Silicone Hydrogel Lens Release Using PEG Surfactants

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Solution Overview

Problem

Existing methods for releasing silicone hydrogel contact lenses from molds are inefficient, often requiring organic solvents that pose safety hazards, increase manufacturing downtime, and are costly, and may cause collateral damage due to flammability concerns.

Innovation Solution

Incorporating polyethylene glycol (PEG) or polyethylene oxide (PEO) into the monomer, mold material, or hydration solution to facilitate the release of silicone hydrogel lenses from molds without the need for organic solvents, using their surfactant properties to reduce adhesion and enhance release efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If organic solvents are used to release silicone hydrogel lenses from molds, then release efficiency is improved, but safety hazards and manufacturing downtime increase

Engineering Contradiction:

Improverelease efficiencyVSAvoidsafety hazards

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the chemical parameter of the release agent from organic solvents to aqueous solutions containing surfactants. This parameter change eliminates the safety hazards and flammability issues associated with organic solvents while maintaining effective lens release through the surfactant properties of the aqueous solution.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces surfactants as intermediary substances in the aqueous solution to facilitate lens release. These surfactants act as mediators between the lens material and the release process, enabling effective release without requiring flammable organic solvents.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If organic solvents are used to release silicone hydrogel lenses from molds, then release efficiency is improved, but manufacturing cost increases

Engineering Contradiction:

Improverelease efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent changes the composition parameter of the release solution from organic-based to aqueous-based formulations. This parameter change reduces manufacturing costs by eliminating the need for expensive organic solvents while maintaining effective release performance through surfactant additives.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If organic solvents are used to release silicone hydrogel lenses from molds, then release efficiency is improved, but collateral damage increases

Engineering Contradiction:

Improverelease efficiencyVSAvoidcollateral damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effects of organic solvents (flammability, safety hazards) into beneficial aqueous-based release processes. By using surfactants in water-based solutions, the patent achieves effective release without the collateral damage of flammability and safety risks, turning a harmful process into a safe one.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

The use of PEG or PEO enables a safer, more efficient, and cost-effective release process for silicone hydrogel lenses, reducing the risk of accidents and downtime while maintaining lens quality.

Implementation Method 1

a surfactant is utilized to aid the release of the lens from the mold part

Methodology Applied

Scientific EffectSurfactant: Surfactant

Implementation Method 2

loosen adhesion of the lens to the mold

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS7789507B2Facilitating release of silicone hydrogel ophthalmic lenses

Publication Date: 2010.09.07 JOHNSON & JOHNSON VISION CARE INC

AI summary

This invention includes methods and systems for processing hydrogel biomedical devices, such as ophthalmic lenses using polyethylene glycol to facilitate release of the devices from a mold part.