Intraocular Lens Mold Segmentation for Mask Border Precision
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Solution Overview
Problem
The existing methods for manufacturing intraocular lenses with masks struggle to produce precise border lines between optically transmissive and opaque materials, which can compromise the optical performance of the lenses.
Innovation Solution
The method involves molding the mask and optic from the same material, such as acrylic or silicone, using a mask-forming feature in the lens mold to prevent mixing and blending of materials, ensuring precise border definition between the mask and optic, and utilizing UV light and heat cycles for curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molding is performed with both optically transmissive and opaque materials, then intraocular lenses with mask structure can be produced, but precise border lines between optic and aperture cannot be achieved
Solution Approach 1:
The mold is segmented into distinct regions: a first mold region for forming the optically transmissive optic and a second mold region for forming the opaque mask. This spatial segmentation of the molding process enables precise border line formation by physically separating the material deposition zones, preventing material mixing while maintaining manufacturing efficiency.
Solution Approach 2:
A barrier layer is introduced as an intermediary element between the first and second mold regions. This barrier layer acts as a physical boundary that prevents mixing of optically transmissive and opaque materials during molding, ensuring precise border line definition while facilitating the simultaneous formation of both optic and mask structures.
2Adaptability or versatility
If mask and optic are made from different materials, then functional requirements can be met, but material mixing and blending occurs during molding
Solution Approach 1:
The barrier layer serves as a mediator that maintains composition stability between different materials. It prevents interdiffusion and mixing of the optically transmissive and opaque materials during the molding process, ensuring that each material maintains its distinct properties and functional characteristics in the final product.
Solution Approach 2:
Different regions of the intraocular lens are assigned different material properties through localized molding. The optic region receives optically transmissive material while the mask region receives opaque material, with the barrier layer ensuring sharp differentiation. This local quality assignment maintains both functional versatility and compositional stability.
3Manufacturing precision
If precise border lines are achieved, then optical performance is enhanced, but manufacturing complexity increases
Solution Approach 1:
The molding process merges the formation of the optic and mask into a single simultaneous operation using the multi-region mold. The barrier layer is integrated into the mold structure itself, allowing precise border line formation without requiring separate masking steps or post-processing operations, thus managing complexity while achieving high precision.
Solution Approach 2:
The barrier layer performs the dual function of both defining the border line geometry and preventing material mixing automatically during the molding process. This self-service functionality eliminates the need for additional complex control mechanisms or post-molding processing steps to achieve precise border lines.
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 allows for the production of intraocular lenses with precise mask borders, enhancing optical performance by maintaining the optical clarity and refractive power while preventing light transmission issues.
Implementation Method 1
curing the material with a combination of UV light and heat temperature cycles
Implementation Method 2
curing the material with a combination of UV light and heat temperature cycles
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~2D
AI summary
Intraocular implants and methods of making intraocular implants are disclosed. The intraocular implant can include a mask adapted to increase depth of focus. The method of manufacturing the implant can include filling an annular mask-forming trough with an opaque mask material and adding an optically transmissive optic material over the opaque mask material.