Stacked integrated component media insert for an ophthalmic device

• US 9,889,615 B2
• Filed: 01/26/2012
• Issued: 02/13/2018
• Est. Priority Date: 03/18/2011
• 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): BELL, WILLIAM P
• Application Number:
  US13/358,575
• Publication Number:
  US 20120234453A1
• Time in Patent Office: 2,210 Days
• Field of Search: 156242, 264 17
• 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: B29D 11/00826 with energy receptors for wireless energy transmission
• CPC Class Codes: B32B 38/1841 during laying up
• 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

Abstract

This invention discloses methods and apparatus for providing a media insert with an energy source to an ophthalmic lens. The energy source is capable of powering a component included within the ophthalmic lens. In some embodiments, an ophthalmic lens is cast molded from a silicone hydrogel and the component includes an electro-optical lens portion.

Claims

1. A method of forming a stacked integrated component media insert for an ophthalmic lens, the method comprising:

forming a plurality of substrate layers with functionality;

assembling the substrate layers into a stack;

forming electrical interconnections between the substrate layers;

encapsulating the stacked with one or more materials suitable for inclusion within a body of a molded ophthalmic lens;

wherein at least one of the substrate layers comprises a plurality of discrete portions,

wherein each of the discrete portions performs a separate function attributed to the discrete portion,

wherein at least two of the substrate layers in the stack have a different functionality, and

wherein each of the substrate layers in the stack has an annular shape or a portion of an annular shape having opposed non-intersecting arcuate edges configured to at least partially encircle the optical axis of the lens.

2. The method of claim 1, wherein one of the substrate layers comprises a solid state energy source.

3. The method of claim 2, additionally comprising placing a variable focus lens in proximity to the stacked integrated component media insert.

4. The method of claim 3, wherein the variable focus lens is fixed to the stacked integrated component media insert.

5. The method of claim 1, wherein the stacked integrated component media insert comprises an annular shape.

6. The method of claim 1, wherein the stacked integrated component media insert comprises an arcuate shape.

7. The method of claim 1, wherein at least a portion of one or more of the substrate layers comprises an adhesive film.

8. The method of claim 7, wherein two or more substrate layers are adhered to one another through the adhesive film in at least a portion of one or more of the substrate layers.

9. The method of claim 1, wherein the one or more materials for encapsulation comprises a polysilicone based polymer.

10. The method of claim 1, wherein at least one of the substrate layers comprises a semiconductor substrate with electronic circuitry in proximity to its first surface;

and at least another one of the substrate layers comprises an energizing component.

11. The method of claim 10, wherein one or more of the substrate layers comprises a semiconductor layer with electronic circuitry capable to control electric current flow from the energizing component.

12. The method of claim 11, additionally comprising an electroactive lens component within the ophthalmic device.

13. The method of claim 12, wherein the electronic circuitry is electrically connected to the electroactive lens component within the ophthalmic device.

14. The method of claim 1, wherein one or more of the substrate layers is a metallic layer that functions as an antenna.

15. The method of claim 1, wherein one or more of the substrate layers are electrically connected to a second substrate layer with at least one solder ball located between them.

16. The method of claim 1, wherein a first substrate layer is electrically connected to a second substrate layer with at least a wire bond between a contact pad located between them.

17. The method of claim 16, wherein the second substrate layer is shaped into at least a portion of an annulus with an external radius that is smaller than that of said first substrate layer.

18. The method of claim 1, wherein one or more of the substrate layers comprise a metallic feature surface.

19. The method of claim 18, wherein a solder film is placed upon the surface of the one or more substrate layers comprising the metallic feature surface.

20. The method of claim 1, wherein one of the discrete portions comprises at least one energy source and another one of the discrete portions comprises at least one of a semiconductor type chip, a passive electrical device and an optical device.

21. The method of claim 1, wherein the substrate layer comprising the discrete portions is an annular shape.

22. The method of claim 21, wherein each of the discrete portions comprises a portion of the annular shape.

23. The method of claim 1, wherein the assembled substrate layers are adhered to one or more insulating layers forming the stacked integrated component media insert.