Static Liquid Interface Lens Production via Polymerization Inhibition

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Solution Overview

Problem

Current methods for manufacturing contoured objects like lenses, such as intraocular lenses, are inefficient due to the need for molds and are not well-suited for rapid production of small, curved lenses, especially when producing large quantities or when molds require cleaning for reuse.

Innovation Solution

An apparatus and method using a window with an inhibitor of polymerization, such as oxygen, to create a dead zone in a light-polymerizable resin, allowing for the rapid production of contoured surfaces under stationary conditions by spatially modulating light dosage, enabling the production of lenses without the need for moving parts or molds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If continuous liquid interface production (CLIP) is used to rapidly produce contoured objects, then production speed is improved, but the objects require adhesion to a moving carrier plate or static carrier plate facing a moving window during production

Engineering Contradiction:

Improveproduction speedVSAvoidcarrier plate and window movement mechanism

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent divides the system into two independent windows (first window with inhibitor for creating dead zone, second window for contacting resin) that can be stationary relative to each other, eliminating the need for a moving carrier plate or moving window mechanism while maintaining the ability to produce contoured objects rapidly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a light-polymerizable resin as an intermediary medium between the two stationary windows, allowing the resin to flow and be shaped between the windows without requiring the windows themselves to move, thus simplifying the mechanical complexity while maintaining production speed

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If traditional casting techniques with molds are used to manufacture lenses, then manufacturing precision is maintained, but production time increases and molds require cleaning for reuse

Engineering Contradiction:

Improvelens contour accuracyVSAvoidproduction time and mold cleaning time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent uses a disposable or easily replaceable resin system between stationary windows, eliminating the need for expensive, time-consuming mold cleaning and reuse. The resin acts as a temporary form that is discarded after use, allowing rapid production without mold maintenance

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces the mechanical mold system with a chemical/photochemical system where light-polymerizable resin is shaped through photopolymerization between windows, eliminating the need for physical molds and their associated cleaning and reuse requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables the rapid and efficient production of contoured lenses, including intraocular and microlenses, by forming objects adhered to a substrate while maintaining stationary conditions, reducing production time and eliminating the need for molds, thus improving manufacturing efficiency.

Implementation Method 1

a polymerizing light source operatively associated with the window and positioned for projecting polymerizing light through the window; a controller operatively associated with said light source and configured to pattern and project said polymerizing light at a first light dosage sufficient to form the object in the resin

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

a window containing an inhibitor of polymerization, on which window a coating of light polymerizable resin can be placed, with the inhibitor of polymerization forming a first dead zone of unpolymerizable resin in the light polymerizable resin

Methodology Applied

Scientific EffectPolymerization inhibition:

Data Source

PatentUS11440223B2Static liquid interface production of lenses and other contoured objects

Publication Date: 2022.09.13 CARBON INC

AI summary

An apparatus useful for rapidly producing at least one object having a contoured surface portion from a light-polymerizable resin is provided. The apparatus includes (a) a window containing an inhibitor of polymerization, on which window a coating of light polymerizable resin can be placed, with the inhibitor of polymerization forming a first dead zone of unpolymerizable resin in the light polymerizable resin; (b) a polymerizing light source operatively associated with the window and positioned for projecting polymerizing light through the window; (c) a controller operatively associated with said light source and configured to pattern and project said polymerizing light at a first light dosage sufficient to form the object in the resin under stationary conditions, while spatially modulating the first light dosage so that the first dead zone is spatially contoured in thickness, to produce a first contoured surface portion on each object, which first contoured surface portion is in contact with the first dead zone of unpolymerizable resin.