EDM Wire-Cut IOL Mold Inserts for Controlled Surface Roughness
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Solution Overview
Problem
Existing methods for forming intraocular lenses (IOLs) are time-consuming, labor-intensive, and expensive, particularly in creating IOLs with specific surface characteristics on supporting portions to address rotation and glare issues, and can result in scarring or imperfections on the optical portion.
Innovation Solution
A method involving electrical discharge machining (EDM) wire cutting is used to form a mold insert for IOLs, with precise cutting paths and starting and ending points to achieve desired surface roughness on the supporting and optical portions, minimizing scarring and imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (milling, molding, lathing) are used to form IOLs with specific surface characteristics on supporting portions, then rotation and glare issues can be addressed, but the process becomes time-consuming, labor-intensive, and expensive
Solution Approach 1:
The patent replaces conventional mechanical methods (milling, molding, lathing) with electrical discharge machining (EDM) wire cutting to form the mold insert. This substitution eliminates the need for time-consuming mechanical operations while achieving the desired surface characteristics on supporting portions that prevent rotation and glare, thereby improving both reliability and productivity
Solution Approach 2:
The patent creates a mold insert with pre-formed surface characteristics on the supporting portions through EDM wire cutting. This preliminary action embeds the anti-rotation and anti-glare features directly into the mold insert before IOL production, eliminating the need for subsequent processing steps on individual IOLs and significantly improving manufacturing efficiency
2Ease of manufacture
If conventional cutting methods are used to form mold inserts, then manufacturing can be simplified, but scarring or imperfections manifest on the optical portion of the IOL
Solution Approach 1:
The patent replaces mechanical cutting methods with EDM wire cutting to form the mold insert. This substitution eliminates mechanical contact that causes scarring and imperfections on the optical portion, while still allowing for easy and efficient mold insert fabrication through the non-contact electrical discharge process
Solution Approach 2:
The patent uses EDM wire cutting as an intermediary process to form the mold insert with precise geometry and clean surfaces. The electrical discharge mechanism acts as a mediator that transfers the desired shape without mechanical contact, preventing scarring on the optical portion while maintaining ease of manufacture
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 method efficiently produces IOLs with controlled surface characteristics, reducing rotation and glare, while avoiding scarring and imperfections, thus improving manufacturing efficiency and cost-effectiveness.
Implementation Method 1
The cutting steps are performed using electrical discharge machining (EDM) wire cutting
Data Source
AI summary
A method of forming a mold insert used to produce an intraocular lens (IOL) mold is disclosed herein. The method includes providing stock material and cutting the stock material, which includes multiple cutting steps. The cutting steps are performed on transitional regions of supporting portions of the mold insert. Peripheral surfaces of the mold insert have varying roughness values, and supporting portions of the mold insert have a greater roughness than the optical portion of the mold insert. An IOL is also disclosed herein that is formed using an IOL mold that is injection molded using the mold insert. A method of forming the IOL is also disclosed herein.