Hydrogel Ophthalmic Devices with Electronic Elements Adhesion
Solution Overview
Problem
Existing methods for manufacturing energized ophthalmic devices, such as contact lenses with electronic components, face challenges in promoting the adhesion of rigid inserts and electronic components to hydrogel portions, which is crucial for their functionality and durability.
Innovation Solution
A method involving pre-dosing and post-dosing of reactive monomer mixtures, functionalizing and coating media inserts and electronic elements with adhesion promoters, and forming a mold assembly to ensure controlled adhesion and encapsulation within the hydrogel, using techniques like plasma treatment and parylene coating to enhance bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used for energized ophthalmic devices, then the device structure is simpler, but the adhesion of rigid inserts and electronic components to hydrogel portions is insufficient
Solution Approach 1:
The mold parts are pre-dosed with reactive monomer mixture before the hydrogel material is applied. This preliminary placement of adhesive material ensures that when electronic components and rigid inserts are added, they immediately have bonding material available, creating strong adhesion without requiring complex post-assembly bonding steps.
Solution Approach 2:
A reactive monomer mixture acts as an intermediary bonding material between the hydrogel portions and the rigid inserts/electronic components. This intermediary substance cures to form a strong adhesive bond, solving the adhesion problem without requiring direct bonding between incompatible materials.
2Reliability
If adhesion promoters and functionalization steps are added, then the adhesion of electronic components to hydrogel is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The adhesion promoter application, functionalization, and reactive monomer dosing steps are merged into a single integrated manufacturing sequence. The mold parts are pre-dosed with reactive monomer mixture that contains or is followed by adhesion promoters, combining multiple functions into one process step rather than separate sequential operations.
Solution Approach 2:
The reactive monomer mixture undergoes parameter changes through curing - transitioning from a liquid or semi-liquid state to a solid bonded state. This parameter change (from uncured to cured) creates the strong adhesive bond while the process remains relatively simple because it utilizes the natural curing properties of the material rather than requiring complex bonding equipment or multiple processing stages.
3Manufacturing precision
If pre-dosing and post-dosing of reactive monomer mixture is implemented, then controlled adhesion is achieved, but the manufacturing time increases
Solution Approach 1:
The mold parts are pre-dosed with reactive monomer mixture before assembly is complete. This preliminary placement of bonding material allows for controlled adhesion as the material is already positioned where needed. The pre-dosed material remains ready to bond, and when the mold is closed and curing occurs, the adhesion is precisely controlled by the pre-placed material distribution.
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 effectively promotes the adhesion of rigid inserts and electronic components to hydrogel, ensuring the integrity and functionality of energized ophthalmic devices by forming a stable and biocompatible bond, enhancing their performance and compatibility with the eye environment.
Implementation Method 1
functionalizing a media insert so that an adhesion promoter can bind to a surface of the media insert
Implementation Method 2
curing at least the post-dosed reactive monomer mixture to form the ophthalmic lens
Data Source
AI summary
The present invention provides methods for forming an ophthalmic lens that can include a media insert and/or electronic components. In particular, the present disclosure provides for adhesion promoting functionalization steps for a biocompatible coating to bind a hydrogel material to a plastic surface or electronic component prior to the polymerization of the hydrogel. In some aspects, the media insert can be used to contain energy sources and/or functional electronic components which may be, for example, in a stacked integrated component configuration to permit a generally arcuate shape that can conform to the anterior surface of an eye.