made primarily of hydrogel polymers to enhance the wettability of contact lens 120, particularly those portions of contact lens 120 that contact the eye and / or eyelid.

[0051] The silicone material 122 is arranged in a pattern of isolated portions encapsulated within the surrounding polymeric material of layers 104, 106. The isolated portions allow layers 104, 106 to contact and bond together between the portions. This configuration provides greater structural strength to the contact lens 120. Note that the gaps between the portions are filled by the second lens layer 106 as it bonds to the first lens layer 104.

[0052] In one embodiment, the isolated portions of silicone material 122 are not covalently bonded to the surrounding polymeric material forming layers 104, 106. In other embodiments, the isolated portions may be covalently bonded to the surrounding polymeric material. If silicone material 122 is covalently bonded to layers 104, 106, it could also be provided as a separate layer.

[0053] 15-22 show further embodiments of the contact lens 120. One thing these figures show is that the portions may be of any suitable size and the portions may be arranged in any suitable manner. In one embodiment, the silicone material 122 is arranged in a uniform grid with the portions all being roughly the same size. In another embodiment, the silicone material 122 is arranged in portions of varying sizes and positions across the contact lens 120.

[0054] The thickness of the silicone material 122 may also vary widely. For example, the silicone material in Figures 13-14 is relatively thin compared to the thickness of the contact lens 120, while the silicone material in Figures 15-16 is relatively thick compared to the thickness of the contact lens 120.

[0055] It is generally desirable to make the silicone material 122 as thick as possible to increase oxygen permeability and promote eye health, which necessarily dictates that it is desirable to minimize the thickness of the polymeric material between the silicone material 122 and the exterior surface 110 and the interior surface 108. In one embodiment, the polymeric material between the silicone material 122 and each of the surfaces 108, 110 is 0.001 mm or less in thickness, 0.002 mm or less in thickness, 0.005 mm or less in thickness, 0.01 mm or less in thickness, 0.02 mm or less in thickness, 0.03 mm or less in thickness, or 0.04 mm or less in thickness.

[0056] It should be appreciated that the silicone material 122 can be disposed in the peripheral zone and / or the optic zone of the contact lens 120. Figures 13-16 illustrate embodiments in which the silicone material 122 is placed in the peripheral zone of the contact lens 120, while Figures 17-22 illustrate embodiments in which the silicone material 122 is disposed in the optic zone of the contact lens 120. It should be appreciated that the silicone material 122 can also be disposed in both the peripheral zone and the optic zone of the contact lens 120.

[0057] It should be appreciated that additional embodiments of contact lenses may be produced that utilize different lens enhancing materials, such as medicinal agents, etc. The medicinal agents may be deposited on the first lens layer 104 in the same manner as the markings 102 and / or silicone material 122. The medicinal agent and / or the polymeric material surrounding the medicinal agent may be configured to provide a desired release rate to provide a therapeutic effect to the user's eye.

[0058] A method of making contact lenses having a pattern of legible characters formed thereon is also described below. The method is generally shown in Figure 23. The method begins with forming a first lens layer having a first lens surface at step 130. At step 132, a pattern of lens reinforcement material is formed and / or a lens reinforcement material is deposited on the first surface. At step 134, a second lens layer is formed over the lens reinforcement material on the first surface.

[0059] It should be appreciated that the result of this method is to encapsulate or encase the lens reinforcement material between the first and second lens layers, which helps to protect the lens reinforcement material and also helps to impart desirable properties to the lens reinforcement material, for example, the lens reinforcement material includes a silicone material that enhances oxygen permeability.

[0060] At step 130, the first lens layer will be formed using any suitable process. Examples of suitable processes include centrifugal spin casting, cast molding, and / or turning. In one embodiment, the first lens layer is formed using a mold and centrifugal spinning and curing techniques. A liquid polymer material is poured into the mold, centrifugally spun, and cured to form the first lens layer. The spinning and curing steps are partial such that the first lens layer is not completely cured upon completion of step 130.

[0061] The mold used to form the first lens layer can be any mold suitable for use in forming contact lenses. In one embodiment, the mold is laser etched to impart the desired optical properties to the final contact lens. The mold can be designed and shaped in any of a variety of ways to achieve the desired optical properties for the final contact lens product.

[0062] The amount of liquid polymeric material poured into the mold is generally not limited and may be adjusted based on the desired final properties of the contact lens, including physical properties such as thickness and various optical properties.

[0063] The polymeric material can be any of the materials described above in connection with layers 104, 106. In one embodiment, the polymeric material used to form the first lens layer is at least substantially entirely hydrogel polymers such as HEMA-GMA, in another embodiment, the polymeric material may include a silicone hydrogel material.

[0064] The spinning and curing steps may be varied based on the desired properties of the final contact lens. For example, it is generally desirable to cure the first lens layer sufficiently so that it can support the lens reinforcement material, but not so much that it cannot properly bond to the second lens layer when the second lens layer is added. This can be accomplished by partially curing the lens material to a gel point, allowing crosslinks to form within the partially cured monomers at that stage.

[0065] In one embodiment, the first lens layer is formed from a non-uniform stack of other materials. The different materials can form separate and distinct domains in the first lens layer. In one embodiment, the non-uniform stack is three-dimensional in nature, meaning that the domains are non-uniform in all three directions.

[0066] A pattern is formed on the first surface of the first lens layer at step 132. The manner in which the pattern is formed on the first lens layer is generally not limited and may include any printing method suitable for use in printing contact lenses. Exemplary printing techniques include, but are not limited to, pad printing, copperplate printing, etchant printing, dot matrix printing, dye sublimation and a carrier sheet (laser printing) and a photoreceptor that is then subjected to laser processing.

[0067] In one embodiment, the printing method is a tamp printing technique. The tamp printing technique is a form of pad printing in which a laser etched pad is used to transfer the lens enhancing material to the first surface of the first lens layer. The pad taps a reservoir of the lens enhancing material (e.g., ink) before each tap onto the first surface. Machines capable of printing in this manner are available from TAMPOPRINT, Germany.

[0068] In another embodiment, the lens enhancing material is printed onto the first lens layer using a liquid jet printing system, in one embodiment the liquid is ink and the printing system is an inkjet printing system, while in another embodiment the liquid may include a silicone material.

[0069] A second lens layer is formed over the pattern in step 134. The second lens layer is formed in such a way that the pattern and / or lens enhancement material is sandwiched between or encapsulated by the first and second lens layers.

[0070] In one embodiment, step 134 is performed in a similar or identical manner to step 130 to form the first lens layer, and includes pouring a liquid polymeric material into a mold and centrifugally spinning it and curing it to form the second lens layer. Other techniques known to those skilled in the art can also be used to form the second lens layer.

[0071] Note that the liquid polymer material fills in any gaps between the lens reinforcement materials, which in practice means that the second lens layer includes polymer material disposed between the lens reinforcement materials.

[0072] In one embodiment, the same mold is used to form the first and second lens layers. Alternatively, separate molds may be used. The mold may be any mold suitable for use in forming contact lenses.

[0073] The amount of liquid polymer material poured into the mold is generally not limited and may be adjusted based on the desired final properties of the contact lens, including physical properties such as thickness and various optical properties. In many situations, the second lens layer requires additional polymer material to fill any gaps between the lens reinforcement materials and / or to provide a thicker layer than the first lens layer (FIG. 1).

[0074] The material used to form the second lens layer may be the same as or different from the material used to form the first lens layer. Any of the above materials may be used to form the second lens layer. In one embodiment, the second lens layer is at least substantially entirely made of hydrogel polymers. In another embodiment, the second lens layer includes a silicone hydrogel material.

[0075] In some embodiments of the contact lenses and manufacturing methods described herein, the edge blur (myopia) of the contact lens can be controlled by lens enhancement materials, which may be applied in a manner that uses diffractive optics and / or creates a peripheral aspheric surface to achieve this result.

[0076] Terms recited in the claims are to be given their ordinary and customary meanings, as determined by reference to the relevant entries in a commonly used general dictionary and / or related art dictionary, as generally understood by one of ordinary skill in the art, and the like, with the understanding that the broadest meaning given to the claim terms by any one or any combination of such sources (e.g., two or more relevant dictionary entries are to be combined to provide the broadest meaning of the combination of the entries, etc.), except where (a) a term is used in a manner that is more expansive than its ordinary and customary meaning, the element shall be given a meaning equal to its ordinary and customary meaning plus the additional expanded meaning, or (b) a term has been expressly defined to have a different meaning by reciting the term following the phrase "as used herein, shall mean" or similar phrase (e.g., "herein, the term means," "as defined herein," "for purposes of this disclosure, the term shall mean," etc.).

[0077] The references to specific examples, the use of "i.e.," the use of the word "invention," etc. are not intended to invoke exception (b) or to limit the scope of the claim terms as they are recited. Nothing contained herein should be construed as a disclaimer or negation of the scope of the patent other than those circumstances in which exception (b) applies.

[0078] The subject matter recited in the claims is not, and should not be construed as, coextensive with any particular embodiment, feature, or combination of features disclosed herein, even if only a single embodiment of that particular feature or combination of features is shown and described herein, and the appended claims should be given their broadest interpretation in light of the prior art and the meaning of the claim terms.

[0079] As used herein, spatial or directional terms such as "left," "right," "front," "rear," and the like, refer to the subject matter as depicted in the drawings, although it is to be understood that the subject matter being described may be in a variety of orientations, and thus such terms should not be considered limiting.

[0080] The English articles "the," "a," or "an" can imply singular or plural. Furthermore, the word "or" should be construed as inclusive (e.g., "x or y" means either x or y, or both) when used without the antecedent "either" (or other similar phrases that clearly suggest that "or" is meant to be exclusive, e.g., only x or y).

[0081] The term "and / or" should also be construed as inclusive (e.g., "x and / or y" means either x or y, or both). When "and / or" or "or" is used as a conjunction with respect to a group of three or more items, the group should be construed as including one item alone, all of the items together, or any combination of or any number of the items. Additionally, as used in the specification and claims, terms such as "have," "having," "include," and "including" should be considered synonymous with the terms "comprise" and "comprising."

[0082] Unless otherwise noted, all numbers and expressions used in this specification (other than the claims) such as expressing dimensions, physical characteristics, and the like, are understood to be modified in all instances by the term "approximately." As a minimum, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims using the term "approximately" should be construed in light of at least the number of significant digits recited or by applying ordinary rounding techniques.

[0083] All ranges disclosed herein should be understood to encompass any and all subranges therein or any and all individual values ​​subsumed therein, with the claims providing support as though the subranges or individual values ​​were recited. For example, a recited range of 1 to 10 should be considered to include any and all subranges or individual values ​​between and / or including a minimum value of 1 and a maximum value of 10, i.e., all subranges starting at or above the minimum value of 1 and ending at or below the maximum value of 10 (e.g., 5.5 to 10, 2.34 to 3.56, etc.) or any value between 1 and 10 (e.g., 3, 5.8, 9.9994, etc.), with the claims providing support as though the subranges or individual values ​​were recited. [Explanation of symbols]

[0084] 100 Contact Lenses 102 Visible Markings 104 First lens layer 106 Second lens layer 108 Inner surface of contact lens, second surface of second lens layer 110 Outer surface of contact lens, second surface of first lens layer 112: First surface of first lens layer 114: First surface of second lens layer 116 legible characters 120 Contact Lenses 122 Silicone Materials

Claims

1. forming a first lens layer including a first surface; forming a pattern of a plurality of isolated portions on the first surface of the first lens layer by depositing a lens enhancing material on the first surface; forming a second lens layer over the lens reinforcement material; Including, the lens reinforcement material is made of a silicone hydrogel material; A method of making a contact lens, wherein the first lens layer and the second lens layer are comprised of a non-silicone hydrogel material.

2. The method of claim 1 , wherein forming the first lens layer and / or the second lens layer comprises molding, casting, and / or turning a non-silicone hydrogel material.

3. The method of claim 1 , wherein forming the first lens layer and / or the second lens layer comprises at least partially curing a liquid non-silicone hydrogel material.

4. 10. The method of claim 1, wherein forming the first lens layer comprises pouring a liquid non-silicone hydrogel material into a mold and partially centrifuging and curing the liquid non-silicone hydrogel material. method.

5. 5. The method of claim 4, wherein forming the second lens layer comprises pouring a liquid non-silicone hydrogel material over the pattern on the first lens layer and centrifugally spinning the liquid non-silicone hydrogel material to harden.

6. The method of claim 1 , wherein the first surface is a concave inner surface of the first lens layer.

7. The method of claim 1 , wherein the lens enhancing material comprises a medicinal material.

8. The method of claim 7, wherein the dressing material comprises a drug and / or vitamin delivery material. Law.

9. wherein the depositing step includes printing the pattern on the first surface. The method according to claim 1.

10. The method of claim 9 , wherein the printing step comprises tamp printing the pattern onto the first surface.

11. The method of claim 1 , wherein the pattern is formed in a peripheral zone of the first lens layer.

12. The method of claim 1 , wherein the pattern is formed in an optical zone of the first lens layer.

13. a lens body configured to be worn directly on the surface of the eye, the lens body being made of a non-silicone hydrogel material; a lens reinforcement material encapsulated in the non-silicone hydrogel material; A contact lens, wherein the lens reinforcement material includes a plurality of isolated portions of a silicone hydrogel material.

14. The contact lens of claim 13, wherein the lens strengthening material comprises a medicinal material.

15. 15. The method of claim 14, wherein the dressing material includes a drug and / or vitamin delivery material. Contact lens.

16. 1. A contact lens comprising a lens body adapted for direct fit to an eye surface, the lens body being comprised of a non-silicone hydrogel material having encapsulated therein a pattern of a plurality of isolated portions of a silicone material; A contact lens, wherein the silicone material comprises a silicone hydrogel.

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