Method of forming a functionalized insert with segmented ring layers for an ophthalmic lens

• US 9,102,111 B2
• Filed: 02/22/2012
• Issued: 08/11/2015
• Est. Priority Date: 03/21/2011
• Status: Active Grant

• Current Assignee: Johnson & Johnson Vision Care Incorporated (Johnson & Johnson)
• Original Assignee: Johnson & Johnson Vision Care Incorporated (Johnson & Johnson)
• Inventors: Pugh, Randall B., Flitsch, Frederick A., Otts, Daniel B., Riall, James Daniel, Toner, Adam
• Primary Examiner(s): GRAY, LINDA LAMEY
• Application Number:
  US13/402,273
• Publication Number:
  US 20130213568A1
• Time in Patent Office: 1,266 Days
• Field of Search: 156/263, 156/264, 156/266, 351/159.73, 623/618, 623/622
• US Class Current: 1/1
• CPC Class Codes: B29D 11/00038 Production of contact lenses
• CPC Class Codes: B29D 11/00817 Producing electro-active lenses or lenses with energy receptors, e.g. batteries or antennas
• CPC Class Codes: G02C 7/02 Lenses; Lens systems ; Methods of designing lenses
• CPC Class Codes: G02C 7/04 Contact lenses for the eyes disinfection or sterilisation of contact lenses A61L12/00
• CPC Class Codes: G02C 7/083 Electrooptic lenses
• CPC Class Codes: G02C 7/101 having an electro-optical light valve electro-optical elements per se G02F
• CPC Class Codes: Y10T 156/1075 of plural laminae from single stock and assembling to each other or to additional lamina

Abstract

The present invention relates to a method of forming an insert for contact lens. The insert having rings and ring segments that make up functionalized layers in a functional layer insert, for incorporation into an ophthalmic lens. The layer insert which can include substrate layers that are intact full rings, segmented rings or a combination of both. The method includes the steps of forming the ring segments, assembling the ring segments into ring substrate layers, forming electrical interconnections and encapsulating the insert in a contact lens.

Claims

1. A method of forming an active lens insert for an ophthalmic lens, the method comprising:

forming arcuate shape ring segments;

assembling said arcuate shape ring segments into ring substrate layers, which are formed into a stack with one or both of electrical and logical functionality;

wherein a size, a shape and a stacking structure for the stacked ring substrate layers is based on a predetermined thickness in a region around an optical zone of the ophthalmic lens;

forming electrical interconnections between the ring substrate layers to create an active lens insert; and

encapsulating the active lens insert with one or more materials that may be bonded within a body of a molded ophthalmic lens.

2. The method of claim 1, additionally comprising adhering the substrate layers to insulating layers thereby forming a stacked feature.

3. The method of claim 1, wherein the arcuate shaped ring segments are cut from a wafer.

4. The method of claim 1, wherein one or more of the arcuate shaped ring segments have one or both tapered ends.

5. The method of claim 1, wherein the arcuate ring segments comprise Arc Matched segments.

6. The method of claim 1, wherein two or more of the arcuate ring segments can form a full ring.

7. The method of claim 1, wherein a design of each of the arcuate ring segments is based on factors comprising functionality optimization.

8. The method of claim 7, wherein a design of each of the arcuate ring segments is further based on surface area maximization of the arcuate ring segments within the active lens insert.

9. The method of claim 1, wherein the arcuate ring segments sections are non-arc matched segments.

10. The method of claim 1, wherein the arcuate ring segments comprise both Arc Matched sections and non-arc matched segments.

11. The method of claim 1, wherein the substrate layers include both said ring substrate layers from the arcuate shape ring and full ring sections.

12. The method of claim 11, wherein the full ring substrate layer comprises a metallic layer which functions as an antenna.

13. The method of claim 1, wherein the size, shape and stacking structure of each ring substrate layers is further based on a base curve of an ophthalmic lens.

14. The method of claim 1, wherein the size, shape and stacking structure of the ring substrate layers is further based on a diameter of an ophthalmic lens.

15. The method of claim 1, wherein the size, shape and stacking structure of the ring substrate layers is further based on encapsulation parameters of the active lens insert.

16. The method of claim 1, wherein the substrate layers comprise silicon based wafer layers.

17. The method of claim 1, wherein the substrate layers comprise ceramic based wafer layers.

18. The method of claim 1, wherein the substrate layers comprise polymide film based wafer layers.