U.S. patent application number 13/044743 was filed with the patent office on 2011-06-30 for ophthalmic lens media insert.
Invention is credited to Daniel B. Otts, Randall B. Pugh.
Application Number | 20110157544 13/044743 |
Document ID | / |
Family ID | 41116652 |
Filed Date | 2011-06-30 |
United States Patent
Application |
20110157544 |
Kind Code |
A1 |
Pugh; Randall B. ; et
al. |
June 30, 2011 |
OPHTHALMIC LENS MEDIA INSERT
Abstract
This invention discloses methods and apparatus for providing an
ophthalmic lens with media including an energy receptor. In some
embodiments, the media includes an insert placed in a cavity formed
to cast mold an ophthalmic lens from a reactive mixture.
Inventors: |
Pugh; Randall B.;
(Jacksonville, FL) ; Otts; Daniel B.;
(Jacksonville, FL) |
Family ID: |
41116652 |
Appl. No.: |
13/044743 |
Filed: |
March 10, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12405586 |
Mar 17, 2009 |
7931832 |
|
|
13044743 |
|
|
|
|
61040772 |
Mar 31, 2008 |
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Current U.S.
Class: |
351/158 ;
623/6.11 |
Current CPC
Class: |
G02C 7/04 20130101; B29D
11/00038 20130101; B29D 11/00826 20130101 |
Class at
Publication: |
351/158 ;
623/6.11 |
International
Class: |
G02C 11/00 20060101
G02C011/00; A61F 2/16 20060101 A61F002/16 |
Claims
1-11. (canceled)
12. A method of transmitting data to or from an ophthalmic lens
comprising an electrically powered component, the method comprising
the steps of: wirelessly transmitting energy to an energy receptor
portion of the lens; providing sufficient electrical energy to the
component to enable the component to output digital data; and
outputting digital data from the component.
13. The method of claim 12 wherein the ophthalmic lens comprises
and intraocular lens.
14. The method of claim 12 wherein the ophthalmic lens comprises a
contact lens.
15. The method of claim 12 wherein the step of wirelessly
transmitting energy comprises the transmission of radio waves to a
tuned antenna ink jetted onto a media comprising the lens.
16. The method of claim 12 wherein the step of wirelessly
transmitting energy comprises the transmission of magnetic power to
conductive material ink jetted onto a media comprising the
lens.
17. The method of claim 12, wherein the ophthalmic lens
additionally comprises a transmission component and the method
additionally comprises the steps of: providing sufficient
electrical energy to the transmission component to enable the
component to transmit at least a portion of output digital data;
and transmitting digital data from the component beyond the
boundaries of the lens.
Description
RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 12/405,586 filed on Mar. 17, 2009 which claims priority of
U.S. Patent Application Ser. No. 61/040,772, filed on Mar. 31,
2008.
FIELD OF USE
[0002] This invention describes methods and apparatus for the
fabrication of an energized ophthalmic lens and more specifically
of an ophthalmic lens with a media insert including an energy
source.
BACKGROUND
[0003] Traditionally an ophthalmic device, such as a contact lens,
an intraocular lens or a punctal plug included a biocompatible
device with a corrective, cosmetic or therapeutic quality. A
contact lens, for example, can provide one or more of: vision
correcting functionality; cosmetic enhancement; and therapeutic
effects. Each function is provided by a physical characteristic of
the lens. A design incorporating a refractive quality into a lens
can provide a vision corrective function. A pigment incorporated
into the lens can provide a cosmetic enhancement. An active agent
incorporated into a lens can provide a therapeutic functionality.
Such physical characteristics are accomplished without the lens
entering into an energized state.
[0004] More recently, it has been theorized that active components
may be incorporated into a contact lens. Some components can
include semiconductor devices. Some examples have shown
semiconductor devices embedded in a contact lens placed upon animal
eyes. However, such devices lack a free standing energizing
mechanism. Although wires may be run from a lens to a battery to
power such semiconductor devices, and it has been theorized that
the devices may be wirelessly powered, no mechanism for such
wireless power has been available.
[0005] It is desirable therefore to have additional methods and
apparatus conducive to the formation of ophthalmic lenses that are
wirelessly energized to an extent suitable for powering a
semiconductor device incorporated into a biomedical device, such as
an ophthalmic lens.
SUMMARY
[0006] Accordingly, the present invention includes methods and
apparatus for forming an ophthalmic lens, with an energized portion
capable of powering an active component. In some embodiments, the
ophthalmic lens will include a cast molded silicone hydrogel with a
media insert including energy receptor capable of wirelessly
receiving energy and powering an electronic component. The
energized portion can be created, for example via a jetting process
or a pad printing process or automated placement wherein a
conductive material is placed on a media incorporated into the
lens.
[0007] Additional embodiments include methods of forming an
ophthalmic lens which include the steps of depositing a media
including an energy receptor into a mold part for fashioning an
ophthalmic lens.
[0008] The energy receptor can be deposited onto the media via ink
jet, pad print, or mechanical placement. A reactive monomer mix is
placed into one of: the first mold part and the second mold part.
The first mold part is positioned proximate to the second mold part
thereby forming a lens cavity with the media including the energy
receptor and at least some of the reactive monomer mix in the lens
cavity; and exposing the reactive monomer mix to actinic
radiation.
[0009] Lenses are formed via the control of actinic radiation to
which the reactive monomer mixture is exposed.
DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates a mold assembly apparatus and media
according to some embodiments of the present invention.
[0011] FIG. 2A illustrates a top down view of an ophthalmic lens
with a media including a component and energy receptor.
[0012] FIG. 2B illustrates a side view of an ophthalmic lens with a
media including a component and energy receptor.
[0013] FIG. 3 illustrates an apparatus utilized to place a media
with an energy receptor in a lens mold.
[0014] FIG. 4 illustrates method steps according to some
embodiments of the present invention.
[0015] FIG. 5 illustrates method steps according to some additional
aspect of the present invention.
[0016] FIG. 6 illustrates a processor that may be used to implement
some embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention includes ophthalmic lenses and methods
of making the ophthalmic lenses. In particular, the present
invention includes an ophthalmic lens with a wireless energy
receptor and information processing component imparted to a lens or
lens mold part via media insert. In some embodiments, the present
invention includes a hydrogel contact lens including a media
comprising a generally annular energy receptor around a periphery
of an optic zone in the contact lens. Additional embodiments can
include an energy receptor portion that includes a coil or other
pattern of conductive material incorporated into a media included
in an ophthalmic lens. The pattern can be based upon a tuned
wavelength of energy which can be wirelessly transmitted to the
lens.
[0018] In some embodiments, a pattern of conductive material can be
located exterior to an optic zone through which a wearer of a lens
would see, while other embodiments can include a pattern of
conductive material which is small enough to not adversely affect
the sight of a contact lens wearer and therefore can be located
within, or exterior to, an optical zone.
[0019] In general, according to some embodiments of the present
invention, a media insert including an energy receptor is embodied
within an ophthalmic lens. In some embodiments, the energy receptor
can be deposited onto the media via a jet printing process which
places the receptor material in a desired location. The media
insert is mechanically placed in position relative to a mold part
used to fashion the lens. In some embodiments, a component is
placed in electrical communication with the receptor material
included on the media such that the receptor material can provide
electrical power to power the component. Subsequent to placement of
the media insert a Reactive Mixture can be shaped by respective
mold parts and polymerized to form the ophthalmic lens.
DEFINITIONS
[0020] As used herein, "energy receptor" refers to a medium that
functions as an antenna for receiving wireless energy, such as, for
example via radio wave transmission.
[0021] As used herein, "energy reception portion" refers to a
portion of a biomedical device, such as an ophthalmic lens, which
is functional as an energy receptor.
[0022] As referred to herein, "ink jet", refers an apparatus for
propelling droplets of liquid or molten material onto a media. Ink
jet apparatus can include, by way of non-limiting example, one or
more of: piezo electric ink jet apparatus; thermal ink jet and
continuous ink jet apparatus.
[0023] As referred to herein, the term "ink jetting" or "jetting"
refers to an action resulting in the propulsion of droplets or
molten material onto a media.
[0024] As used herein "lens" refers to any ophthalmic device that
resides in or on the eye. These devices can provide optical
correction or may be cosmetic. For example, the term lens can refer
to a contact lens, intraocular lens, overlay lens, ocular insert,
optical insert or other similar device through which vision is
corrected or modified, or through which eye physiology is
cosmetically enhanced (e.g. iris color) without impeding vision. In
some embodiments, the preferred lenses of the invention are soft
contact lenses are made from silicone elastomers or hydrogels,
which include but are not limited to silicone hydrogels, and
fluorohydrogels.
[0025] As used herein, the term "lens forming mixture" or "Reactive
Mixture" or "RMM"(reactive monomer mixture) refers to a monomer or
prepolymer material which can be cured and crosslinked or
crosslinked to form an ophthalmic lens. Various embodiments can
include lens forming mixtures with one or more additives such as:
UV blockers, tints, photoinitiators or catalysts, and other
additives one might desire in an ophthalmic lenses such as, contact
or intraocular lenses.
[0026] As used herein "lens forming surface" means a surface that
is used to mold a lens. In some embodiments, any such surface
103-104 can have an optical quality surface finish, which indicates
that it is sufficiently smooth and formed so that a lens surface
fashioned by the polymerization of a lens forming material in
contact with the molding surface is optically acceptable. Further,
in some embodiments, the lens forming surface 103-104 can have a
geometry that is necessary to impart to the lens surface the
desired optical characteristics, including without limitation,
spherical, aspherical and cylinder power, wave front aberration
correction, corneal topography correction and the like as well as
any combinations thereof.
[0027] As used herein, the term "media insert" refers to a rigid,
semi rigid or flexible platform for supporting an energy
receptor.
[0028] As used herein, the term "mold" refers to a rigid or
semi-rigid object that may be used to form lenses from uncured
formulations. Some preferred molds include two mold parts forming a
front curve mold part and a back curve mold part.
[0029] As used herein, "optical zone" means that area of an
ophthalmic lens through which a wearer of the ophthalmic lens
sees.
[0030] As used herein, "released from a mold," means that a lens is
either completely separated from the mold, or is only loosely
attached so that it can be removed with mild agitation or pushed
off with a swab.
Molds
[0031] Referring now to FIG. 1, a diagram of an exemplary mold 100
for an ophthalmic lens is illustrated with an energy receiving
portion 109. As used herein, the terms a mold includes a form 100
having a cavity 105 into which a lens forming mixture 110 can be
dispensed such that upon reaction or cure of the lens forming
mixture, an ophthalmic lens of a desired shape is produced. The
molds and mold assemblies 100 of this invention are made up of more
than one "mold parts" or "mold pieces" 101-102. The mold parts
101-102 can be brought together such that a cavity 105 is formed
between the mold parts 101-102 in which a lens can be formed. This
combination of mold parts 101-102 is preferably temporary. Upon
formation of the lens, the mold parts 101-102 can again be
separated for removal of the lens.
[0032] At least one mold part 101-102 has at least a portion of its
surface 103-104 in contact with the lens forming mixture such that
upon reaction or cure of the lens forming mixture 110 that surface
103-104 provides a desired shape and form to the portion of the
lens with which it is in contact. The same is true of at least one
other mold part 101-102.
[0033] Thus, for example, in a preferred embodiment a mold assembly
100 is formed from two parts 101-102, a female concave piece (front
piece) 102 and a male convex piece (back piece) 101 with a cavity
formed between them. The portion of the concave surface 104 which
makes contact with lens forming mixture has the curvature of the
front curve of an ophthalmic lens to be produced in the mold
assembly 100 and is sufficiently smooth and formed such that the
surface of an ophthalmic lens formed by polymerization of the lens
forming mixture which is in contact with the concave surface 104 is
optically acceptable.
[0034] In some embodiments, the front mold piece 102 can also have
an annular flange integral with and surrounding circular
circumferential edge 108 and extends from it in a plane normal to
the axis and extending from the flange (not shown).
[0035] A lens forming surface can include a surface 103-104 with an
optical quality surface finish, which indicates that it is
sufficiently smooth and formed so that a lens surface fashioned by
the polymerization of a lens forming material in contact with the
molding surface is optically acceptable. Further, in some
embodiments, the lens forming surface 103-104 can have a geometry
that is necessary to impart to the lens surface the desired optical
characteristics, including without limitation, spherical,
aspherical and cylinder power, wave front aberration correction,
corneal topography correction and the like as well as any
combinations thereof.
[0036] At 111, a media is illustrated onto which an energy receptor
may be placed, such as, for example, via ink jet or pad printing.
The media 111 may be any receiving material onto which supports the
conductive material. In some embodiments, the media 111 can be a
clear coat of a material which can be incorporated into a lens when
the lens is formed. The clear coat can include for example a
pigment as described below, a monomer or other biocompatible
material. Additional embodiments can include a media comprising an
insert, which can be either rigid or formable. In some embodiments,
a rigid insert may include an optical zone providing an optical
property (such as those utilized for vision correction) and a
non-optical zone portion. An energy receptor can be deposited on
one or both of the optic zone and non-optic zone of the insert.
[0037] Rigid inserts can include any material compatible with the
lens material and in various embodiments, may include opaque or
non-opaque materials.
[0038] Various embodiments also include ink jetting an energy
receptor onto an insert prior to placement of the insert into a
mold portion used to form a lens. An insert, or other media 111,
may also include one or more components which will receive an
electrical charge via the energy receptor 109.
[0039] Mold part 101-102 material can include a polyolefin of one
or more of: polypropylene, polystyrene, polyethylene, polymethyl
methacrylate, and modified polyolefins.
[0040] A preferred alicyclic co-polymer contains two different
alicyclic polymers and is sold by Zeon Chemicals L.P. under the
trade name ZEONOR. There are several different grades of ZEONOR.
Various grades may have glass transition temperatures ranging from
105.degree. C. to 160.degree. C. A specifically preferred material
is ZEONOR 1060R.
[0041] Other mold materials that may be combined with one or more
additives to form an ophthalmic lens mold include, for example,
Zieglar-Natta polypropylene resins (sometimes referred to as znPP).
On exemplary Zieglar-Natta polypropylene resin is available under
the name PP 9544 MED. PP 9544 MED is a clarified random copolymer
for clean molding as per FDA regulation 21 CFR (c)3.2 made
available by ExxonMobile Chemical Company. PP 9544 MED is a random
copolymer (znPP) with ethylene group (hereinafter 9544 MED). Other
exemplary Zieglar-Natta polypropylene resins include: Atofina
Polypropylene 3761 and Atofina Polypropylene 3620WZ.
[0042] Still further, in some embodiments, the molds of the
invention may contain polymers such as polypropylene, polyethylene,
polystyrene, polymethyl methacrylate, modified polyolefins
containing an alicyclic moiety in the main chain and cyclic
polyolefins. This blend can be used on either or both mold halves,
where it is preferred that this blend is used on the back curve and
the front curve consists of the alicyclic co-polymers.
[0043] In some preferred methods of making molds 100 according to
the present invention, injection molding is utilized according to
known techniques, however, embodiments can also include molds
fashioned by other techniques including, for example: lathing,
diamond turning, or laser cutting.
[0044] Typically, lenses are formed on at least one surface of both
mold parts 101-102. However, in some embodiments, one surface of a
lens may be formed from a mold part 101-102 and another surface of
a lens can be formed using a lathing method, or other methods.
Lenses
[0045] Referring now to FIG. 2A, an ophthalmic lens 201 is
illustrated with an energy receptor 109 and a component 203. As
illustrated, the energy receptor 109 can include a conductive
material, such as, for example, carbon fibers; carbon
nano-structures, including carbon nano tubes; and a metallic
material. Suitable metallic materials can include, for example,
gold, silver and copper. Carbon nanostructures can include single
walled carbon nanotubes or multiple walled carbon nanotubes.
[0046] The energy receptor 109 can be in electrical communication
with a component 203. The component 203 can include any device
which responds to an electrical charge with a change in state, such
as, for example: a semiconductor type chip; a passive electrical
device; or an optical device such as a crystal lens. In some
specific embodiments, the component 203 includes an electrical
storage device, such as, for example, a capacitor; ultracapacitor;
supercapacitor; a battery or other storage component. An electrical
storage component 203 can include, for example: a lithium ion
battery located in the periphery of an ophthalmic lens outside of
the optic zone and be chargeable via one or more of radio frequency
and magnetic inductance into an energy receptor deposited via ink
jetting. Other electrical storage device components may also
receive an electrical charge via the energy receptor 109.
[0047] Other exemplary embodiments can include a component
comprising a radio frequency identification chip ("RFID chip")
chip. The component 203 may also include multiple devices or
circuitry. In an effort to provide simplicity in this description,
the one or more devices will generally be referred to in the
singular, as a component 203.
[0048] FIG. 2B further illustrates that an energy receptor 109 can
be placed; ink jetted or pad printed in a pattern 109A onto the
media 111. A pattern 109A can be used to increase the electrical
length of an energy receptor present in the lens. In addition, a
pattern 109A can be tuned to a wireless wavelength to facilitate or
control efficient wireless transfer of energy.
[0049] As illustrated, in some embodiments, the energy receptor
portion 109 and the component 203 is located outside of an optic
zone 202, wherein the optic zone 202 includes that portion of the
lens 201 providing line of sight for a wearer of the lens 201.
Other embodiments may include an energy receptor 109 in the optic
zone portion of an ophthalmic lens. For example, such embodiments
can include a receptor portion 109 of conductive particles too
small to be viewable without aid to the human eye.
[0050] In some embodiments, a preferred lens type can include a
lens 201 that includes a silicone containing component. A
"silicone-containing component" is one that contains at least one
[--Si--O--] unit in a monomer, macromer or prepolymer. Preferably,
the total Si and attached O are present in the silicone-containing
component in an amount greater than about 20 weight percent, and
more preferably greater than 30 weight percent of the total
molecular weight of the silicone-containing component. Useful
silicone-containing components preferably comprise polymerizable
functional groups such as acrylate, methacrylate, acrylamide,
methacrylamide, vinyl, N-vinyl lactam, N-vinylamide, and styryl
functional groups.
[0051] Suitable silicone containing components include compounds of
Formula I
##STR00001##
where
[0052] R.sup.1 is independently selected from monovalent reactive
groups, monovalent alkyl groups, or monovalent aryl groups, any of
the foregoing which may further comprise functionality selected
from hydroxy, amino, oxa, carboxy, alkyl carboxy, alkoxy, amido,
carbamate, carbonate, halogen or combinations thereof; and
monovalent siloxane chains comprising 1-100 Si--O repeat units
which may further comprise functionality selected from alkyl,
hydroxy, amino, oxa, carboxy, alkyl carboxy, alkoxy, amido,
carbamate, halogen or combinations thereof;
[0053] where b=0 to 500, where it is understood that when b is
other than 0, b is a distribution having a mode equal to a stated
value;
[0054] wherein at least one R.sup.1 comprises a monovalent reactive
group, and in some embodiments between one and 3 R.sup.1 comprise
monovalent reactive groups.
[0055] As used herein "monovalent reactive groups" are groups that
can undergo free radical and/or cationic polymerization.
Non-limiting examples of free radical reactive groups include
(meth)acrylates, styryls, vinyls, vinyl ethers,
C.sub.1-6alkyl(meth)acrylates, (meth)acrylamides,
C.sub.1-6alkyl(meth)acrylamides, N-vinyllactams, N-vinylamides,
C.sub.2-12alkenyls, C.sub.2-12alkenylphenyls,
C.sub.2-12alkenylnaphthyls, C.sub.2-6alkenylphenylC.sub.1-6alkyls,
O-vinylcarbamates and O-vinylcarbonates. Non-limiting examples of
cationic reactive groups include vinyl ethers or epoxide groups and
mixtures thereof. In one embodiment the free radical reactive
groups comprises (meth)acrylate, acryloxy, (meth)acrylamide, and
mixtures thereof.
[0056] Suitable monovalent alkyl and aryl groups include
unsubstituted monovalent C.sub.1 to C.sub.16alkyl groups,
C.sub.6-C.sub.14 aryl groups, such as substituted and unsubstituted
methyl, ethyl, propyl, butyl, 2-hydroxypropyl, propoxypropyl,
polyethyleneoxypropyl, combinations thereof and the like.
[0057] In one embodiment b is zero, one R.sup.1 is a monovalent
reactive group, and at least 3 R.sup.1 are selected from monovalent
alkyl groups having one to 16 carbon atoms, and in another
embodiment from monovalent alkyl groups having one to 6 carbon
atoms. Non-limiting examples of silicone components of this
embodiment include
2-methyl-,2-hydroxy-3-[3-[1,3,3,3-tetramethyl-1-[(trimethylsilyl)oxy]disi-
loxanyl]propoxy]propyl ester ("SiGMA"),
2-hydroxy-3-methacryloxypropyloxypropyl-tris(trimethylsiloxy)silane,
3-methacryloxypropyltris(trimethylsiloxy)silane ("TRIS"),
3-methacryloxypropylbis(trimethylsiloxy)methylsilane and
3-methacryloxypropylpentamethyl disiloxane.
[0058] In another embodiment, b is 2 to 20, 3 to 15 or in some
embodiments 3 to 10; at least one terminal R.sup.1 comprises a
monovalent reactive group and the remaining R.sup.1 are selected
from monovalent alkyl groups having 1 to 16 carbon atoms, and in
another embodiment from monovalent alkyl groups having 1 to 6
carbon atoms. In yet another embodiment, b is 3 to 15, one terminal
R.sup.1 comprises a monovalent reactive group, the other terminal
R.sup.1 comprises a monovalent alkyl group having 1 to 6 carbon
atoms and the remaining R.sup.1 comprise monovalent alkyl group
having 1 to 3 carbon atoms. Non-limiting examples of silicone
components of this embodiment include
(mono-(2-hydroxy-3-methacryloxypropyl)-propyl ether terminated
polydimethylsiloxane (400-1000 MW)) ("OH-mPDMS"),
monomethacryloxypropyl terminated mono-n-butyl terminated
polydimethylsiloxanes (800-1000 MW), ("mPDMS").
[0059] In another embodiment b is 5 to 400 or from 10 to 300, both
terminal R.sup.1 comprise monovalent reactive groups and the
remaining R.sup.1 are independently selected from monovalent alkyl
groups having 1 to 18 carbon atoms which may have ether linkages
between carbon atoms and may further comprise halogen.
[0060] In one embodiment, where a silicone hydrogel lens is
desired, the lens of the present invention will be made from a
reactive mixture comprising at least about 20 and preferably
between about 20 and 70% wt silicone containing components based on
total weight of reactive monomer components from which the polymer
is made.
[0061] In another embodiment, one to four R.sup.1 comprises a vinyl
carbonate or carbamate of the formula:
##STR00002##
[0062] wherein: Y denotes O--, S-- or NH--;
R denotes, hydrogen or methyl; d is 1, 2, 3 or 4; and q is 0 or
1.
[0063] The silicone-containing vinyl carbonate or vinyl carbamate
monomers specifically include:
1,3-bis[4-(vinyloxycarbonyloxy)but-1-yl]tetramethyl-disiloxane;
3-(vinyloxycarbonylthio)propyl-[tris(trimethylsiloxy)silane];
3-[tris(trimethylsiloxy)silyl]propyl allyl carbamate;
3-[tris(trimethylsiloxy)silyl]propyl vinyl carbamate;
trimethylsilylethyl vinyl carbonate; trimethylsilylmethyl vinyl
carbonate, and
##STR00003##
[0064] Where biomedical devices with modulus below about 200 are
desired, only one R.sup.1 shall comprise a monovalent reactive
group and no more than two of the remaining R.sup.1 groups will
comprise monovalent siloxane groups.
[0065] Another class of silicone-containing components includes
polyurethane macromers of the following formulae:
(*D*A*D*G).sub.a*D*D*E.sup.1;
E(*D*G*D*A).sub.a*D*G*D*E.sup.1 or;
E(*D*A*D*G).sub.a*D*A*D*E.sup.1 Formulae IV-VI
wherein:
[0066] D denotes an alkyl diradical, an alkyl cycloalkyl diradical,
a cycloalkyl diradical, an aryl diradical or an alkylaryl diradical
having 6 to 30 carbon atoms,
[0067] G denotes an alkyl diradical, a cycloalkyl diradical, an
alkyl cycloalkyl diradical, an aryl diradical or an alkylaryl
diradical having 1 to 40 carbon atoms and which may contain ether,
thio or amine linkages in the main chain;
[0068] denotes a urethane or ureido linkage;
[0069] .sub.a is at least 1;
[0070] A denotes a divalent polymeric radical of formula:
##STR00004##
R.sup.11 independently denotes an alkyl or fluoro-substituted alkyl
group having 1 to 10 carbon atoms which may contain ether linkages
between carbon atoms; y is at least 1; and p provides a moiety
weight of 400 to 10,000; each of E and E.sup.1 independently
denotes a polymerizable unsaturated organic radical represented by
formula:
##STR00005##
wherein: R.sup.12 is hydrogen or methyl; R.sup.13 is hydrogen, an
alkyl radical having 1 to 6 carbon atoms, or a --CO--Y--R.sup.15
radical wherein Y is --O--Y--S-- or --NH--; R.sup.14 is a divalent
radical having 1 to 12 carbon atoms; X denotes --CO-- or --OCO--; Z
denotes --O-- or --NH--; Ar denotes an aromatic radical having 6 to
30 carbon atoms; w is 0 to 6; x is 0 or 1; y is 0 or 1; and z is 0
or 1.
[0071] A preferred silicone-containing component is a polyurethane
macromer represented by the following formula:
##STR00006##
wherein R.sup.16 is a diradical of a diisocyanate after removal of
the isocyanate group, such as the diradical of isophorone
diisocyanate. Another suitable silicone containing macromer is
compound of formula X (in which x+y is a number in the range of 10
to 30) formed by the reaction of fluoroether, hydroxy-terminated
polydimethylsiloxane, isophorone diisocyanate and
isocyanatoethylmethacrylate.
##STR00007##
[0072] Other silicone containing components suitable for use in
this invention include macromers containing polysiloxane,
polyalkylene ether, diisocyanate, polyfluorinated hydrocarbon,
polyfluorinated ether and polysaccharide groups; polysiloxanes with
a polar fluorinated graft or side group having a hydrogen atom
attached to a terminal difluoro-substituted carbon atom;
hydrophilic siloxanyl methacrylates containing ether and siloxanyl
linkanges and crosslinkable monomers containing polyether and
polysiloxanyl groups. Any of the foregoing polysiloxanes can also
be used as the silicone containing component in this invention.
Processes
[0073] The following method steps are provided as examples of
processes that may be implemented according to some aspects of the
present invention. It should be understood that the order in which
the method steps are presented is not meant to be limiting and
other orders may be used to implement the invention. In addition,
not all of the steps are required to implement the present
invention and additional steps may be included in various
embodiments of the present invention.
[0074] Referring now to FIG. 4, a flowchart illustrates exemplary
steps that may be used to implement the present invention, at 401,
a conductive material which can act as an energy receptor 109 is
applied to a media. The media 111 may or may not also contain one
or more of: a component 203, battery and capacitor or other energy
storage device.
[0075] At 402, a reactive monomer mix can be deposited into a mold
part 101-102.
[0076] At 403, the media 111 with the energy receptor 109 can be
placed into the mold part 101-102. In some preferred embodiments,
the media 111 is placed in the mold part 101-102 via mechanical
placement. Mechanical placement can include, for example, a robot
or other automation, such as those known in the industry to place
surface mount components. Human placement of a media 111 with an
energy receptor 109 is also within the scope of the present
invention. Accordingly, any mechanical placement effective to place
a media 111 with an energy receptor 109 within a cast mold part
such that the polymerization of a Reactive Mixture 110 contained by
the mold part will include the energy receptor 109 in a resultant
ophthalmic lens.
[0077] In some embodiments, a binder layer 111 can be applied to a
mold part 101-102 prior to placement of the energy receptor on the
mold part 101-102. A binder layer 111 can include, by way of
non-limiting example, a pigment or a monomer. The binding layer may
be applied for example via an ink jetting or pad printing process.
In some embodiments, a processor device, 203 may also be placed
into the binder 109 in electrical contact with the ink jetted
energy receptor 111.
[0078] At 404, the first mold part can be placed proximate to the
second mold part to form a lens forming cavity with at least some
of the reactive monomer mix and the energy receptor in the cavity.
At 405, the reactive monomer mix within the cavity can be
polymerized. Polymerization can be accomplished for example via
exposure to one or both of actinic radiation and heat. At 406, the
lens is removed from the mold parts.
[0079] In some embodiments, a binding layer can include a binding
polymer that is capable of forming an interpenetrating polymer
network with a lens material, the need for formation of covalent
bonds between the binder and lens material to form a stable lens
110 is eliminated. Stability of a lens 110 with an energy receptor
placed into the binder is provided by entrapment of the energy
receptor 109 in the binding polymer and the lens base polymer. The
binding polymers of the invention can include, for example, those
made from a homopolymer or copolymer, or combinations thereof,
having similar solubility parameters to each other and the binding
polymer has similar solubility parameters to the lens material.
Binding polymers may contain functional groups that render the
polymers and copolymers of the binding polymer capable of
interactions with each other. The functional groups can include
groups of one polymer or copolymer interact with that of another in
a manner that increases the density of the interactions helping to
inhibit the mobility of and/or entrap the pigment particles. The
interactions between the functional groups may be polar,
dispersive, or of a charge transfer complex nature. The functional
groups may be located on the polymer or copolymer backbones or be
pendant from the backbones.
[0080] By way of non-limiting example, a monomer, or mixture of
monomers, that form a polymer with a positive charge may be used in
conjunction with a monomer or monomers that form a polymer with a
negative charge to form the binding polymer. As a more specific
example, methacrylic acid ("MAA") and 2-hydroxyethylmethacrylate
("HEMA") may be used to provide a MAA/HEMA copolymer that is then
mixed with a HEMA/3-(N,N-dimethyl) propyl acrylamide copolymer to
form the binding polymer.
[0081] As another example, the binding polymer may be composed of
hydrophobically-modified monomers including, without limitation,
amides and esters of the formula:
CH.sub.3(CH.sub.2).sub.x-L-COCHR.dbd.CH.sub.2
wherein L may be --NH or oxygen, x may be a whole number from 2 to
24, R may be a C.sub.1 to C.sub.6 alkyl or hydrogen and preferably
is methyl or hydrogen. Examples of such amides and esters include,
without limitation, lauryl methacrylamide, and hexyl methacrylate.
As yet another example, polymers of aliphatic chain extended
carbamates and ureas may be used to form the binding polymer.
[0082] Binding polymers suitable for a binding layer may also
include a random block copolymer of HEMA, MAA and lauryl
methacrylate ("LMA"), a random block copolymer of HEMA and MAA or
HEMA and LMA, or a homopolymer of HEMA. The weight percentages,
based on the total weight of the binding polymer, of each component
in these embodiments is about 93 to about 100 weight percent HEMA,
about 0 to about 2 weight percent MAA, and about 0 to about 5
weight percent LMA.
[0083] The molecular weight of the binding polymer can be such that
it is somewhat soluble in the lens material and swells in it. The
lens material diffuses into the binding polymer and is polymerized
and/or cross-linked. However, at the same time, the molecular
weight of the binding polymer cannot be so high as to impact the
quality of the printed image. Preferably, the molecular weight of
the binding polymer is about 7,000 to about 100,000, more
preferably about 7,000 to about 40,000, most preferably about
17,000 to about 35,000 M.sub.peak which corresponds to the
molecular weight of the highest peak in the SEC analyses
(=(M.sub.n.times.M.sub.w).sup.1/2)
[0084] For purposes of the invention, the molecular weight can be
determined using a gel permeation chromatograph with a 90.degree.
light scattering and refractive index detectors. Two columns of
PW4000 and PW2500, a methanol-water eluent of 75/25 wt/wt adjusted
to 50 mM sodium chloride and a mixture of polyethylene glycol and
polyethylene oxide molecules with well defined molecular weights
ranging from 325,000 to 194 are used.
[0085] One ordinarily skilled in the art will recognize that, by
using chain transfer agents in the production of the binding
polymer, by using large amounts of initiator, by using living
polymerization, by selection of appropriate monomer and initiator
concentrations, by selection of amounts and types of solvent, or
combinations thereof, the desired binding polymer molecular weight
may be obtained. Preferably, a chain transfer agent is used in
conjunction with an initiator, or more preferably with an initiator
and one or more solvents to achieve the desired molecular weight.
Alternatively, small amounts of very high molecular weight binding
polymer may be used in conjunction with large amounts of solvent to
maintain a desired viscosity for the binding polymer. Preferably,
the viscosity of the binding polymer will be about 4,000 to about
15,000 centipoise at 23.degree. C.
[0086] Chain transfer agents useful in forming the binding polymers
used in the invention have chain transfer constants values of
greater than about 0.01, preferably greater than about 7, and more
preferably greater than about 25,000.
[0087] Any desirable initiators may be used including, without
limitation, ultra-violet, visible light, thermal initiators and the
like and combinations thereof. Preferably, a thermal initiator is
used, more preferably 2,2-azobis isobutyronitrile and 2,2-azobis
2-methylbutyronitrile. The amount of initiator used will be about
0.1 to about 5 weight percent based on the total weight of the
formulation. Preferably, 2,2-azobis 2-methylbutyronitrile is used
with dodecanethiol.
[0088] A binding polymer layer or other media 111 may be made by
any convenient polymerization process including, without
limitation, radical chain polymerization, step polymerization,
emulsion polymerization, ionic chain polymerization, ring opening,
group transfer polymerization, atom transfer polymerization, and
the like. Preferably, a thermal-initiated, free-radical
polymerization is used. Conditions for carrying out the
polymerization are within the knowledge of one ordinarily skilled
in the art.
[0089] Solvents useful in the production of the binding polymer are
medium boiling solvents having boiling points between about 120 and
230.degree. C. Selection of the solvent to be used will be based on
the type of binding polymer to be produced and its molecular
weight. Suitable solvents include, without limitation, diacetone
alcohol, cyclohexanone, isopropyl lactate, 3-methoxy 1-butanol,
1-ethoxy-2-propanol, and the like.
[0090] In some embodiments, a binding polymer layer 111 of the
invention may be tailored, in terms of expansion factor in water,
to the lens material with which it will be used. Matching, or
substantially matching, the expansion factor of the binding polymer
with that of the cured lens material in packing solution may
facilitate the avoidance of development of stresses within the lens
that result in poor optics and lens parameter shifts. Additionally,
the binding polymer can be swellable in the lens material,
permitting swelling of the image printed using the colorant of the
invention. Due to this swelling, the image becomes entrapped within
the lens material without any impact on lens comfort.
[0091] In some embodiments, colorants may be included in the
binding layer. Pigments useful with the binding polymer in the
colorants of the invention are those organic or inorganic pigments
suitable for use in contact lenses, or combinations of such
pigments. The opacity may be controlled by varying the
concentration of the pigment and opacifying agent used, with higher
amounts yielding greater opacity. Illustrative organic pigments
include, without limitation, pthalocyanine blue, pthalocyanine
green, carbazole violet, vat orange # 1, and the like and
combinations thereof. Examples of useful inorganic pigments
include, without limitation, iron oxide black, iron oxide brown,
iron oxide yellow, iron oxide red, titanium dioxide, and the like,
and combinations thereof. In addition to these pigments, soluble
and non-soluble dyes may be used including, without limitation,
dichlorotriazine and vinyl sulfone-based dyes. Useful dyes and
pigments are commercially available.
[0092] Coating, or wetting, of the pigment particles with binding
polymer provides better dispersion of the pigment particles in the
bulk binding polymer. The coating may be achieved by use of
electrostatic, dispersive, or hydrogen bonding forces to cover the
pigment's surface. Preferably, a high shear force is used to
disperse the pigment into the binding polymer. The pigment may be
added to the binding polymer by dispensing the polymer and pigment
into a suitable mixer, such as a rotary shaft mixer and mixing
until a homogeneous mixture results, typically for a period of up
to about 30 minutes. The mixture may be then fed into a high shear
mill, such as an Eiger mill to disperse the pigment into the
binding polymer. Repeated milling is carried out as necessary to
achieve complete dispersion. Generally, milling is carried out
until the pigments are about 0.2 to about 3 microns in size.
Milling may be carried out using any suitable, commercially
available device including, without limitation, a high shear or
ball milling device.
[0093] In addition to the pigment and binding polymer, in some
embodiments, the binding layer contains one or more solvents that
aid in coating of the binding layer onto the mold part 101-102. It
is another discovery of the invention that, to facilitate a binding
layer that does not bleed or run on the mold part 101-102 surface
to which it is applied, it is desirable, and preferred, that the
binding layer 101-102 have a surface tension below about 27 mN/m.
This surface tension may be achieved by treatment of the surface,
for example a mold surface, to which the binding layer will be
applied. Surface treatments may be effected by methods known in the
art, such as, but not limited to plasma and corona treatments.
Alternatively, and preferably, the desired surface tension may be
achieved by the choice of solvents used in the colorant.
[0094] Accordingly, exemplary solvents useful in the binding layer
include those solvents that are capable of increasing or decreasing
the viscosity of the binding layer and aiding in controlling the
surface tension. Suitable solvents include, without limitation,
cyclopentanones, 4-methyl-2-pentanone, 1-methoxy-2-propanol,
1-ethoxy-2-propanol, isopropyl lactate and the like and
combinations thereof. Preferably, 1-ethoxy-2-propanol and isopropyl
lactate are used.
[0095] In some preferred embodiments, at least three different
solvents are used in the binding layer material of the invention.
The first two of these solvents, both medium boiling point
solvents, are used in the production of the binding polymer.
Although these solvents may be stripped from the binding polymer
after its formation, it is preferred that they are retained.
Preferably, the two solvents are 1-ethoxy-2-propanol and isopropyl
lactate. An additional low boiling solvent, meaning a solvent the
boiling point of which is between about 75 and about 120.degree.
C., can be used to decrease the viscosity of the colorant as
desired. Suitable low boiling solvents include, without limitation,
2-propanol, 1-methoxy-2-propanol, 1-propanol, and the like and
combinations thereof. Preferably, 1-propanol is used.
[0096] The specific amount of solvents used can depend on a number
of factors. For example, the amount of solvents used in forming the
binding polymer will depend upon the molecular weight of the
binding polymer desired and the constituents, such as the monomers
and copolymers, used in the binding polymer. The amount of low
boiling solvent used will depend upon the viscosity and surface
tension desired for the colorant. Further, if the colorant is to be
applied to a mold and cured with a lens material, the amount of
solvent used will depend upon the lens and mold materials used and
whether the mold material has undergone any surface treatment to
increase its wettability. Determination of the precise amount of
solvent to be used is within the skill of one ordinarily skilled in
the art. Generally, the total weight of the solvents used will be
about 40 to about 75 weight percent of solvent will be used.
[0097] In addition to the solvents, a plasticizer may be and,
preferably is, added to the binding layer to reduce cracking during
the drying of the binding layer and to enhance the diffusion and
swelling of the binding layer by the lens material. The type and
amount of plasticizer used will depend on the molecular weight of
the binding polymer used and, for colorants placed onto molds that
are stored prior to use, the shelf-life stability desired. Useful
plasticizers include, without limitation, glycerol, propylene
glycol, dipropylene glycol, tripropylene glycol, polyethylene
glycol 200, 400, or 600, and the like and combinations thereof.
Preferably, glycerol is used. Amounts of plasticizer used generally
will be 0 to about 10 weight percent based on the weight of the
colorant.
[0098] One ordinarily skilled in the art will recognize that
additives other than those discussed also may be included in the
binding layer composition of the invention. Suitable additives
include, without limitation, additives that aid flow and leveling,
additives for foam prevention, additives for rheology modification,
and the like, and combinations thereof.
[0099] In some embodiments of the present invention, the binding
layer becomes embedded in the lens material upon curing of the lens
material. Thus, the binding layer may embed closer to the front or
back surface of the lens formed depending on the surface of the
mold to which the lens the binding layer 11 is applied.
Additionally, one or more layers of binding layer 11 may be applied
in any order.
[0100] Although invention may be used to provide hard or soft
contact lenses made of any known lens material, or material
suitable for manufacturing such lenses, preferably, the lenses of
the invention are soft contact lenses having water contents of
about 0 to about 90 percent. More preferably, the lenses are made
of monomers containing hydroxy groups, carboxyl groups, or both or
be made from silicone-containing polymers, such as siloxanes,
hydrogels, silicone hydrogels, and combinations thereof. Material
useful for forming the lenses of the invention may be made by
reacting blends of macromers, monomers, and combinations thereof
along with additives such as polymerization initiators. Suitable
materials include, without limitation, silicone hydrogels made from
silicone macromers and hydrophilic monomers.
[0101] Referring now again to FIG. 4, at 403, the media 111 is
positioned with the reactive mixture in between a first mold part
and a second mold part with the media 111 in contact with the
reactive mixture 110.
[0102] At 404, a first mold part 101 is placed proximate to the
second mold part 102 to form a lens cavity with the Reactive
Monomer mix 110 and the media insert 111 in the lens cavity. At
405, the reactive mixture is polymerized, such as for example via
exposure to one or both of actinic radiation and heat. At 406, an
ophthalmic device 201 incorporating the energy receptor 109 is
removed from the mold parts 101-102 used to form an ophthalmic lens
202.
[0103] Referring now to FIG. 5 in another aspect of the present
invention, a component 203 incorporated into an ophthalmic device
201 can be powered via wirelessly transmitted energy. At 501,
wireless energy is transmitted to an energy receptor included with
a media and incorporated into an ophthalmic lens, such as an
ophthalmic lens. In some embodiments, the energy can be transmitted
at a frequency tuned to an energy receptor 111 included in an
ophthalmic lens 201. At 502, energy is received into the energy
receptor included in the ophthalmic lens. In some embodiments, the
energy receptor 111 can store the energy as an electrical
charge.
[0104] At 503, the energy received is directed into the information
component 203. The energy can be directed, for example, via
electrical circuitry capable of conducting the electrical charge.
At 504 the component 203 performs some action on information. The
action can include one or more of: receiving, transmitting, storing
and manipulating information. Preferred embodiments will include
the information being processed and stored as digital values.
[0105] At 505, in some embodiments, information can be transmitted
from the processing device. Some embodiments can also include the
transmission of information based upon the action performed upon
the information.
Apparatus
[0106] Referring now to FIG. 3, an automation apparatus 310 is
illustrated with one or more media handling devices 311. As
illustrated, multiple mold parts, each with an associated media 314
can be contained on a pallet 313 and presented to an ink jetting
nozzle 311. Embodiments, can include a media handling device 311
individually placing energy receptors 109 in respective media 314,
or multiple media handling devices 311 simultaneously placing media
with energy receptors respective mold parts 314.
[0107] Referring now to FIG. 6 a controller 600 is illustrated that
may be used in some embodiments of the present invention. The
controller 603 includes a processor 610, which may include one or
more processor components coupled to a communication device 620. In
some embodiments, a controller 600 can be used to transmit energy
to the energy receptor placed in the ophthalmic lens.
[0108] The controller can include a one or more processors, coupled
to a communication device configured to communicate energy via a
communication channel. The communication device may be used to
electronically control one or more of: the transfer of energy to
the ophthalmic lens receptor and the transfer of digital data to
and from an ophthalmic lens.
[0109] The communication device 620 may be used to communicate, for
example, with one or more controller apparatus or manufacturing
equipment components, such as for example ink jet printing
apparatus for ink jetting conductive material.
[0110] The processor 610 is also in communication with a storage
device 630. The storage device 630 may comprise any appropriate
information storage device, including combinations of magnetic
storage devices (e.g., magnetic tape and hard disk drives), optical
storage devices, and/or semiconductor memory devices such as Random
Access Memory (RAM) devices and Read Only Memory (ROM) devices.
[0111] The storage device 630 can store a program 616 for
controlling the processor 610. The processor 610 performs
instructions of the program 616, and thereby operates in accordance
with the present invention. For example, the processor 610 may
receive information descriptive of media placement, processing
device placement, and the like. The storage device 630 can also
store ophthalmic related data in one or more databases. The
database may include customized energy receptor designs, metrology
data, and specific control sequences for ink jetting conductive
material to form an energy receptor.
[0112] In some embodiments, an ophthalmic lens with a component,
such as processor device can be matched with a wireless energy
source located on the person in such form factors as jewelry, shirt
collar, hat, or into a pair of glasses.
CONCLUSION
[0113] The present invention, as described above and as further
defined by the claims below, provides methods of processing
ophthalmic lenses and apparatus for implementing such methods, as
well as ophthalmic lenses formed thereby.
* * * * *