RU2629902C2 - Bearing insert for ophthalmological device with overlapped integrated components - Google Patents

Abstract

FIELD: physics.

SUBSTANCE: formation of bearing insert with overlapped integrated components for ophthalmological lens comprises: forming a plurality of substrate layers, each carrying at least one energy source or functional component; assembling a plurality of substrate layers into a pack, configured to be mounted in the ophthalmological lens outside the optical zone; forming electrical connections between the energy source and the functional components of the mentioned substrate layers in the pack; and sealing the pack with a material for pasting a cast ophthalmological lens inside the body.

EFFECT: providing the possibility of wireless power supply of devices in the contact lens.

20 cl, 10 dwg

Description

The present invention relates to a method for forming a carrier insert with integrated components for an ophthalmic lens superimposed on one another and to a carrier insert with integrated components for an ophthalmic lens superimposed on each other.

BACKGROUND OF THE INVENTION

An ophthalmic device, such as a contact lens, an intraocular lens or a lacrimal plug, is traditionally a biocompatible device with corrective, cosmetic or therapeutic properties. For example, the use of a contact lens may have one or more of the following objectives: correction of vision, cosmetic improvement, and therapeutic effects. Each of the functions is determined by a specific physical characteristic of the lens. The configuration of the lens taking into account the light-reflecting properties allows the function of vision correction. The introduction of a pigment into the lens allows for cosmetic improvement. The introduction of an active agent into the lens allows the lens to be used for therapeutic purposes. Such physical characteristics can be achieved without putting the lens in a state with energy supply.

Recently, there have been suggestions about the possibility of introducing active components into the contact lens. Some components may include semiconductor devices. In some examples, the introduction of semiconductor devices into contact lenses placed on the eyes of an animal is presented. However, an autonomous energy supply mechanism has not yet been proposed for such devices. To power such semiconductor devices, in principle, you can use the wires connecting the lens to the battery, in addition, suggestions were made for the wireless power supply of such devices, but so far no mechanism has been proposed for implementing such a wireless power supply.

Therefore, it is desirable to have additional methods and apparatus for implementing ophthalmic lenses with an energy supply sufficient to provide one or more of the functionality of an ophthalmic lens and a controlled change in the optical characteristics of an ophthalmic lens or other biomedical device.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, a method for forming a carrier insert with integrated components for an ophthalmic lens superimposed on one another is provided. The method comprises: forming substrate layers with functionality; assembly of substrate layers; the formation of electrical connections between the layers of the substrate; sealing a multilayer element with a material for gluing an ophthalmic lens inside the body.

During assembly, the substrate layers may be given one of a circular annular shape or part of an annular shape.

The functional layers superimposed on each other can adhesively adhere to the insulating layers to form a multilayer element.

The second layer of superimposed integrated components can be shaped into at least part of a circular annular structure whose outer radius is smaller than the radius of the first layer.

One or more layers may comprise a surface with a metallic characteristic.

A solder film may be applied to the surface of one or more of the layers having a metal characteristic.

The method may comprise placing the battery on a carrier insert with integrated components superimposed on each other, the battery being rechargeable by one or more of radio frequency radiation and magnetic induction.

The method may include placing a thin-film battery on a carrier insert with integrated components superimposed on each other and modifying the surface of the battery to determine its appearance.

Substrate layers can be flexible.

In accordance with a further aspect, a method is provided comprising the steps of forming a carrier insert with integrated components superimposed on one another and gluing the carrier insert into an ophthalmic lens.

In accordance with a further aspect, an insert with layers of stacked integrated components is provided. The insert contains: substrate layers with functionality; moreover, the substrate layers are assembled with the formation of electrical connections between the layers of the substrate, forming a multilayer element; moreover, the multilayer element is sealed with a material for gluing inside the body of a cast ophthalmic lens.

During assembly, the substrate layers may be given one of a circular annular shape or part of an annular shape.

The functional layers superimposed on each other can adhesively adhere to the insulating layers to form a multilayer element.

An insert with layers of integrated components stacked on top of each other may comprise a second layer of integrated components stacked on top of each other in the form of at least a portion of a circular annular structure whose outer radius is smaller than the outer radius of the first layer.

One or more layers may comprise a surface with a metallic characteristic.

An insert with layers of integrated components superimposed on each other may comprise a solder film deposited on the surface of one or more layers having a metal characteristic.

The insert with layers of superimposed integrated components may comprise a battery that is rechargeable by one or more of radio frequency radiation and magnetic induction.

The insert with layers of integrated components superimposed on each other may comprise a thin-film battery, the surface of the battery being configured to determine a predetermined appearance.

Substrate layers can be flexible.

In accordance with a further aspect, an ophthalmic lens is provided comprising an insert glued into it with layers of integrated components superimposed on top of one another.

This document describes a carrier insert, which can be made with energy supply and built into an ophthalmic device, such as, for example, a contact lens or a tube for a lacrimal opening. In addition, the present invention also includes a method and apparatus for forming an ophthalmic lens containing a carrier insert with energy supply. In some illustrative examples, an environment in an energy-capable state is capable of providing power to a component capable of consuming current. Components may include, for example, one or more of: a variable optical property lens element, a semiconductor device, and an active or passive electronic device. Some examples may also include a molded silicone hydrogel contact lens with a rigid or formable insert with energy supply contained in an ophthalmic lens in compliance with the biocompatibility principle.

This document describes an ophthalmic lens with a part of a medium with energy supply, a device for forming an ophthalmic lens with a part of a medium with energy supply and methods for their production. The energy source can be placed in the carrier insert, and the insert can be placed in close proximity to one or both of the first part of the mold and the second part of the mold. The monomer reaction mixture is placed between the first part of the mold and the second part of the mold. The first part of the mold is located in close proximity to the second part of the mold, thereby forming a cavity for the lens, and in the cavity for the lens there is a carrier insert with energy supply and at least part of the reaction mixture of the monomer. The reaction monomer mixture is irradiated with actinic radiation to form an ophthalmic lens. Lenses are formed by controlling the flow of actinic radiation, which affects the reaction mixture of the monomer.

DESCRIPTION OF DRAWINGS

In FIG. 1 shows a mold assembly assembly device in accordance with an embodiment of the present invention.

In FIG. 2A-2D illustrate various carrier inserts that can be mounted in an ophthalmic lens in accordance with an embodiment of the present invention.

In FIG. 3 shows a device for placing a power source inside a part of an ophthalmic lens injection mold.

In FIG. 4 shows the steps of a method in accordance with an embodiment of the present invention.

In FIG. 5 illustrates process steps in accordance with a further aspect of the present invention.

In FIG. 6 shows a processor that can be used to implement the method in accordance with an embodiment of the present invention.

In FIG. 7 is an illustration of an example of a carrier insert.

In FIG. 8 is a cross-sectional view of an example of a carrier insert.

In FIG. 9 is a cross-sectional view of a device with integrated components superimposed on top of one another, which provides power supply to carrier inserts with integrated components superimposed in accordance with an embodiment of the invention.

In FIG. 10 shows a carrier insert with integrated components stacked on top of each other as part of an ophthalmic lens example.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a method for forming a carrier insert and a carrier insert for an ophthalmic lens. In addition, the carrier insert can be integrated into the ophthalmic lens.

A power supply lens 100 can be formed with an integrated carrier insert and an energy source, such as an electrochemical cell or a battery, as an energy storage means and optionally a means for sealing and isolating materials containing the energy source from the environment in which the ophthalmic lens is placed.

In some illustrative examples, the carrier insert also includes a set of circuits, components, and energy sources. The carrier insert, which houses a set of circuits, components and energy sources, can be located on the periphery of the optical zone through which the lens user will look, while in an alternative embodiment, a set of circuits, components and energy sources that are small enough and not obstruct normal vision of the user of the contact lens, therefore, they can be placed in the carrier insert inside or outside the optical zone.

In general, the carrier insert is integrated into the ophthalmic lens through an automation element that places the energy source in the desired location relative to the part of the casting mold used for casting the lens.

In some illustrative examples, the energy source is in electrical connection with a component that can be activated by command and which draws electrical current from an energy source included in the ophthalmic lens. A component may include, for example, a semiconductor device, an active or passive electrical device, or an electrically activated mechanism, including, for example: microelectromechanical systems (MEMS), nanoelectromechanical systems (NEMS), or micromechanisms. After the energy source and the component of the reaction mixture are placed, they are molded using a casting mold and the mixture is polymerized to form an ophthalmic lens.

The following sections provide a detailed description of embodiments of the present invention. Descriptions of both preferred and alternative embodiments are only exemplary embodiments. It is intended that those skilled in the art will appreciate the possibility of creating variations, modifications, and changes. Therefore, it is assumed that these embodiments do not limit the scope of the present invention.

LIST OF TERMS

In this description and the claims of the present invention, various terms are used for which the following definitions are adopted.

Component - as used herein, refers to a device capable of receiving electric current from an energy source to change one or more of a logical state or physical state.

Power Supply — when used herein, refers to a state in which a device can supply electrical current or accumulate electrical energy.

Energy - when used in this document refers to the ability of a physical system to do work. Many areas of application within the framework of the present invention may relate to the indicated ability to perform electrical actions when performing work.

Energy source - when used herein, refers to a device configured to supply energy or bring a biomedical device into a state of energy supply.

Energy harvesting device - when used herein, refers to a device capable of extracting energy from the environment and converting it into electrical energy.

Lens - refers to any ophthalmic device inside or on the eye. These devices can be used for optical correction or used as a cosmetic product. For example, the term may refer to a contact lens, intraocular lens, patch lens, ocular insertion, optical insertion, or other similar device that is used to correct or modify vision, or to cosmeticly improve the physiology of the eye (e.g., changing the color of the iris) without reducing vision . Preferred lenses are soft contact lenses derived from silicone elastomers or hydrogels.

Lens-forming mixture or “reaction mixture” (monomer reaction mixture (PCM)), as used herein, refers to a monomer or prepolymer material that can be polymerized and cross-linked or cross-linked to form an ophthalmic lens. Lens-forming mixtures may include one or more additives, such as: UV blockers, dyes, photoinitiators or catalysts, and other additives that may be required as part of ophthalmic lenses, such as contact or intraocular lenses.

Lens-forming surface - refers to the surface that is used to cast the lens. Any such surface may be a surface of optical cleanliness and quality, which indicates that it is sufficiently smooth and formed in such a way that the lens surface formed by polymerization of the lens-forming material in contact with the surface of the mold is characterized by optically acceptable quality. The lens-forming surface 103-104 may additionally have the geometry necessary to impart the required optical characteristics to the lens surface, including, without limitation, spherical, aspherical and cylindrical optical power, correction of the wavefront aberration, correction of the topography of the cornea, etc., as well as any of them combinations.

Lithium-ion cell - refers to an electrochemical cell in which electrical energy is generated by the movement of lithium ions through a cell. This electrochemical cell, usually called a battery, in its typical form can be returned to a state with a higher charge or recharged.

Carrier insert — when used herein, means a moldable or rigid substrate capable of supporting an energy source within an ophthalmic lens. The carrier insert may also support one or more components.

Casting mold - refers to a rigid or semi-rigid object that can be used to form lenses from unpolymerized formulations. Some preferred molds include two parts of the mold: the front curved part of the mold and the back curved part of the mold.

Optical zone — when used herein, indicates the area of the ophthalmic lens through which the user of the ophthalmic lens looks.

Power - when used in this document, means work performed or energy transferred per unit of time.

Rechargeable or rechargeable - when used in this document, means the ability to be recharged or transferred to a state with a higher ability to do work. Many fields of application within the framework of the present invention may relate to the possibility of restoring the ability at which an electric current of a certain magnitude is emitted over a period of time.

Reconnect to the power source or recharge - return to the state of the work with higher power. Many areas of application within the framework of the present invention may relate to restoring the ability of a device to emit a certain amount of electric current over a period of time.

Released from the mold — indicates that the lens is either completely detached from the mold or only loosely attached to it so that it can be removed with a gentle shake or swapped.

“Devices with integrated components superimposed on one another” - when used in this document, the term is sometimes replaced by the term “SIC devices”, the term refers to the result of the application of packaging technologies that allow the assembly of thin layers of substrates, which can contain electrical and electromechanical devices, into functional integrated devices by overlaying at least part of each layer on top of each other. Layers may contain multicomponent devices of various types, materials, shapes and sizes. Moreover, the layers can be obtained using various technologies for the production of devices to obtain various necessary forms.

Molds

In FIG. 1 is a block diagram of an injection device 100 of an ophthalmic lens with a carrier insert 111. As used herein, the term “injection device” 100 includes plastic elements for forming a cavity 105; moreover, the lens-forming mixture can be supplied into the cavity in such a way that during a chemical reaction or during polymerization of the lens-forming mixture, an ophthalmic lens of the desired shape is obtained. The casting molds and casting mold assemblies 100 constituting the subject of the present invention consist of more than one “part of the casting mold” 101-102. Parts of the mold 101-102 can be brought closer together so that a cavity 105 is formed between the parts of the mold 101-102, in which the lens can be formed. This combination of parts of the mold 101-102 is preferably temporary. After forming the lens, portions of the injection mold 101-102 can again be detached to remove the lens.

At least one part of the surface 103-104 of at least one part of the mold 101-102 is in contact with the lens-forming mixture, so that during a chemical reaction or during polymerization of the lens-forming mixture, this surface 103-104 provides the necessary contour and shape of the part the lens with which she is in contact. This is also true for at least one more part of the mold 101-102.

Thus, for example, the casting device 100 is formed of two parts 101-102: a concave part (front part) 102 and a convex part (back part) 101, between which a cavity is formed. The portion of the concave surface 104 in contact with the lens-forming mixture has a curvature that matches the curvature of the front surface of the ophthalmic lens formed in the casting device 100, and a sufficiently smooth surface and such a design that the surface of the ophthalmic lens formed by polymerization of the lens-forming mixture, which in contact with concave surface 104, will be of optically acceptable quality.

The front part of the mold 102 may also have an annular flange, made integral with the surrounding edge of the circle, and departs from it in a plane perpendicular to the axis and passing from the flange (not shown).

The surface for forming the lens may include a surface 103-104 with a surface coating of optical quality, which indicates that it is sufficiently smooth and formed so that the surface of the lens formed by polymerization of the lens-forming material in contact with the surface of the mold, characterized by optically acceptable quality. In addition, the lens-forming surface 103-104 may have the geometry required to impart the required optical characteristics to the lens surface, including, without limitation, spherical, aspherical and cylindrical optical power, wavefront aberration correction, corneal topography correction, etc., as well as any combination of them.

Element 111 shows a carrier insert on which an energy source 109 and component 108 are mounted. The carrier insert 111 may be made of any suitable material on which the energy source 109 can be placed, and may also include circuit connections, components, and other aspects suitable to provide electrical communication between the energy source 109 and the component 108 and allowing the component to consume electric current from the energy source 109.

The carrier insert 111 may include a flexible substrate. Additional examples may include a carrier insert 111 that is rigid, such as a silicon wafer. A rigid insert may include an optical zone providing a specific optical property (for example, such as properties used to correct vision) and part of a non-optical zone. The energy source may be located in one or both of the optical zone and the non-optical zone of the insert. Other examples may include an annular insert, either rigid, or moldable, or having some shape surrounding the optical zone through which the user is looking.

Other examples include a carrier insert 111 formed from a transparent layer of material, which will then be included in the lens when it is formed. The transparent layer may include, for example, the pigment, monomer or other biocompatible material described below.

An energy source 109 can be placed on the carrier insert 111 before the carrier insert 111 is placed in a portion of the casting mold used to form the lens. The carrier insert 111 may also include one or more components that will receive electrical energy from an energy source 109.

A lens with a carrier insert 111 may have a configuration with a rigid center and a soft edge, in which the central hard optical element is in direct contact with the atmosphere and the surface of the cornea of the eye, respectively, on the front and rear surfaces, and the soft edge of the lens material (usually obtained made of hydrogel material) is fixed on the peripheral zone of the rigid optical element, and the rigid optical element also acts as a carrier insert, providing energy and awn operation for the resulting ophthalmic lens.

Some examples include a carrier insert 111, which is a rigid lens insert fully sealed with a hydrogel matrix. The carrier insert 111, which is a rigid lens insert, can be produced, for example, using micro-injection molding technology. For example, a poly (4-methylpent-1-ena) copolymer resin with a diameter of about 6 mm to 10 mm, a front surface radius of about 6 mm to 10 mm, a back surface radius of about 6 mm to 10 mm, and a central thickness may be included. parts from about 0.050 mm to 0.5 mm. An insert with a diameter of approximately 8.9 mm, a radius of the front surface of approximately 7.9 mm, a radius of the rear surface of approximately 7.8 mm, a thickness of the central portion of approximately 0.100 mm and an edge profile of approximately 0.050 radius may be included. A microcasting machine may include a five-ton Microsystem 50 manufactured by Battenfield Inc.

The carrier insert can be placed in a portion of the mold 101-102 used to form the ophthalmic lens.

The material of the parts of the injection mold 101-102 may include, for example, a polyolefin or one or more of: polypropylene, polystyrene, polyethylene, polymethyl methacrylate and modified polyolefins. Other molds may include ceramic or metallic material.

Other casting mold materials that can be used in combination with one or more additives to form an ophthalmic lens casting mold include, for example, Zieglar-Natta polypropylene resins (sometimes referred to as znPP); refined random clean cast random copolymers in accordance with paragraph (c) 3.2 of section 21 of the United States Code of Federal Regulations (CFR) of the United States Food and Drug Administration (FDA); random copolymer (znPP) with an ethylene group.

Injection molds may also include polymers such as polypropylene, polyethylene, polystyrene, polymethyl methacrylate, modified polyolefins with an alicyclic moiety in the backbone, and cyclic polyolefins. The mixture can be used on either or both of the halves of the casting mold, preferably this mixture is used to form the rear curved surface, and the front curved surface consists of alicyclic copolymers.

Some preferred methods for making injection molds 100 use injection molding in accordance with known techniques, however, the methods may also include injection molds made using other technologies, including turning, diamond turning, or laser cutting.

Typically, lenses are formed on at least one surface of both parts of the mold 101-102. However, one surface of the lens can be formed from part of the mold 101-102, and the other surface of the lens can be formed by a turning method or other methods.

Lenses

In FIG. 2A-2D illustrate examples of configurations of carrier inserts 211-214. In FIG. 2A shows an annular carrier insert 211. Other carrier inserts may have various shapes compatible with their placement inside an ophthalmic lens. Some preferred forms include those with arched configurations consistent in overall shape with an ophthalmic lens. In FIG. 2B shows a carrier insert 212, which includes an area equal to approximately Ѕ of the total area of the annular configuration, and also has an arcuate region and can surround the optical area of the lens into which the carrier insert 212 is placed. Similarly, in FIG. 2C shows a carrier insert 213, the area of which is approximately 1/3 of the total area of the annular configuration. In FIG. 2D shows an annular configuration 214 in which the carrier insert 214 consists of many separate sections 215, 216, 21. The individual sections 215, 216, 21 may be suitable for separating the various functions performed by the individual sections 215, 216, 21. For example, one of the individual sections 215, 216, 21 may contain one or more sources of energy, and the other of the individual sections 215, 216, 21 may include components.

The carrier insert 211-214 may optionally have an optical zone including an element with variable optical properties powered by an energy source located on the carrier insert 211-214. The carrier insert 211-214 may also include a circuit for controlling an element with variable optical properties located in the optical zone 211-214. In this description, an element with variable optical properties can be considered a component in the above sense.

The energy source may be in electrical communication with the component. A component may include any device that responds to an electric charge by a state change, such as, for example, a semiconductor chip, a passive electrical device, or an optical device, such as a crystalline lens.

An energy source includes, for example: a battery or other electrochemical cell, capacitor, ultracapacitor, supercapacitor, or other storage component. The lithium-ion battery can be placed on the carrier insert 211-214 on the periphery of the ophthalmic lens outside the optical zone, and it can be recharged by one or more of radio frequency radiation and magnetic induction to obtain an energy source deposited by inkjet printing.

A preferred type of lens may include a lens that includes a silicone-containing component. By “silicone-containing component” is meant any component containing at least one [-Si-O-] unit in the composition of a monomer, macromer or prepolymer. The total content of Si and directly bonded to it O in the considered silicone-containing component is preferably more than about 20% by weight. and more preferably more than 30% by weight. of the total molecular weight of the silicone-containing component. Suitable silicone-containing components preferably contain polymerizable functional groups, such as acrylate, methacrylate, acrylamide, methacrylamide, vinyl, N-vinyl lactam, N-vinyl amide and styryl functional groups.

Suitable silicone-containing components include compounds of formula I:

Where:

R ¹ independently selected from monovalent reactive groups, monovalent alkyl groups or monovalent aryl groups, each of the above groups may additionally contain functional groups selected from hydroxy, amino, oxa, carboxy, alkylcarboxy, alkoxy, amido, carbamate, carbonate halogen or combinations thereof; moreover, monovalent siloxane chains contain 1-100 repeating Si-O units, which may additionally contain functional groups selected from alkyl, hydroxy, amino, oxa, carboxy, alkylcarboxy, alkoxy, amido, carbamate, halogen, or combinations thereof;

b = from 0 to 500, and it is understood that if b is different from 0, then with respect to b there is a distribution with a mode equal to the specified value; moreover, at least one R ¹ contains a monovalent reactive group, and in some examples from one to 3 R ¹ contain a monovalent reactive group.

As used herein, the term “monovalent reactive groups” refers to groups capable of free radical and / or cationic polymerization reactions. Non-limiting examples of free radical reactive groups include (meth) acrylates, styryls, vinyls, vinyl esters, C _1-6 alkyl (meth) acrylates, (meth) acrylamides, C _1-6 alkyl (meth) acrylamides, N-vinyl lactams, N-vinyl amides, C _2-12 alkenyls, C _2-12 alkenylphenyls, C _2-12 alkenylnaphthyls, C _2-6 alkenylphenyl-C _1-6 alkyls, O-vinyl carbamates and O-vinyl carbonates. Non-limiting examples of cationic reactive groups include vinyl ester or epoxy groups and mixtures thereof. In one embodiment, the free radical reactive groups comprise (meth) acrylate, acryloxy, (meth) acrylamide, and mixtures thereof.

Suitable monovalent alkyl and aryl groups include unsubstituted monovalent C ₁ -C ₁₆ alkyl groups, C ₆ -C ₁₄ aryl groups such as substituted and unsubstituted methyl, ethyl, propyl, butyl, 2-hydroxypropyl, propoxypropyl, polyethyleneoxypropyl, combinations thereof etc.

In one example, b is zero, one R ¹ represents a monovalent reactive group, and at least 3 R ¹ selected from monovalent alkyl groups having from one to 16 carbon atoms, and in another example from monovalent alkyl groups having from one to 6 carbon atoms. Non-limiting examples of silicone-containing components include 2-methyl-, 2-hydroxy-3- [3- [1,3,3,3-tetramethyl-1 - [(trimethylsilyl) oxy] disiloxanyl] propoxy] propyl ether ( SiGMA)

2-hydroxy-3-methacryloxypropyloxypropyltris (trimethylsiloxy) silane,

3-methacryloxypropyltris (trimethylsiloxy) silane (TRIS),

3-methacryloxypropylbis (trimethylsiloxy) methylsilane and

3-methacryloxypropylpentamethyldisiloxane.

In another example, b is 2 to 20, 3 to 15, or 3 to 10; at least one terminal R ¹ contains a monovalent reactive group, and the remaining R ^{1 is} selected from monovalent alkyl groups having from 1 to 16 carbon atoms, and in another example, from monovalent alkyl groups having from 1 to 6 carbon atoms. In another example, b is from 3 to 15, one terminal R ¹ contains a monovalent reactive group, the other terminal R ¹ contains a monovalent alkyl group having from 1 to 6 carbon atoms, and the remaining R ¹ contains a monovalent alkyl group having from 1 up to 3 carbon atoms. Non-limiting examples of silicone-containing components include polydimethylsiloxane (MM 400-1000) with a terminal mono (2-hydroxy-3-methacryloxypropyl) propyl ether group (OH-mPDMS), polydimethylsiloxanes (MM 800-1000) with a terminal mono- n-butyl and terminal monomethacryloxypropyl groups (mPDMS).

In another example, b is from 5 to 400 or from 10 to 300, both terminal R ¹ contain monovalent reactive groups, and the remaining R ^{1 are} independently selected from monovalent alkyl groups having from 1 to 18 carbon atoms that may have ether bonds between carbon atoms and may additionally contain halogen.

In one example, when it is necessary to obtain a lens based on silicone hydrogel, it is obtained from a reaction mixture containing at least about 20 and preferably from about 20 to 70% by weight. silicone-containing components based on the total weight of the components containing the reaction monomer from which the polymer is obtained.

In another example, one to four R ¹ are vinyl carbonate or carbamate of the formula:

Formula II

Where:

Y is O-, S- or NH-;

R is hydrogen or methyl; d is 1, 2, 3 or 4; and q is 0 or 1.

Silicone-containing vinyl carbonate or vinyl carbamate monomers specifically include: 1,3-bis [4- (vinyloxycarbonyloxy) but-1-yl] tetramethyldisiloxane, 3- (vinyloxycarbonylthio) propyl- [tris (trimethylsiloxy) silane],

3- [tris (trimethylsiloxy) silyl] propylallyl carbamate,

3- [tris (trimethylsiloxy) silyl] propyl vinyl carbamate, trimethylsilylethyl vinyl vinyl carbonate, trimethylsilyl methyl vinyl vinyl carbonate and:

For biomedical devices with an elastic modulus of less than about 200, only one R ¹ should be a monovalent reactive group, and no more than two of the remaining R ¹ should be a monovalent siloxane group.

Another class of silicone-containing components includes polyurethane macromers of the following formulas:

Formulas IV-VI

(* D * A * D * G) _a * D * D * E ¹ ;

E (* D * G * D * A) _a * D * G * D * E ¹ ; or

E (* D * A * D * G) _a * D * A * D * E ¹ ;

Where:

D means alkyl diradical, alkylcycloalkyl diradical, cycloalkyl diradical, aryl diradical or alkylaryl diradical containing from 6 to 30 carbon atoms,

G is an alkyl diradical, cycloalkyl diradical, alkylcycloalkyl diradical, aryl diradical or alkylaryl diradical containing from 1 to 40 carbon atoms, which may contain ether, thioether or amine bonds in the main chain;

* means urethane or ureido bond;

_a is at least 1;

A means a divalent polymer radical of the formula:

Formula VII

R ¹¹ independently means an alkyl or fluoro-substituted alkyl group having from 1 to 10 carbon atoms, which may contain ether bonds between carbon atoms; y is at least 1; and p provides a molecular weight of the fragment from 400 to 10,000; each of E and E ¹ independently means a polymerizable unsaturated organic radical represented by the formula:

Formula VIII

where: R ¹² represents hydrogen or methyl; R ¹³ represents hydrogen, an alkyl radical having from 1 to 6 carbon atoms, or a —CO — YR ¹⁵ radical, in which Y represents —O—, YS— or —NH—; R ¹⁴ represents a divalent radical having from 1 to 12 carbon atoms; X is —CO— or —OCO—; Z is —O— or —NH—; Ar means an aromatic radical having from 6 to 30 carbon atoms; w is from 0 to 6; x is 0 or 1; y is 0 or 1; and z is 0 or 1.

A preferred silicone-containing component is a polyurethane macromer represented by the following formula:

Formula IX

where R ¹⁶ is a diisocyanate diradical after removal of an isocyanate group, such as an isophorondiisocyanate diradical. Another suitable silicone-containing macromer is a compound of formula X (where x + y is a number in the range from 10 to 30) formed by the reaction of fluoroether, hydroxyl-terminated polydimethylsiloxane, isophorone diisocyanate and isocyanatoethyl methacrylate.

Formula X

Other silicone-containing components suitable for use in the present invention include macromers containing polysiloxane, polyalkylene ether, diisocyanate, polyfluorocarbon, polyfluoroether and polysaccharide groups; polysiloxanes with a polar fluorinated grafted or side group having a hydrogen atom attached to a terminal difluoro-substituted carbon atom; hydrophilic siloxanyl methacrylates containing ether and siloxanilic bonds, as well as crosslinkable monomers containing polyester and polysiloxanilic groups. Any of the above polysiloxanes can also be used as the silicone-containing component in the present invention.

Ways

The following process steps are provided as examples of methods that can be implemented in accordance with some aspects of the present invention. It should be understood that the order of presentation of the stages of the method is not limiting, and other sequences can be used to implement the present invention. In addition, not all steps are necessary to implement the present invention, and additional steps may be included in various examples of the present invention.

In FIG. 4 is a flowchart showing steps that can be used to implement the present invention. At step 401, the energy source is placed on the carrier insert. The carrier insert may or may not contain one or more components.

At 402, the reaction monomer mixture can be placed in the first part of the mold.

At step 403, the carrier insert is placed in the cavity formed by the first part of the mold. The carrier insert 111 may be mechanically inserted into a portion of the mold 101-102. The room in a mechanical way may include, for example, the use of a robot or other automation means known in the art as being used to install components by surface mounting. The placement of the carrier insert 111 manually is also within the scope of the present invention. Accordingly, any room by mechanical means, allowing the carrier insert 111 with an energy source 109 to be placed in a part of the mold, and the polymerization of the reaction mixture 110 contained in the mold part allows the energy source 109 to be included in the resulting ophthalmic lens.

It is also possible to install a processor device, MEMS, NEMS, or another component, which are in electrical communication with an energy source, on a carrier insert.

At 404, the first part of the mold can be placed in close proximity to the second part of the mold to form a cavity for forming a lens containing at least a portion of the reaction monomer mixture and an energy source. At 405, polymerization of the monomer reaction mixture in the cavity can be carried out. The polymerization can be carried out, for example, under the influence of one or more of actinic radiation and heat. At 406, the lens is removed from parts of the mold.

Although the present invention can be used to form hard or soft contact lenses obtained from any known lens forming material or material suitable for the manufacture of such lenses, the lenses of the present invention are preferably soft contact lenses with a water content of from about 0 to approximately 90 percent. More preferably, the lenses are obtained from monomers containing hydroxyl groups, carboxyl groups, or both types of groups, or are obtained from silicone-containing polymers such as siloxanes, hydrogels, silicone hydrogels, and combinations thereof. A material suitable for forming the lenses of the present invention can be obtained by reacting mixtures of macromers, monomers and their combinations with additives, such as polymerization initiators. Suitable materials include, without limitation, silicone hydrogels derived from silicone macromers and hydrophilic monomers.

As shown in FIG. 4, in step 402, the reaction mixture is placed between the first part of the mold and the second part of the mold, and in step 403, the carrier insert is placed in contact with the reaction mixture. At 404, the first part of the mold is placed in close proximity to the second part of the mold to form a cavity for forming a lens containing the reaction mixture of monomer and medium.

At step 405, the reaction mixture is polymerized, for example, under the influence of one or more of actinic radiation and heat. At 406, an ophthalmic device with an integrated carrier and an energy source is removed from the parts of the casting mold used to form the ophthalmic device.

As shown in FIG. 5, in another aspect of the present invention, a carrier insert integrated in an ophthalmic device may receive power from an integrated energy source. At step 501, the carrier insert is placed in an ophthalmic lens as described above. At step 502, an electrical connection is made between the carrier insert and a component included in the carrier insert or otherwise included in the ophthalmic lens 105. The electrical connection can be established, for example, using the circuit included in the carrier insert or using contact tracks applied by inkjet printing or otherwise directly onto the lens material.

At 503, energy is directed to a component embedded in the ophthalmic lens. Energy can be directed to the device, for example, by means of an electrical circuit capable of conducting electric current. At step 504, the component performs some action based on the energy received in it. The action may include a mechanical action that changes the characteristics of the lens, or some action related to the processing of information, including one or more of: receiving, transmitting, storing and processing information. Examples include information that is stored and processed digitally.

At 505, information may be transmitted from a component embedded in the lens.

Device

In FIG. 3 depicts an automatic device 310 with one or more transfer mechanisms 311 of a carrier insert 314. As shown in the figure, a plurality of parts of the injection molds, each with a related carrier insert 314, are mounted on a pallet 313 that is processed by the transfer mechanisms of the medium 311. Examples may include one mechanism that separately holds the carrier 314, or a plurality of mechanisms (not shown) that simultaneously place the carrier 314 in many parts of the mold, and in some examples, in each mold.

Another aspect includes an apparatus for supporting the carrier insert 314, while an ophthalmic lens body is molded around these components. The energy source may be fixed at fixation points in a mold for casting a lens (not shown). Fixation points can be fixed with polymerized material of the same type from which the lens body is formed.

In FIG. 6 illustrates a controller 600 that can be used in some examples of the present invention. The controller 600 includes one or more processors 610, which may include one or more processor components associated with a communication device 620. In some examples, the controller 600 can be used to transfer energy to a power source located in an ophthalmic lens.

Processors 610 are associated with a communication device configured to transmit energy through a communication channel. The communication device can be used for electronic control of one or more of: automation tools used to place the medium with the energy source in the part of the mold for casting an ophthalmic lens and transmit digital data to a component mounted on the medium and placed inside the part of the mold for casting an ophthalmic lens, and from it or to control a component embedded in an ophthalmic lens.

Communication device 620 can also be used to communicate, for example, with one or more controller devices or components of manufacturing equipment.

The processor 610 is also in communication with the storage device 630. The storage device 630 may comprise any appropriate storage devices, including combinations of magnetic storage devices (eg, magnetic tape and hard drives), optical and / or semiconductor storage devices, such as random access memory (RAM) and read-only memory (ROM).

The storage device 630 may store a program 640 for controlling the processor 610. The processor 610 executes the instructions of the software program 640 and thus operates in accordance with the present invention. For example, the processor 610 may obtain information characterizing the location of the carrier insert, the location of the component, and the like. The data storage device 630 may also store ophthalmic data in one or more databases 650 and 660. The database may include non-standard configurations of the carrier insert, metrological data, and specialized control sequences for controlling the flow of energy to and from the carrier insert .

In FIG. 7 is a top-down image of a carrier insert 700. In this image, an energy source 710 is shown in the peripheral portion 711 of a carrier insert 700. The energy source 710 may include, for example, a thin-film rechargeable lithium-ion battery. An energy source 710 may be connected to contact points 714 to provide interconnection. To the contact points 714, wires can be connected connecting the energy source 710 to the photovoltaic cell 715, which can be used to recharge the battery power source 710. Additional wires can connect the energy source 710 to a flexible circuit using a wire connection.

The carrier insert 700 may include a flexible substrate. This flexible substrate may have a shape close to the typical shape of the lens, similar to what was described above. However, for greater flexibility, the carrier insert 700 may include additional design features, such as radial cuts along the entire length. Various electronic components 712 may also be included, such as integrated circuits, individual components, passive components, and other such devices.

The optical zone 713 is also shown in the figure. The optical zone may be optically passive and not introduce optical changes or may have predetermined optical characteristics, for example, introduce a predetermined optical correction. Other examples of lenses include an optical zone with a component with command-variable optical properties.

In FIG. 8 shows a carrier insert 800 in cross section. The carrier insert 800 may include an optical region 830, as described above, and also one or more peripheral parts 810-820. The carrier insert and components may be located in the peripheral parts 810-820.

Some examples provide options for changing the appearance of an ophthalmic lens. The aesthetics of the surface of a thin-film micro-battery can be adjusted in various ways to obtain the specific appearance of a battery built into an electroactive contact lens or other hydrogel element. For example, a thin-film micro-battery can be obtained using packaging materials with an aesthetically attractive texture and / or color, which will either mask the presence of a thin-film micro-battery, or alternatively create iris-like color patterns, plain and / or mixed color patterns that reflect configurations, rainbow patterns, metal-like configurations or any other possible artistic configurations or drawings. In other examples, the thin-film micro-battery may be partially covered by other components inside the lens, for example, a photovoltaic cell mounted on the outer surface of the battery, or alternatively, the battery may be placed behind all or part of the flexible circuit. In addition, the thin-film battery can be strategically placed so that the upper or lower eyelid partially or completely obscures its presence. The person skilled in the art will determine that there are many examples relating to the appearance of an ophthalmic device with energy supply, and methods for determining them.

There are many examples related to the method of forming an ophthalmic device with energy supply of the various types described above. In a number of examples, the invention described herein may include the assembly of subcomponents of a particular ophthalmic lens with energy supply in separate steps. Such a “separate” assembly of predominantly thin-film microbatteries, flexible circuits, connecting elements, microelectronic components and / or electroactive components in combination with the application of a biocompatible inert uniform coating allows you to get a single built-in unit containing all the required elements that can be easily integrated into the lens when used standard contact lens manufacturing technology. Flexible schemes may include schemes obtained from a copper-coated polyimide film or other similar substrates. A uniform coating may include, without limitation, parylene (classes N, C, D, HT and any combination thereof), poly (p-xylylene), dielectric coatings, uniform silicone coatings, or any other advantageous biocompatible coatings.

Some examples of the present invention are methods aimed at developing the geometry of the configurations of thin-film microbatteries, allowing them to be embedded in materials of ophthalmic lenses and / or sealing with these materials. Other examples may include methods for incorporating thin film microbatteries into various materials, such as, without limitation, hydrogels, silicone hydrogels, materials for producing rigid gas permeable contact lenses, silicones, thermoplastic polymers, thermoplastic elastomers, thermoset polymers, uniform dielectric / insulating coatings and coatings to create airtight barriers.

Other examples may include methods for strategically placing an energy source within the geometry of an ophthalmic lens. More specifically, the energy source may be an opaque element. Since the energy source should not impede the passage of light through the ophthalmic lens, configuration methods are aimed at providing a free area of 5-8 mm in the center of the contact lens, which is not blocked by opaque parts of the energy source. One of skill in the art will recognize that various embodiments are possible related to the configuration of various energy sources that interact favorably with optically important parts of an ophthalmic lens.

The mass and density of the energy source can facilitate configurations, since the specified energy source, alone or in combination with other stabilization zones in the body of the ophthalmic lens, can also act as a stabilizer of the angular position of the lens located on the eye. Such examples may have advantages for a number of applications, including, without limitation, astigmatism correction, increased comfort when wearing a lens, or providing a constant / controlled location of the remaining components in an ophthalmic lens with energy supply.

In addition, the energy source can be placed at a certain distance from the outer edge of the contact lens to provide an advantageous edge profile of the contact lens, which is necessary to increase wearing comfort while minimizing the risk of unwanted effects. Examples of such undesirable effects that must be avoided may include arched lesions of the external epithelium or giant papillary conjunctivitis.

As a non-limiting example, the cathode, electrolyte and anode of the embedded electrochemical cells can be formed by applying the corresponding compositions by printing in the geometry required to form such sections of the cathode, electrolyte and anode. It should be understood that the batteries thus formed can include both disposable cells, for example based on magnesium oxide and zinc, and rechargeable thin lithium-based batteries similar to the above thin-film batteries. The person skilled in the art will determine that a wide range of different examples of different elements and methods for forming ophthalmic lenses with energy supply involves the use of printing technologies.

In addition, it is also possible to use energy harvesting devices in electrical connection such that the energy harvesting devices can recharge one or more energy sources. Energy harvesting devices may include, for example: photovoltaic cells, thermoelectric cells, or piezoelectric cells. A positive aspect of energy harvesting devices is their ability to absorb energy from the environment and then provide electrical energy without the need for an external wired connection. Energy harvesting devices can be an energy source in an ophthalmic lens with energy supply. However, the energy harvesting device can be used in combination with other sources capable of storing energy in electrical form.

Other types of energy sources include the use of capacitor-type devices. It should be understood that capacitors can provide a higher energy density than energy harvesting devices, but less than batteries.

Capacitors are a type of energy source that stores energy in electrical form and, therefore, can be one of the energy sources that can be used in combination with energy harvesting devices to create a wireless energy source that can store energy. Essentially, capacitors have an advantage over rechargeable batteries because they generally provide higher power density than rechargeable batteries. There are many types of capacitors, from standard thin-film electric capacitors, Mylar film capacitors and electrolytic capacitors to relatively new and more advanced technologies of nanoscale capacitors of high energy density or supercapacitors.

In addition, energy sources, including electrochemical cells or batteries, can determine a relatively desired operating point. Rechargeable batteries have many advantageous characteristics. For example, batteries store energy in a form that allows direct conversion to electrical energy. Some batteries may be rechargeable or rechargeable and, therefore, represent a different category of energy sources that may be associated with energy harvesting devices. Typically, batteries have a relatively high energy density, and the energy stored in the battery can be used to perform operations with relatively higher energy source requirements compared to other miniature energy sources. In addition, batteries can be manufactured as flexible devices. One of skill in the art will determine that in the case of applications requiring high energy performance, the battery can also be connected to capacitors. Numerous embodiments are possible in which the battery is at least a portion of the energy source in an ophthalmic lens with energy supply.

A fuel cell may be included as an energy source. Fuel cells generate electricity when consumed from a chemical fuel source, generating electrical energy and by-products, including thermal energy. In energy sources with fuel cells, it is possible to use bioavailable materials as a fuel source.

There are many types of batteries that can be included in ophthalmic lenses with energy supply. For example, disposable batteries may be formed from various cathode and anode materials. By way of non-limiting examples, these materials may include one or more of: zinc, carbon, silver, manganese, cobalt, lithium, and silicon. Other examples may be based on the use of rechargeable batteries. Such batteries, in turn, can be obtained by one or more of: lithium-ion technology; silver technology; magnesium technology; niobium technology or other technology that uses other conductive materials. The person skilled in the art will determine that as an energy source for ophthalmic lenses with energy supply, various modern battery manufacturing techniques can be applied to produce disposable or rechargeable battery systems.

Due to the physical and spatial limitations imposed by the operating conditions of the battery in the contact lens, thin-film batteries can be used as an energy source. Thin-film batteries may occupy a small amount of space compatible with examples of ophthalmic devices for human use. Moreover, they can be formed on a flexible substrate, which allows you to freely bend as the battery itself with the substrate, and including their ophthalmic lens.

In the case of thin-film batteries, examples may include disposable and rechargeable forms. Rechargeable batteries allow you to get a product with a longer service life and, therefore, higher speeds of energy consumption. Much effort has been directed towards the development of technology for the production of ophthalmic lenses with energy supply with rechargeable thin-film batteries, but the present invention is not limited to this subclass.

Rechargeable thin-film batteries are commercially available, for example, the Oak Ridge National Laboratory has been manufacturing them in various forms since the early 1990s. Currently, companies such as Excellatron Solid State, LLC (Atlanta, GA), Infinite Power Solutions (Littleton, Colorado) and Cymbet Corporation (Elk River) are engaged in the production and delivery of such batteries to the market. , Minnesota). The dominant direction in the development of technology is the development of flat thin-film batteries. The use of such rechargeable batteries may comprise forming from a thin-film rechargeable battery a three-dimensional shape, for example, with a spherical radius of curvature. The entire variety of shapes of such three-dimensional batteries is within the scope of the present invention.

Carrier inserts with integrated components superimposed

Thin-film batteries and / or energy-efficient electronic elements can be incorporated into the carrier insert as integrated components superimposed on top of one another. In FIG. 9, element 900, by way of non-limiting example, an illustration of a cross section of this type is presented. The carrier insert may include many layers of various types, which are sealed in forms corresponding to the ophthalmic environment in which they will be enclosed. These inserts with layers of integrated components superimposed on each other can occupy the entire insert volume, as shown in the various examples shown in FIG. 2A, 2B, 2C and 2D. In alternative embodiments, in some cases, the carrier insert may take these forms, while the multilayer integrated component may occupy only part of the volume of the entire insert.

As shown in the example by element 900, a carrier insert with superimposed integrated components may have various functional aspects. As shown in FIG. 9, thin film batteries may contain one or more layers superposed on one another. In this case, the layers 906 and 907 may be layers of a battery, and many components may be located in the layers. One such battery component is referred to as cell 940. As shown in the figure, in almost all layers there may be joints that are located between two superposed layers. In this area there are many possible ways to create these compounds, however, as shown by elements 930 and 931, the connection between the layers 907 and 908 can be obtained using ball leads. In some cases, only these connections are required, but in other cases, the ball terminals can be in contact with other connecting elements, for example, through holes through the layer. A through-hole may be provided in the thin-film battery component layer 907 having connections 930 and 931, which provides an electrical connection between one side of the component and the other side. Some of these pass-through components of the substrate can then form another interlayer connection on the opposite side of the substrate with a layer located above the component, as is the case with component 940.

In other layers of the carrier insert with integrated components superimposed on each other, there may be a connecting layer for connecting various components in interconnected layers, for example, layer 905. This layer may contain holes and tracks that conduct signals from various components to other components. For example, layer 905 may provide connections for various battery cells to a power control unit, which may be located among the process components of layer 904. Also, the connection layer may provide connections between components in the process layer and components outside the process layer; for example, this may relate to an integrated passive device (IPD) component shown as element 920. Special connection layers allow various methods for distributing electrical signals to be provided.

There are two elements, referred to as process layers and indicated by elements 904 and 902. These elements represent various technological options that can be included in the carrier inserts. One of the layers may include technological elements based on CMOS, bipolar CMOS, bipolar technology or memory technology, while the other layer may include another technology. In an alternative embodiment, the two layers may belong to different technological subfamilies within the general family; for example, layer 902 may include electronic elements manufactured using 0.5-micron CMOS technology, and layer 904 may include elements manufactured using 20-nanometer CMOS technology. It should be understood that many other combinations of various types of electronic technologies fall within the scope of the present invention.

Additional connecting layers similar to layer 905 may be provided. The additional layer may be another completely connecting layer, as shown in element 903. In an alternative embodiment, the additional layer may be part of a multilayer layer, as shown in element 910. In some cases, the data additional elements can provide an electrical connection, in other cases, they can be structural connections made due to the presence of a layer. Between the various layers, both structural and electrical connections may be present.

The carrier insert may include locations for electrical connections to components outside the insert, as described above. However, in other examples, the carrier insert may also include connecting to external components wirelessly. In such cases, the use of antennas is an example of a wireless connection method. A layer designated as element 901 may also be present, in which an example of such an antenna may be located. In many cases, such an antenna layer can be placed in the carrier insert above or below the device with integrated components superimposed on one another. As shown in element 908, such a layer located above or below may also not include an antenna with a wireless communication method and, therefore, may act as a support substrate for forming a multilayer device.

In some examples described herein, battery cells may be included as cells in at least one of the layers themselves superimposed. It should also be noted that other embodiments are possible in which the battery cells are placed outside the layers of integrated components superimposed on one another. Also, a separate battery or other energy supply component may be present in the carrier insert, or in an alternative embodiment, these individual energy components may be located outside the carrier insert.

In FIG. 10, element 1000 shows a carrier insert with integrated components superimposed on each other, element 1040, inside an ophthalmic lens, element 1030. The border of the material of the carrier insert is shown by the element designated 1040. In this example, layers of superimposed integrated layers are placed within the boundaries of the carrier insert components designated as element 1010. In some examples of this type, an electroactive lens may appear outside the carrier insert, but inside the ophthalmic lens 1030, shown as ment 1020. Control signals for the components within the lens may be formed from a wireless signal, as described above. The layers of superimposed components inside the carrier insert can receive this wireless signal and, in some cases, regulate the electrical signal coming through the wires passing outside the carrier insert 1040 and connected to the electroactive lens 1020. It should be understood that many alternative uses and connections are possible a carrier insert containing integrated components superimposed on each other in an ophthalmic lens, which may include superimposed on each other egrirovannye components in devices which are not the ophthalmic lenses, as well as, without limitation, any type of biomedical devices with power supply.

Various examples and aspects of the present invention are described below.

A method is proposed for forming a carrier insert with integrated components for an ophthalmic lens superimposed on one another. The method comprises: forming substrate layers with functionality; assembly of substrate layers; the formation of electrical connections between the layers of the substrate; sealing a multilayer element with materials that can be glued inside the body of a cast ophthalmic lens.

One of the layers of the carrier insert with integrated components superimposed on each other may comprise a solid state energy source.

The carrier insert with integrated components superimposed on each other may have an annular shape.

A carrier insert with integrated components superimposed on one another may have an arched shape.

The method may further comprise the step of placing the lens with a variable focus in close proximity to the carrier insert with integrated components superimposed on one another.

A variable focus lens can be attached to a carrier insert with integrated components superimposed on one another.

At least a portion of the one or more layers may comprise an adhesive film.

Two or more layers can be adhesively bonded to each other with an adhesive film on at least part of one or more layers.

The superimposed layers can be sealed with one or more materials that can be glued inside the body of the cast ophthalmic lens.

One or more of the sealing materials may comprise an organosilicon polymer.

The layer may contain a semiconductor substrate with an electronic circuit in close proximity to its first surface.

The method may further comprise a layer with one or more substrates with layers for an electrochemical power component.

At least one layer in a carrier insert with integrated components superimposed on each other may comprise a semiconductor layer with an electronic circuit capable of controlling the electric current generated by electrochemical cells.

The method may further comprise an electroactive lens component within an ophthalmic device.

The electronic circuit may be in electrical communication with a component of the electroactive lens inside an ophthalmic device.

The layers may contain one or more layers of metal that act as an antenna.

During assembly, the substrate layers may be given one of a circular annular shape or part of an annular shape.

The functional layers superimposed on each other can adhesively adhere to the insulating layers to form a multilayer element.

The insert with layers of integrated components may contain one or more layers made in the form of at least part of a circular annular structure.

One or more layers may be in electrical communication with the second layer using at least one ball lead located between them.

One or more layers may be in electrical communication with the second layer by means of at least one wire connection with a contact pad located between them.

The second layer of superimposed integrated components can be shaped into at least part of a circular annular structure whose outer radius is smaller than the radius of the first layer.

One or more layers may comprise a surface with a metallic characteristic.

A solder film may be applied to the surface of one or more of the layers having a metal characteristic.

An insert with layers of integrated components superimposed on top of one another is proposed. An insert with layers of integrated components superimposed on each other contains: substrate layers with functional capabilities; moreover, the substrate layers are assembled with the formation of electrical connections between the layers of the substrate, forming a multilayer element; moreover, the multilayer element is sealed with materials that can be glued inside the body of the cast ophthalmic lens.

One of the layers of superimposed integrated components or a carrier insert may comprise a solid state energy source.

A layer of superimposed integrated components or a carrier insert with superimposed integrated components may have an annular shape.

A layer of superimposed integrated components or a carrier insert with superimposed integrated components may have an arcuate shape.

An insert with layers of superimposed integrated components may further comprise placing the lens with a variable focus in close proximity to a layer of superimposed components or a carrier insert with superimposed integrated components.

A variable focus lens is attached to a layer of superimposed integrated components or to a carrier insert with superimposed integrated components.

At least a portion of one or more of the layers may comprise an adhesive film.

Two or more layers can adhere adhesively to each other with an adhesive film on at least a portion of one or more of the layers.

The superimposed layers can be sealed with one or more of the materials that can be glued inside the body of the cast ophthalmic lens.

One or more of the sealing materials may comprise an organosilicon polymer.

The layer may contain a semiconductor substrate with an electronic circuit in close proximity to its first surface.

The insert with layers of superimposed integrated components may further comprise a layer with one or more substrates with layers for the electrochemical power supply component.

At least one layer of superimposed integrated components or at least one layer in a carrier insert with layers of superimposed integrated components may comprise a semiconductor layer with an electronic circuit capable of controlling an electric current generated by electrochemical cells.

The insert with layers of superimposed integrated components may further comprise an electroactive lens component within the ophthalmic device.

The electronic circuit is in electrical communication with a component of an electroactive lens inside an ophthalmic device.

The layers may contain one or more layers of metal that act as an antenna.

During assembly, the substrate layers may be given one of a circular annular shape or part of an annular shape.

The functional layers superimposed on each other can adhesively adhere to the insulating layers to form a multilayer element.

The insert with layers of integrated components may contain one or more layers made in the form of at least part of a circular annular structure.

One or more layers may be in electrical communication with the second layer using at least one ball lead located between them.

One or more layers may be in electrical communication with the second layer by means of at least one wire connection with a contact pad located between them.

The second layer of superimposed integrated components can be shaped into at least part of a circular annular structure whose outer radius is smaller than the radius of the first layer.

One or more layers may comprise a surface with a metallic characteristic.

A solder film may be applied to the surface of one or more of the layers having a metal characteristic.

A device for manufacturing a carrier insert with integrated components superimposed on one another is described. The device contains: a rigid protruding surface of essentially conical shape; shelves along the edges of the protruding surface, configured to support thin layers on the open surface of the shelves; and adjustment elements along the azimuth of the conical projecting surface.

At least a portion of the protruding surface may be coated with a non-adhesive surface film.

Non-adhesive surface film may be made of Teflon.

The device may further comprise automation means for placing the multilayer elements on the protruding surface.

The device may further comprise: a processor for controlling automation means; a digital data storage device containing on-demand software, said software combined with a processor, capable of placing a functionalized multilayer insert in a part of the mold.

The processor may be configured to receive programmed instruction sets from a network in logical communication with said processor.

Conclusion

As described above and further defined below in the claims, methods for forming load-bearing inserts, load-bearing inserts and an apparatus for implementing such methods, as well as ophthalmic lenses made with load-bearing inserts, are proposed.

Claims (28)

1. A method of forming a carrier insert with integrated components for an ophthalmic lens superimposed on one another, comprising: forming a plurality of substrate layers, each of which carries at least one energy source or functional component; assembling a plurality of substrate layers into a bag configured to be mounted in an ophthalmic lens outside the optical zone; the formation of electrical connections between the energy source and the functional components of the said layers of the substrate in the package; and sealing the bag with a material for gluing an ophthalmic lens inside the body. 2. The method according to claim 1, in which the layers of the substrate during assembly give one of a circular annular shape or part of an annular shape. 3. The method according to claim 1, in which the superimposed functional layers are adhesive attached to the insulating layers with the formation of a multilayer element. 4. The method according to claim 1, in which the second layer of superimposed integrated components is shaped into at least part of a circular annular structure, the outer radius of which is less than the outer radius of the first layer. 5. The method according to claim 1, in which one or more layers contain a surface with a metal characteristic. 6. The method according to claim 5, in which on the surface of said one or more layers having a metal characteristic, a film of solder is applied. 7. The method according to claim 1, comprising placing the battery on a carrier insert with integrated components superimposed on each other, the battery being rechargeable by one or more of radio frequency radiation and magnetic induction. 8. The method according to claim 1, comprising placing a thin-film battery on a carrier insert with integrated components superimposed on each other and modifying the surface of the battery to give the battery a predetermined appearance. 9. The method according to claim 1, wherein the substrate layers are flexible. 10. A method comprising the steps of forming a carrier insert with integrated components superimposed according to any one of claims 1 to 9 and gluing the carrier insert into an ophthalmic lens. 11. A carrier insert with superimposed integrated components for an ophthalmic lens, comprising: a plurality of stacked substrate layers, each of which carries an energy source or functional component; electrical connections between the energy source and the functional components in the package; and material for gluing inside the body of a cast ophthalmic lens, sealing said package. 12. The carrier insert according to claim 11, in which the layers of the substrate during assembly is given one of a circular annular shape or part of an annular shape. 13. The carrier insert according to claim 11, in which the superimposed functional layers are adhesive attached to the insulating layers to form a multilayer element. 14. The carrier insert according to claim 11, in which the second layer of superimposed integrated components is shaped into at least part of a circular annular structure, the outer radius of which is less than the outer radius of the first layer. 15. The carrier insert according to claim 11, in which one or more layers contain a surface with a metal characteristic. 16. The carrier insert according to clause 15, in which a solder film is deposited on the surface of said one or more layers having a metal characteristic. 17. The carrier insert according to claim 11, containing a battery, and the battery is configured to  recharge by one or more of radio frequency radiation and magnetic induction. 18. The carrier insert according to claim 11, containing a thin-film battery, and the surface of the battery is configured to give a given appearance. 19. The carrier insert according to claim 11, in which the substrate layers are flexible. 20. An ophthalmic lens containing a carrier insert glued into it with integrated components superimposed on each other according to any one of claims 11-19.

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