Magnetic Centering for Embedded Hydrogel Contact Lens Inserts
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Solution Overview
Problem
There is a challenge in producing embedded hydrogel contact lenses with accurately positioned inserts, as existing methods using molds with positioning guides result in small holes that are susceptible to bioburden trapping.
Innovation Solution
A method involving a magnetized insert with magnetic particles, which is centered in a lens mold using a magnet, allowing for precise positioning without the need for positioning guides, thereby eliminating holes and bioburden buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If positioning guides (posts) are used in molds to precisely position inserts, then manufacturing precision is improved, but small holes are formed in the resultant lenses which are susceptible to bioburden trapping
Solution Approach 1:
The invention removes the positioning guides (posts) from the mold structure entirely. Instead of using physical guides that leave holes, the method relies on the magnetic field generated by the magnetized insert itself to achieve precise positioning during molding, thereby eliminating the source of bioburden trapping while maintaining positioning precision
Solution Approach 2:
The invention replaces the mechanical positioning system (positioning guides/posts) with a magnetic field-based positioning system. The magnetized insert interacts with a magnet in the mold through magnetic attraction to achieve precise positioning without physical contact guides, eliminating the harmful holes while maintaining manufacturing precision
2Manufacturing precision
If conventional molds with positioning guides are used, then insert positioning is achieved, but the process complexity increases and productivity decreases
Solution Approach 1:
By removing the complex positioning guide structures from the mold, the invention simplifies the mold design and reduces the number of components. This extraction of unnecessary elements streamlines the manufacturing process, allowing for faster cycle times and improved productivity while maintaining positioning accuracy through magnetic fields
Solution Approach 2:
Replacing the mechanical positioning guide system with a magnetic field system eliminates the need for complex mechanical structures and adjustments. The magnetic positioning occurs automatically during the molding process, reducing cycle time and improving overall production efficiency without sacrificing positioning 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
This method enables the efficient and consistent production of embedded hydrogel contact lenses with accurately positioned inserts, reducing the risk of bioburden trapping and improving the lenses' integrity.
Implementation Method 1
centered in the lens mold by using a magnet which is place below the lens mold
Data Source
Figure 1A~1B
AI summary
The invention relates to a method for producing embedded hydrogel contact lenses each having a magnetized insert that comprises magnetic particles and is centrally embedded in the bulk hydrogel material of the embedded hydrogel contact lens. During molding, a magnetized insert can be centered and held in position in a lens mold by using a magnet placed below the lens mold. The invention also relates to an embedded hydrogel contact lens produced from a method of the invention.