Contact Lens Internal Cavity via Soluble Insert Dissolution
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Solution Overview
Problem
Existing contact lens manufacturing methods are complex and inefficient, particularly for accommodating lenses with internal fluidic structures, which are difficult to produce and often result in less than ideal optical performance and increased cost due to embedded modules that provide non-ideal resistance and complexity.
Innovation Solution
A soft contact lens with an internal cavity formed by dissolving a soluble insert material, allowing for a dynamic change in shape with reduced pressure and fewer manufacturing steps, using a hydrogel material that inhibits expansion and allows for fluid exchange, enabling improved optical performance and easier production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If embedded modules are used to create internal fluidic structures in contact lenses, then the lens can achieve accommodating functionality, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The patent removes the complex embedded module structure and replaces it with a simpler internal cavity formed by dissolving a soluble insert material. This extraction of the problematic element (embedded module) and replacement with a simpler structure (dissolved insert cavity) directly reduces manufacturing complexity while maintaining the fluidic chamber functionality needed for accommodation.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: forming the lens with a soluble insert, allowing selective dissolution of the insert to create the cavity, and subsequent hydration. This segmentation allows each step to be optimized independently and simplifies the overall process compared to embedding complex modules.
2Adaptability or versatility
If embedded modules are used in contact lenses, then internal fluidic structures can be created, but manufacturing cost increases
Solution Approach 1:
The patent uses a soluble insert material that is inexpensive and temporarily present only during manufacturing. This disposable-like insert is dissolved after serving its purpose of defining the cavity shape, eliminating the need for expensive, durable embedded modules and reducing manufacturing cost.
Solution Approach 2:
The soluble insert acts as an intermediary tool during manufacturing that defines the cavity geometry. It is not part of the final product but serves as a temporary mold that is dissolved away, replacing the need for expensive embedded fluidic modules.
3Productivity
If conventional manufacturing methods are used for accommodating lenses, then lenses can be produced, but optical performance is less than ideal
Solution Approach 1:
The patent changes the physical-chemical parameters of the lens material by using hydrogel with specific cross-linking density and water content. These parameter changes enable the lens to achieve optimal optical performance while maintaining the simplified cavity structure formed by the soluble insert method.
Solution Approach 2:
The patent employs composite material structures combining hydrogel with specific properties and the soluble insert material. This composite approach allows optimization of both the optical properties and the cavity formation, achieving superior optical performance compared to conventional methods.
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
The solution enables contact lenses that change shape easily with minimal pressure, reducing manufacturing complexity and cost, while providing enhanced optical performance and hydration, with the ability to correct vision and potentially incorporate therapeutic agents or sensors.
Implementation Method 1
A soft contact lens with an internal cavity formed by dissolving a soluble insert material
Implementation Method 2
The cross-linked polymer allows water to diffuse in and out of the contact lens body to the cavity from an external surface of the body
Implementation Method 3
using a hydrogel material that inhibits expansion and allows for fluid exchange
Data Source
AI summary
A lens comprises an internal cavity structure formed by dissolution of a soluble insert material. The internal soluble material may dissolve through a body of a lens such as a contact lens in order to form the cavity within the contact lens. The cavity within the lens can be shaped in many ways, and corresponds to the shape of the dissolved material, such that many internal cavity shapes can be readily fabricated within the contact lens. The insert can be placed in a mold with a pre-polymer material, and the pre-polymer material cured with the insert placed in the mold to form the lens body. The polymerized polymer may comprise a low expansion polymer in order to inhibit expansion of the lens when hydrated. The polymer may comprise a hydrogel when hydrated. The soft contact lens material comprises a sufficient amount of cross-linking to provide structure to the lens and shape the cavity.