U.S. patent application number 17/155029 was filed with the patent office on 2021-05-13 for methods and apparatus for biomedical devices with customized appearance.
The applicant listed for this patent is Johnson & Johnson Vision Care, Inc.. Invention is credited to Frederick A. Flitsch, Randall B. Pugh.
Application Number | 20210141243 17/155029 |
Document ID | / |
Family ID | 1000005358763 |
Filed Date | 2021-05-13 |
![](/patent/app/20210141243/US20210141243A1-20210513\US20210141243A1-2021051)
United States Patent
Application |
20210141243 |
Kind Code |
A1 |
Flitsch; Frederick A. ; et
al. |
May 13, 2021 |
METHODS AND APPARATUS FOR BIOMEDICAL DEVICES WITH CUSTOMIZED
APPEARANCE
Abstract
Designs, apparatus and methods to form contact lenses with
aesthetic elements on demand are described. In some examples, the
method of defining the aesthetic aspect includes printing patterns.
Other examples include photochromic or thermochromic elements which
may provide patterning on exposure to electromagnetic irradiation.
In some further examples, energized components in contact lenses
may provide aesthetic characteristics.
Inventors: |
Flitsch; Frederick A.; (New
Windsor, NY) ; Pugh; Randall B.; (St. Johns,
FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson & Johnson Vision Care, Inc. |
Jacksonville |
FL |
US |
|
|
Family ID: |
1000005358763 |
Appl. No.: |
17/155029 |
Filed: |
January 21, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16396627 |
Apr 26, 2019 |
10935813 |
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17155029 |
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15386467 |
Dec 21, 2016 |
10466506 |
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16396627 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G02B 26/0833 20130101;
B29D 11/00653 20130101; B41J 3/4073 20130101; B29D 11/00048
20130101; G02F 1/13 20130101; G02C 7/102 20130101; G02C 7/101
20130101; B41J 2/01 20130101; B29D 11/00317 20130101; B29D 11/00038
20130101; G02C 7/046 20130101 |
International
Class: |
G02C 7/04 20060101
G02C007/04; G02C 7/10 20060101 G02C007/10; B41J 2/01 20060101
B41J002/01; B29D 11/00 20060101 B29D011/00 |
Claims
1. A contact lens device comprising: a hydrogel base, wherein a
lower surface of the hydrogel base is shaped to comfortably fit on
a surface of a user's cornea; and an element that imparts a color
to a location within a body of the contact lens, wherein the
location of the element that imparts a color and a nature of the
color at that location is determined by interaction of the user
with a software program which displays an image of a pattern of
color.
2. The contact lens device of claim 1 wherein the determination of
the location of the element that imparts a color is made before the
element that imparts a color is placed.
3. The contact lens device of claim 2 wherein the element that
imparts a color comprises an ink.
4. The contact lens device of claim 3 wherein the ink is placed
within the contact lens by an inkjet printer.
5. The contact lens device of claim 3 wherein the ink is placed
within the contact lens by a needle.
6. The contact lens device of claim 2 wherein the element that
imparts a color comprises a photochromic dye.
7. The contact lens device of claim 6 wherein the element that
imparts a color comprising a photochromic dye is turned color by an
exposure to ultraviolet radiation.
8. The contact lens device of claim 1 further comprising a second
layer of polymeric material, wherein the second layer of polymeric
material lies above the element that imparts a color and together
with the hydrogel base encapsulates the element that imparts a
color.
9. The contact lens device of claim 1 further comprising an insert
device, wherein the insert device is encapsulated within the
hydrogel base, and wherein the insert device comprises embedded
micronized pieces of polymer wherein a photochromic dye is located
within the micronized pieces of polymer.
10. The contact lens device of claim 1 further comprising an insert
device, wherein the insert device is encapsulated within the
hydrogel base, and wherein the insert device comprises embedded
micronized pieces of polymer wherein a photochromic dye is located
within the micronized pieces of polymer.
11. The contact lens device of claim 1 further comprising an insert
device, wherein the insert device is encapsulated within the
hydrogel base, and wherein the insert device comprises embedded
micronized pieces of polymer wherein a thermochromic dye is located
within the micronized pieces of polymer.
12. A method of forming a pattern within a contact lens, the method
comprising: forming a contact lens base, wherein the forming
comprises molding; placing the contact lens base into a package for
storage; interacting with a design system to select a pattern
design; imparting a colorant to the contact lens base; depositing a
monomer mixture upon the contact lens base, wherein the monomer
mixture surrounds an exposed surface of the colorant; and fixing
the monomer mixture by polymerization/.
13. The method of claim 12 wherein the imparting of the colorant to
the contact lens base is performed by printing an ink upon the
contact lens base.
14. The method of claim 12 wherein the imparting of the colorant to
the contact lens base is performed by penetrating the contact lens
base with needles, wherein the needle is coated with an ink.
15. The method of claim 12 wherein the imparting of the colorant to
the contact lens base is performed by irradiating a photochromic
dye, wherein the photochromic dye is located within a body of the
contact lens base.
16. The method of claim 12 wherein the imparting of the colorant to
the contact lens base is performed by irradiating a thermochromics
dye, wherein the thermochromics dye is located within a body of the
contact lens base.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation of U.S. patent
application Ser. No. 16/396,627 filed Apr. 26, 2019, and entitled
"METHODS AND APPARATUS FOR BIOMEDICAL DEVICES WITH CUSTOMIZED
APPEARANCE," which is a continuation of U.S. patent application
Ser. No. 15/386,467 filed Dec. 21, 2016, and entitled "METHODS AND
APPARATUS FOR BIOMEDICAL DEVICES WITH CUSTOMIZED APPEARANCE."
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to methods and apparatus to
construct and provide aesthetic content for contact lenses, along
with apparatus and methods to provide individuals with that
functionality.
2. Description of the Related Art
[0003] Contact lenses or contacts are simply lenses placed on the
eye. Contact lenses are considered medical devices and may be worn
to correct vision and/or for cosmetic or other therapeutic reasons.
Contact lenses have been utilized commercially to improve vision
since the 1950s. Early contact lenses made or fabricated from hard
materials were relatively expensive and fragile. In addition, these
early contact lenses were fabricated from materials that did not
allow sufficient oxygen transmission through the contact lens to
the conjunctiva and cornea which potentially could cause a number
of adverse clinical effects. Although these contact lenses are
still utilized, they are not suitable for all patients due to their
poor initial comfort. Later developments in the field gave rise to
soft contact lenses, based upon hydrogels, which are extremely
popular and widely utilized today. Silicone hydrogel contact lenses
that are available today combine the benefit of silicone, which has
extremely high oxygen permeability, with the proven comfort and
clinical performance of hydrogels. Essentially, these silicone
hydrogel based contact lenses have higher oxygen permeability
values and are generally more comfortable to wear than the contact
lenses made of the earlier hard materials. Rigid gas permeable hard
contact lenses, on the other hand, are made from
siloxane-containing polymers but are more rigid than soft contact
lenses and thus hold their shape and are more durable.
[0004] Currently available contact lenses remain a cost effective
means for vision correction. The thin plastic lenses fit over the
cornea of the eye to correct vision defects, including myopia or
nearsightedness, hyperopia or farsightedness, astigmatism, i.e.
asphericity in the cornea, and presbyopia i.e. the loss of the
ability of the crystalline lens to accommodate. Contact lenses are
available in a variety of forms and are made of a variety of
materials to provide different functionality. Daily wear soft
contact lenses are typically made from soft polymer materials
combined with water for oxygen permeability. Daily wear soft
contact lenses may be daily disposable or extended wear disposable.
Daily disposable contact lenses are usually worn for a single day
and then thrown away, while extended wear disposable contact lenses
are usually worn for a period of up to thirty days. Colored soft
contact lenses use different materials to provide different
functionality. For example, a visibility tint contact lens uses a
light tint to aid the wearer in locating a dropped contact lens,
enhancement tint contact lenses have a transparent or translucent
tint that is meant to enhance one's natural eye color, the color
tint contact lens comprises an opaque tint meant to change one's
eye color, and the light filtering tint contact lens functions to
enhance certain colors while muting others. Bifocal and multifocal
contact lenses are designed specifically for patients with
presbyopia and are available in both soft and rigid varieties.
Toric contact lenses are designed specifically for patients with
astigmatism and are also available in both soft and rigid
varieties. Combination lenses combining different aspects of the
above are also available, for example, hybrid contact lenses.
[0005] Cosmetic contact lenses may comprise patterns composed of
one or more elements that completely, or more preferably, partially
overlie the wearer's iris. These lenses may also comprise a limbal
ring. A limbal ring is essentially an annular band of color that
when the lens is on the eye and centered, partially or completely
overlies the lens wearer's limbal region which is the junction of
the sclera and the cornea. The inclusion of a limbal ring may make
the iris appear larger, darker and/or more defined. The combination
of the limbal ring and an iris pattern makes the appearance of the
lens on eye more natural. In other words, an iris pattern allows
the limbal ring to blend in naturally with the wearer's eyes and
the combination of an iris pattern and a limbal ring creates
blending, depth, contrast and definition.
[0006] Other cosmetic contact lenses focus on the sclera rather
than or in addition to the iris. For example, a contact lens may
comprise a brightly colored peripheral portion, i.e. outside of the
iris region, that may be opaque, semi-opaque and/or translucent.
The bright portion may extend from the edge of the limbus to the
edge of the contact lens creating the impression of a brighter or
whiter sclera. These contact lenses may also include a limbal ring
which as stated above, may make the iris appear larger, darker
and/or more defined than it would otherwise.
[0007] With developments in fabrication technology for contact
lenses, customized lenses may be readily available at lower cost.
While this customization may relate to the geometry of the lens,
constructing the lens to an individual's prescription for example,
then further customization options may also be possible. An example
of these possible customization options may include aesthetic,
rather than purely functional or geometric, options. A notable
aesthetic customization need may include pigmentation of a contact
lens; this may achieve various aesthetic qualities for a wearer,
including changing the apparent eye color of the wearer, or masking
the eye with special and possibly intricate aesthetic patterns.
[0008] Due to the decreasing costs and increasing manufacturability
of customized lenses, the means by which they are sold has
similarly evolved. As a notable example, patterned lenses are
particularly popular among teenage girls in many parts of the
world. Many of these girls use lenses which do not provide any
visual correction, the function of the lenses is purely aesthetic.
Shops and kiosks exist in malls and stores that may sell thousands
of different aesthetic based lenses, allowing for large selection.
These lenses may not always be of the highest quality, but their
appeal may be their relative uniqueness. With relative ease, an
individual can own a set of lenses that is different from all of
their friends. There may be so many options that it may be
difficult for a user's friends to even find the same pair of
lenses, and this uniqueness, the fact that the special pattern can
be `theirs`, is useful. Nevertheless, there may be needs to further
enhance the ability of users to obtain unique designs and
potentially even participate in the design of the lenses.
[0009] As mentioned earlier, there may be some reduction of the
quality of the lenses that are currently being afforded. Hereto, an
ability to provide aesthetic customization while also providing
high levels of quality is desirable. Such lenses may provide the
aesthetic aspect while protecting such quality aspects as user
comfort and safety.
[0010] Accessibility of recent technologies, from instant online
access to television shows nearly anywhere with the push of a
button, to additive manufacturing allowing for the printing of
customized 3D objects in the comfort of one's home, have evolved to
grant the ability for consumers to instantly access the products or
services they desire on demand. It may be desirable to provide for
similar methods to provide customized high quality lenses with
aesthetic characteristics along with high quality and safety.
SUMMARY OF THE INVENTION
[0011] Accordingly, designs and methods for devices to construct
customized contact lenses with an aesthetic characteristic are
described herein.
[0012] One general aspect includes a device that allows for a user
to aestheticize a contact lens or set of contact lenses. This
process of aestheticizing a lens may include printing or otherwise
dispensing ink or other dye that is pigmented, phosphorescent,
luminescent, or otherwise able to cause a visible change to a
contact lens under various wavelengths of light.
[0013] One general aspect includes a contact lens device including:
a hydrogel base, where a lower surface of the hydrogel base is
shaped to comfortably fit on a surface of a user's cornea; and an
element that imparts a color to a location within a body of the
contact lens, where the location of the element that imparts a
color and a nature of the color at that location is determined by
interaction of the user with a software program which displays an
image of a pattern of color.
[0014] Implementations may include one or more of the following
features. The contact lens device where the determination of the
location of the element that imparts a color is made before the
element that imparts a color is placed. The element that imparts a
color may use ink to impart the color. In some examples, the ink is
printed onto the contact lens with an inkjet printer. In other
examples, the ink is placed within the contact lens by a needle. In
an embodiment, the element that imparts a color includes a
photochromic dye. For embodiments with photochromic dyes, the dye
may be turned color by an exposure to ultraviolet radiation. The
contact lens device further includes a second layer of polymeric
material, where the second layer of polymeric material lies above
the element that imparts a color and together with the hydrogel
base encapsulates the element that imparts a color.
[0015] In some embodiments a contact lens device includes an insert
device, where the insert device is encapsulated within the hydrogel
base, and where the insert device includes embedded micronized
pieces of polymer where a photochromic dye is located within the
micronized pieces of polymer. The micronized pieces may range in
size from tens of nanometers to approximately 100 microns. In order
to impart a pattern to a contact lens which comprises micronized
pieces a contact lens pattern imaging device may be used which
controllably irradiates select regions of the micronized pieces of
polymer comprising a photochromic dye. In some examples, the
contact lens pattern imaging device includes a light source which
irradiates in the ultraviolet spectrum. The contact lens pattern
imaging device may also have functionality where the light source
sources multiple discrete bands of radiation in an ultraviolet
region, and where the multiple discrete bands of radiation are used
to pattern multiple different colors within the pattern in the
contact lens. The contact lens pattern imaging device may include
different types of imaging apparatus including where the light
intensity modulator includes a layer of liquid crystal material. In
these examples, the layer of liquid crystal material lies between
electrodes, and application of an electrical signal to the
electrodes modulates an intensity of light that passes through the
imaging device in a region bounded by the electrodes. In some
examples, the contact lens pattern imaging device may use a DMD
device to control the light intensity at select locations of the
contact lens.
[0016] In some implementations, the method of forming a custom
patterned contact lens may include imparting a colorant to a
contact lens base by printing an ink upon the contact lens base. In
a variation, the imparting of the colorant to the contact lens base
is performed by penetrating the contact lens base with needles,
where the needle is coated with an ink.
[0017] In some implementations, the method of imparting the
colorant to the contact lens base is performed by irradiating a
photochromic dye, where the photochromic dye is located within a
body of the contact lens base. In similar implementations, the
imparting of the colorant to the contact lens base is performed by
irradiating a thermochromic dye, where the thermochromic dye is
located within a body of the contact lens base. Implementations of
the described techniques may include hardware, a method or process,
or computer software on a computer-accessible medium.
[0018] One general aspect includes a contact lens pattern imaging
device where the contact lens pattern imaging device includes the
following: a receptacle configured to hold a package containing a
pair of contact lens bases, where the contact lens base includes an
imbedded photochromic dye, and where the receptacle holds the pair
of contact lens bases in an aligned location; a light source, where
the light source is located within the contact lens pattern imaging
device in a position to illuminate the pair of contact lens bases
in their aligned positions; a light intensity modulator, where the
light intensity modulator blocks portions of the light from the
light source in a pattern; a controller, where the controller sends
control information to the light intensity modulator to turn
elements within the light intensity modulator on and off to form
the pattern; and a communication device, where the communication
device receives communication of data and passes it on to the light
intensity modulator. Other embodiments of this aspect include
corresponding computer systems, apparatus, and computer programs
recorded on one or more computer storage devices, each configured
to perform the actions of the methods.
[0019] Implementations may include one or more of the following
features. The contact lens pattern imaging device may include a
light source which sources ultraviolet radiation. The contact lens
pattern imaging device may include a light source which sources
multiple discrete bands of radiation in an ultraviolet region, and
where the multiple discrete bands of radiation are used to pattern
multiple different colors within the pattern in the contact lens.
The contact lens pattern imaging device may include a light
intensity modulator which includes a layer of liquid crystal
material, where the layer of liquid crystal material lies between
electrodes, and where an electrical signal applied to the
electrodes modulates an intensity of light that passes through the
imaging device in a region bounded by the electrodes. The contact
lens pattern imaging device may include a light intensity modulator
which includes a DMD device.
[0020] One general aspect includes a contact lens patterning device
including: a receptacle configured to hold a package containing a
pair of contact lens bases, where the contact lens base includes a
surface treatment that makes the surface adherent to ink droplets;
a first print head printing element, where the first print head
printing element is located within the contact lens patterning
device in a position to print directly upon the pair of contact
lens bases in their aligned positions, and where the first print
head printing element prints ink; a second print head printing
element, where the second print head printing element is located
within the contact lens patterning device in a position to print
directly upon the pair of contact lens bases in their aligned
positions, and where the second print head printing element prints
a reactive monomer mixture; a controller, where the controller
sends control information to the print head to turn elements within
the print head on and off to form a pattern of ink droplets; and a
communication device, where the communication device receives
communication of data into the controller. Other embodiments of
this aspect include corresponding computer systems, apparatus, and
computer programs recorded on one or more computer storage devices,
each configured to perform the actions of the methods.
[0021] One general aspect includes a method of forming a pattern
within a contact lens, the method including: forming a contact lens
base, where the forming includes molding; placing the contact lens
base into a package for storage; interacting with a design system
to select a pattern design; imparting a colorant to the contact
lens base; depositing a monomer mixture upon the contact lens base,
where the monomer mixture surrounds an exposed surface of the
colorant; and fixing the monomer mixture by polymerization/. Other
embodiments of this aspect include corresponding computer systems,
apparatus, and computer programs recorded on one or more computer
storage devices, each configured to perform the actions of the
methods.
[0022] One general aspect includes a method of displaying a pattern
in a contact lens including: forming a contact lens including: an
insert device, the insert device including: an energization
element; an electroactive layer including an aligned liquid crystal
material surrounded by a first and second electrode, where an
application of an electrical potential across the first and second
electrode changes an orientation of molecules of the liquid crystal
material which reduces a transmission of electromagnetic radiation
through contact lens, and where the electroactive layer is located
in a non-optic zone of the contact lens; a controller, where the
controller controls the electrical potential that is applied across
the first electrode and the second electrode; and a communication
device, where the communication device receives data relating to a
pattern that determines whether the electrical potential is applied
by the controller; transmitting a communication from an external
device to the communication device within the contact lens; and
placing the contact lens upon an eye of a user. Other embodiments
of this aspect include corresponding computer systems, apparatus,
and computer programs recorded on one or more computer storage
devices, each configured to perform the actions of the methods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The foregoing and other features and advantages of the
invention will be apparent from the following, more particular
description of preferred embodiments of the invention, as
illustrated in the accompanying drawings.
[0024] FIGS. 1A-1G illustrate exemplary lenses with aesthetic
characteristics.
[0025] FIG. 2A illustrates a cross section close-up view of an
exemplary lens with aesthetic characteristics.
[0026] FIG. 2B illustrates a flow chart of an exemplary method for
producing an exemplary lens with aesthetic characteristics.
[0027] FIG. 2C illustrates a close-up view of an exemplary
apparatus printing an aesthetic characteristic on an exemplary
lens.
[0028] FIG. 2D illustrates a close-up view of an exemplary
apparatus printing a coating layer upon the top surface of an
exemplary lens with aesthetic characteristics.
[0029] FIG. 2E illustrates a cross section close-up view of an
exemplary lens with aesthetic characteristics comprising multiple
layers.
[0030] FIG. 3A illustrates an exemplary commercial location which
offers digitally printed aesthetic lenses.
[0031] FIG. 3B illustrates an exemplary home location employing
digital aesthetic lens printing apparatus.
[0032] FIG. 4 illustrates an exemplary self-contained digital
aesthetic lens printing apparatus.
[0033] FIG. 5A illustrates an exemplary cross section view of a
lens base comprising photochromic or thermochromic dye.
[0034] FIG. 5B illustrates an exemplary package for containing lens
bases comprising photochromic or thermochromic dye.
[0035] FIG. 5C illustrates an exemplary apparatus for creating an
aesthetic characteristic in a lens comprising photochromic or
thermochromic dye.
[0036] FIG. 5D illustrates an exemplary cross section view of a
lens base comprising photochromic or thermochromic dye where some
dye regions have been processed to have a color.
[0037] FIG. 6A illustrates an apparatus for conveying an aesthetic
pattern to a contact lens using an array of needles.
[0038] FIG. 6B illustrates an exemplary cross section of a lens
base with color imbedded by needle processing.
[0039] FIG. 7A illustrates an exemplary view of an insert device
comprising an electroactive patterning device.
[0040] FIG. 7B illustrates an exemplary lens comprising the insert
of FIG. 7A.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Designs and methods for various embodiments of a device to
construct and/or aestheticize customized contact lenses have been
disclosed. The descriptions of examples are exemplary embodiments
only, and various modifications and alterations may be apparent to
those skilled in the art. Therefore, the examples do not limit the
scope of this application.
Glossary
[0042] In the description and claims below, various terms may be
used for which the following definitions will apply:
[0043] "Actinic Radiation" as used herein, refers to radiation that
is capable of initiating a chemical reaction.
[0044] "Arcuate" as used herein, refers to a curve or bend like a
bow.
[0045] "DMD" as used herein, refers to a digital micro-mirror
device that is a bistable spatial light modulator consisting of an
array of movable micro-mirrors functionally mounted over a CMOS
SRAM. Each mirror is independently controlled by loading data into
the memory cell below the mirror to steer reflected light,
spatially mapping a pixel of video data to a pixel on a display.
The data electrostatically controls the mirror's tilt angle in a
binary fashion, where the mirror states are either +X degrees (on)
or -X degrees (off). For current devices, X can be either 10
degrees or 12 degrees (nominal). Light reflected by the on mirrors
then is passed through a projection lens and onto a screen. Light
is reflected off to create a dark field, and defines the
black-level floor for the image. Images are created by gray-scale
modulation between on and off levels at a rate fast enough to be
integrated by the observer. The DMD (digital micro-mirror device)
is sometimes referred to as a DLP projection system.
[0046] "DMD Script" as used herein shall refer to a control
protocol for a spatial light modulator and also to the control
signals of any system component, for example, a light source or
filter wheel either of which may include a series of command
sequences in time. Use of the acronym DMD is not meant to limit the
use of this term to any one particular type or size of spatial
light modulator.
[0047] "Fixing Radiation" as used herein, refers to Actinic
Radiation sufficient to one or more of: polymerize and crosslink
essentially all Reactive Mixture comprising a Lens Precursor or
lens.
[0048] "Fluent Lens Reactive Media" as used herein means a Reactive
Mixture that is flowable in either its native form, reacted form,
or partially reacted form and is formed upon further processing
into a part of an ophthalmic lens.
[0049] "Gel Point" as used herein shall refer to the point at which
a gel or insoluble fraction is first observed. Gel point is the
extent of conversion at which the liquid polymerization mixture
becomes a solid. Gel point can be determined using a soxhlet
experiment: Polymer reaction is stopped at different time points
and the resulting polymer is analyzed to determine the weight
fraction of residual insoluble polymer. The data can be
extrapolated to the point where no gel is present. This point where
no gel is present is the gel point. The gel point may also be
determined by analyzing the viscosity of the reaction mixture
during the reaction. The viscosity can be measured using a parallel
plate rheometer, with the reaction mixture between the plates. At
least one plate should be transparent to radiation at the
wavelength used for polymerization. The point at which the
viscosity approaches infinity is the gel point. Gel point occurs at
the same degree of conversion for a given polymer system and
specified reaction conditions.
[0050] "Lens" as used herein 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 made from silicone elastomers or hydrogels, which
include but are not limited to silicone hydrogels, and
fluorohydrogels.
[0051] "Lens Precursor" as used herein, means a composite object
consisting of a Lens Precursor Form and a Fluent Lens Reactive
Mixture in contact with the Lens Precursor Form. For example, in
some embodiments Fluent Lens Reactive Media is formed in the course
of producing a Lens Precursor Form within a volume of Reactive
Mixture. Separating the Lens Precursor Form and adhered Fluent Lens
Reactive Media from the volume of Reactive Mixture used to produce
the Lens Precursor Form can generate a Lens Precursor.
Additionally, a Lens Precursor can be converted to a different
entity by either the removal of significant amounts of Fluent Lens
Reactive Mixture or the conversion of a significant amount of
Fluent Lens Reactive Media into non-fluent incorporated
material.
[0052] "Lens Precursor Form" as used herein, means a non-fluent
object with at least one optical quality surface which is
consistent with being incorporated upon further processing into an
ophthalmic lens.
[0053] "Lens Forming Mixture," "Reactive Mixture" or "RMM"
(reactive monomer mixture) as used herein 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 lens such as, contact
or intraocular lenses.
[0054] "Mold" as used herein, 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.
[0055] "Optical Zone" as used herein refers to an area of an
ophthalmic lens through which a wearer of the ophthalmic lens
sees.
[0056] "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.
[0057] "Xgel" as used herein, is the extent of chemical conversion
of a crosslinkable Reactive Mixture at which the gel fraction
becomes greater than zero.
Exemplary Aesthetic Modification of Contact Lenses
[0058] Referring now to FIG. 1A, there is illustrated a plan view
of an exemplary non-cosmetic contact lens 100. The contact lens 100
comprises an optic zone 102, a peripheral zone 104 surrounding the
optic zone 102, a back curve surface designed to make contact with
an individual's eye when worn and a front curve surface opposite
the back curve surface. The optic zone 102 is the portion of the
contact lens 100 through which vision correction may be obtained.
In other words, the optic zone 102 provides vision correction and
is designed for a specific need such as single vision myopia or
hyperopia correction, astigmatism vision correction, bi-focal
vision correction, multi-focal vision correction, custom correction
or any other design that may provide vision correction. The
peripheral zone 104 surrounds the optic zone 102 and provides
mechanical stability for the contact lens 100 on the eye. In other
words, the peripheral zone 104 provides mechanical features which
influence positioning and stabilization of the contact lens 100 on
the eye, including centration and orientation. Orientation is
fundamental when the optic zone 102 includes non-rotationally
symmetric features, such as astigmatic correction and/or high order
aberration correction. In some contact lens designs, an optional
intermediate zone between the optic zone 102 and the peripheral
zone 104 may be utilized. The optional intermediate zone ensures
that the optic zone 102 and the peripheral zone 104 are smoothly
blended.
[0059] The lens 100 illustrated in FIG. 1A is circular, but may be
any convenient shape for a contact lens, such as an elliptical or
truncated circular shape. In addition to being round or non-round,
the contact lens 100 may be planar or non-planar.
[0060] A cosmetic contact lens is designed to enhance or alter the
appearance of the eye upon which it is worn. While not a
requirement, cosmetic contact lenses may also be utilized for the
correction of refractive error. In addition, cosmetic contact
lenses may also have direct medical application, for example, to
restore the appearance of a damaged eye. Individuals who suffer
from aniridia, the absence of an iris, dyscoria, damage of the
iris, and/or arcus senilis or arcus senilus corneae, a disorder
that lightens or discolors the limbus area, may utilize colored
contact lenses that will give the appearance of a complete iris.
Cosmetic contact lenses may include translucent/transparent color
enhancement, tint, opaque color tint, artificial iris patterns,
limbal rings, sclera brightening tints and/or any combination of
the above.
[0061] More specifically, cosmetic contact lenses may be utilized
to brighten the sclera and/or have a pattern that includes a limbal
ring that serves to enhance the definition of the wearer's iris
resulting in the iris appearing larger to viewers of the lens
wearer. Additionally, cosmetic contact lenses may have additional
pattern elements that completely or, preferably, partially overlie
the wearer's iris. The cosmetic lenses may be utilized for
enhancing a dark-eyed individual's iris, but also may be used to
enhance the iris of a light-eyed lens wearer as well.
[0062] Referring to FIG. 1B, an example of aesthetic modification
of contact lenses 110 that has been previously described by the
inventive entity of the present disclosure is illustrated. The
example illustrates an exemplary iris pattern that is printed upon
an insert that is encapsulated into a hydrogel skirt to form a
contact lens as is explained in greater detail herein. The internal
electronic and energization components are aesthetically covered
with the iris pattern when a user wears the contact lens.
[0063] In other examples, a printed pattern in a contact lens may
have the sole function of providing an appearance when worn and may
be printed on a contact lens body that has no internal components.
Referring to FIG. 1C, a contact lens with aesthetic modification
120 is illustrated where the aesthetic modification may be a solid
printed pattern that may give the impression of a large pupil.
[0064] As mentioned previously, there may be an immense number of
patterns that may be applied to contact lenses for aesthetic
patterning. Referring to FIGS. 1D, 1E and 1F variations on an iris
pattern are illustrated with brush strokes 130, line patterns 140
and combinations of line patterns and geometric shapes 150. These
patterns may invoke a more artificial lens appearance than some of
the more standard aesthetic modifications as shown in FIGS. 1B and
1C.
[0065] Further enablement for manufacturing of lenses with
predesigned aesthetic patterning may be found as set forth in U.S.
patent application Ser. No. 14/687,321 filed Apr. 15, 2015, which
is incorporated herein by reference.
[0066] Patterns may be formed that have only patterns with no
reference to normal features like iris patterns. Referring to FIG.
1G an example of a graphic pattern 160 is illustrated. In many
examples, arbitrary patterns of monochrome or multicolors may be
fabricated to give a user a unique appearance when others look at
their eyes. As mentioned earlier, examples of such aesthetic lenses
may be formed where there is to optical modifying characteristic of
the contact lens, the lens may be used merely to give the aesthetic
effect.
Fabrication of Comfortable Contact Lenses with Aesthetic
Content
[0067] Referring to FIG. 2A an exemplary cross section of a lens
with aesthetic content is illustrated. A base layer 215 of the lens
may be formed into a lens body. The formation may occur in numerous
manners that are standard in the manufacture of contact lenses
including molding of polymerizable materials between mold surfaces
to form a shaped body in an appropriate form for a contact
lens.
[0068] There may be numerous types of materials that may be used to
form the base layer 215. In some examples, a preferred base
material and in other examples which have an insert device in the
contact lens an encapsulating material may include 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.
[0069] In some examples, the ophthalmic lens skirt, also called an
insert-encapsulating layer, that surrounds an insert may be
comprised of standard hydrogel ophthalmic lens formulations.
Exemplary materials with characteristics that may provide an
acceptable match to numerous insert materials may include, the
Narafilcon family (including Narafilcon A and Narafilcon B), and
the Etafilcon family (including Etafilcon A). A more technically
inclusive discussion follows on the nature of materials consistent
with the art herein. One ordinarily skilled in the art may
recognize that other material other than those discussed may also
form an acceptable enclosure or partial enclosure of the sealed and
encapsulated inserts and should be considered consistent and
included within the scope of the claims and by the same logic may
form an acceptable base layer on examples of contact lenses without
inserts.
[0070] Suitable silicone containing components include compounds of
Formula I
##STR00001##
[0071] where
[0072] R1 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; 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;
[0073] wherein at least one R1 comprises a monovalent reactive
group, and in some examples between one and 3 R1 comprise
monovalent reactive groups.
[0074] As used herein "monovalent reactive groups" are groups that
may undergo free radical and/or cationic polymerization.
Non-limiting examples of free radical reactive groups include
(meth)acrylates, styryls, vinyls, vinyl ethers,
C1-6alkyl(meth)acrylates, (meth)acrylamides,
C1-6alkyl(meth)acrylamides, N-vinyllactams, N-vinylamides,
C2-12alkenyls, C2-12alkenylphenyls, C2-12alkenylnaphthyls,
C2-6alkenylphenylC1-6alkyls, 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 comprise
(meth)acrylate, acryloxy, (meth)acrylamide, and mixtures
thereof.
[0075] Suitable monovalent alkyl and aryl groups include
unsubstituted monovalent C1 to C16alkyl groups, C6-C14 aryl groups,
such as substituted and unsubstituted methyl, ethyl, propyl, butyl,
2-hydroxypropyl, propoxypropyl, polyethyleneoxypropyl, combinations
thereof and the like.
[0076] In one example, b is zero, one R1 is a monovalent reactive
group, and at least 3 R1 are selected from monovalent alkyl groups
having one to 16 carbon atoms, and in another example 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"),
[0077] 2-hydroxy-3-methacryloxypropyloxypropyl-tris
(trimethylsiloxy)silane,
[0078] 3-methacryloxypropyltris(trimethylsiloxy)silane
("TRIS"),
[0079] 3-methacryloxypropylbis(trimethylsiloxy)methylsilane and
[0080] 3-methacryloxypropylpentamethyl disiloxane.
[0081] In another example, b is 2 to 20, 3 to 15 or in some
examples 3 to 10; at least one terminal R1 comprises a monovalent
reactive group and the remaining R1 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 R1 comprises a
monovalent reactive group, the other terminal R1 comprises a
monovalent alkyl group having 1 to 6 carbon atoms and the remaining
R1 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").
[0082] In another example, b is 5 to 400 or from 10 to 300, both
terminal R1 comprise monovalent reactive groups and the remaining
R1 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.
[0083] In one example, 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.
[0084] In another embodiment, one to four R1 comprises a vinyl
carbonate or carbamate of the formula:
##STR00002##
[0085] wherein: Y denotes O--, S-- or NH--;
[0086] R denotes, hydrogen or methyl; d is 1, 2, 3 or 4; and q is 0
or 1.
[0087] 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##
[0088] Where biomedical devices with modulus below about 200 are
desired, only one R1 shall comprise a monovalent reactive group and
no more than two of the remaining R1 groups will comprise
monovalent siloxane groups.
[0089] Another class of silicone-containing components includes
polyurethane macromers of the following formulae:
Formulae IV-VI
(*D*A*D*G)a*D*D*E1;
E(*D*G*D*A)a*D*G*D*E1 or;
E(*D*A*D*G)a*D*A*D*E1
[0090] wherein:
[0091] 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,
[0092] 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;
[0093] * denotes a urethane or ureido linkage;
[0094] a is at least 1;
[0095] A denotes a divalent polymeric radical of formula:
##STR00004##
[0096] R11 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 E1 independently
denotes a polymerizable unsaturated organic radical represented by
formula:
##STR00005##
[0097] wherein: R12 is hydrogen or methyl; R13 is hydrogen, an
alkyl radical having 1 to 6 carbon atoms, or a --CO--Y--R15 radical
wherein Y is --O--, Y--S-- or --NH--; R14 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.
[0098] A preferred silicone-containing component is a polyurethane
macromer represented by the following formula:
##STR00006##
[0099] wherein R16 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##
[0100] 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. In some examples, the polymer backbone may
have zwitterions incorporated into it. These zwitterions may
exhibit charges of both polarity along the polymer chain when the
material is in the presence of a solvent. The presence of the
zwitterions may improve wettability of the polymerized material. In
some examples, any of the foregoing polysiloxanes may also be used
as an encapsulating layer in the present invention.
[0101] Referring again to FIG. 2A, a colored material may be used
to create the aesthetic element 210. In the following sections
numerous means to place colored material into or upon the surface
of the base element of a contact lens are described. These means
may be used to embed color into the contact lens or deposit the
color onto the surface. The color may include a black ink or other
various colors that may be formed from inks, dyes and other
colorants that are safe in the ocular environment. After the
aesthetic element 210 is formed in or upon the base layer 215, it
may be encapsulated by a top coating layer 220. In other examples,
where the colorants are implanted into the base layer, the top
coating layer may represent the depth through which the colorant is
implanted.
[0102] In examples where a top coating layer may be applied, a
silicone hydrogel formulation containing polymeric wetting agents,
such as poly(N-vinylpyrrolidone) (PVP) and acyclic polyamides may
be used. In some examples, these polymers may be quite large and
may require the use of special compatibilizing components, which
need to be custom manufactured. Examples of compatibilizing
components may include 2-propenoic acid,
2-methyl-,2-hydroxy-3-[3-[1,3,3,3-tetramethyl-1-[(trimethylsilyl)oxy]disi-
-loxanyl]propoxy]propyl ester (SiGMA). The top coat comprising
monomeric form and polymeric wetting agents may be applied and then
may be further polymerized.
Method to Form Aesthetic Lenses with Ink Printing
[0103] Referring to FIG. 2B, a method for forming aesthetic lenses
is illustrated. At step 231 a contact lens base is formed. The
method to form the base may be drawn from known methods in the art
including cast molding, lens machining and freeform deposition as
examples. In some examples, the lens back curve surface may be
fully defined in step 231 whereas the front curve surface may be
covered with subsequent coatings. At step 232 the contact lens base
may be placed into packaging for storage of the lens base until an
aesthetic element is applied. In some examples, the lens may be
stored in packaging solution. In some examples, the lens may be
stored under controlled or reduced temperatures. At a later time,
and in some examples at a remote location, a user may interact with
a design system to choose a pattern 233 for the lens that they want
to have patterned. At step 234, a colorant may be imparted to the
lens base. There may be numerous manners to impart the colorant as
discussed in proceeding sections which may include ink printing,
photo-induced reactions or needle imprinting as examples. In some
examples, at step 235, the colorized base may be coated with an
encapsulating coat. In some examples, the encapsulating coat may be
sprayed or otherwise coated onto the front curve surface of the
lens only. In other examples, both the front curve and back curve
surface may be coated, for example by dipping into a solution. In
some examples, the encapsulant coat may be a monomer mixture which
at step 236 may be polymerized. For the user's comfort, the
polymerized and encapsulated colorized lens may be placed into
packaging solution to hydrate the lens as shown in step 237.
Printing of Colorant onto Contact Lens
[0104] Referring to FIG. 2C, an illustration of printing pigment
upon a contact lens is found. As shown in the illustration, in some
examples an ink jet type printing head 240 may be used to print
colorant upon the contact lens. The ink jet type printing head 240
may be moved 241 across the surface of the contact lenses in
controlled means to establish a pattern of droplets 243 which will
impinge upon the contact lens 244. There may be numerous types of
biocompatible inks that may be useful for the ink jet print head.
The ink jet print head may be controlled by a print controller
which may incorporate sensing devices to establish the location of
the print head and its rate of movement to calculate the correct
timing of electrical signals to cause the printing head elements
242 to release a droplet of ink 243. In some examples, the
controller may have an ability to perform an algorithmic
calculation which may adjust the print pattern for various factors
such as the curvature of the lens and for printing issues where one
or more of the printing elements may not be dispensing ink. In some
examples, the print head may be located on a stationary printer
into which lenses for customization are place. In other examples,
the printing mechanism may be located into the packing of the lens
bases which will be customized.
[0105] Referring to FIG. 2D a second pass of printing may be
performed to encapsulate the printed surface in a cover layer of
lens material so that the colorant is buried beneath the surface.
There may be numerous materials that may be consistent with
encapsulating the printed surface including PVP or other materials
as mentioned previously which impart a comfortable and hydrated
surface to the user. Referring to FIG. 2D, a print head 250 may be
moved 251 across the lens surface. As the print head 250 is moved
251 voltage signals may be sent to the print head which may cause
the printing head elements 252 to release a droplet of ink 253
creating a pattern 254 on the surface of the lens. In some examples
the same print head that printed the ink may use different
releasing elements to release the encapsulating layer material
across the surface of the lens. In other examples, a second print
head may release the encapsulating material. In general, the
encapsulating layer may be released onto the entire surface of the
lens; therefore, a spray process may dispense the encapsulating
material. In some examples, the dispensed material may be allowed
to flow over the surface for a time period before it is
polymerized. The polymerization may be chemically triggered or an
initiating light source may be used to initiate polymerization. In
some examples, the lens with polymerized layers may be next
immersed into an aqueous liquid such as packaging solution to allow
the top layers to be hydrated.
[0106] Referring to FIG. 2E, an exemplary illustration of a
multilevel pattern is provided. In some examples it may be
desirable to print patterns on multiple levels of the lens body.
Patterns on multiple levels may give the aesthetic pattern a
feeling of "depth". In some examples, multilevel patterns may be
formed by repeating the printing steps as laid out in relationship
to FIG. 2A. Again a substrate may have color printed on the base
layer. The color may include a black ink or other various colors
that may be formed from inks, dyes and other colorants that are
safe in the ocular environment. After the aesthetic element 210 is
formed in or upon the base layer 215, it may be encapsulated by a
top coating layer 220. Thereafter, another layer of colorant may be
applied created a second aesthetic element 280. It may be
encapsulated by another layer of a top coating layer 270. In
general, any of the printing techniques herein may be configured to
form patterns in multi-layer fashion to impart apparent depth to
the patterns that result on the lens.
Distribution Models for Customized Aesthetic Lenses
[0107] There may be numerous manners to make and distribute
customized aesthetic lenses. In a first example, a commercial
outlet may be established with a printing system capable of
performing the printing of aesthetic characteristics as described
herein. Referring to FIG. 3A, a commercial entity 300 may offer
customized aesthetic lenses. A service agent 310 may interact with
a customer 320. The service agent 310 may assist the customer 320
to determine the pattern that he or she desires. A printing system
330 located at the commercial outlet may then produce the
customized lens.
[0108] In another model, a customized lens may be produced at a
user's home. Referring to FIG. 3B, a printing system may be located
in a user's house. For example, a printer 360 may be located in a
user's bedroom 340. The user may interact with a design system on a
personal computer, tablet or smart device 350. The user may be
provided with blank lenses that are pre-fit and customized to the
user's optical needs. Custom ink cartridges and encapsulating layer
cartridges may also be obtained by the user. A communication
between the personal computer, tablet or smart device 350 may send
the desired pattern information to the printer. The user may
perform basic steps with the printer to obtain a customized printed
aesthetic lens.
A Packaged Aesthetic Lens Printing System
[0109] In another model, a package may contain all the elements a
user needs to print their customized lens. The package may have a
set of blank lenses appropriate to a user. Referring to FIG. 4, a
package 410 may contain a pair of blank lenses 420. The package 410
may contain the print head 430 with a pre-supplied type of ink and
encapsulating material. The print head 430 may be moved within the
package by a movement element 440. Movement of the print head may
be actuated by elements such as small motors, for example precision
stepper motors, connected to simple lead screws. In other examples,
electroactive elastomers may be used to cause and control movement.
In still further examples, piezo-electric actuators may be used to
cause movement. Any movement device which may be powered by a
battery device may be used to control the movement. Control of the
movement element 440 may be made by a movement actuator element
450. The movement actuator element 450 may provide electrical
signals such as high voltage signals in the case of elastomeric and
piezoelectric based actuators or digital stepping signals or analog
control signals for motor based movement. In the illustrated
example, there is only one dimension of movement shown since the
printing element may be large enough to span the lenses upon which
the pattern is printed. In some other examples, two dimensions of
movement may be enabled to allow a smaller print head to be
rastered across the lenses in between being moved along the lenses.
In other examples, the printing element may have small enough and
dense enough printing elements that it may sit above lens elements
and print in a static orientation. An energization element along
with a controller and a communication element 460 which may control
power distribution and also control signals to the print head as
well as to the movement element if there is one may be found. The
controller may have interconnection outside of the package to
receive data corresponding to the pattern that is desired to be
printed. Communication into the package of the pattern data may be
made with a wired connection 470 or a wireless communication 480.
The wired connection may be made via serial port connection such as
USB or other serial communication schemes such as SPI or I2C as
non-limiting examples. Wireless communication may be coordinated
via numerous wireless standards such as Bluetooth, Zigbee, WiFi and
other such protocols. The pattern data may in some examples be
presented to the user on a touch screen mounted upon the package in
some examples. A touch screen signal, or a communication through
the various communication means mentioned may allow the user to
start a print and may indicate when the processing is
completed.
[0110] In some examples, the base contact lens elements may be
stored in a dry condition and processed as a dry starting lens. In
such cases the finished product may need to be hydrated before it
may be worn by a user.
[0111] In some other examples, the lens blanks may be stored in an
aqueous solution, and when the printing is to be performed, the
liquid may need to be drained away from the lens body. In some
examples, a drying period may be required before printing may
begin. In some examples, draining of fluid may be accomplished by
the direction that the packaging is placed where when then lens is
placed on end, the lens blanks may be immersed in packaging
solution whereas when in is laid flat, the fluid spreads out along
the bottom of the package length and uncovers the lens blanks. In
some other examples a valve may allow for the liquid to be drawn
away from the lens blanks. In some other examples, a pump or an air
flow may push the fluid away from or to the lens blanks depending
on the need.
Photopatterning of Aesthetic Lenses
[0112] There may be numerous methods of creating a pattern on a
contact lens by writing the pattern into the lens with light.
Referring to FIG. 5A, an illustration of a photosensitive insert
layer within a contact lens is depicted. A base contact lens layer
503 may be molded with standard contact lens hydrogel molding
formulations. An insert layer comprising photoactive elements 501
may be sandwiched between the base contact lens layer 503 and a top
contact lens layer 502. In some examples, the insert layer
comprising photoactive elements 501 may be formed before the
molding operation and then placed into a mold comprising the front
contact lens optic shape and a back contact lens optic shape.
Photo-polymerizable material may be injected into the mold pieces
and then the insert may be encapsulated into the lens by hydrogel
material as illustrated. The photo-polymerizable material may be
imbedded into an insert piece, and the insert piece layer may
comprise thermoformable material allowing the insert to be shaped
into the desired curve and shape of a contact lens.
[0113] In an example, the insert layer comprising photoactive
elements 501 may have small features embedded, or adhered to the
layer where each of the photoactive elements may comprise an amount
of photochromic ink. There are numerous types of photochromic ink,
some of which change color irreversibly upon exposure to
ultraviolet light. The photochromic ink may be encapsulated in a
polymer matrix and/or ground into small discrete pieces which may
be spherically shaped as illustrated. Other shapes may be possible.
Irreversible photochromic pigments such as OliKrom's hvOne pigments
available from OliKrom company as a non-limiting example may be
incorporated into the insert.
[0114] A molded blank comprising an insert with photochromic
pigment may be transparent before any exposure to UV light. Thus,
such a lens may be patterned by exposing it to ultraviolet light in
patterns that correspond to the desired pattern. The exposure
process is described in greater detail subsequently. The resulting
pattern may be considered a monochrome pattern. In some examples, a
multicolor pattern may be formed by including multiple layers of
inserts where each of the insert layers may comprise a different
colored photochromic dye. When there are multiple insert layers,
laser irradiation of the insert layers at discrete wavelengths may
allow for one of the multiple layers to be patterned. The
encapsulating layer surrounding the photochromic dye may include
absorbing dyes that may define narrow bands of UV light that may
penetrate into the encapsulated photochromic dye. Thus, with
multiple different imaging irradiation steps, each at a different
wavelength of UV light multicolor patterns may also be imaged.
[0115] In some examples, a photochromic dye may be replaced with a
thermochromics dye. In these cases, different thermochromics dyes
may be mixed with absorbent materials, where the absorbent
materials may absorb relatively narrow bands of electromagnetic
radiation, such as in the UV band or spectrum. The absorption of
the light by a discrete element filled with thermochromic dye may
raise the local temperature significantly, thereby turning the dye
from non-colored to colored. In some examples, the light may be
formed by a laser light which may be scanned across the lens body
and turned on when a pattern element is required. In other
examples, a light source, which may be collimated, may irradiate a
masking element across the projection of the light onto a lens and
allow light to penetrate in designated areas. Again, the locations
where light irradiates the lens may absorb the light energy and
heat the photochromic dye yielding a pattern.
[0116] Referring to FIG. 5B, a package 510 containing lens bases
515 for a user may be illustrated. In some examples, the lens bases
may be clear lenses with no prescription or power to them. In other
examples, the lens bases may have a unique prescription to them for
the user. In order to pattern the lenses with good precision, the
lens packaging solution may need to be drained away from the lens
bases before irradiation. A reservoir 520 may be located within the
package 510 to allow for the draining of the packing solution from
the area of the lenses. In an example, an actuating mechanism 530
may actuate a valve 525 which may allow the packing solution to
drain away from the lens bases and into a storage location. An
energization element with a controller and a communication function
535 may control power distribution and also control signals to the
valve actuator. The controller may have interconnection outside of
the package to receive data corresponding to the pattern that is
desired to be printed. Communication into the package may be made
with a wired connection 540 or a wireless communication 545. The
wired connection may be made via serial port connection such as USB
or other serial communication schemes such as SPI or I2C as
non-limiting examples. Wireless communication may be coordinated
via numerous wireless standards such as Bluetooth, Zigbee, WiFi and
other such protocols. The status of pattern writing may in some
examples be presented to the user on a touch screen mounted upon
the package. A touch screen signal, or a communication through the
various communication means mentioned may allow the user to start a
print and may cause the draining of aqueous solution.
[0117] Referring to FIG. 5C, an exemplary irradiation apparatus 590
is illustrated. The package 510 or a similar one may be inserted
into the irradiation apparatus 590 for a pattern to be written. The
irradiation apparatus may have a UV irradiation source 565. The
light emission from the UV irradiation source 565 may be collimated
560 in some examples. The collimated UV light 560 may then pass
through an imaging element 555 which may image the light into
pixels that are passed through to the lens and those that are not.
The imaging element may comprise a DMD type mirror imaging device
in some examples. In other examples, an imaging element may be
formed from a liquid crystal device which may block light or let
light through based on electrical control signals to electrodes
that surround a region of liquid crystal. The electrodes may be
formed into a pixel pattern that allows for the patterning of the
photochromic or thermochromic elements in the contact lens. The UV
light that emerges from the imaging element 555 may be focused in
various manners with a focusing system 550 to allow the size of the
image to be adjusted onto the lens bases.
[0118] Referring to FIG. 5D, an example of imaged photochromic or
thermochromic elements is illustrated. The lens encapsulating
layers 502 and 503 may surround the insert in which are micronized
photochromic or thermochromic elements as discussed. As shown as
imaged photochromic or thermochromic elements 580, combinations of
the elements may be imaged to create a pattern in the lens.
Needle Patterning of Aesthetic Lenses
[0119] Referring to FIG. 6A, a needle patterning device is
illustrated. Needles may be used to both carry ink as well as to
puncture the surface of a lens based that is meant to be patterned.
In some examples, an array of needle heads may be attached upon
elements capable of expanding length with the application of
electrical signals. In some examples, the application of an
electric potential may cause a needle to expand so that when the
array of needles is brought in contact with a reservoir of ink,
only those needles that have been expanded by the electrical signal
will come in contact with the ink. At a later time, the array of
needles may be pressed into the lens blanks. The needles with ink
on them will transfer the ink into the lens base. By repeating the
process numerous times, a pattern may be imparted into the lens
base much as a tattoo is formed on human skin with needle
penetration.
[0120] In other examples, the array of needles may all be at the
same length when the array is brought in contact with ink. At a
later time, electrical signals may be used to expand the length of
the support for the needle. Those needles that are extended from
the surface may be able to penetrate the lens base while the other
needles may not penetrate the surface of the lens base. The
supports for the needles may be formed of materials such as
piezoelectric materials which can expand in length with applied
voltage or of electroactive elastomeric materials which also may
expand in the presence of electric potential.
[0121] In still further examples, a surface of the needles may be
coated with materials that may make the needle's affinity for the
ink low. Electrodes within the needle and the ink reservoir may
allow for transformation of the wetting of a particular needle by
application of an electrical potential to the needle. If the needle
becomes hydrophilic on the application of electrical potential,
then an array of needles can have selected needles coated with
colorant. When the array is pressed into the lens base, those
needles with ink may leave coloration in a pattern determined by
the pattern of electrical potential applied to the needles. The
array of needles may be stepped across the surface of the lens base
to form a complete pattern.
[0122] When needles penetrate the surface and leave ink on the
surfaces that the needle touch, it may be desirable to provide an
encapsulating layer to cover the penetration holes. In some
examples, a PVP containing monomer mixture may be sprayed or
printed onto the lens base as describe in earlier sections. A
thermal or photochemical polymerization of the monomer mixture may
be used to fix the coating and effectively segregate the deposited
ink within the body of the lens. In other examples, a top layer
that the needles penetrate through may be formed to be partially
gelled. After the needles penetrate the surface layer, the
partially gelled layer may tend to fill in the hole by diffusion.
The partially gelled layer may be fixed by further exposure to
photochemical sources. Referring to FIG. 6A, the lens base layer
635 may support a top layer 630 of the lens. As mentioned in some
examples the top layer 630 may be attached to the lens base 635
when the needles 620 penetrate the lens as they are moved into and
out of the location of the lens base 635 as the array is moved 610
over the lens base 635. The top layer may be partially gelled as
mentioned, or an extra amount of polymerizable material may be
added to the lens. Either of these treatments may then be exposed
to UV light to fix the polymerizable material. As illustrated in
FIG. 6B, a deposit of colorant 640 may be buried into the lens
base, providing coloration in a pattern.
Electroactive Aesthetic Patterned Lens
[0123] In some examples, it may be possible to create an aesthetic
pattern on a contact lens based on an electroactive function within
the lens itself. A contact lens with an embedded energy source such
as a battery may have the ability to perform function based on the
control of electrical energy. In an example, an array of liquid
crystal diodes may be used to control the transmission of light and
thereby create patterns. In some examples, a reflective surface may
be located behind the liquid crystal devices so that incident light
may be reflected back. As well the stack of elements may include
polarizing filters which may be oriented at perpendicular angles.
When electrical signals across electrodes that span the liquid
crystal layer are activated they may cause a shift in the alignment
of the liquid crystal molecules and begin to stop light from
proceeding through the liquid crystal layer. By arranging the
electrodes in a pattern and selectively determining which
electrodes are activated and which are not, complex patterns may be
formed in the non-optic zone of the lens. In some other examples, a
low level light source may shine light from behind the liquid
crystal devices. When they are energized, the light emitted may be
absorbed. When the liquid crystal devices are not energized, light
may proceed through liquid crystal layer and emerge from the
contact lens giving the impression of lighted and dark pattern
regions on the eye of the contact lens wearer. The contact lens may
have an energy source such as a battery as well as electronic
circuits which may control the application of electrical potential
across the electrodes that space regions of liquid crystal.
Portions of the circuit may be designed to receive wireless
communication from an outside transmitter which may write a pattern
into memory of the contact lens. The memory elements may be used to
control the application of electrical potential across the pixels
of liquid crystal material.
[0124] Referring to FIG. 7A, an example of a contact lens insert
that may be used to create an electroactive pattern on the lens is
depicted as contact lens insert 700. In the contact lens insert
700, there may be the array of electroactive patterning elements
770 that may accommodate forming patterns. A circuit 705 to provide
controlling voltage signals as well as to provide other function
such as controlling sensing of the environment for external control
signals may be powered by an energization element such as a
biocompatible battery element The energization elements may have
various interconnect features to join together pieces as may be
depicted underlying the region of interconnect 714. The
energization elements may be connected to a circuit element that
may have its substrate 711 upon which interconnect features 725 may
be located. The circuit 705, which may be in the form of an
integrated circuit, may be electrically and physically connected to
the substrate 711 and its interconnect features 725. The
electroactive patterning elements 770 may lie above these other
components and may comprise a complete ring in the non-optic zone
of the contact lens (even though for illustration the dark pattern
is broken in places to allow underlying structure to be observed).
The non-optic zone may be the region outside of the circular optic
zone 720 which is the portion which a user may look through when
the lens is worn.
[0125] Referring to FIG. 7B, a cross sectional relief of a contact
lens 750 may contain contact lens insert 700 and its discussed
constituents. The contact lens insert 700 may be encapsulated into
a skirt of contact lens hydrogel 755 which may encapsulate the
insert and provide a comfortable interface of the contact lens 750
to a user's eye.
[0126] There may be numerous other types of patterning devices that
may operate in an electroactive manner. In non-limiting examples,
these may include electro-microfluidic pixel elements that switch a
dark aqueous ink layer with a light oil layer to create patterns.
In another example, miniature light emitting elements such as light
emitting diodes may be formed into an extremely thin array with
very small patterned electrodes to provide electrical signal to
control light being emitted into intended patterns.
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