FULL RINGS FOR A FUNCTIONALIZED LAYER INSERT OF AN OPHTHALMIC LENS
This invention discloses various designs for rings that make up the functionalized layers in a functional layer insert. More specifically, design parameters for the rings for incorporation into an ophthalmic lens. Additionally, functional aspects of the rings and materials for encapsulating the functional insert into an area outside the optical zone of the ophthalmic lens.
The present application claims priority as a Continuation in Part Application to U.S. patent application Ser. No. 13/401,959 filed Feb. 22, 2012, and entitled, “Methods and Apparatus for Functional Insert with Power Layer” the contents of which are relied upon and incorporated herein by reference.
FIELD OF USEThis invention describes a functionalized layer insert for an ophthalmic device formed from multiple functional layers which are stacked. More specifically, various designs for full rings that comprise the functional layers.
BACKGROUNDTraditionally an ophthalmic device, such as a contact lens, an intraocular lens or a punctal plug included a biocompatible device with a corrective, cosmetic or therapeutic quality. A contact lens, for example, can provide one or more of: vision correcting functionality; cosmetic enhancement; and therapeutic effects. Each function is provided by a physical characteristic of the lens. A design incorporating a refractive quality into a lens can provide a vision corrective function. A pigment incorporated into the lens can provide a cosmetic enhancement. An active agent incorporated into a lens can provide a therapeutic functionality. Such physical characteristics are accomplished without the lens entering into an energized state. A punctal plug has traditionally been a passive device.
More recently, it has been theorized that active components may be incorporated into a contact lens. Some components can include semiconductor devices. Some examples have shown semiconductor devices embedded in a contact lens placed upon animal eyes. It has also been described how the active components may be energized and activated in numerous manners within the lens structure itself. The topology and size of the space defined by the lens structure creates a novel and challenging environment for the definition of various functionalities. Generally, such disclosures have included discrete devices. However, the size and power requirements for available discrete devices are not necessarily conducive for inclusion in a device to be worn on a human eye.
SUMMARYAccordingly, the present invention includes a functionalized layer insert that can be energized and incorporated into an ophthalmic device. The insert can be formed of multiple layers which may have unique functionality for each layer; or alternatively mixed functionality but in multiple layers. The layers may in some embodiments have layers dedicated to the energization of the product or the activation of the product or for control of functional components within the lens body.
In some embodiments, the functionalized layer insert may contain a layer in an energized state which is capable of powering a component capable of drawing a current. Components may include, for example, one or more of: a variable optic lens element, and a semiconductor device, which may either be located in the stacked layer insert or otherwise connected to it. Some embodiments can also include a cast molded silicone hydrogel contact lens with a rigid or formable insert of stacked functionalized layers contained within the ophthalmic lens in a biocompatible fashion.
Accordingly, the present invention includes a disclosure of an ophthalmic lens with a stacked functionalized layer portion as well as various designs for rings that comprise the functional layers. Full ring designs parameters can include, for example, thickness, shape, stacking structure, etc. In some embodiments, design parameters may be influenced by one or more of; the thickness around an optical zone of the lens, the base curve of the lens, the diameter of the lens and encapsulation parameters.
An insert may be formed from multiple layers in various manners and placed in proximity to one, or both of, a first mold part and a second mold part. A reactive monomer mix is placed between the first mold part and the second mold part. The first mold part is positioned proximate to the second mold part thereby forming a lens cavity with the energized substrate insert and at least some of the reactive monomer mix in the lens cavity; the reactive monomer mix is exposed to actinic radiation to form an ophthalmic lens. Lenses may be formed via the control of actinic radiation to which the reactive monomer mixture is exposed.
The present invention includes a substrate insert device formed through the stacking of multiple functionalized layers. Additionally the present invention includes various designs for a wafer including rings that may be used to make up functionalized layers in a functional layer insert, for incorporation into an ophthalmic lens. In the following sections detailed descriptions of embodiments of the invention will be given. The description of both preferred and alternative embodiments are exemplary embodiments only, and it is understood that to those skilled in the art that variations, modifications and alterations may be apparent. It is therefore to be understood that said exemplary embodiments do not limit the scope of the underlying invention.
GlossaryIn this description and claims directed to the presented invention, various terms may be used for which the following definitions will apply:
Active Lens Insert: as used herein refers to an electronic or electromechanical device with controls based upon logic circuits.
Arc-matched (or arc matching): as used herein refers to the design of a Ring Segment which includes an identical External Radius and Internal Radius, such that the curvature of the External Arc matches the curvature of the Internal Arc. Arc matching is used to efficiently nest Ring Segments on a Wafer, maximizing wafer utilization.
Dicing Street Width: as used herein refers to the width of a thin non-functional space between integrated circuits on a Wafer, where a saw or other device or method can safely cut the Wafer into individual Die without damaging the circuits.
Die: as used herein refers to a block of semiconducting material, on which a given functional circuit is fabricated. Die are created on and cut from a Wafer.
Energized: as used herein refers to the state of being able to supply electrical current to or to have electrical energy stored within.
Energy: as used herein refers to the capacity of a physical system to do work. Many uses within this invention may relate to the said capacity being able to perform electrical actions in doing work.
Energy Source: as used herein refers to device capable of supplying Energy or placing a biomedical device in an Energized state.
External Arc: as used herein refers to the external or convex edge of a Ring Segment, which is a portion of the circumference of the circle defined by the External Radius.
External Radius: as used herein refers to the radius of the circle that defines the external edge of a Full Ring or Ring Segment. The External Radius determines the curvature of the External Arc.
Full Ring: as used herein refers to one complete ring-shaped layer in a Functionalized Layer Insert. A Full Ring may be comprised of multiple Ring Segments or may be one Intact Ring.
Functionalized: as used herein refers to making a layer or device able to perform a function including for example, energization, activation, or control.
Functionalized Layer Insert: as used herein refers to an insert for an ophthalmic device formed from multiple functional layers which are stacked. The multiple layers may have unique functionality for each layer; or alternatively mixed functionality but in multiple layers. In some preferred embodiments, the layers are rings.
Intact Ring: as used herein refers to one complete ring-shaped layer in a Functionalized Layer Insert which is made of a single intact Die.
Internal Arc: as used herein refers to the internal or concave edge of a Ring Segment. The Internal Arc may, in some embodiments, be a single arc segment, the curvature of which is determined by the Internal Radius. In other embodiments the Internal Arc may be comprised of multiple arc segments of different curvatures, defined by different Internal Radii.
Internal Radius: as used herein refers to the radius of the circle that defines the internal edge or a portion of the internal edge of a Full Ring or Ring Segment. The Internal Radius determines the curvature of the Internal Arc.
Lens: refers to any ophthalmic device that resides in or on the eye. These devices can provide optical correction or may be cosmetic. For example, the term lens can refer to a contact lens, intraocular lens, overlay lens, ocular insert, optical insert or other similar device through which vision is corrected or modified, or through which eye physiology is cosmetically enhanced (e.g. iris color) without impeding vision. In some embodiments, the preferred lenses of the invention are soft contact lenses are made from silicone elastomers or hydrogels, which include but are not limited to silicone hydrogels, and fluorohydrogels.
Mold: refers to a rigid or semi-rigid object that may be used to form lenses from uncured formulations. Some preferred molds include two mold parts forming a front curve mold part and a back curve mold part.
Power: as used herein refers to work done or energy transferred per unit of time.
Ring Segment: as used herein refers to one Die which may be combined with other Die to construct a Full Ring. As used in this invention, a Ring Segment is generally flat and is formed in an arcuate shape.
Stacked: as used herein means to place at least two component layers in proximity to each other such that at least a portion of one surface of one of the layers contacts a first surface of a second layer. In some embodiments, a film, whether for adhesion or other functions may reside between the two layers that are in contact with each other through said film.
Substrate insert: as used herein refers to a formable or rigid substrate capable of supporting an Energy Source within an ophthalmic lens. In some embodiments, the Substrate insert also supports one or more components.
Wafer: as used herein refers to a thin slice of semiconductor material, such as silicon crystal, used in the fabrication of integrated circuits and other microdevices. The wafer serves as the substrate for microelectronic devices built in and over the wafer and undergoes many microfabrication process steps.
ApparatusReferring now to
Layers 130, 131 and 132 illustrate three of numerous layers that may be found in a functionalized layer insert 110. In some embodiments, a single layer may include one or more of: active and passive components and portions with structural, electrical or physical properties conducive to a particular purpose.
In some embodiments, a layer 130 may include an energization source, such as, for example, one or more of: a battery, a capacitor and a receiver within the layer 130. Item 131 then, in a non limiting exemplary sense, may comprise microcircuitry in a layer that detects actuation signals for an active lens insert 140. In some embodiments, a power regulation layer 132, may be included that is capable of receiving power from external sources, charging the battery layer 130 and controlling the use of battery power from layer 130 when the lens is not in a charging environment. The power regulation layer 132 may also control signals to an exemplary active lens insert 140 in the center annular cutout of the functionalized layer insert 110.
In general, according to this embodiment, a functionalized layer insert 110 is embodied within an ophthalmic lens via automation which places an energy source a desired location relative to a mold part used to fashion the lens.
The size, shape, and stacking structure of the die that may be used to form layers such as 130, 131 and 132 in a functionalized layer insert 110 is influenced by several factors, as shown in
Depicted in
The embodiment depicted in this invention includes a functionalized layer insert in the shape of a ring, formed as an intact ring-shaped die.
Full Ring LayoutReferring now to
Referring now to
The present invention, as described above and as further defined by the claims below, provides various designs for rings that make up the functionalized layers in a functional layer insert, for incorporation into an ophthalmic lens.
Claims
1. An active lens insert for an ophthalmic lens comprising:
- annular shaped full ring substrate layers with one or both of electrical and logical Functionality; wherein the size, shape and stacking structure of each of the annular shaped substrate layers is based on the thickness around an optical zone of the ophthalmic lens;
- electrical interconnections between substrate layers; and
- the active lens insert encapsulated with one or more materials that may be bonded within the body material of a molded ophthalmic lens.
2. The active lens insert of claim 1, wherein the substrate functional layers are adhered to insulating layers forming a stacked feature.
3. The active lens insert of claim 1, wherein the annular shaped full ring substrate layers are cut from a wafer.
4. The active lens insert of claim 1, wherein the size, shape and stacking structure of each of the annular shaped substrate layers is further based on the base curve of an ophthalmic lens.
5. The active lens insert of claim 1, wherein the size, shape and stacking structure of each of the annular shaped substrate layers is further based on by the diameter of an ophthalmic lens.
6. The active lens insert of claim 1, wherein the size, shape and stacking structure of each of the annular shaped substrate layers is further based on by encapsulation parameters of the active lens insert.
7. The active lens insert of claim 6, further comprising an encapsulating biocompatible polymer.
8. The active lens insert of claim 7, wherein the biocompatible polymer for encapsulation is a polysilicone based polymer.
9. The active lens insert of claim 7, wherein the encapsulation of the active lens insert maintains a minimum thickness between an edge of a substrate layer and an outer edge of a lens of less than about 150 micron thickness.
10. The active lens insert of claim 1, wherein the active lens insert comprises three (3) or more annular shaped substrate layers.
11. The active lens insert of claim 1, wherein the substrate insert comprises a full ring annular shape.
12. The active lens insert of claim 1, wherein one or more of the substrate layers of the active lens insert comprises one or more individually functionalized layer.
13. The active lens insert of claim 1, wherein one or more of the individually functionalized layer comprises a metallic layer which functions as an antenna.
14. The active lens insert of claim 10, wherein one or more of the substrate layers of the active lens insert comprises an energization source.
15. The active lens insert of claim 10, wherein one or more of the substrate layers of the substrate insert comprises power regulation source.
16. The active lens insert of claim 15, wherein the power regulation source comprises at least one semiconductor layer with electronic microcircuitry capable to control electric current flow from the electrochemical cells.
17. The active lens insert of claim 16, wherein the electronic microcircuitry is electrically connected to an electroactive lens component within the ophthalmic lens.
18. The active lens insert of claim 16, wherein the power regulation one or more substrate layers are capable of receiving power from external sources.
19. The active lens insert of claim 16, wherein the power regulation one or more substrate layers are capable of charging the battery layer.
20. The active lens insert of claim 16, wherein the power regulation one or more substrate layers are capable of controlling the use of power when the ophthalmic lens is not in a charging environment.
21. The active lens insert of claim 16, wherein the power regulation one or more substrate layers are capable of controlling the use of power when the ophthalmic lens is in a charging environment.
22. The active lens insert of claim 16, wherein one or more of the substrate layers of the substrate insert comprises solid state energy source.
23. The active lens insert of claim 1, wherein one or more of the substrate layers comprises microcircuitry to detect actuation signals for the active lens insert.
Type: Application
Filed: Feb 22, 2012
Publication Date: Mar 19, 2015
Patent Grant number: 9195075
Inventors: Randall B. Pugh (Jacksonville, FL), Frederick A. Flitsch (New Windsor, NY), Daniel B. Otts (Fruit Cove, FL), James Daniel Riall (St. Johns, FL), Adam Toner (Jacksonville, FL)
Application Number: 13/402,255