Hybrid Contact Lens Insert Placement Using Vacuum 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, and can be integrated with minimal modifications to existing manufacturing systems.
Engineering Contradictions & Design Principles
Engineering 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 and holes are created on the lens surface
Solution Approach 1:
The invention removes the post structures from the molding system entirely. Instead of using posts to support and position the insert, the system employs a vacuum field applied through the transparent mold to hold the insert in place during curing. This extraction of the post structure eliminates the source of surface discontinuities and holes, allowing the lens surface to remain continuous and intact while still achieving precise insert positioning.
Solution Approach 2:
The invention replaces the mechanical post support system with a vacuum field-based positioning system. The vacuum field is applied through the transparent mold to the insert, creating a non-contact holding mechanism that eliminates mechanical interference with the lens surface. This substitution maintains insert positioning accuracy while avoiding the creation of surface discontinuities.
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
Solution Approach 1:
The transparent mold serves multiple functions: it acts as the forming cavity for the lens, provides the vacuum field distribution mechanism for insert positioning, and serves as the curing chamber. This multi-functionality eliminates the need for separate complex positioning equipment, enabling precise insert placement while maintaining simplicity and scalability for high-volume automated production.
Solution Approach 2:
The system uses the existing transparent mold structure to generate and distribute the vacuum field for insert positioning, rather than requiring an external complex positioning system. The mold itself performs the positioning function, simplifying the overall system and making it suitable for automated high-volume production while maintaining precision.
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, while being scalable for high-volume automated production.
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
Data Source
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.