Method of forming a multi-piece insert device with seal for ophthalmic devices

Patent metadata

Field	Value
Publication number	US-9757911-B2
Application number	US-201314135001-A
Country	US
Kind code	B2
Filing date	Dec 19, 2013
Priority date	Jan 9, 2013
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

The present invention discloses a method of forming a multi-piece insert for an ophthalmic lens, comprising: forming a insert back curve piece; forming a insert front curve piece; depositing a conductive material onto one or both of the insert front curve piece and the insert back curve piece; attaching an electronic component to one or both of the insert front curve piece and the insert back curve pieces, wherein the attachment is made to the conductive material; placing a material to form a first upon a surface of either or both of the insert front curve piece and the insert back curve piece; and combining the insert back curve piece with the insert front curve piece to form a ophthalmic insert piece, wherein the combining causes the material to seal a cavity interior to the combination of the back curve piece and the front curve piece.

First claim

The invention claimed is:

1. A method of forming a multi-piece insert for an ophthalmic lens, the method comprising:
forming at least a first insert back curve piece;
forming at least a first insert front curve piece;
wherein one of the first insert front curve piece and the first insert back curve piece is larger than the other and has a peripheral edge that extends beyond the peripheral edge of the other, and wherein the larger of the first insert front curve piece and the first insert back curve piece has a groove formed in its surface and the other has a corresponding sealing feature formed in its peripheral edge to register with the groove;
depositing a conductive material onto one or both of the first insert front curve piece and the first insert back curve piece;
attaching an electronic component to one or both of the first insert front curve piece and the first insert back curve pieces, wherein the attachment is made to the conductive material;
placing a first material within the groove and/or upon the sealing feature to form a first seal upon registry of the sealing feature within the groove;
combining the first insert back curve piece with the first insert front curve piece to form a first ophthalmic insert piece, wherein the combining causes the first material to engage the sealing feature to seal a first cavity interior to the combination of the first back curve piece and the first front curve piece and creates a gap between the peripheral edge of the first insert front curve piece and the peripheral edge of the first insert back curve piece; and
placing an adhesive material into the gap to lock the sealing feature into engagement with the first material in the groove, wherein the adhesive material is different than the first material.

2. The method of claim 1 additionally comprising the steps of:
forming at least a second insert back curve piece;
placing a second material to form a second seal upon either or both of the first insert front curve piece and second insert back curve piece; and
combining the first ophthalmic insert piece with the second insert back curve piece to form a second ophthalmic insert piece, wherein the combining causes the second material to seal a second cavity interior to the combination of the first ophthalmic insert piece and the second insert back curve piece.

3. The method of claim 1 wherein:
the first cavity contains the electronic component.

4. The method of claim 1 wherein:
the electronic component is exterior to the sealed first cavity.

5. The method of claim 1 additionally comprising:
at least a partial filling of the first cavity with at least a first liquid before it is sealed or during the sealing process.

6. The method of claim 1 additionally comprising:
at least a partial filling of the first cavity with at least a first a liquid after it is sealed.

7. The method of claim 1 wherein:
the first material is an epoxy adhesive.

8. The method of claim 1 wherein:
the first material is preformed into a shape to form the seal.

9. The method of claim 1 wherein:
a first self-locking feature maintains the physical contact of at least a portion of either or both the first insert back curve piece and the first insert front curve piece to the first material.

10. The method of claim 1 wherein:
during the combining, a self-locking feature fixedly holds the first insert back curve piece in a relative position to the first insert front curve piece.

11. The method of claim 1 additionally comprising:
applying a sealing agent to at least a portion of the electronic component after attachment of the electronic component is made to the conductive material.

12. The method of claim 1 additionally comprising:
applying a sealing agent to at least a portion of the conductive material.

13. The method of claim 2 additionally comprising:
applying a sealing agent to at least a portion of the conductive material.

14. The method of claim 1 additionally comprising the steps of:
depositing a reactive mixture on a concave surface that is included in a first ophthalmic lens mold part;
positioning the first ophthalmic insert piece in contact with the reactive mixture;
positioning a second ophthalmic lens mold part proximate to the first ophthalmic lens mold part to form an ophthalmic lens cavity, wherein the reactive mixture and the first ophthalmic insert are located within the cavity;
polymerizing the reactive mixture to form an ophthalmic lens; and
removing the ophthalmic lens.

15. The method of claim 2 additionally comprising:
depositing a reactive mixture on a surface that is upon a first ophthalmic lens mold part;
positioning the second ophthalmic insert of claim 2 in contact with the reactive mixture;
positioning a second ophthalmic lens mold part proximate to the first ophthalmic lens mold part to form an ophthalmic lens cavity, wherein the reactive mixture and the second ophthalmic insert piece are located within the cavity;
polymerizing the reactive mixture to form an ophthalmic lens; and
removing the ophthalmic lens.

16. The method of claim 14 wherein:
the reactive mixture comprises or forms a hydrogel.

17. The method of claim 16 wherein:
the second ophthalmic insert includes an energization component.

18. The method of claim 17 wherein:
the second ophthalmic insert includes a liquid meniscus ophthalmic lens.

Assignees

• Johnson & Johnson Vision Care
• Johnson & Johson Vision Care Inc

Inventors

• Riall James Daniel
• Pugh Randall B
• Otts Daniel B
• Flitsch Frederick A
• Toner Adam

Classifications

• B29C45/26

  Moulds · CPC title

• B62D31/00

  Superstructures for passenger vehicles (passenger vehicles specially adapted to co-operate with aircraft or terminal buildings B64F1/31) · CPC title

• B29C39/10

  incorporating preformed parts or layers, e.g. casting around inserts or for coating articles {(coating a surface by casting in general B05D1/30, B29C39/126 takes precedence)} · CPC title

• B29D11/00817

  Producing electro-active lenses or lenses with energy receptors, e.g. batteries or antennas · CPC title

• B29C2033/422

  Moulding surfaces provided with a shape to promote flow of material in the mould cavity · CPC title