Partial Intraocular Lens Coating for Reduced Tack and Stable Unfolding
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Solution Overview
Problem
Existing methods for coating intraocular lenses to reduce self-tackiness are inefficient, time-consuming, and prone to lens damage, with potential for incomplete coatings and adverse optical effects.
Innovation Solution
The use of spatial atomic layer deposition (s-ALD) to apply a thin, uniform coating to intraocular lenses while they are still in their formation device, utilizing a system with inert gas, precursor, and plasma sources to achieve a controlled and consistent coating thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional coating methods (spin coating, dip coating, spray coating) are used to apply hydrophobic coating to the entire surface of intraocular lenses, then complete coverage is achieved, but protein adhesion occurs on the entire lens surface including the optical zone
Solution Approach 1:
The patent applies local quality by creating different surface properties in different regions of the lens. The hydrophobic coating is applied selectively to the haptic and suspension zones while leaving the optical zone hydrophilic, achieving local differentiation of surface characteristics to prevent protein adhesion only where needed
2Object-affected harmful factors
If hydrophobic coating is applied to the entire lens surface to prevent protein adhesion, then protein resistance is improved, but visual quality deteriorates due to coating on the optical zone
Solution Approach 1:
The patent uses local quality to apply the hydrophobic coating only to specific non-optical regions (haptic and suspension zones) while maintaining the optical zone free of coating, thus preventing protein adhesion without compromising visual quality or optical performance
3Illumination intensity
If spatially selective coating is applied only to haptic and suspension zones, then visual quality is maintained, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-marking or pre-positioning indicators on the lens before coating application. These markers guide the precise application of hydrophobic coating to the correct regions, ensuring accurate spatial selectivity and reducing manufacturing complexity
Solution Approach 2:
The patent uses an intermediary approach by employing a coating application system with controlled deposition that can selectively target specific zones. This intermediary mechanism enables precise spatial control of the coating process without requiring extremely high manufacturing precision across the entire lens
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 method reduces self-tackiness and improves unfold time consistency, minimizes lens handling, and maintains optical performance by applying a thin, uniform coating that is chemically bonded to the substrate.
Implementation Method 1
The corona discharge treated the polymer coating to render it hydrophilic and resistant to protein adhesion
Implementation Method 2
spatially selective corona discharge...creating a gradient of hydrophilicity that extended from the haptic toward the optical zone
Data Source
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AI summary
A system and method for efficiently modifying the surface of an intraocular lenses to reduce tackiness and improve lens unfold time and unfold time consistency, and a product created using the system and method, is disclosed. In some aspects, the system and method utilizes at least part of a lens-forming device as a mask..