Thermoformed Ophthalmic Insert with Embedded Circuitry
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing ophthalmic lenses with integrated inserts lack efficiency and complexity in incorporating energized components, such as energy sources and circuitry, which are difficult to integrate without affecting the lens's optical quality and functionality.
Innovation Solution
The method involves thermoforming a rigid insert with embedded energy sources and circuitry, which can be placed around the optic zone or within the lens, using a thermoformed insert device with a hydrogel encapsulant and alignment features to ensure precise placement and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If energized components are incorporated into the ophthalmic lens, then functionality is enhanced, but device complexity increases
Solution Approach 1:
The ophthalmic lens is divided into separate functional zones: an energized insert portion containing energy sources and circuitry, and a hydrogel encapsulant portion. This segmentation allows independent optimization of each component and simplifies manufacturing by enabling separate fabrication and assembly of complex elements.
Solution Approach 2:
The energized components (energy sources, circuitry) are nested within the insert portion, which is then encapsulated by the hydrogel material. This nested structure integrates multiple functional elements into a compact configuration that maintains optical quality while providing enhanced functionality.
2Adaptability or versatility
If energized components are integrated into the lens, then functionality is enhanced, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct steps: forming the insert portion with energized components, preparing the hydrogel encapsulant, and assembling the final lens. This segmentation enables specialized manufacturing techniques for each component and simplifies quality control.
Solution Approach 2:
The insert portion with energy sources and circuitry is prepared in advance as a pre-assembled unit before being integrated into the final lens structure. This preliminary action simplifies the overall manufacturing process by reducing the number of assembly steps required for the final product.
3Manufacturing precision
If align features are incorporated into the insert device, then placement precision is improved, but device complexity increases
Solution Approach 1:
Alignment features such as asymmetric notches, protrusions, or marked patterns are incorporated into the insert portion to provide unique orientation references. These asymmetric features enable precise rotational and positional alignment during assembly without requiring complex alignment mechanisms.
Solution Approach 2:
The alignment features act as intermediary elements that facilitate precise positioning between the insert portion and the hydrogel encapsulant during assembly. These features provide mechanical or visual references that simplify the alignment process without requiring complex external tooling.
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 allows for the creation of ophthalmic lenses with integrated energized components that maintain optical quality while providing enhanced functionality, such as variable optic power and active agent delivery, through the use of thermoformed inserts that can be precisely aligned and sealed within the lens.
Implementation Method 1
a first insert piece which is a thermoformed material of a three-dimensional shape
Data Source
AI summary
The present invention describes 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 include activation and energization elements. The present invention also includes methods and apparatus for forming the Rigid Inserts.