Systems and methods for insert placement to fabricate hybrid contact lenses

Patent metadata

Field	Value
Publication number	US-12358245-B2
Application number	US-202218070189-A
Country	US
Kind code	B2
Filing date	Nov 28, 2022
Priority date	Nov 29, 2021
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

Systems, devices, and methods are disclosed for fabricating a hybrid contact lens product having a lens insert embedded at a precisely controlled location within a lens body. A mold engagement and support base engages and retains a lens forming mold in a substantially fixed position. An insert placement and positioning device includes an insert pickup head with a contact face configured for releasable engagement of the lens insert and at least one suction opening in the contact face for applying suction to engage the insert on the contact face. A positioning housing interacts with the mold and/or the support base to provide precise locational positioning of the lens insert within the mold. A lens body forming material is delivered to the mold to encapsulate the lens insert.

First claim

What is claimed is:

1. An insert placement and molding system for fabricating a hybrid contact lens product having a lens insert embedded within a lens body, the lens insert comprising a first material and having a concave back surface and an opposite convex front surface, and the lens body comprising a second material different from the first material, wherein the insert placement and molding system comprises:
a lens forming mold element which is a female mold half having a circular and concave central mold receptacle and a circumferential flange defining an internal geometry and surrounding the central mold receptacle;
a mold engagement and support base comprising a body having a planar top and a bottom surface and at least one mold engagement feature configured to engage a lens forming mold element and retain the lens forming mold element in a substantially fixed position relative to the mold engagement and support base;
an insert placement and positioning device comprising a positioning housing, a suction conduit connected to an external suction source and extending centrally and axially through the positioning housing from top to base, an insert pick-up head mounted to the suction conduit, and a positioning ring coupling the suction conduit with the positioning housing at the top of the positioning housing, wherein the insert pickup head comprises an insert contact face configured for cooperative releasable engagement of the lens insert, at least one suction opening in fluid communication with the suction conduit, and at least one pressure relief channel, wherein the positioning housing comprises at least one positioning feature which comprises an external geometry and outside diameter around its base that is configured for a clearance or interference fit within the internal geometry of the circumferential flange of the lens forming mold element to provide precise locational positioning of the insert pickup head relative to the lens forming mold element both in an axial dimension and in a transverse dimension orthogonal to the axial dimension; and
a centering jig for positioning the lens insert for pickup by the insert placement and positioning device.

2. The system of claim 1 , wherein the at least one mold engagement feature comprises a collar projecting axially from the planar top surface of the mold engagement and support base, the collar being configured for engagement within a cooperatively configured receiver of the lens forming mold element.

3. The system of claim 2 , wherein the collar comprises an at least partially annular structure and projects axially upward from the planar top surface of the mold engagement and support base.

4. The system of claim 3 , wherein the female mold half comprises an annular rim with a flat upper positioning surface surrounding the central mold receptacle near the outer periphery of the female mold half, and a peripheral recess surrounding the central mold receptacle adjacent the rim, wherein the female mold half comprises a L-shaped external circumferential flange when viewed in cross-section having a horizontal base ring portion and a vertical upright cylindrical or tubular wall portion, wherein the female mold half comprises an inverted annular recess beneath the upper positioning surface and between the peripheral recess and the upright wall portion forms a receiver for engagement over the collar of the mold engagement and support base when the female mold half is mounted onto the mold engagement and support base.

5. The system of claim 4 , wherein the lens forming mold element at least partially comprises a UV-transmissive material.

6. The system of claim 4 , wherein the lens forming mold element comprises a diametrically opposed pair of engagement wings, and wherein at least one mold engagement feature of the mold engagement and support base comprises a diametrically opposed pair of slots, each slot configured to receive a corresponding engagement wing.

7. The system of claim 1 , wherein the positioning ring comprises a locking nut that can be manually loosened and tightened by hand to allow adjustment and locking of the axial position of the insert pick-up head relative to the positioning housing, and.

8. The system of claim 1 , wherein the body of the mold engagement and support base is cylindrical in shape and comprises at least one partially annular or ring-shaped collar extended upwardly from the planar top surface and an open chamber extending through the body to a top opening bounded by the collar.

9. The system of claim 1 , wherein the insert contact face comprises a smoothly radiused a convex surface configured to match and closely conform to the back surface of the lens insert.

10. The system of claim 1 , wherein the insert pickup head is positionally adjustable relative to the positioning housing.

11. The system of claim 10 , wherein the positional adjustment of the insert pickup head relative to the positioning housing is provided by a threaded coupling between the insert pickup head and the suction conduit.

12. The system of claim 1 , wherein the insert pickup head comprises a plurality of suction openings in fluid communication with the suction conduit.

13. The system of claim 12 , wherein the plurality of suction openings are arranged in a circular array.

14. The system of claim 1 , further comprising one additional lens forming element which is a male mold half.

15. The system of claim 1 , further comprising an insert mold for forming the lens insert.

16. The system of claim 1 , wherein the centering jig comprises a cylindrical housing with a chamfered top opening, a floor at bottom, a cylindrical sidewall, and a recess formed at the center of the floor and concentric with the cylindrical housing, wherein the recess has a size and shape closely conforming to the size and shape of the lens insert.

17. The system of claim 1 , further comprising dosing means for delivery of the second material to the lens forming mold element.

18. The system of claim 1 , further comprising energy delivery means for curing the second material within the lens forming mold element.

19. The system of claim 1 , further comprising a vacuum source for delivery of suction through the suction conduit.

20. The system of claim 1 , further comprising a sensor and feedback controller configured to position the insert pickup head relative to the lens forming mold element.

21. The system of claim 20 , wherein the sensor comprises a low coherence interferometer sensor.

22. An insert placement and positioning device for precisely positioning a lens insert relative to a lens forming mold element having a circumferential flange defining an internal geometry to fabricate a hybrid contact lens product, the insert placement and positioning device comprising: a positioning housing; a suction conduit connected to an external suction source and extending centrally and axially through the positioning housing from top to base; an insert pick-up head mounted to the suction conduit; and a positioning ring coupling the suction conduit with the positioning housing at the top of the positioning housing,
wherein the insert pick-up head comprises an insert contact face configured for cooperative releasable engagement of the lens insert, and at least one suction opening formed in the insert contact face;
wherein the positioning housing comprises at least one positioning feature which comprises an external geometry and outside diameter around its base that is configured for a clea

Assignees

• Alcon Inc

Inventors

• Zheng Yang
• Niculas Cornelius Daniel
• Chang Yuan
• Ge Junhao
• Zhang Steve Yun
• Aguayo Justin Joel
• Icenogle David Andrew
• Asif Muhammad Waqas
• Reece Daryl

Classifications

• G02C7/04

  Contact lenses for the eyes (disinfection or sterilisation of contact lenses A61L12/00) · CPC title

• G02B1/043

  Contact lenses · CPC title

• B29K2105/0061

  Gel or sol · CPC title

• B29K2083/00

  Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material · CPC title

• B29D11/00038

  Production of contact lenses · CPC title