Myopia Control Lens with Embedded Scattering Particles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for creating functionalized optical articles, such as ophthalmic lenses, often require complex surface coating processes that are costly, time-consuming, and prone to issues like peeling and thermal expansion incompatibility.
Innovation Solution
The introduction of diffusive particulate optical elements embedded in the sub-surface of a polymer substrate, which provides controlled light scattering properties without the need for laser engraving or surface coatings, thereby simplifying the manufacturing process and enhancing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface coating processes are used to functionalize optical articles, then additional optical or mechanical properties can be imparted, but the manufacturing process becomes complex and time-consuming with issues like peeling and thermal expansion incompatibility
Solution Approach 1:
The invention merges the substrate and functional coating into a single integrated structure by embedding particles directly into the polymer matrix during injection molding. This eliminates the separate coating layer and its associated adhesion problems, while maintaining the light-scattering functionality through particles distributed throughout the substrate material.
Solution Approach 2:
The particles are incorporated into the substrate during the injection molding process itself, before the substrate is fully formed. This preliminary incorporation ensures uniform distribution and strong integration of the light-scattering particles within the substrate matrix, avoiding subsequent coating steps.
2Manufacturing precision
If multiple surface coating steps are applied to achieve desired functionality, then optical properties can be improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The invention combines the substrate formation and functional particle incorporation into a single injection molding operation. This eliminates multiple sequential coating steps while achieving the same optical functionality through particles embedded within the substrate during its primary manufacturing process.
Solution Approach 2:
The injection molding process is made multi-functional by simultaneously forming the substrate geometry and incorporating the light-scattering particles. This single process achieves both structural formation and optical functionalization, eliminating the need for separate coating operations.
3Reliability
If laser engraving is used to create light-scattering centers, then myopia control functionality can be achieved, but the equipment is not suitable for mass production and productivity is reduced
Solution Approach 1:
The invention replaces the laser engraving mechanical system with an injection molding process. Instead of using laser energy to create surface features, the light-scattering functionality is achieved through particles embedded during mold-based injection molding, which is inherently suited for high-volume mass production.
Solution Approach 2:
The light-scattering pattern is copied into the substrate during injection molding by distributing particles throughout the material. This creates the same optical effect as laser engraving but through a manufacturing process that can be rapidly replicated for mass production without requiring complex laser equipment.
4Illumination intensity
If nanoparticles are embedded in the external layer of substrate, then light transmission properties are improved, but the manufacturing process requires particle application and evaporation steps
Solution Approach 1:
The invention replaces the multi-step particle application and evaporation process with a single injection molding operation. The particles are incorporated into the substrate during the molding process itself, eliminating the need for separate application, drying, and evaporation steps required by conventional particle embedding methods.
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 prevents eye-length related disorders such as myopia by uniformly scattering light, while maintaining high visual acuity and aesthetics, and allowing for mass production of optical articles with improved light transmission and abrasion resistance.
Implementation Method 1
the substrate comprises an external layer in which particles functionalized with a coupling agent are embedded into the polymer matrix, the refractive index of the particles Rp being lower than the refractive index of the polymer matrix Rs. The external layer of embedded particles improves the light transmission properties of the substrate.
Implementation Method 2
particles functionalized with a coupling agent are embedded into the polymer matrix
Data Source
Figure 1
AI summary
The invention relates to an optical article having a substrate made of an optical material comprising a polymer matrix, the substrate comprising a bulk part, and an external part, and said external part of the substrate is made of said optical material comprising said polymer matrix, and particles functionalized with a coupling agent embedded into said polymer matrix of the external part of the substrate, said bulk part of the substrate is made of said optical material comprising said polymer matrix, and said particles are not embedded into the bulk part of the substrate, and the haze value of a 2 mm-thick substrate as determined according to the standard ASTM D1003-00 is higher than or equal to 4 %.