Method of manufacturing hydrogel ophthalmic devices with electronic elements

Patent metadata

Field	Value
Publication number	US-9731437-B2
Application number	US-201314087366-A
Country	US
Kind code	B2
Filing date	Nov 22, 2013
Priority date	Nov 22, 2013
Publication date	Aug 15, 2017
Grant date	Aug 15, 2017

Abstract

The present invention provides methods for forming an ophthalmic lens that can include a media insert and/or electronic components. In particular, the present disclosure provides for adhesion promoting functionalization steps for a biocompatible coating to bind a hydrogel material to a plastic surface or electronic component prior to the polymerization of the hydrogel. In some aspects, the media insert can be used to contain energy sources and/or functional electronic components which may be, for example, in a stacked integrated component configuration to permit a generally arcuate shape that can conform to the anterior surface of an eye.

First claim

The invention claimed is:

1. A method of forming an energized ophthalmic device, the method comprising:
pre-dosing a first mold part with a pre-dose amount of a reactive monomer mixture;
forming a media insert including at least one of energization or functional electronic components formed in a stacked integrated component device configuration, the media insert being a separate component that is configured to mount and encapsulate the at least one energization or functional electronic component;
functionalizing the media insert so that an adhesion promoter can bind to a surface of said media insert;
applying an adhesion promoter to the functionalized media insert;
coating said media insert including the adhesion promoter;
placing the media insert on said pre-dose of reactive monomer mixture;
pre-curing the pre-dosed reactive monomer mixture to fixedly hold the media insert proximate to the first mold part;
post-dosing the first mold part with a post-dose of a reactive monomer mixture;
placing a second mold part proximate to the first mold part, wherein the placing forms a ophthalmic device mold assembly with a lens forming cavity; and
curing at least the post-dosed reactive monomer mixture to form the ophthalmic lens, wherein the media insert is encapsulated in the ophthalmic lens.

2. The method of claim 1 , wherein the functionalizing step includes providing a plasma treatment in an oxygen environment.

3. The method of claim 1 , wherein the functionalizing step includes exposing the media insert to an ozone environment.

4. The method of claim 1 , wherein the functionalizing step includes crosslinking a chemical with the media insert.

5. The method of claim 4 , wherein the functionalizing step further includes exposing the media insert to a radiation to crosslink said chemical with the media insert.

6. The method of claim 1 , wherein the adhesion promoter includes a methoxy-silane chemical.

7. The method of claim 6 , wherein the methoxy-silane can include one of more of a vinyldimethylethoxysilane, a methoxysilane, a trimethoxysilane, a styrylethyltrimethoxysilane, a bis(trimethoxysilyl)hexane, and a vinylmethoxysiloxane homopolymer.

8. The method of claim 1 , wherein the coating is a parylene coating.

9. The method of claim 1 , wherein the coating is a polymerizable hydrogel coating.

Assignees

• Johnson & Johnson Vision Care

Inventors

• Pugh Randall Braxton
• Putt Karson
• Ferran Michael
• Hardy Katherine Rowan
• Otts Daniel B

Classifications

• B29C39/18

  incorporating preformed parts or layers, e.g. casting around inserts or for coating articles {(B29C39/206 takes precedence)} · CPC title

• B29D11/00125

  Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere · CPC title

• B29C43/02 Primary

  of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)} · 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

• B29D11/00807

  Producing lenses combined with electronics, e.g. chips · CPC title