Method of making an ocular implant

• US 20060118263A1
• Filed: 12/01/2004
• Published: 06/08/2006
• Est. Priority Date: 12/01/2004
• Status: Active Grant

• Current Assignee: Healthcare Royalty Partners II LP (Toronto-Dominion Bank)
• Original Assignee: Acufocus, Inc.
• Inventors: Silvestrini, Thomas A.
• Granted Patent: US 7,491,350 B2
• Time in Patent Office: Days
• US Class Current: 164/46
• CPC Class Codes: A61F 2/142 Cornea, e.g. artificial corneae, keratoprostheses or corneal implants for repair of defective corneal tissue
• CPC Class Codes: A61F 2/15 Implant having one or more holes, e.g. for nutrient transport, for facilitating handling
• CPC Class Codes: A61F 2240/002 Designing or making customized prostheses
• CPC Class Codes: A61F 9/00834 Inlays; Onlays; Intraocular lenses [IOL]
• CPC Class Codes: C23C 14/0005 Separation of the coating from the substrate
• CPC Class Codes: G02C 7/04 Contact lenses for the eyes disinfection or sterilisation of contact lenses A61L12/00
• CPC Class Codes: G02C 7/165 with stenopaeic apertures

Abstract

A method is provided for making a mask configured to improve the depth of focus of an eye of a patient. A substrate is provided with a mask forming feature. The mask forming feature comprises an annular surface that has a curved profile that corresponds to the curvature of a corneal layer of the eye. A release layer is formed on the annular surface. A mask layer of a biocompatible metal is formed above the release layer. The mask layer is separated from the substrate.

Claims

1. A method of making a mask configured to improve the depth of focus of an eye of a patient, the method comprising:

providing a substrate with a mask forming feature comprising an annular surface extending between an inner periphery and an outer periphery, the annular surface being centered on a central axis of the mask forming feature, the annular surface having a curved profile between the inner periphery and the outer periphery corresponding to the curvature of a corneal layer of the eye;

forming a release layer on the annular surface;

forming a mask layer of a biocompatible metal such that the release layer is between the mask layer and the substrate; and

separating the mask layer from the substrate.

2. The method of claim 1, further comprising configuring a surface of the mask layer to have a blending characteristic.

3. The method of claim 2, wherein the surface of the mask layer is darkened to have a similar appearance to a pupil of the eye.

4. The method of claim 2, wherein a layer of carbon is formed on the surface of the mask.

5. The method of claim 1, wherein the substrate further comprises a planar portion and the annular surface is a convex surface protruding from the planar portion.

6. The method of claim 1, wherein forming the release layer comprises sputtering the release layer.

7. The method of claim 6, wherein forming the mask layer comprises sputtering the mask layer.

8. The method of claim 1, wherein forming the mask layer comprises sputtering the mask layer.

9. The method of claim 1, wherein the release layer is formed of a material that can be eroded by applying an etchant.

10. The method of claim 1, wherein the release layer comprises chromium.

11. The method of claim 10, wherein separating the mask layer from the substrate comprises immersing the release layer in a chromium etching bath.

12. The method of claim 1, wherein separating the mask layer from the substrate comprises immersing the release layer in an etchant.

13. The method of claim 1, wherein the mask layer comprises gold.

14. The method of claim 1, wherein the mask layer comprises tantalum.

15. The method of claim 1, wherein the mask layer is formed of titanium.

16. The method of claim 1, wherein the mask layer comprises a titanium alloy.

17. The method of claim 1, wherein the mask layer comprises platinum.

18. The method of claim 1, wherein the mask forming feature further comprises an outer recess extending from the outer periphery away from the central axis.

19. The method of claim 18, wherein the mask forming feature further comprises an inner recess extending from the inner periphery toward the central axis.

20. The method of claim 1, wherein separating the mask layer from the substrate comprises contacting the release layer with an agent that removes the release layer from the mask layer.

21. The method of claim 1 further comprising:

positioning in a process chamber a first target comprising a first material suitable for use as the release layer;

positioning in the process chamber adjacent to the first target a second target comprising the biocompatible metal;

sputtering the release layer from the first target; and

sputtering the mask layer from the second target.

22. The method of claim 1, further comprising forming a transport structure in the mask layer capable of substantially maintaining natural nutrient flow in adjacent tissue when the mask is applied to the eye.

23. The method of claim 22, wherein the transport structure is configured to not producing visible diffraction patterns.

24. The method of claim 1, further comprising

forming a first mask layer comprising an anterior tissue contacting surface and a first hole portion extending along a first axis;

and

forming a second mask layer comprising a posterior tissue contacting surface and a second hole portion extending along a second axis;

wherein the first and second transport axes are not collinear.