CN105682906A - 制造包括超薄光学部件的眼科镜片的方法以及此类镜片 - Google Patents

制造包括超薄光学部件的眼科镜片的方法以及此类镜片 Download PDF

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Publication number
CN105682906A
CN105682906A CN201480059054.3A CN201480059054A CN105682906A CN 105682906 A CN105682906 A CN 105682906A CN 201480059054 A CN201480059054 A CN 201480059054A CN 105682906 A CN105682906 A CN 105682906A
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China
Prior art keywords
thin optical
ultra thin
optical part
ultra
substrate
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V.H.巴雷
V.鲁斯特
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Johnson and Johnson Vision Care Inc
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Johnson and Johnson Vision Care Inc
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Publication of CN105682906A publication Critical patent/CN105682906A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00038—Production of contact lenses
    • B29D11/00048—Production of contact lenses composed of parts with dissimilar composition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/54—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/54—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts
    • B29C65/542—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts by injection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7336—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light
    • B29C66/73365—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light
    • B29C66/73366—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light both parts to be joined being transparent or translucent to visible light
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
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Abstract

本发明提供了一种光学组件以及形成所述组件的方法，所述组件使用限定具有液芯的所述组件的外边界的两个超薄光学件(102、202)。具体地，本发明公开了所述超薄光学件的处理和布置以防止所述超薄光学件的变形和光学性能损耗。超薄光学件可以从25微米至200微米，并且它们的结构完整性可以通过基片(101、201)在可用于形成液体弯月面镜片的一种或多种流体，例如盐水溶液(301)和油溶液(305)的整个封装中不间断支撑而保持。在一些实施方案中，可以包括被包括在超薄光学部件中的联锁特征部(115)，以便帮助产生密封件和/或将结构支撑提供至液体镜片组件。在另一实施方案中，超薄光学元件的支撑件具有联锁机构或置中机构以辅助所述光学组件的组装和密封。

Description

制造包括超薄光学部件的眼科镜片的方法以及此类镜片
技术领域
本公开涉及眼科镜片并且更具体涉及用于模塑并组装超薄光学部件以用作眼科装置或用于眼科装置中的方法。
背景技术
接触镜片已经用于改善视力很多年。早期设计的接触镜片是由硬质材料制成的，诸如聚甲基丙烯酸甲酯(PMMA)。然而，由于这些镜片对于氧气的相对低渗透性，它们对于患者而言是不舒适的并且造成了各种问题。随后使用基于水凝胶的材料来开发氧气可渗透的软性接触镜片。尽管水凝胶镜片在今天非常受欢迎，但是工业不断寻求改善镜片的设计或开发特定于某些条件的镜片。
例如，老花眼通常是与年龄有关的病症，其中眼睛聚焦近处物体的能力逐渐减弱。对于许多人的结果是需要变焦距或双焦距眼镜。这些眼镜中的一些包含试图用相同镜片既矫正近视又矫正远视的镜片。关于接触镜片，一些人选择接触镜片以矫正一只近视的眼和一只远视的眼，尽管副作用可包括由于损失一只眼睛相对于另一只眼睛的同时聚焦而导致的对深度感知的干扰。
液体镜片技术关于用于医疗成像装置、微型照相机以及光纤通信系统中已经得到了良好的发展。液体镜片使用一种或多种流体以产生可变的聚焦镜片而不需要任何移动部件。在大多数情况下，两种不可混溶的流体(一种流体是导电水溶液并且一种流体是不导电的油)在闭合装置中提供。疏水性涂层可以应用于装置的内部，例如，以促使水溶液朝向不具有疏水性涂层的装置的一部分进入半球镜片形构造中。在称为电润湿的过程中，疏水性涂层两端的非常微小的直流电压的施加降低了涂层的排斥性。液体表面张力通过该过程而改变，其改变了弯月面的曲率半径，继而改变了镜片的焦距。因此液体镜片能够用低至1微焦的电压并在仅几微秒内从凸面(会聚的)转换为凹面(发散的)镜片形状。
用于老花眼的解决办法可依靠产生多状态液体弯月面镜片的能力，所述多状态液体弯月面镜片允许人控制例如镜片的放大和缩小能力。然而，制造这种类型的眼科镜片的能力取决于产生并组装在制造期间不会变形的超薄光学性能部件的能力。
根据本公开方面的眼科装置的设计依赖于使用需要极其小心元件部件的成形和处理的超薄材料。即使小心地处理，超薄部件也可经常翘曲、卷曲或不可逆的变形。需要使得使用超薄部件的例如液体填充的眼科装置的组装能够进行的方法和系统，所述超薄部件在成形、处理以及组装期间不会变形。
发明内容
本公开包括用于使用具有可弹出模具部件的模具组件来组装超薄元件光学性能部件/片材件的方法和设备。该模具部件经设计在整个组装过程中支撑并保持易碎超薄部件的完整性。
本发明包括由多个超薄部件构造的眼科镜片的公开内容，其中所述超薄部件中的每个在整个组装过程中保持与模具部件的支撑表面接触。分离的模具部件(每个具有固定于其中的超薄部件)在进入液体镜片组装工位之前从模塑设备中弹出。模具部件可被配置成在从基片移除之前，以有利于液体镜片最终组装的方式在液体镜片组装工位中在水溶液内配合。
根据本公开的一些方面，公开了能够被佩戴在眼睛的前表面上的眼科液体镜片装置。该眼科液体镜片装置包括：液体镜片组件，其包括由第一模具块的凹面基片表面限定的第一超薄光学部件、由第二模具块的凸面基片表面限定的第二超薄光学部件，被容纳在由第一超薄光学部件和第二超薄光学部件形成的腔体之间的一种或多种流体；密封件，其在位于第一超薄光学部件与第二超薄光学部件之间的腔体中容纳一种或多种流体，所述密封件包括联锁特征部，所述联锁特征部被包括在所述第一超薄光学部件和所述第二超薄光学部件的周边区域中；以及被配置成支撑所述液体镜片组件的水凝胶部分。
在本公开的又一附加方面，公开了一种制造适用于眼科装置的液体镜片的方法。该方法包括：限定第一模具块的凹面基片表面或凸面基片表面上的第一超薄光学部件；限定第二模具块的凹面基片表面或凸面基片表面上的第二超薄光学部件；在腔体之间容纳一种或多种流体，所述腔体通过由第一模具块的凹面基片表面支撑的第一超薄光学部件和由第二模具块的凸面基片表面支撑的第二超薄光学部件形成；产生在腔体中容纳一种或多种流体的密封件，所述腔体在由所述第一模具块的凹面基片表面或凸面基片表面支撑的第一超薄光学部件与由第二模具块的凹面基片表面或凸面基片表面支撑的第二超薄光学部件之间。以及将所述第一超薄光学部件从第一模具块的支撑凹面基片表面移除，并且/或者将所述第二超薄光学部件从第二模具块的支撑凸面基片表面移除。
通过考虑以下具体的描述和附图，本发明的另外的特征、优点和实施方案可以得到阐述出或是显而易见的。此外，应当理解，本发明的前述发明内容和以下具体描述都是示例性的，并且旨在提供进一步说明而不限制如要求保护的本发明的范围。
附图说明
图1示出根据本公开的方面的在凹面基片101上的示例性超薄光学件102的剖视图A，以及倚靠在基片101上的超薄光学件102的边缘的放大截面B；
图2示出根据本公开的方面的支撑超薄光学件202的示例性凸面基片201的剖视图；
图3示出根据本公开的方面的在流体下组装的图1的示例性凹面基片101和图2的示例性凸面基片201；
图4示出根据本公开的方面的组装且密封在一起的超薄光学件102和超薄光学件202，它们之间容纳一种或多种液体；
图5示出根据本公开的方面的在组装超薄光学件101和超薄光学件202之后从模具组件400释放的液体镜片500；以及
图6示出可用于制造根据本公开的方面的用于液体镜片的超薄光学部件的方法步骤。
具体实施方式
现在将结合附图来描述本公开，其中类似的参考标记始终表示类似的部件。
可通过描述被联接、密封、附接和/或接合在一起的元件来描述用于模塑超薄光学部件的方法和设备的各个方面。如本文中所使用的，术语“联接”、“密封”、“附接”和/或“接合”用于指示两个元件之间的直接连接或者适当情况下的彼此之间通过居间元件或中间元件的间接连接。相比之下，当元件被称为“直接联接”、“直接密封”、“直接附接”和/或“直接接合”到另一个元件时，不存在居间元件。
诸如“下部”或“底部”以及“上部”或“顶部”的相对术语在本文中可以用于描述附图所示的一个元件相对于另一个元件的关系。应当理解，相对术语旨在涵盖除了附图中所描绘取向之外的不同取向。以举例的方式，如果附图中所示的模具组件的方面被翻转，则描述为位于其它元件的“底”侧上的元件将取向成位于其它元件的“顶”侧上。术语“底部”因此可涵盖“底部”和“顶部”两者的取向，这取决于设备的具体取向。
用于模塑超薄光学件/部件的方法和设备的各个方面可以参考一个或多个示例性实施方案来说明。如本文中所用的，术语“示例性”是指“用作示例、实例或例证”，并且不应必须理解成相对于本文所公开的方法和装置的其它实施方案为优选的或有利的。
术语表
在涉及所公开的本发明的该说明书和权利要求书中，可使用的各个术语将采用如下定义：
如本文中所使用的“接触角”可指的是在油/盐水溶液界面(也称为液体弯月边界)与弯月壁交汇处的角度。就线性弯月壁而言，接触角为在液体弯月边界与弯月壁交汇的点处，在弯月壁与相切于液体弯月边界的线之间测量的角度。就曲面弯月壁而言，接触角为在液体弯月边界与弯月壁交汇的点处，在相切于弯月壁和液体弯月边界的线之间测量的角度。
如本文中所用的“联锁特征部”，可指的是沿着超薄光学部件的周边区定位的结构特征部，所述超薄光学部件用于在两个或更多个超薄光学部件之间形成的弯月腔体中容纳一种或多种流体。在一些实施方案中，沿着周边的结构特征部可包括一系列延伸突起，所述延伸突起可由与超薄部件相同的材料或可为刚性的另一种材料制成。结构特征部可将结构刚度添加至由超薄光学部件形成的整个光学组件中。在一些实施方案中，使用模具块上的对准特征部，可将结构特征部与一个超薄光学件的对应节段配合到另一个超薄光学件。模具块可包括一个或更多基片形成表面，在所述基片形成表面上光学超薄部件可以形成并且保持直至将组件放在一起从而防止部件的变形。
如本文中所用的“液体弯月边界”可指的是盐水溶液与油之间的弓形表面界面。一般来讲，该表面将形成在一侧上为凹面而在另一侧上为凸面的镜片。
如本文所用的“介质插入物”可指的是能够支撑眼科镜片内的能量源的可成形或刚性的基片。在一些实施方案中，介质插入物可包括一种或多种可变光学镜片。
如本文中所用的“弯月腔体”可指的是位于弓形液体弯月形镜片中的、介于前曲面镜片和后曲面镜片之间的空间，其中保持有油和盐水溶液。
如本文中所用的“弯月壁”可指的是前曲面镜片的内部上的特定区域，使得其位于弯月腔体内，而液体弯月边界沿弯月腔体运动。
如本文所用的“眼科镜片”可指的是能够位于眼睛中或眼睛上的任何眼科装置。这些装置可提供如下的一种或多种：光学矫正、治疗，并且可具有美容作用。例如，生物医学眼科装置可指的是用于矫正或改进视力、增强或预防眼睛病症和/或美容上提升眼睛生理机能(例如虹膜颜色)的通电的接触镜片、眼内镜片、覆盖镜片、眼部插入物、光学插入物、泪点塞或其它类似眼科装置。在一些实施方案中，本发明的眼科装置可包括由有机硅弹性体或水凝胶制成的软性接触镜片，其中水凝胶包括但不限于有机硅水凝胶和含氟水凝胶。
如本文所用的“光学区”可指的是眼科镜片佩戴者透过其观看的眼科镜片区域。
如本文所用的“周边区”，术语“周边区”或“非光学区”可指的是眼科镜片的光学区之外的眼科镜片和/或液体镜片组件的区域，并因此是当以通常规定的方式将眼科镜片佩戴在眼睛上、眼睛附近或眼睛中时，镜片佩戴者从中透过进行观看的眼科镜片的一部分之外的区域。
如本文所用的“从模具释放”可指的是液体镜片组件与一个或多个模具表面完全分离或仅附接，以使其可以借助轻微搅动或通过装置来移除而不需另外的模具移动。移除技术的示例可包括但不限于用拭子推离、由吸盘抓取，或使用另一个处理装置。
如本文中所用的“锐缘”可指的是前曲面镜片件或后曲面镜片件的内表面的几何特征部，该几何特征部足以容纳光学件上的两种预定义流体的接触线的位置。所述锐缘通常为外角而非内角。从流体的角度来看，其为大于180度的角度。
如本文中所用的“基片形成表面”可指的是用来模塑镜片件的表面。在一些实施方案中，任何这种表面可包括光学光洁度，其表示表面是足够光滑和成形的，以使通过与模具表面接触的镜片形成材料的聚合而成形的镜片表面可以是光学可接受的。此外，在一些实施方案中，基片形成表面可具有这样的几何结构，其对于赋予镜片件表面期望的光学特性来说是必要的，所述期望的光学特性包括但不限于：球面、非球面和柱面光焦度、波前像差校正、角膜形貌学校正等，以及它们的任意组合。
如本文所用的“基片”，术语基片、模具、块、或模具块可指的是在上面可放置或形成其它实体的物理实体。
现参考图1，示出了在基片101上的示例性超薄光学件102的剖视图A和倚靠在基片101上的超薄光学件102的边缘的放大截面B。在一些实施方案中，基片101可优选地为具有至少一个光学性能形成表面105的可弹出模具部件。基片101和基片201(图2中所示)材料可包括任何标准模具制备材料，诸如但不限于钢、铝、类似黄铜的高导电性合金。更一般地，这些基片可以具有可精确保持超薄光学件102和超薄光学件202的形状的任何材料。就交联超薄光学部件而言，基片101和基片201可以改型自另外的一系列材料，所述一系列材料不具有对于金属合金的耐高温性，诸如模塑的聚合物、或其它模塑的交联结构。
在一些实施方案中，基片101可包括对准特征部110，所述对准特征部可对应于在第二基片或模具件，例如基片201(图2中所示)上的对准特征部。在一些方面中，对准特征部110可以用于使用由凹面基片形成表面105支撑的超薄光学件102组装液体镜片组件500(图5中所示)。在一些实施方案中，对准特征部110可包括机械特征部诸如运动安装件，和附加的机电装置。
所形成的超薄光学件102可以是例如介于200微米和25微米之间并优选地为约100微米厚。因此，在没有来自基片101的支撑的情况下，如果超薄光学件102在形成液体镜片组件500之前从光学性能形成表面105释放，则超薄光学件102可变形失去其光学特性，例如，在常规模具系统中，固化的超薄光学件102通常会从基片101的光学性能形成表面105弹出或物理移除。然后该移除或弹出的超薄光学件102可与与模具分离的其它超薄光学件202组装。然而，当处理此类超薄元件时，正如超薄光学件102和超薄光学件202(图2中所示)中一样，通过基片101或102之外的超薄光学件102的任何措施或处理的弹出可必然导致许多情况下的弯曲、卷曲或变形。
因此，根据本公开的各个方面，为了避免关于超薄光学件102和超薄光学件202从它们各自的基片101和基片201弹出或移除的上述提到的问题，直至液体镜片组件500被完全组装，超薄光学件102和超薄光学件202才从它们各自的光学性能形成表面例如105移除。相反，在超薄光学件102和超薄光学件202自身从用于形成超薄光学件102和超薄光学件202的可弹出块弹出后，基片101和基片201可以在组装期间负责保持每个超薄光学件102和超薄光学件202的结构完整性。因此，超薄光学件102和超薄光学件202中的每个在结构上保持由从模具组件弹出的基片101或基片201的至少一部分，诸如由凹面形成表面105支撑。
在一些示例性实施方案中，模具部件可包括后表面基片101和前表面基片201。如本文所用的，术语“前表面模具部件”指的是其凹面光学性能形成表面105可以用于形成超薄光学件102的前表面的模具部件。类似地，术语“后表面模具部件”指的是其凸面光学性能形成表面205可形成超薄光学件202(图2中所示)的后表面的基片201。在一些实施方案中，基片101和基片201可以具有包括平坦的环形凸缘的凹面-凸面形状，所述平坦环形凸缘可围绕基片101和/或基片201的凹面-凸面区域最上方边缘的圆周。
现参考图1的放大截面B，示出了由基片101支撑的超薄光学件102的边缘。具体地，描绘了沿着超薄光学件102的周边区定位的联锁特征部115。在一些实施方案中，通过一旦将联锁特征部115“联锁”或“接合”就帮助提供密封件，该联锁特征部115可用于有助于液体镜片组件500(图5中所示)的结构完整性。该密封件可用于容纳位于两个或更多个超薄光学件(例如超薄光学件102和超薄光学件202)之间的一种或多种液体。联锁特征部115可以由与超薄光学件102的其余部分相同的材料或由也是刚性或半刚性的不同材料形成。材料可包括例如聚烯烃、Zenor、Topas、聚苯乙烯等等。
在一些实施方案中，联锁特征部115可将结构刚度添加至超薄光学件102和超薄光学件202中的每个并且添加至所形成的整个液体镜片组件500(图5中所示)。联锁特征部115可以是需要径向对准和相对于彼此整体对准的径向对称或非对称的。超薄光学件102和超薄光学件202的对准可以通过以下方式而完成，例如，分别使用基片101和基片201的对应的对准特征部110和对准特征部210、使用运动安装件、机电对准装置等。
现参考图2，示出了根据本公开的方面支撑超薄光学件202的示例性凸面基片201的剖视图。凸面基片201可包括与先前描述的示例性凹面基片101类似的方面。例如，类似凹面基片101的凸面基片201，可以是用于形成超薄光学件202的块组件(未示出)的部件，以使在超薄光学件102和超薄光学件202形成之后，基片101和基片201可以从模具组件弹出，其中超薄光学件102和超薄光学件202中的每个分别支撑在光学性能形成表面105和光学性能形成表面205上。因此，超薄光学件202在基片201从模具组件(未示出)弹出之后可在结构上保持由光学性能基片形成表面205支撑，以防止超薄光学件202的任何变形和光学性能损耗。如先前所提及的，由于超薄光学件102和超薄光学件202的极其薄的性质，可发生超薄光学件202的变形和光学性能损耗，因为任一部件的独立处理可类似于柔性膜状材料的处理。
由于通常模具系统中的常规模具机构和处理装置不能够在组装期间处理单独超薄光学件102和超薄光学件202，而不会使这些部件的精密结构发生弯曲、卷曲或变形。在整个模具处理中需要恒定的结构支撑件，以在液体镜片组件500生产期间保持超薄光学件102和超薄光学件202的形状完整性和材料特性。只有当完全组装成液体镜片组件500为组合的部件时，其在结构上才能够以可接受方式执行而没有由部件单独经历的问题。
超薄光学件202可以类似于超薄光学件102的方式而形成，不同的是基片101和基片201可以被不同地配置。以该方式，可以使用用于超薄光学件202的第二模具组件，其被配置成不同于公开的超薄光学件102，以便赋予对于液体镜片组件500的后光学部分所需要的必要光学性能。例如，向超薄光学件202所赋予的弯曲量相比于向超薄光学件102所赋予的弯曲量可以是不同的。因此，尽管本公开的一些方面可以仅相对于超薄光学件102和/或相对于模具组件(未示出)或基片101和基片201而描述，但是应该理解，基本上相同的方法、部件或装置对于本领域技术人员将是显而易见的。
在一些实施方案中，可移除基片201的方面可以被特别地形成以在液体镜片形成期间辅助基片201的定位，和/或在超薄光学件202形成后便于基片201从模具组件(未示出)的弹出。例如，基片的对准特征部210可包括机械特征部诸如运动安装件，和附加的机电装置。
现参考图3，示出了根据本公开的方面的在流体301下组装的图1的示例性凹面基片101和图2的示例性凸面基片201。如先前呈现的，可弹出基片101和可弹出基片201可支撑超薄光学件102和超薄光学件202用于在一种或多种流体下形成液体镜片组件500。例如，盐水溶液301和油305可被容纳于在两个超薄光学件102与202之间形成的弓形腔体中。在一些优选的实施方案中，被容纳在腔体内的盐水溶液301的体积大于被容纳在腔体内的油305的体积。此外，一些优选的实施方案可包括基本上与后曲面超薄光学件202的整个内表面接触的盐水溶液301。一些实施方案可包括一定体积的油305，该一定体积的油相比于一定量的盐水溶液301为约66体积％或更多。一些附加的实施方案可包括弓形液体弯月面镜片组件500，其中一定体积的油305相比于一定量的盐水溶液301为约90体积％或更少。
根据本公开的方面，基片101和基片201可以浸入水溶液301中，并且当浸入水溶液中时，基片101和基片201可以进行如图4所示的配合。因此，如所描述的，基片101和基片201是用于形成超薄光学件102和超薄光学件202的块的可移除元件。基片101和基片201可以排列为模具组件400中的“夹心构造”(图4中所示)。前表面模具基片101位于顶部上，其中该模具部件的凹面形成表面105面向下方。后表面基片201可对称地设置在前表面基片101的底部上，其中后表面基片101的凸面形成表面205部分地突至前表面基片101的凹形区域中。优选地，后表面基片201的尺寸可被设定成使其凸面表面205接合前曲面基片101的凹面表面105的外边缘的整个周边，从而共同形成容纳盐水溶液301和油305的密封腔体。
现参考图4，描绘了根据本公开的方面的在其间容纳一种或多种液体的组装且密封在一起的超薄光学件102和超薄光学件202。前曲面基片101和后曲面基片201被组装在一起以形成用于将超薄光学件102和超薄光学件202与盐水溶液301和油溶液305接合的模具组件400。在一些实施方案中，模具组件400可包括在基片201或基片202中的一个中的沟槽401，所述沟槽可用于递送粘合剂，所述粘合剂用于密封位于超薄光学件102与超薄光学件202之间的盐水溶液301和油溶液305。在另选的实施方案中，模具组件可包括将超薄光学件102和超薄光学件202热撑在一起的装置。在又一附加实施方案中，可以通过将两个超薄光学件102和202的边缘聚合或者通过将形成超薄光学件102的部件的联锁特征部115与另一个超薄光学件的联锁特征部或该件自身(例如超薄光学件202)接合而产生密封件。在一些实施方案中，可以提供止动器、突起、通道或其它形成物以辅助定位释放的基片101和基片201，从而使得能够与例如粘合剂递送系统或热粘结系统协调。
由于液体镜片组件500(图5中所示)可以组装于水溶液内，一旦超薄光学件102和超薄光学件202彼此互相粘结/接合(优选地在每个部件的外边缘周围)，则可以在超薄光学件102与超薄光学件202之间压缩并捕集一种或多种水溶液301和水溶液305，从而增强部件的结构强度。
现参考图5，描绘了液体镜片500，所述液体镜片在将封装一种或多种液体301和305的超薄光学件102和超薄光学件202接合之后从模具组件400释放。由于在其中容纳的液体301和液体305，超薄光学件102和超薄光学件202的结构完整性是在指数级上更大的。指数级上更大的结构强度可允许液体镜片500的一些操纵，以使其可结合到和/或用作眼科镜片而不影响超薄光学件102和超薄光学件202的光学性能。因此，液体镜片组件500可具有足够的结构，以使液体镜片组件500的任何另外处理、清洁和/或包装对于使单独超薄光学件102和超薄光学件202的镜片表面不可逆弯曲、卷曲或变形将是弹性的。
例如，与第二超薄光学件202的弯曲模量相结合的第一超薄光学件102的弯曲模量提高装置作为整体的结构稳定性。而且，由于可以促使液体镜片组件500进入挠曲状态，诸如通过挤压周边的沿直径相对的部分，因此在超薄光学件102与超薄光学件202之间捕集的液体的二次动量呈指数地增加液体镜片组件500继续挠曲的阻力。液体镜片组件500因此趋向抵抗挠曲，以便借助位于超薄光学件102与超薄光学件202之间的密封溶液保持超薄光学件102和超薄光学件202中的每个的预成形的形状。
液体镜片可以用于提供通电可变功率的液体弯月面眼科镜片。例如，超薄光学件102和超薄光学件202可以是透明的，并且中心可包括可以为绝缘液体的第一液体301和为导电液体的第二液体305。第一液体301和第二液体305一般是具有不同光学折射率的不互溶液体。面向凹槽打开的环形电极(未示出)可以定位在超薄光学件202的背面上。另一电极可被放置为与所述导电液体305接触。利用在电极两端施加电压来产生电润湿并根据施加在电极之间的电压来改变两种液体之间的界面的曲率。穿过电池垂直于上板和下板并位于液滴的区域中的一束光将根据施加到电极的电压以更大程度或更小程度聚焦。导电液体通常是含水盐水液体，例如301，并且绝缘液体通常是油性溶液，例如305。然而，在本公开的范围内的其它实施方案中，中心可包括其它类型的非气态介质或非气态介质的组合。
在一些实施方案中，镜片材料可以是任何合适的聚合物材料，诸如水凝胶、有机硅水凝胶、有机硅丙烯酸酯或氟代有机硅丙烯酸酯。镜片材料最初可以处在熔融状态并且直接注入至例如模具腔体中。根据相同或其它技术可以模塑超薄光学件102和超薄光学件202，所述技术包括例如旋转浇注、车床加工、金刚石车削或激光切削。尽管本文关于前光学部分和后光学部分进行了描述，但是用于模塑和组装超薄光学件102和超薄光学件202的方法和设备可以用于模塑传统上需要分开处理和组装的任意多个模塑的部件。
现参考图6，示出了可用于制造用于根据本公开的方面的液体镜片500的超薄光学部件的方法步骤600。在步骤601开始，第一超薄光学件可以在第一基片101的凹面光学性能形成表面105上形成。在步骤605，第二超薄光学件可以在第二基片201的凸面光学性能形成表面205上形成。所述第一基片101和第二基片201各自可形成块的部件，所述块的部件用于分别形成凸面光学性能形成表面205中的每个。光学性能表面可以是两个不同基片101和基片201的部件，它们各自形成用于形成超薄光学件102和超薄光学件202的块的部件。如先前所提及的，可以通过使用包括如下的技术来形成和/或模塑超薄光学件102和超薄光学件202，例如：注塑、旋转浇注、车床加工、金刚石车削或激光切削。
在步骤610，分别支撑第一超薄光学件102和第二超薄光学件202的所述第一基片101和第二基片201可以彼此互相对准。如在本公开中所讨论的，使用基片101和基片201的对准特征部110和对准特征部210可发生对准。如先前所讨论的，对准特征部110和对准特征部210可包括机电对准装置、机械装置等等。
在步骤615，一种或多种液体可以被容纳在第一超薄光学件102与第二超薄光学件202之间而不需要将超薄光学件102和超薄光学件202与它们各自基片101和基片201分离。一种或多种液体可分别包括盐水溶液和油溶液，例如，301和205，并且可用于形成液体镜片组件500。在一些实施方案中，通过将基片101和基片201两者均浸入溶液中可发生该步骤。通过基片101和基片102中的一个的结构或者通过在基片101和基片201已经浸入盐水溶液301中之后添加一滴油溶液305，可将油305包括在内。在步骤620，可以在其间密封一种或多种溶液从而形成液体镜片组件500。使用在一个或多个超薄光学件102和超薄光学件202上的联锁结构、使用粘合剂、热堆叠和对于本领域中组装光学部件已知的其它合适技术可以提供密封件。在步骤625，液体镜片组件500可以从基片101和/或基片201中的至少一个移除以形成眼科镜片的部件。在一些实施方案中，液体镜片组件500可以放置到水凝胶边缘上。在另选的实施方案中，液体镜片组件500可以由水凝胶封装。
本发明的许多特征和优点将根据详细的说明而显而易见，并因此，通过所附权利要求书旨在涵盖落入本发明的真实实质和范围内的本发明的所有这些特征和优点。另外，因为本领域技术人员将容易进行许多修改和变形，所以不期望将本发明限制于举例说明和描述的精确构造和操作，并因此，可采取落入本发明的范围之内的所有合适的修改形式和等同物。

Claims (20)

1.一种制造适用于眼科装置的液体镜片的方法，所述方法包括：
限定第一块的凹面基片表面上的第一超薄光学件；
限定第二块的凸面基片表面上的第二超薄光学件；
在腔体之间容纳一种或多种流体，所述腔体通过由所述第一块的所述凹面基片表面支撑的所述第一超薄光学件和由所述第二块的所述凸面基片表面支撑的所述第二超薄光学件形成；
产生在所述腔体中容纳所述一种或多种流体的密封件，所述腔体位于由所述第一块的所述凹面基片表面支撑的所述第一超薄光学件与由所述第二块的所述凸面基片表面支撑的所述第二超薄光学件之间；以及
将所述第一超薄光学件从所述第一块的所述支撑凹面基片表面移除，并且/或者将所述第二超薄光学件从所述第二块的所述支撑凸面基片表面移除。
2.根据权利要求1所述的方法，所述方法还包括：
在所述第一超薄光学件和所述第二超薄光学件中的每一者的周边的至少一部分中限定联锁特征部。
3.根据权利要求2所述的方法，所述方法还包括：
将在所述第一超薄光学件中限定的所述联锁结构与在所述第二超薄光学件中限定的联锁结构对准以产生容纳所述一种或多种流体的所述密封件。
4.根据权利要求2所述的方法，其中：
在所述第一超薄光学件中限定的所述联锁结构和在所述第二超薄光学件中限定的所述联锁结构是旋转对称的。
5.根据权利要求2所述的方法，其中：
在一者或两者所述第一超薄光学件中限定的所述联锁结构和在所述第二超薄光学件中限定的所述联锁结构包括围绕所述周边的可用于包含粘合剂的沟槽。
6.根据权利要求2所述的方法，其中：
在所述第一超薄光学件中限定的所述联锁结构和在所述第二超薄光学件中限定的所述联锁结构是非旋转对称的。
7.根据权利要求6所述的方法，其中：
在所述第一超薄光学件中限定的非旋转对称的联锁结构和在所述第二超薄光学件中限定的所述非旋转对称的联锁结构的所述对准通过使用所述第一块和所述第二块的对准特征部来对准。
8.根据权利要求1所述的方法，其中：
当由所述第一块的所述凹面基片表面支撑的所述第一超薄光学件和由所述第二块的所述凸面基片表面支撑的所述第二超薄光学件被浸入在一种或多种流体中时，产生容纳所述一种或多种流体的所述密封件。
9.根据权利要求8所述的方法，其中：
所述一种或多种流体包括亲水性油溶液，所述亲水性油溶液的体积小于所述腔体的总体积的10％。
10.根据权利要求8所述的方法，其中：
所述一种或多种流体包括疏水性盐水溶液，所述疏水性盐水溶液的体积大于所述腔体的总体积的90％。
11.根据权利要求1所述的方法，所述方法还包括将所述液体镜片组件封装于水凝胶材料中的步骤。
12.根据权利要求1所述的方法，所述方法还包括将所述液体镜片组件放置到水凝胶边缘上的步骤。
13.根据权利要求1所述的方法，其中所述油溶液的体积小于所述流体的总体积的15％，所述流体被容纳于在所述第一超薄光学件与所述第二超薄光学件之间形成的所述腔体中。
14.根据权利要求1所述的方法，其中所述超薄件为约100微米厚。
15.根据权利要求1所述的方法，其中产生所述密封件以容纳所述一种或多种流体包括在所述第一超薄光学件的周边的至少一部分之间添加粘合剂，并且所述油溶液的体积小于所述流体的总体积的15％，所述流体被容纳于在所述第一超薄光学件与所述第二超薄光学件之间形成的所述腔体中。
16.一种能够被佩戴在眼睛的前表面上的眼科液体镜片装置，所述眼科液体镜片装置包括：
液体镜片组件，所述液体镜片组件包括，
由第一块的凹面基片表面限定的第一超薄光学件，
由第二块的凸面基片表面限定的第二超薄光学件，
被容纳于由所述第一超薄光学件和所述第二超薄光学件形成的腔体之间的一种或多种流体；
密封件，其在位于所述第一超薄光学件与所述第二超薄光学件之间的所述腔体中容纳所述一种或多种流体，所述密封件包括联锁特征部，所述联锁特征部被包括在所述第一超薄光学件和所述第二超薄光学件的周边区域中；以及
被配置成支撑所述液体镜片组件的水凝胶部分。
17.根据权利要求16所述的眼科镜片，其中在一者或两者所述第一超薄光学件中限定的所述联锁结构和在所述第二超薄光学件中限定的所述联锁结构包括围绕所述周边的可用于包含粘合剂的沟槽。
18.根据权利要求16所述的眼科镜片，其中在所述第一超薄光学件中限定的所述联锁结构和在所述第二超薄光学件中限定的所述联锁结构是非旋转对称的。
19.根据权利要求16所述的眼科镜片，其中所述超薄件为约100微米厚。
20.根据权利要求16所述的眼科镜片，其中所述一种或多种流体包括盐水溶液和油溶液，并且所述油溶液的体积小于所述腔体的总体积的10％。
CN201480059054.3A 2013-08-27 2014-08-25 制造包括超薄光学部件的眼科镜片的方法以及此类镜片 Pending CN105682906A (zh)

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