Accommodating Intraocular Lens Plasma Bonding for Material Optimization

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Solution Overview

Problem

Existing manufacturing methods for accommodating intraocular lenses (AIOLs) restrict material selection by requiring a single material for both optical and non-optical components, limiting the ability to optimize properties such as optical clarity, tensile strength, and tear resistance.

Innovation Solution

The method involves molding individual components with different functional properties and bonding them together using plasma activation without adhesives, allowing for the use of optically clear materials for the optical components and non-optically clear materials for the peripheral components, which are then plasma bonded to form a lens capsule with an internal chamber.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single material is used for both optical and non-optical components, then manufacturing is simplified, but material properties such as optical clarity, tensile strength, and tear resistance cannot be optimized for each component

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmaterial property optimization

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The intraocular lens is divided into multiple components: optical components (optic, optical zone) and non-optical components (peripheral structure, haptics). Each component can be manufactured from different materials optimized for its specific function, allowing the optical zone to use highly transparent materials while the peripheral structure uses materials with superior mechanical properties like tensile strength and tear resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the lens are assigned different material properties based on their functional requirements. The optical zone uses materials optimized for optical clarity and transparency, while the peripheral structure and haptics use materials optimized for mechanical strength, flexibility, and biocompatibility. This local differentiation of material quality resolves the contradiction between manufacturing simplicity and material optimization.

Inventive Principle:

Principle #3Local quality

2Strength

If adhesive bonding is used to join components, then bonding strength is improved, but residual monomers from adhesive curing may cause inflammation or foreign body reaction in the eye

Engineering Contradiction:

Improvebonding strengthVSAvoidbiocompatibility and inflammation risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces chemical bonding (adhesive curing) with physical bonding methods. Specifically, it uses plasma treatment to activate surface groups on the components, enabling covalent bonding without requiring adhesive monomers. This substitution eliminates the harmful residual monomers while maintaining strong bonding between components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The bonding process parameters are changed from chemical (adhesive composition, curing conditions) to physical (plasma treatment parameters, surface activation energy). This parameter change enables bonding without introducing biocompatibility issues associated with adhesive chemicals, while still achieving sufficient bond strength for implantation.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If larger incisions are made for lens insertion, then ease of implantation is improved, but recovery time and patient discomfort increase

Engineering Contradiction:

Improveease of implantationVSAvoidrecovery time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The lens is segmented into multiple components that can be manufactured to smaller sizes and assembled after insertion. This allows the complete lens structure to be delivered through a small incision, reducing surgical trauma and accelerating patient recovery while maintaining the functional integrity of the full lens system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multi-component lens structure allows for nested or compact packaging of components before insertion. The components can be delivered in a collapsed or compressed state through the incision and then expanded or assembled to their full functional configuration, enabling small incision implantation without sacrificing the overall lens size or functionality.

Inventive Principle:

Principle #7Nested doll (Nesting)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables tailored material properties for each component, improving optical quality, reducing straylight and edge glare, and allowing for smaller incision sizes during implantation, while maintaining a secure and uniform bond.

Implementation Method 1

activating surfaces of the optical component and surfaces of the second component in a plasma chamber

Methodology Applied

Scientific EffectPlasma activation: Plasma

Data Source

PatentUS20250222668A1Accommodating intraocular lenses and methods of making same

Publication Date: 2025.07.10 FORSIGHT VISION6 INC

AI summary

A method of manufacturing an accommodating intraocular lens including molding an optical component having at least a central portion formed of an optically clear silicone material; molding a second component, the second component comprising a silicone material; activating surfaces of the optical component and surfaces of the second component in a plasma chamber; and covalently bonding together without adhesive the optical component and the second component to form a lens capsule having an internal chamber.