Hybrid Contact Lens Insert Placement Using Vacuum Alignment

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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, using a mold engagement and support base with a suction conduit and positioning device for accurate alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If post structures are used to support the insert during molding, then the insert can be positioned during fabrication, but surface discontinuities are created that promote bacteria growth and user discomfort

Engineering Contradiction:

Improveinsert positioningVSAvoidbacteria growth and user discomfort

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent removes the post structure support element from the molding process entirely. Instead of using posts to hold the insert during molding, the system allows the insert to be positioned and supported by the mold cavity walls and the lens material itself, eliminating the source of surface discontinuities that cause bacteria growth and discomfort.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Rather than supporting the insert from below with posts, the patent inverts the approach by having the mold cavity walls and lens material support the insert from the sides and top. This reversal of the support mechanism eliminates the need for posts that create harmful surface features.

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If complex equipment and manufacturing processes are used for insert placement, then precise positioning can be achieved, but the system becomes unsuitable for high-volume automated production

Engineering Contradiction:

Improveinsert placement precisionVSAvoidhigh-volume automated production capability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent employs a self-aligning mechanism where the insert is designed with features that automatically position it within the mold cavity without requiring complex active placement systems. The insert works with the mold geometry to achieve precise positioning through passive mechanical alignment, enabling simple, high-speed automated production.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces complex active mechanical placement systems with a simpler system based on geometric alignment and mold cavity design. Instead of using sophisticated positioning equipment, the solution uses the inherent geometry of the mold and insert to achieve precise placement, greatly simplifying the manufacturing system for high-volume production.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If existing lens molds are used without modification, then manufacturing simplicity is maintained, but precise insert placement and continuous surface integrity cannot be achieved

Engineering Contradiction:

Improvemold modification requirementVSAvoidinsert placement and surface integrity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent modifies the mold only in specific local areas where insert placement is required, rather than redesigning the entire mold system. The modifications include adding specific geometric features to the mold cavity walls that provide precise positioning and support for the insert, while leaving the rest of the mold design unchanged for ease of manufacture.

Inventive Principle:

Principle #3Local 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

Enables the production of hybrid contact lenses with intact surfaces that resist bacteria growth and improve comfort, scalable for high-volume production with minimal modifications to existing systems.

Implementation Method 1

A vacuum or suction (i.e., negative pressure relative to ambient) actuated system provides precise placement and positioning of a lens insert

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS20250319678A1Systems and methods for insert placement to fabricate hybrid contact lenses

Publication Date: 2025.10.16 ALCON INC

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.