Contact Lens Voxel Polymerization for Fiducial Mark Integration
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Solution Overview
Problem
Existing methods for incorporating fiducial marks and other cosmetic or functional features into contact lenses are costly, complex, and negatively affect the structural integrity and optical quality of the lenses, often compromising patient comfort.
Innovation Solution
A method involving the use of two distinct Reactive Mixtures, where the first Mixture is selectively polymerized to form lens features like fiducial markers or patterns on a Voxel by Voxel basis, and then covalently bonded with a second Mixture to create a continuous lens structure, eliminating the need for additional manufacturing steps and ensuring optical quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fiducial marks are separately placed or encapsulated within the lens, then lens features can be incorporated, but the structural integrity of the lens layers is negatively affected
Solution Approach 1:
The patent merges the lens feature incorporation process with the lens manufacturing process itself. Fiducial marks and other features are created during the casting process by modifying the mold cavity, rather than being added separately. This integration ensures that features become an inherent part of the lens structure, maintaining structural integrity while achieving feature incorporation.
Solution Approach 2:
The patent applies preliminary action by pre-configuring the mold cavity with the desired lens features before the casting process. The mold cavity is designed to include recesses or protrusions that correspond to the desired fiducial marks or other features, so that when the lens material is cast, these features are automatically formed as part of the lens structure, eliminating the need for post-manufacturing modifications.
2Adaptability or versatility
If additional manufacturing steps are used to place markings on the lens, then lens features can be incorporated, but the cost and complexity of manufacturing increases
Solution Approach 1:
The patent combines multiple functions into a single manufacturing step. The mold cavity is designed to simultaneously form the lens optical surfaces and incorporate fiducial marks or other features during the same casting process. This eliminates the need for separate marking or feature incorporation steps, reducing manufacturing complexity and cost.
Solution Approach 2:
The mold cavity serves multiple functions: it forms the optical surfaces of the lens, creates fiducial marks, and incorporates other lens features all in one operation. This multi-functionality of the mold design eliminates the need for multiple specialized manufacturing steps, simplifying the overall manufacturing process.
3Adaptability or versatility
If markings are placed on the surface of the lens, then lens features can be incorporated, but the optical quality surface is adversely affected
Solution Approach 1:
The patent applies local quality by positioning fiducial marks and other features in specific locations that do not interfere with the optical quality surface. Features are placed in peripheral areas or on surfaces that are not critical for optical performance, while the central optical zones maintain their high-quality smooth surfaces necessary for vision correction.
Solution Approach 2:
The patent segments the lens surface into different functional zones: optical quality zones for vision correction and non-optical zones for fiducial marks or cosmetic features. This segmentation allows each zone to be optimized for its specific function, with optical zones maintaining high precision surfaces and feature zones accommodating markings without compromising overall optical quality.
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 allows for cost-effective integration of lens features without compromising the structural integrity or optical quality, enhancing patient comfort and reducing manufacturing complexity.
Implementation Method 1
the first polymerized Reactive Mixture and the second polymerized Reactive Mixture are covalently bonded
Implementation Method 2
selectively projecting actinic radiation through the optic mandrel and into a vat or bath of a Reactive Mixture
Data Source
AI summary
A Free-form contact lens and method of making the same. The lens includes a posterior optical quality surface having a concave shape, an opposing anterior surface having a convex shape both of which join at a lens edge that defines an outer periphery of the contact lens, and at least a first lens feature having a predetermined shape and made of a first polymerized Reactive Mixture. The remainder of the lens is made of a second polymerized Reactive Mixture that is different than the first polymerized Reactive Mixture, and that is covalently bonded thereto.