Hybrid contact lens system and method

• US 20040179167A1
• Filed: 02/13/2004
• Published: 09/16/2004
• Est. Priority Date: 09/06/2002
• Status: Active Grant

• Current Assignee: SynergEyes, Inc. (The Cooper Cos., Inc.)
• Original Assignee: SynergEyes, Inc. (The Cooper Cos., Inc.)
• Inventors: Legerton, Jerome, Chen, Barry, Dahi, Ali, Collins, Joe
• Granted Patent: US 7,163,292 B2
• Time in Patent Office: Days
• US Class Current: 351/160R
• CPC Class Codes: B29D 11/00048 composed of parts with dissimilar composition B29D11/00057 takes precedence
• CPC Class Codes: B29D 11/0048 Moulds for lenses moulds for plastic articles in general B29C33/00
• CPC Class Codes: G02B 1/043 Contact lenses
• CPC Class Codes: G02C 7/04 Contact lenses for the eyes disinfection or sterilisation of contact lenses A61L12/00
• CPC Class Codes: G02C 7/049 Contact lenses having special fitting or structural features achieved by special materials or material structures

Abstract

Methods of manufacturing hybrid contact lenses using a mold are provided. The methods include pouring liquefied resin of a substantially rigid material within an inner section, curing the substantially rigid material, pouring liquefied resin of a substantially flexible material within an outer section and curing the substantially flexible material. In some embodiments, a wall disposed between the rigid and flexible materials is angled and/or bent to increase bonding strength between the rigid and flexible sections. The curing steps involve the application of heat, UV light, or a combination of both heat and UV light.

Claims

1. A method of manufacturing a hybrid contact lens, comprising the steps of:

providing a mold comprising an inner section and an outer section that are separated by an inner wall;

pouring liquefied resin of a substantially rigid material within the inner section;

curing the substantially rigid material;

pouring liquefied resin of a substantially flexible material within the outer section; and

curing the substantially flexible material.

2. The method of claim 1, wherein the inner wall comprises a pre-form optical grade divider that divides the substantially rigid material and the substantially flexible material.

3. The method of claim 1, wherein the inner wall is bondable with the substantially rigid material and the substantially flexible material.

4. The method of claim 1, wherein the mold is made from a material chosen from the group consisting of polypropylene, polyethylene, polyethylene terephthalate, polycarbonate and optical grade plastics.

5. The method of claim 1, further comprising the step of coating the inner wall with a UV curable adhesive to promote bonding with the substantially rigid material and the substantially flexible material.

6. The method of claim 1, wherein the inner wall remains part of the finished contact lens.

7. The method of claim 1, further comprising the step of removing the outer wall after the step of curing the substantially flexible material.

8. The method of claim 1, wherein the mold further comprises a lower section.

9. The method of claim 8, wherein the step of pouring liquefied resin of the substantially rigid material within the inner section includes the step of pouring liquefied resin of the substantially rigid material within the lower section.

10. The method of claim 8, wherein the lower section is dimensioned to produce a gripping area that conforms to the collet of a computer numerically controlled lathe or other machining apparatus.

11. The method of claim 1, wherein the inner wall is disposed at an angle with respect to the horizontal surface.

12. The method of claim 11, wherein the angle is between 5 and 175.

13. The method of claim 11, wherein the angle is selected to maximize the bonding strength between the rigid and flexible portions of the contact lens.

14. The method of claim 11, wherein the angle is about 90 degrees.

15. The method of claim 11, wherein the angle is acute.

16. The method of claim 11, wherein the angle is obtuse.

17. The method of claim 1, wherein the inner wall includes one or more bends for increasing the bonding strength between the rigid and flexible portions.

18. The method of claim 1, wherein the curing steps involve the application of heat, UV light, or a combination of both heat and UV light.

19. The method of claim 1 wherein the materials for the substantially flexible material are chosen from the group consisting of:

hydroxyethylmethacrylate (HEMA);

methyl methacrylate (MMA);

Ethyl methacylate (EMA);

aminoaklyl containing acrylate or methacrylate;

N-vinyl pyrrolidone (NVP);

2-methoxyethyl methacrylate (MEMA);

ethylene glycol methacrylate (EGMA);

trifluoropropyl methacrylate;

pentafluoropentyl methacylate;

N,N-dimethylacrylamide (DMA);

acrylamide;

methacylamide;

tetramethyldisiloxane ethylene glycol dimethacrylate;

perfluorophenyl methacrylate;

2-(trimethylsiloxyl)ethyl methacrylate;

N-fluoroalkyl methacylamide;

bis(2-methacryloxyphenyl)-propane;

(N,N-dimethylamino-ethyl)methacrylate; and

combinations of any of these monomers and/or silicone hydrogel formulations such Cibavision lotrafilcon.

20. The method of claim 1 wherein the materials for the substantially rigid material are chosen from the group consisting of:

fluorosilicone acrylate;

siliconated, styrene;

fluoroacrylate;

fluorometharylate, perfluorianted acrylate and methacrylate;

any high DK or Hyper DK gas permeable rigid contact lens bottoms with DK of 70 (ISO), such as Boston 7 Envision, Boston EO, Boston Equales, Boston Equalens 2, Boston XO, Fluoroperm 151, Fluoroperm 92, Fluoroperm 92, Fluoro 700, Menicon SE-P, Menicon Z;

any other high DK materials; and

combinations thereof.

21. The method of claim 1, wherein the mold includes a base curve that automatically forms a posterior surface of the hybrid contact lens.

22. The method of claim 1, further comprising the step of lathing the cured lens materials to form anterior and posterior lens surfaces.

23. The method of claim 22, wherein surface modifications to correct aberrations of the lens-eye system are provided on the anterior and/or posterior surfaces.

24. The method of claim 22, wherein the surface profile of the anterior and/or posterior surface is modified to contain a multi-focal feature for the correction of presbyopia.

25. A method of manufacturing a hybrid contact lens, comprising the steps of:

providing a block mold including a central void;

pouring liquefied resin of a substantially rigid material within the central void;

curing the substantially rigid material;

removing the substantially rigid material from the block mold;

attaching a guard to the substantially rigid material;

pouring a predetermined amount of liquefied resin of flexible material into an area between the substantially rigid section and the guard; and

curing the substantially flexible material.

26. The method of claim 25, wherein the central void includes an upper section including an outer wall formed by an inside surface of the block mold halves.

27. The method of claim 26, wherein the outer wall forms the shape of the junction between the substantially rigid material and the substantially material.

28. The method of claim 25, wherein the outer wall is disposed at an angle with respect to a horizontal surface.

29. The method of claim 28, wherein the angle is between 5 and 175.

30. The method of claim 28, wherein the angle is selected to maximize the bonding strength between the rigid and flexible portions of the contact lens.

31. The method of claim 28, wherein the angle is about 90 degrees.

32. The method of claim 28, wherein the angle is acute.

33. The method of claim 28, wherein the angle is obtuse.

34. The method of claim 27, wherein the outer wall includes one or more bends for increasing the bonding strength between the rigid and flexible portions.

35. The method of claim 26, wherein the central void further comprises a lower section.

36. The method of claim 35, wherein the step of pouring liquefied resin of the substantially rigid material within the central void includes the step of pouring liquefied resin of the substantially rigid material within the lower section.

37. The method of claim 35, wherein the lower section is dimensioned to produce a gripping area that conforms to the collet of a computer numerically controlled lathe or other machining apparatus.

38. The method of claim 25, wherein the curing steps involve the application of heat, UV light, or a combination of both heat and UV light.

39. The method of claim 25, wherein the step of removing the substantially rigid material from the block mold includes the step of breaking the block mold along a breaking plane.

40. The method of claim 25, further comprising the step of removing the guard after curing the substantially flexible material.

41. The method of claim 25, wherein the guard includes a horizontal lower surface and a cylindrical sidewall.

42. The method of claim 25 wherein the materials for the substantially flexible material are chosen from the group consisting of:

hydroxyethylmethacrylate (HEMA);

methyl methacrylate (MMA);

Ethyl methacylate (EMA);

aminoaklyl containing acrylate or methacrylate;

N-vinyl pyrrolidone (NVP);

2-methoxyethyl methacrylate (MEMA);

ethylene glycol methacrylate (EGMA);

trifluoropropyl methacrylate;

pentafluoropentyl methacylate;

N,N-dimethylacrylamide (DMA);

acrylamide;

methacylamide;

tetramethyldisiloxane ethylene glycol dimethacrylate;

perfluorophenyl methacrylate;

2-(trimethylsiloxyl)ethyl methacrylate;

N-fluoroalkyl methacylamide;

bis(2-methacryloxyphenyl)-propane;

(N,N-dimethylamino-ethyl)methacrylate; and

combinations of any of these monomers and/or silicone hydrogel formulations such Cibavision lotrafilcon.

43. The method of claim 25 wherein the materials for the substantially rigid material are chosen from the group consisting of:

fluorosilicone acrylate;

siliconated, styrene;

fluoroacrylate;

fluorometharylate, perfluorianted acrylate and methacrylate;

any high DK or Hyper DK gas permeable rigid contact lens bottoms with DK of 70 (ISO), such as Boston 7 Envision, Boston EO, Boston Equales, Boston Equalens 2, Boston XO, Fluoroperm 151, Fluoroperm 92, Fluoroperm 92, Fluoro 700, Menicon SE-P, Menicon Z;

any other high DK materials; and

combinations thereof.

44. The method of claim 25, wherein the mold includes a base curve that automatically forms a posterior surface of the hybrid contact lens.

45. The method of claim 25, further comprising the step of lathing the cured lens materials to form anterior and posterior lens surfaces.

46. The method of claim 45, wherein surface modifications to correct aberrations of the lens-eye system are provided on the anterior and/or posterior surfaces.

47. The method of claim 45, wherein the surface profile of the anterior and/or posterior surfaces are modified to contain a multi-focal feature for the correction of presbyopia.

48. A method of manufacturing a hybrid contact lens, comprising the steps of:

providing a pre-shape mold including a bowl-shaped void;

inserted a pre-formed substantially rigid portion into a center portion of the bowl-shaped void;

injecting a predetermined amount of liquefied resin of flexible material into an outer portion of the bowl-shaped void; and

curing the substantially flexible material.

49. The method of claim 48, wherein the pre-formed substantially rigid portion is pre-coated or pre-treated with an adhesive to promote bonding with the flexible material.

50. The method of claim 48, wherein the pre-shape mold comprises a base curve mold and a pair of block mold halves that are symmetrically disposed about a vertical plane passing through the center of the base curve mold.

51. The method of claim 48, wherein the pre-shape mold includes a central void dimensioned to permit the substantially rigid portion to be inserted into the center portion of the bowl-shaped void.

52. The method of claim 48, wherein the pre-shape mold includes one or more injection apertures for filling the outer portion of the bowl-shaped void.

53. The method of claim 48, wherein the materials for the substantially rigid portion are chosen from the group consisting of:

trimeththyl-siloxyl;

methyl-methacrylate;

ethyl-methacrylate;

ethylene glycol di-methacrylate;

octafluoro pentyl-methacrylate;

tetra-methyldisiloxane;

ethylene glycol di-methacrylate;

pentafluoro phenylacrylate;

2-(trimethylsiloxyl)methacrylate;

bis(2-metharyloxyphenyl) propane;

N-[2-(N,N-dimethylamino)ethyl];

onethacrylate;

N-[2-(n,n-dimethylamino)ethy];

methacryalte;

vinyl-pyrolidone;

N,N-dimathacrylamide;

acrylamine;

hydroxyethyl methacrylate;

siloxane ethylene glycol di-methacrylate;

trifluoroethyl methacrylate;

pentafluorostyrene;

pentafluoropropyl methacrylate;

unsaturated polyester;

p-vinyl benzyl hexafluoroisopropyl ether;

siloxanylalkylamide; and

combinations thereof.

54. The method of claim 48, wherein the materials for the substantially flexible portion are chosen from the group consisting of:

poly HEMA;

hydroxyethyl acrylate;

dihydroxypropyl methacrylate;

polyethylaneglycol;

acetoxysilane;

trimethylesiloxy;

ethyleneglycol-dimethacrylate;

phenylethyl acrylate;

zero-gel;

Silicon-Hydrogel;

polyethylene oxide; and

combinations thereof.

55. The method of claim 49, wherein the materials for the adhesive are chosen from the group consisting of:

vinylacetate;

trifluoroethanol;

methacrylate;

ethanediamine;

2-hydroxyethylmethacrylate (HEMA) and other esters of methacrylic acid formulated from acrylic bases;

fluorine;

silicone;

fluorine/silicone;

styrene and resultant polymers such as polystyrene;

fluorine/styrene;

silicone/styrene; and

combinations thereof.