Thermoformed Ophthalmic Lens Inserts with Embedded Energized Components
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Solution Overview
Problem
Current methods for fabricating ophthalmic devices with integrated inserts lack efficiency and precision in thermoforming processes, particularly in creating complex shapes and functional components like energized inserts with alignment and stabilization features.
Innovation Solution
The method involves thermoforming sheets of material into three-dimensional shapes using molds, incorporating alignment features and stabilizing elements, and combining insert pieces to form ophthalmic lenses with embedded energized components, such as electrochemical cells and circuitry, which can be sealed and encapsulated within the lens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fabrication methods are used for ophthalmic devices with inserts, then the manufacturing process is simpler, but the efficiency and precision in creating complex shapes and functional components deteriorates
Solution Approach 1:
The fabrication process is divided into distinct segments: preparing the sheet material with alignment features, thermoforming the sheet into three-dimensional shapes, cutting out insert pieces, and assembling multiple insert pieces. This segmentation allows each step to be optimized independently for precision while managing overall process complexity.
Solution Approach 2:
Alignment features are added to the sheet material before thermoforming, and stabilizing features are incorporated during the cutting process. These preliminary actions ensure precise positioning and orientation are established early in the process, improving final manufacturing precision without requiring complex adjustments later.
2Adaptability or versatility
If energized components are incorporated into ophthalmic devices, then the functionality of the device is enhanced, but the complexity of the device increases
Solution Approach 1:
Energized components such as electrochemical cells and circuitry are embedded within encapsulating material to form integrated insert pieces. This nesting approach allows complex functional components to be contained within a unified structure that maintains optical clarity and biocompatibility, enhancing functionality while managing structural complexity.
Solution Approach 2:
The ophthalmic device utilizes thin sheet material that can be thermoformed into complex three-dimensional shapes with embedded energized components. The flexible nature of the sheet material allows integration of functional components without significantly increasing overall device complexity or compromising wearability.
3Adaptability or versatility
If multiple insert pieces are combined to form ophthalmic lenses, then the functionality and orientation of the device is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
Stabilizing features are incorporated asymmetrically on insert pieces to provide visual orientation cues that indicate how the ophthalmic lens should be oriented on the eye. This asymmetric design enhances orientation capability while the features are integrated during the cutting process, maintaining ease of manufacture.
Solution Approach 2:
Multiple insert pieces with different functions (optical elements, energized components, stabilizing features) are combined into a single integrated ophthalmic lens structure. The merging of these components during assembly creates a unified device that provides enhanced functionality and orientation capability while streamlining the manufacturing process.
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 precise formation of ophthalmic lenses with embedded energized components and alignment features, enhancing the functionality and orientation of ophthalmic devices while maintaining optical clarity and biocompatibility.
Implementation Method 1
A first sheet of a thermoformable material may be aligned and held in a thermoforming apparatus or fixture. A first portion of the first sheet may be thermoformed into a three-dimensional shape utilizing a first thermoforming mold.
Data Source
AI summary
The present invention describes methods for creating single-piece or multi-piece Rigid Inserts that may be included in an Ophthalmic Lenses or may comprise the Ophthalmic Lens, wherein the Rigid Insert may be formed through the processing of thin sheet material by thermoforming. Single piece annular Rigid Inserts may perform the function of providing a template for printed patterns to be included in Ophthalmic Lenses. Single piece full Rigid Inserts may perform the function of polarizing light or filtering light based on the properties of materials used to form the insert. Multi-piece Rigid Inserts may incorporate activation and energization elements. The present invention also includes apparatus for implementing such methods, as well as Ophthalmic Lenses and inserts formed with the Rigid Insert pieces that have been thermoformed.