Hybrid Contact Lens Insert Placement for Precise Mold Positioning
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Solution Overview
Problem
Existing methods for fabricating hybrid contact lenses with embedded inserts require complex equipment and processes, leading to surface discontinuities that promote bacteria growth and user discomfort, and are not suitable for high-volume automated production.
Innovation Solution
A vacuum or suction actuated system for precise placement and positioning of lens inserts within a lens mold, eliminating the need for post structures and allowing for continuous surfaces, scalable for high-volume production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional contact lenses are made entirely of hydrogel or rigid gas permeable material, then manufacturing simplicity is maintained, but the ability to provide both oxygen permeability and hydrophilic comfort is compromised
Solution Approach 1:
The contact lens is divided into multiple zones with different material properties: a central hydrophilic zone for comfort and peripheral hydrophobic zones for oxygen permeability. This segmentation allows each region to perform its specific function optimally without requiring the entire lens to be complex.
Solution Approach 2:
Different regions of the contact lens are assigned different material qualities - the central portion uses hydrophilic material for comfort while the peripheral portions use hydrophobic, oxygen-permeable material. This local differentiation resolves the contradiction by providing material property versatility where needed without making the entire device complex.
2Reliability
If contact lenses are designed with multiple material zones for optimized performance, then oxygen permeability and comfort are improved, but manufacturing precision requirements increase
Solution Approach 1:
The hydrophilic insert is pre-formed with asymmetric features (protrusion and recess) that automatically guide its placement into the correct orientation within the hydrophobic contact lens. This preliminary preparation of positioning features eliminates the need for high-precision placement during manufacturing, as the insert self-aligns through its asymmetric geometry.
Solution Approach 2:
The asymmetric protrusion and recess features act as mechanical intermediaries that mediate the alignment between the hydrophilic insert and the hydrophobic lens. These features provide a simple mechanical interface that ensures correct positioning without requiring complex alignment procedures or high-precision manufacturing equipment.
3Adaptability or versatility
If hydrophilic inserts are used within hydrophobic contact lenses, then comfort and oxygen permeability are enhanced, but the complexity of the fabrication process increases
Solution Approach 1:
The fabrication process is segmented into independent steps: first forming the hydrophobic contact lens, then separately forming the hydrophilic insert with asymmetric features, and finally assembling them through a simple insertion process. This segmentation allows each component to be manufactured using standard techniques without requiring complex integrated fabrication processes.
Solution Approach 2:
The asymmetric protrusion and recess features enable the hydrophilic insert to self-align and self-position within the hydrophobic lens during assembly. This self-service mechanism eliminates the need for complex alignment equipment or procedures, maintaining ease of manufacture while achieving enhanced material property versatility.
Data Source
Figure 1
Figure 2A~3A
Figure 3B~3C
AI summary
Systems, devices, and methods are disclosed for fabricating a hybrid contact lens product having a lens insert embedded at a precisely controlled location within a lens body. A mold engagement and support base engages and retains a lens forming mold in a substantially fixed position. An insert placement and positioning device includes an insert pickup head with a contact face configured for releasable engagement of the lens insert and at least one suction opening in the contact face for applying suction to engage the insert on the contact face. A positioning housing interacts with the mold and/or the support base to provide precise locational positioning of the lens insert within the mold. A lens body forming material is delivered to the mold to encapsulate the lens insert.