Embedded Contact Lens Assembly for Precise Insert Alignment
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Solution Overview
Problem
Existing systems for manufacturing hybrid contact lenses with embedded lens elements are inefficient, require complex equipment, produce surface discontinuities, and lack precise placement, leading to performance issues and user discomfort.
Innovation Solution
An automated system utilizing computer vision, optical gauges, and precise actinic curing to accurately position and embed lens elements within contact lenses, ensuring high concentricity and surface continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If voxel-based lithography, 3-D printing, or lathe cutting is used to form embedded lens elements, then the embedded elements can be created with precise geometry, but the manufacturing process becomes complex and unsuitable for high-volume automated production
Solution Approach 1:
The manufacturing process is segmented into distinct automated stages: insert placement on the front curve, mold closure, and curing. This segmentation allows each stage to be optimized independently for automation while maintaining precision, resolving the contradiction between precision and complexity.
Solution Approach 2:
Traditional mechanical machining methods (lathe cutting, 3-D printing) are replaced with a mold-based assembly process where precision is achieved through automated placement and curing rather than complex mechanical fabrication, reducing device complexity while maintaining manufacturing precision.
2Manufacturing precision
If post structures are used on the front curve to support the insert during molding, then the insert can be positioned during manufacturing, but holes or material discontinuities are left on the lens surface that cause bacteria growth and user discomfort
Solution Approach 1:
The support structures (posts) are extracted from the final lens design. Instead of leaving permanent support posts on the lens surface, the process uses temporary support during manufacturing that is removed or avoided in the final product, eliminating surface discontinuities while maintaining positioning precision through alternative means.
Solution Approach 2:
The insert is placed and secured on the front curve before mold closure. This preliminary positioning action ensures accurate insert placement without requiring permanent support structures in the final lens, thereby avoiding surface discontinuities that would cause harmful effects.
3Manufacturing precision
If traditional manufacturing processes are used to achieve precise placement of embedded elements, then concentricity can be improved, but production speed decreases and automation becomes difficult
Solution Approach 1:
Complex mechanical positioning systems are replaced with an automated process using optical alignment and UV curing. The front curve with its optical zone provides natural alignment references, and UV curing rapidly secures the insert position, achieving high concentricity without sacrificing production speed or automatability.
Solution Approach 2:
The process changes from mechanical adjustment to optical-parameter-based alignment using the front curve's optical zone as a reference. This parameter change enables automated positioning with high precision while maintaining fast production cycles suitable for high-volume manufacturing.
4Manufacturing precision
If manual or semi-automated processes are used for insert placement, then positioning accuracy can be monitored and adjusted, but production volume is limited and costs increase
Solution Approach 1:
Manual monitoring and adjustment mechanisms are replaced with automated UV curing. The optical alignment is performed automatically using the front curve's optical zone as a reference, and UV curing rapidly secures the insert position without requiring manual intervention, enabling high-volume production while maintaining precision.
Solution Approach 2:
The manufacturing process achieves continuity by combining automated insert placement, optical alignment, and UV curing in a seamless flow. This continuous automated process eliminates manual intervention steps, enabling high production volume while maintaining consistent placement accuracy throughout production.
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 system enables efficient, automated production of hybrid contact lenses with embedded elements, achieving high production yields and eliminating surface discontinuities, thereby improving lens performance and user comfort.
Implementation Method 1
the lens forming material is actinically cured (i.e., cured by using UV and/or visible light) to fix the positioned lens insert in place within the mold
Data Source
AI summary
A system and method for automated production of a hybrid lens product comprising a lens insert embedded within a lens body. The system preferably includes a first carrier for holding at least one first mold half, a second carrier for holding at least one lens insert, and a third carrier for holding at least one second mold half. The system preferably also includes an automated movement enabling pick-and-place subassembly for positioning a lens insert within a first mold half, and for engaging a second mold half with a first mold half.