Intraocular Lens Mold Segmentation for Flash Reduction
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Solution Overview
Problem
The manufacturing of complex-shaped intraocular lenses with hollow structures or open frameworks is challenging due to difficulties in casting and assembly, particularly in achieving accurate alignment of optical surfaces and reducing the need for bonded regions, which can result in weak spots or excess material issues.
Innovation Solution
The use of two mold components with different materials, where a harder outer mold and a softer inner mold define the shape of the lens, allowing for casting of the lens-forming material between them, reducing flash and eliminating the need for bonded regions, and enabling the formation of complex shapes like accommodative IOLs with internal voids or chambers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If complex-shaped IOLs with hollow structures are manufactured using traditional casting or extrusion methods, then the lens shape can be formed, but manufacturing precision deteriorates due to difficulty in achieving accurate alignment of optical surfaces and proper positioning of internal voids
Solution Approach 1:
The manufacturing process is segmented into two distinct mold components: an outer mold that defines the external geometry and an inner mold that defines the internal voids and chambers. This segmentation allows each mold to be independently precision-engineered and positioned, ensuring accurate alignment of both optical surfaces and internal structures without the complexity of single-step casting or extrusion methods.
2Shape
If complex-shaped IOLs are assembled from multiple components, then the hollow structure can be formed, but device complexity increases due to the need for proper alignment of optics and supporting structures
Solution Approach 1:
The outer mold and inner mold are combined in a single manufacturing operation to form the complete hollow structure of the IOL. The inner mold is positioned within the outer mold, and both are used simultaneously to cast or form the lens material, creating the hollow structure and external geometry in one integrated process rather than through separate assembly steps.
3Shape
If bonded joints are used to construct complex-shaped IOLs, then the hollow structure can be assembled, but reliability deteriorates due to weak spots from insufficient material or overflow from excess joinder material
Solution Approach 1:
The inner mold is designed as a removable component that can be extracted from the formed IOL after manufacturing. This extraction eliminates the need for bonded joints to create the hollow structure, as the internal voids are formed by the presence and subsequent removal of the inner mold rather than by joining separate components. The result is a continuous, structurally integrity hollow geometry without weak spots or overflow issues.
Data Source
Figure 1A~2
AI summary
An apparatus and method for manufacturing intraocular lenses (IOLs) (50) is disclosed. Two mold components (an outer mold component (12) and an inner mold component (14)) of different composition may be employed. The outer mold (12) may be composed of a metal or other refractory material and may serve as the outer die into which a lens forming material can be introduced. The inner mold component (14) may be composed of a softer or more compliant material and may be deployed within the outer mold component (12). The IOL (50) may be formed by casting the lens-forming material into a shape defined by the space between the two mold components (12, 14). In certain embodiments, the present disclosure may reduce or eliminate flash in IOLs, improve alignment of their optical surfaces, and/or reduce or eliminate the need for bonded regions.