JP2005124727A - Mold and manufacturing method for intraocular lens - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mold with a new structure, which easily manufactures an intraocular lens integrally equipped with an optical part and a supporting part, while can prevent a defective molding such as a burr or the like. <P>SOLUTION: The mold for an intraocular lens includes a molding plate 14 with a molding hole 50 corresponding to the whole peripheral shape of an optical part 24 and a supporting part 26, which is sandwiched and sealed with an upper mold 16, a lower mold 12 and an intermediate mold 18 being overlapped so that both openings of the molding hole 50 can be sealed with the lower mold 12 and the intermediate mold 18 and a molding cavity 20 can be formed. Polymerized molding of polymerized monomer 22 in the molding cavity 20 enables the manufacture of an integrated intraocular lens 28. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a mold for molding an intraocular lens, and more particularly, to an intraocular lens having a novel structure capable of easily manufacturing a one-piece intraocular lens in which an optical part and a support part are integrally formed. The present invention relates to a molding die and a manufacturing method.

  Conventionally, intraocular lenses that are inserted into the eye and used for the purpose of supplementing the refractive power of the aphakic eye from which the lens has been removed by cataract surgery or the like have been known. In recent years, intraocular lenses for phakic eyes have been used. The application of is also being considered. In such an intraocular lens, in addition to a two-piece intraocular lens or a three-piece intraocular lens as a separate intraocular lens produced by assembling an optical part and a support part formed separately, respectively, an optical part and A one-piece intraocular lens as an integral intraocular lens formed by integrally forming a support portion is known. Particularly in recent years, one-piece intraocular lenses have been studied for the reason that complicated post-processing is unnecessary and manufacturing efficiency is good.

  By the way, as a manufacturing method of an integral intraocular lens, conventionally, a molding method using a molding die is known. In such a molding method, as shown in Patent Documents 1 and 2, a female mold that cooperates to form a molding cavity for integrally molding an optical part and a support part by being matched with each other. And a mold made of a male mold is used. Then, by molding a predetermined polymerizable monomer in a molding cavity defined between the mold-matching surfaces of both the male and female molds, an objective intraocular lens integrally provided with an optical part and a support part is obtained. Will be manufactured.

  However, such a conventional molding method may cause molding defects such as sink marks and voids in the intraocular lens which is a molded product due to shrinkage during polymerization of the polymerizable monomer. In particular, in an optical part having a large thickness dimension, there is a problem that an adverse effect on optical characteristics may occur due to residual stress that is difficult to recognize on the appearance due to polymerization shrinkage of a polymerizable monomer.

  Moreover, in the conventional mold, the position of the support part formed on the female mold and the position of the support part formed on the male mold must be accurately aligned in the circumferential direction and the mold closed. If both the male and female molds are relatively slightly displaced in the circumferential direction at the time of alignment, molding defects such as burrs will occur, so it is difficult to ensure the accuracy of the mold matching operation, and the quality of the intraocular lens as a molded product can be obtained stably. There was a problem that it was difficult. In addition, since there is a concern about the occurrence of burrs due to mold alignment errors between both male and female molds, in reality, there is a problem that deburring work is indispensable, making the production complicated and expensive. .

  Furthermore, it is necessary to prepare multiple types of intraocular lenses with different optical parts and support parts depending on the patient, especially for those with the same characteristics and shape of the optical part, Depending on the shape and the like, it is necessary to prepare a plurality of support portions having different shapes and sizes. However, with conventional molds, if the optical part is the same, but the support part is different, the entire mold must be changed.Therefore, many types of molds must be prepared. However, there are problems that it is cumbersome, inefficient, and expensive to manufacture.

JP-A-1-247121 US Pat. No. 5,620,720

  The present invention has been made in the background as described above, and the problem to be solved is that an integrated intraocular lens integrally including an optical part and a support part has a molding defect such as a burr. Can be produced with good and stable quality, and for example, it is also possible to efficiently produce a plurality of types of intraocular lenses having the same optical part but different shapes and sizes of the support part. An object of the present invention is to provide a mold for molding an intraocular lens having a novel structure and a novel method for producing an intraocular lens.

  Further, according to the present invention, in the integrated intraocular lens integrally including the optical part and the support part, the design and the shape of the optical part and the support part can be easily changed. It is another object of the present invention to provide a novel method for manufacturing an intraocular lens in which an intraocular lens according to an application is advantageously realized.

  Hereinafter, the aspect of this invention made | formed in order to solve such a subject is described. In addition, the component employ | adopted in each aspect as described below is employable by arbitrary combinations as much as possible. In addition, aspects or technical features of the present invention are not limited to those described below, but are described in the entire specification and drawings, or can be understood by those skilled in the art from those descriptions. It should be understood that it is recognized on the basis of.

(Aspect 1 of the present invention relating to a mold for molding an intraocular lens)
A feature of aspect 1 of the present invention relating to the mold for molding an intraocular lens is that (a) a fitting recess is provided, and the optical part of the target intraocular lens is provided at the center of the bottom surface of the fitting recess. A lower die provided with an optical part molding surface for forming one surface, and (b) having a substantially flat plate shape, including an optical part and a support part of a target intraocular lens in the central part A mold plate corresponding to the entire outer peripheral shape is provided, and a mold plate is fitted into the fitting recess of the lower mold and overlapped with the bottom surface of the fitting recess, and (c) the mold plate An upper die having a guide hole that opens toward the die plate, which is matched with the lower die by being fitted into the fitting recess of the lower die from above; (D) The upper mold is displaceably fitted into the guide hole. The upper mold is superimposed on the upper surface of the mold plate so as to be displaceable in the approach / separation direction in a state in which the upper mold is aligned with the lower mold, and is superimposed on the mold plate. And a middle mold provided with an optical part molding surface for forming the other surface of the optical part of the target intraocular lens at the center of the bottom surface to be combined. The entire mold cavity including the support part and the support part is in the mold for molding an intraocular lens, the periphery of which is defined by the mold plate between the opposed surfaces of the lower mold and the middle mold.

  In the mold for molding an intraocular lens having the structure according to this aspect, the outer peripheral wall surface of the molding cavity of the integral intraocular lens including the optical part and the support part is configured by a mold plate over the entire circumference. The Rukoto. Therefore, even if the lower mold and the middle mold forming both sides of the optical section and the support section are displaced from each other in the circumferential direction, the molding cavity of the support section, and thus the support section, can be stably formed with the desired shape. As a result, the intended integral intraocular lens can be stably molded with good quality.

  Further, the relative displacement of the middle mold with respect to the lower mold allows the volume of the molding cavity to be reduced without any change in the shape of the support portion or the optical surface. Therefore, the occurrence of molding defects such as sink marks and voids due to polymerization shrinkage during polymerization molding of the polymerizable monomer and the residual stress in the optical part can be effectively avoided by reducing the volume of the molding cavity. An integrated intraocular lens can be manufactured with stable quality.

(Aspect 2 of the present invention relating to a mold for molding an intraocular lens)
The aspect of the second aspect of the present invention relating to the mold for molding an intraocular lens is characterized in that in the mold for molding an intraocular lens according to the first aspect of the present invention, the inner surface of the outer peripheral wall of the fitting recess in the lower mold. A locking part is formed, and the upper mold is locked in the mold alignment direction with respect to the lower mold by the locking part, whereby the upper surface of the mold plate superimposed on the bottom surface of the fitting recess A communication gap is formed between the lower surface of the upper mold.

  In this embodiment, a communication gap is formed between the opposing surfaces of the lower mold and the upper mold in a state where the molding cavity formed between the opposing surfaces of the lower mold and the intermediate mold communicates. The Rukoto. Therefore, at the time of molding, it is possible to replenish the polymerizable monomer from the communication gap to the molding cavity when the shrinkage is caused by filling the communication gap with the polymerizable monomer. Thereby, the occurrence of molding defects and residual stress due to polymerization shrinkage of the polymerizable monomer during molding can be reduced or avoided more advantageously.

(Aspect 3 of the present invention relating to a mold for molding an intraocular lens)
The aspect 3 of the present invention relating to the mold for molding an intraocular lens is characterized by the mold for molding an intraocular lens according to the first or second aspect of the present invention, wherein the fitting recess An opening recess is formed that spreads outward from the opening of the upper mold, and the upper mold is fitted to the lower mold, and the fitting recess is fitted into the fitting recess in the opening recess. In the outer periphery side of the upper mold, there is an external liquid reservoir that accommodates excess polymerizable monomer.

  In such an embodiment, when a predetermined amount of polymerizable monomer is supplied to the cavity forming portion of the lower mold and then the upper mold and the middle mold are combined to define the molding cavity, the excess polymerizable monomer is supplied in advance. In this case, the polymerizable monomer can be easily and stably filled into the molding cavity by allowing it to overflow into the external liquid reservoir during mold matching. In addition, the external liquid reservoir and the molding cavity can be communicated with each other through a gap existing between the overlapping surfaces of each mold member consisting of the lower mold, upper mold, middle mold, and mold plate. A configuration in which the gap is positively provided may also be employed. Therefore, at the time of polymerization shrinkage of the monomer at the time of polymerization, it is possible to supplement the molding cavity with excess polymerizable monomer stored in the external liquid reservoir, and to suppress the occurrence of molding defects and residual stress due to polymerization shrinkage. It is. Therefore, more preferably, this aspect can be adopted in combination with the above-described aspect 2 of the present invention, thereby making the molding cavity and the external liquid reservoir communicate with each other using the communication gap. Configuration is realized.

(Aspect 4 of the present invention relating to a mold for molding an intraocular lens)
The aspect 4 of the present invention relating to the mold for molding an intraocular lens is characterized in that in the mold for molding an intraocular lens according to any one of the first to third aspects of the present invention, the guide hole of the upper mold The inner peripheral surface and the outer peripheral surface of the middle mold are fitted in a substantially close state with a minute gap so that the polymerizable monomer does not enter at least at the edge portion on the mold plate side. .

  In the mold for molding an intraocular lens according to the present invention, it is necessary to allow relative displacement in the approaching direction with respect to the lower mold of the middle mold at the time of polymerization molding of the polymerizable monomer. Increasing the gap between the upper guide hole and the middle mold as realized is often inconvenient. That is, if the gap between the upper mold guide hole and the middle mold is increased, the polymerizable monomer easily penetrates into the upper mold guide hole. This is because there is a possibility that the displacement of the medium mold inside may be hindered, and in addition, burrs are likely to occur in the molded product due to the polymerizable monomer that has entered the gap. Therefore, in this aspect, it is possible to prevent the occurrence of burrs caused by the entry of the polymerizable monomer into the gap between the upper mold guide hole and the middle mold while allowing the middle mold to be displaced with respect to the upper mold. Therefore, the quality and molding stability of the intraocular lens can be further improved.

(Aspect 5 of the present invention relating to a mold for molding an intraocular lens)
A feature of the fifth aspect of the present invention relating to the mold for molding an intraocular lens is the mold for molding an intraocular lens according to any one of the first to fourth aspects of the present invention, wherein the mold plate includes the mold An opening that penetrates in the thickness direction on the outer peripheral side of the molding hole is formed independently of the molding hole, and the lower mold in the opening is aligned with the upper mold aligned with the lower mold. An internal liquid reservoir for accommodating excess polymerizable monomer is formed between the opposing surfaces of the mold and the middle mold.

  In this embodiment, the excess polymerizable monomer filled in the internal liquid reservoir is free from problems such as sink marks and residual stress caused by polymerization shrinkage of the polymerizable monomer caused by polymerization in the molding cavity. It is possible to reduce or avoid using. That is, since an excess polymerizable monomer (polymerizable monomer exceeding the filling amount in the molding cavity) is accommodated in the internal liquid reservoir formed close to the outer peripheral side of the molding cavity, As the polymerization shrinks during polymerization molding, the polymerizable monomer in the internal liquid reservoir can move to the molding cavity through the gap between the overlapping surfaces of the mold plate and the lower mold and the middle mold and be replenished. In addition, this aspect can be preferably employed in combination with the above-described aspect 3 of the present invention, whereby an excess polymerizable monomer can be more advantageously secured in quantity, and polymerization during polymerization molding can be performed. It becomes possible to more efficiently replenish the forming cavity with the molding monomer.

(Aspect 6 of the present invention relating to a mold for molding an intraocular lens)
A feature of the aspect 6 of the present invention relating to the mold for molding an intraocular lens is that in the mold for molding an intraocular lens according to the aspect 5 of the present invention, the mold plate includes: (e) the molding hole. A rim portion extending in the circumferential direction on the outer peripheral wall portion; and (f) an outer peripheral abutting portion positioned on the bottom surface of the fitting concave portion by being brought into contact with the inner peripheral surface of the fitting concave portion of the lower mold. (G) formed by projecting from the rim portion toward the outer peripheral side and integrally connecting the rim portion to the outer peripheral abutting portion; The mold cavity is formed on the inner peripheral side and the internal liquid reservoir is formed on the outer peripheral side with the rim portion sandwiched between the molds in a matched state. .

  In this embodiment, the volume of the internal liquid reservoir is advantageously reduced between the lower mold and the opposed surfaces of the middle mold and the upper mold while forming a molding cavity with good positional accuracy between the opposed surfaces of the lower mold and the middle mold. It can be secured. In this aspect, preferably, the rim portion is formed with a substantially constant cross-sectional shape over the entire circumference. As a result, the volume of the internal liquid reservoir can be secured more advantageously, and the replenishment of the polymerizable monomer from the internal liquid reservoir to the molding cavity during polymerization molding of the polymerizable monomer can be performed all around the molding cavity. It can be done efficiently over time.

(Aspect 7 of the present invention relating to a mold for molding an intraocular lens)
A feature of aspect 7 of the present invention relating to a mold for molding an intraocular lens is a mold for molding an intraocular lens according to any one of aspects 1 to 6 of the present invention, wherein the mold plate includes: At least one opening edge in the plate thickness direction of the forming hole has an acute edge-shaped cross-sectional shape so that the inner peripheral edge of the edge is pressed against the opposing surface of the lower mold and / or the middle mold. It is in that.

  In such a mode, when the molds are aligned, the edge of the opening of the molding hole having an edge-shaped cross section is continuously and firmly abutted in the circumferential direction with a sufficiently small area with respect to the lower mold and the middle mold. As a result, the molding cavity located on the inner peripheral side of the molding hole is accurately sealed, and the occurrence of molding defects such as burrs due to poor sealing can be prevented.

(Aspect 8 of the present invention relating to a mold for molding an intraocular lens)
The aspect 8 of the present invention relating to the mold for molding an intraocular lens is characterized in that in the mold for molding an intraocular lens according to any one of the first to seventh aspects of the present invention, the molding hole in the mold plate The inner peripheral surface of the lower die and the middle die are at least rougher than the molding surfaces of the lower die and the middle die.

  In such an embodiment, the outer peripheral surface of the optical part of the intraocular lens that is a molded product is roughly molded as compared with the optical surface, so that the outer periphery of the optical part does not require special post-processing. It is possible to easily obtain an intraocular lens of good quality that can reduce glare caused by internal reflection of the surface. In particular, in this aspect, the mold plate having the inner peripheral surface of the molding hole for molding the outer peripheral surface of the optical part includes a middle mold and a lower mold for molding the lens surfaces on both sides in the optical axis direction of the optical part as the optical surface. Since it is a separate member, it is easy to form the inner peripheral surface of the molding hole with a roughness different from that of the molding surface of the optical surface.

(Aspect 9 of the present invention relating to a mold for molding an intraocular lens)
The aspect 9 of the present invention relating to the mold for molding an intraocular lens is characterized in that in the mold for molding an intraocular lens according to any one of the first to eighth aspects of the present invention, the lower part that forms the molding cavity. That is, at least one of the mold and the middle mold is formed of a material having rigidity smaller than that of the mold plate.

  In this embodiment, the mold plate can be tightly brought into close contact with the lower mold and the middle mold at the time of mold matching, so that the mold cavity can be sealed more highly and stably. It becomes. In addition, this aspect is preferably configured in combination with the above-described aspect 7, whereby the inner peripheral edge of the molding hole of the mold plate is more advantageously digged into the lower mold and the middle mold, thereby forming a hermetically sealed mold. A cavity can be defined. In addition, this aspect is preferably combined with the above-described aspect 5 or 6, and thereby, an internal liquid reservoir is formed on the outer peripheral side of the molding cavity while stably securing the shape of the molding cavity by the rigidity of the mold plate. The portion can be formed advantageously.

(Aspect 10 of the present invention relating to a mold for molding an intraocular lens)
A feature of the aspect 10 of the present invention relating to the mold for molding an intraocular lens is the mold for molding an intraocular lens according to any one of the above aspects 1 to 9 of the present invention, in the bottom surface of the middle mold, A region extending further to the outer peripheral side from the outer peripheral edge of the optical part molding surface for forming the other surface of the optical part of the target intraocular lens gradually protrudes toward the mold plate as it goes to the outer peripheral side. In other words, the tapered shape is inclined.

  In this embodiment, the middle mold that is displaced in the approaching direction with respect to the lower mold during the polymerization molding is more closely attached to the inner peripheral edge of the molding hole in the mold plate over the entire circumference. The occurrence of molding defects such as burrs can be prevented more effectively. That is, in the integral type intraocular lens, since the molding cavity of the support part is provided to greatly extend outward from the optical part, the support part molding surface and the center part positioned on the outer peripheral part of the lower mold or the middle mold are provided. In the optical part molding surface to be positioned, the ease of securing the adhesion to the lower mold and the middle mold plate at the site is different. Specifically, the middle mold is supported by the upper mold on the outer peripheral surface, and the lower mold has a thick peripheral wall part integrally formed on the outer circumferential part, so that the middle mold and the lower mold are made of the same material as a whole. Even if it exists, the rigidity (displacement amount with respect to the external force of the unit amount) of the outer peripheral portion is larger than that of the central portion. In addition, since a concave cavity forming surface for forming an optical part is generally provided in the central portion of the middle mold, a concave cavity is applied by a mold clamping force due to polymerization shrinkage of the monomer. When the forming surface is pulled toward the mold plate, the outer peripheral portion of the middle mold tends to receive a force in the direction of lifting from the mold plate. Therefore, when the lower mold and the middle mold are brought into contact with the mold plate by the clamping force exerted by the polymerization shrinkage of the polymerizable monomer at the time of molding, stable adhesion is ensured over the entire circumference of the molding cavity. However, in this embodiment, the outer peripheral portion where it is difficult to obtain adhesion to the mold plate in the middle mold is positioned in advance so as to protrude toward the mold plate as compared with the central portion where adhesion is easily obtained. Therefore, the sealing state of the molding cavity can be advantageously and stably realized not only in the optical part located in the central part but also in the support part extended and positioned on the outer peripheral side. Therefore, in the polymerization molding, the edge cutting state of the outer peripheral edge of the molding cavity is satisfactorily realized, and the occurrence of molding defects such as burrs in the intraocular lens as a molded product is more effectively prevented.

(Aspect 11 of the present invention relating to a mold for molding an intraocular lens)
A feature of the aspect 11 of the present invention relating to the mold for molding an intraocular lens is the mold for molding an intraocular lens according to any one of the above aspects 1 to 10 of the present invention, in the bottom surface of the middle mold, Inverted taper shape in which the outer peripheral edge region outside the region forming the entire molding cavity including the optical part and the support part of the target intraocular lens is gradually inclined away from the mold plate side toward the outer peripheral side. It is in that.

  In this embodiment, it is possible to avoid the action of the pressing force in the diameter-enlarging direction on the upper mold, which is caused by the diameter-expanding deformation of the lower peripheral edge of the middle mold at the time of polymerization molding. The mold alignment state and the middle mold mobility at the time can be realized more stably, and the target intraocular lens can be polymerized and molded stably with higher accuracy. That is, in the polymerization molding, for example, due to the bending deformation of the entire middle mold caused by the central portion of the middle mold provided with the optical part molding surface being deformed and displaced toward the mold plate, the lower peripheral edge of the middle mold is expanded in diameter. If there is a risk of deformation, when such a diameter expansion deformation occurs, the upper mold into which the middle mold is fitted is pressed by the middle mold, the lower end of the upper mold is pushed wide, or the entire upper mold is tapered downward. It may be curved and deformed to form a shape. Here, in this aspect, the pressing force on the upper mold of the middle mold can be reduced or avoided because the lower peripheral edge region of the middle mold has a reverse taper shape, and as described above due to the pressing force. Problems can be advantageously avoided.

(Aspect 12 of the present invention relating to a mold for molding an intraocular lens)
A feature of the aspect 12 of the present invention relating to the mold for molding an intraocular lens is the mold for molding an intraocular lens according to any one of the aspects 1 to 11 of the present invention. A leg portion that is located on the outer peripheral edge and protrudes downward is provided so that the leg portion is placed on a predetermined base, and the lower surface of the lower mold is located at the center located below the fitting recess. The portion is spaced apart from the base so that a void is formed below the bottom wall forming the fitting recess, and the central portion of the lower surface of the bottom wall forming the fitting recess is By projecting into the space corresponding to the molding surface of the molding cavity formed in the fitting recess, the thickness of the bottom wall forming the fitting recess is the entire molding surface of the molding cavity. It is that it is made to be substantially constant over time.

  In the molding die having such a structure according to the present embodiment, even when appropriate curved irregularities are formed on the bottom surface of the fitting recess of the lower mold forming the molding surface of the optical part or the support part. The thickness of the bottom wall portion of the fitting recess can be made substantially constant throughout, thereby preventing uneven deformation of the bottom wall portion due to polymerization shrinkage and the like exerted upon polymerization molding. Is possible. Therefore, the shape accuracy of the molding cavity can be maintained at a higher level.

(Aspect 13 of the present invention relating to a mold for molding an intraocular lens)
A feature of the thirteenth aspect of the present invention relating to the mold for molding an intraocular lens is the mold for molding an intraocular lens according to any one of the first to twelfth aspects of the present invention, wherein the lower mold and the middle mold There is provided a circumferential positioning means for positioning at least one of the above relative to the mold plate directly or indirectly in the circumferential direction.

  In such a mold according to this embodiment, for example, in an intraocular lens provided with an optical part in which different shapes and optical characteristics are set in the circumferential direction, it is necessary to form a support part in a specific direction. In some cases, it can be adopted. Even in such a case, since the outer peripheral surface of the molding cavity of the support portion is formed by a single mold plate, the occurrence of molding defects such as burrs due to misalignment of the molding die can be advantageously prevented. Thus, the effects of the present invention as described above are effectively exhibited. In addition, the circumferential positioning means of this aspect forms fitting unevenness and the like that are fitted to each other at appropriate portions such as the outer peripheral edge portions of the mold plate and the lower mold and / or the middle mold. This is feasible.

(Aspect 1 of the present invention relating to a method for producing an intraocular lens)
A feature of aspect 1 of the present invention relating to a method of manufacturing an intraocular lens is that a mold plate having a hole for molding corresponding to the entire outer peripheral shape including an optical part and a support part of the target intraocular lens is provided. A mold cavity is defined by overlapping a pair of molds with respect to the mold plate from both sides in the thickness direction and covering the mold holes from both sides, and a predetermined polymerizable monomer is formed in the mold cavity. In the intraocular lens manufacturing method, an intraocular lens in which a support part is integrally formed with an optical part is obtained by polymerization molding.

  According to such a method of the present invention, the outer peripheral surface of the integral intraocular lens is molded with one mold plate over the entire circumference including the optical part and the support part. Even if the pair of molds for molding the lens surface are displaced from each other in the circumferential direction, the molding cavity of the support portion can be stably defined, and the target integral intraocular lens can be formed with a burr or the like. Stable molding can be performed while suppressing the occurrence of molding defects. Therefore, when aligning a pair of molds, a high degree of positioning accuracy in the circumferential direction is not required, and a desired intraocular lens can be stably manufactured by an easy molding operation. It becomes.

  In addition, for example, an intraocular lens having high flexibility such as an acrylic resin is difficult to perform secondary machining such as cutting or polishing after molding. However, in the method of the present invention, the occurrence of molding defects such as burrs can be effectively suppressed and special secondary processing such as deburring can be dispensed with. The practical application of the lens can also be advantageously achieved.

  Furthermore, according to the method of the present invention, for example, by changing the mold plate only by using a pair of molds that form the mold cavities of the lens surfaces on both sides of the optical part, It is also possible to easily mold a plurality of types of intraocular lenses provided with support portions having different sizes.

(Aspect 2 of the present invention relating to a method for producing an intraocular lens)
A feature of aspect 2 of the present invention relating to a method for manufacturing an intraocular lens is that, in the method for manufacturing an intraocular lens according to aspect 1 of the present invention, in the polymerization molding of the polymerizable monomer in the molding cavity, It is intended to displace at least one of the pair of molds in the approaching direction with respect to the mold plate.

  In this embodiment, the relative displacement of the pair of molds in the approaching direction reduces the volume of the mold cavity without changing the shape of the optical surface, thereby causing polymerization shrinkage of the polymerizable monomer. Occurrence of molding defects such as sink marks and voids and residual stresses in the optical part can be effectively avoided, and the intended integrated intraocular lens can be manufactured with excellent quality.

(Aspect 3 of the present invention relating to a method for producing an intraocular lens)
A feature of aspect 3 of the present invention relating to a method for producing an intraocular lens is that, in the method for producing an intraocular lens according to aspect 1 or 2 of the present invention, an acrylic monomer is included as the polymerizable monomer. is there.

  In this embodiment, in general, even when an acrylic monomer having a large shrinkage rate in polymerization molding is employed as a lens molding material, due to the relative displacement of the pair of molding dies. Molding defects such as sink marks and voids due to polymerization shrinkage and occurrence of optical defects due to residual stress are effectively reduced or avoided. Therefore, practical application of an intraocular lens made of an acrylic resin material can be advantageously achieved.

(Aspect 4 of the present invention relating to a method for producing an intraocular lens)
A feature of aspect 4 of the present invention relating to a method for producing an intraocular lens is that in the method for producing an intraocular lens according to any one of aspects 1 to 3 of the present invention, the polymerizable monomer in the molding cavity is in the polymerization molding, the inner periphery of the molding hole of the mold plate to so as to bite to at least one of the pair of molds.

  In such an embodiment, the outer peripheral edge of the molding cavity formed by the molding hole is more reliably divided into a rimmed state, and therefore, molding defects such as burrs in the intraocular lens are eliminated. This can be prevented more effectively to improve molding accuracy, and troublesome work for post-processing such as deburring can be reduced or eliminated. In this aspect, the means for causing the inner peripheral edge portion of the molding hole in the mold plate to bite into the molding die is, for example, a protrusion protruding toward the molding die over the entire circumference with respect to the inner peripheral edge portion of the molding hole. It is advantageously realized by providing them continuously, or by forming the mold with a material having rigidity smaller than that of the mold plate.

(Aspect 5 of the present invention relating to a method for producing an intraocular lens)
A feature of the fifth aspect of the present invention relating to a method for manufacturing an intraocular lens is that in the method for manufacturing an intraocular lens according to any one of the first to fourth aspects of the present invention, the polymerizable monomer in the molding cavity is In the polymerization molding, the polymerizable monomer is put into the molding cavity from a surplus polymerizable monomer reservoir provided outside the molding cavity through the overlapping surface of the mold plate and at least one of the molding dies. It is to replenish.

  In such an embodiment, sink marks and voids caused by polymerization shrinkage accompanying such polymerization molding are obtained by replenishing the molding cavity with the polymerizable monomer contained in the liquid reservoir during polymerization molding of the polymerizable monomer. Alternatively, defects such as residual stress can be reduced or avoided more effectively. In addition, the liquid reservoir is substantially sealed and provided at an appropriate position such as the outer peripheral side of the molding cavity, thereby assisting the mold clamping force in the pair of molds by polymerization shrinkage of the polymerizable monomer in the liquid reservoir. It is also possible to increase the sealing performance of the molding cavity and to stabilize it.

(Aspect 6 of the present invention relating to a method of manufacturing an intraocular lens)
A feature of aspect 6 of the present invention relating to a method for producing an intraocular lens is that, in the method for producing an intraocular lens according to any of aspects 1 to 5 of the present invention, the mold after polymerization molding of the polymerizable monomer. When opening, the molded product formed in the molding cavity is released from the pair of molding dies while being attached to the mold plate, and then the molded product is removed from the mold plate.

  According to this aspect, after the intraocular lens is polymerized and molded, the intraocular lens as a molded product is released from the mold in a state of being protected by being attached to the mold plate. Damage to the intraocular lens during molding is prevented, and the mold release operation can be easily performed without directly touching the intraocular lens.

  In this aspect, since the shape of the outer peripheral surface of the intraocular lens that is a molded product is complicated, when the mold is opened, a pair of intraocular lenses are attached to the mold plate. The mold will be released from the mold. For example, by selecting a material having better releasability than the mold plate for the pair of molds, the intraocular lens is fixed to the mold plate and the pair of molds is formed. The operation of releasing the mold from the mold can be performed more stably. In addition, when removing the intraocular lens from the mold plate, it is desirable to employ an appropriate solvent, thereby preventing the intraocular lens from being damaged by the action of external force on the intraocular lens, while the intraocular lens is removed from the mold plate. Can be easily removed. In addition, although the solvent used when demolding an intraocular lens from a type | mold plate changes also with the material of a type | mold plate or an intraocular lens, ethanol, methanol, acetone, etc. can be employ | adopted, for example.

(Aspect 7 of the present invention relating to a method for producing an intraocular lens)
A feature of aspect 7 of the present invention relating to a method for manufacturing an intraocular lens is that, in the method for manufacturing an intraocular lens according to any one of aspects 1 to 6 of the present invention, the same as at least one of the pair of molds. The object is to mold different types of intraocular lenses by changing the mold plate.

  In this embodiment, many types of intraocular lenses can be manufactured by using only a small number of molds and different mold plates. For example, in an optical unit having a certain optical characteristic. On the other hand, intraocular lenses provided with support portions having different shapes and sizes can be efficiently manufactured at low cost with a small number of molds as series products.

(Aspect 8 of the present invention relating to a method for producing an intraocular lens)
A feature of aspect 8 of the present invention relating to a method for manufacturing an intraocular lens is that, in the method for manufacturing an intraocular lens according to any one of aspects 1 to 6 of the present invention, the same mold plate is used, The object is to mold a plurality of different types of intraocular lenses by changing at least one of the pair of molds.

  In this embodiment, for example, there are few intraocular lenses having the same shape and size of the support portion, and different in the shape, size, optical characteristics, etc. of the optical portion as series products. The mold plate can be efficiently manufactured at low cost.

(Aspect 9 of the present invention relating to a method for producing an intraocular lens)
A feature of the aspect 9 of the present invention relating to the method for manufacturing an intraocular lens is that the intraocular lens molding die according to any one of the above aspects 1 to 13 of the present invention relating to the molding die as described above is used. In the method of manufacturing an intraocular lens, a polymerizable monomer is polymerized and molded in the molding cavity to obtain an intraocular lens in which a support portion is integrally formed with an optical portion.

  According to such a method of the present invention, the method for manufacturing an intraocular lens according to any one of the aforementioned aspects 1 to 8 can be advantageously implemented.

  In the intraocular lens mold or manufacturing method according to the present invention, the material used as the polymerizable monomer is not limited to the acrylic monomer as shown in the aspect 3 of the method of the present invention. Various polymerizable materials used for the intraocular lens can be used without being limited by the size of shrinkage, the hardness, or the like. Specifically, for example, linear, branched or cyclic alkyl acrylates or methacrylates, silicon-containing acrylates or methacrylates, styrene or derivatives thereof, aromatic ring-containing acrylates or methacrylates, fluorine-containing styrene derivatives, Examples thereof include vinyl benzyl fluoroalkyl ethers, N-vinyl lactams, hydroxyl group-containing acrylates or methacrylates, acrylic acid or methacrylic acid, acrylamide, methacrylamide or derivatives thereof. Moreover, the crosslinking agent which has at least 2 or more polymeric group (unsaturated bond) in a molecule | numerator will also be used as one structural component of a polymerizable monomer like the past.

  Furthermore, a polymerization auxiliary agent such as a polymerization initiator, a sensitizer, a dye, or an ultraviolet absorber is appropriately blended with the polymerizable monomer. Examples of the polymerization initiator include radical polymerization initiators such as azobisisobutyronitrile, azobisdimethylvaleronitrile, benzoyl peroxide, tert-butyl hydroperoxide, cumene hydroperoxide, and the like. And these polymerization initiators are used individually or in mixture of 2 or more types. The amount of the polymerization initiator or sensitizer added to the polymerizable monomer is not particularly limited, but is preferably 0.002 to 10 parts by weight, more preferably 100 parts by weight of the polymerizable monomer. 0.01 to 2 parts by weight.

(The present invention relating to an intraocular lens)
A feature of the present invention relating to an intraocular lens is that it is manufactured by the method for manufacturing an intraocular lens according to any one of aspects 1 to 9 of the method of the present invention as described above, and the support portion is integrally formed with the optical portion. Is in the intraocular lens.

  In such an intraocular lens structured according to this embodiment, the occurrence of burrs and the like during polymerization molding is prevented, and the quality is good without the need for secondary processing such as deburring. .

  As is apparent from the above description, according to the mold for molding an intraocular lens having a structure according to the present invention, or according to the method for manufacturing an intraocular lens according to the present invention, an integral type including an optical part and a support part is provided. The intraocular lens is stably provided with excellent quality while suppressing the occurrence of molding defects such as burrs caused by variations in the mold alignment position in the circumferential direction.

  Further, according to the mold for molding an intraocular lens having a structure according to the present invention or the method for producing an intraocular lens according to the present invention, for example, a mold such as a lower mold or a middle mold can be commonly used without changing the mold plate. It is possible to efficiently mold multiple types of intraocular lenses with the same shape and size of the support part and different optical parts such as the lens power, or by changing the mold such as the lower mold and the middle mold. By changing only the mold plate in common without changing, it is possible to efficiently mold a plurality of types of intraocular lenses having the same optical part and different shapes and sizes of the support part.

  Hereinafter, in order to clarify the present invention more specifically, embodiments of the present invention will be described. First, FIG. 1 shows a mold 10 for molding an intraocular lens as one embodiment of the present invention. The molding die 10 is combined with the lower die 12 so that the die plate 14, the upper die 16 and the middle die 18 are overlapped on the same central axis from above in FIG. It is supposed to be a structure. A molding cavity 20 is formed between the opposing surfaces of the lower mold 12 and the middle mold 18 by defining the periphery with the mold plate 14. Thus, by polymer-molding a predetermined polymerizable monomer 22 in the molding cavity 20 (see FIG. 15 and the like), for example, as shown in FIGS. A target intraocular lens 28 formed by integrally molding the pair of support portions 26 and 26 can be formed. In the following description, the vertical direction means the vertical direction in FIG. 1 in principle.

  More specifically, as shown in FIG. 4, the lower mold 12 includes a bottom wall portion 30 having a substantially flat bottom surface having a disk shape and an upper peripheral edge of the bottom wall portion 30. It is formed with the surrounding wall part 32 which stands | starts up toward. Moreover, the lower mold | type 12 is equipped with the large diameter recess 34 opened to an upper surface. The recess 34 as the opening recess has a mortar-shaped inner peripheral wall surface, and a fitting recess 40 is formed at the center of the bottom surface.

  As shown in FIG. 5 in an enlarged manner, the fitting recess 40 includes a substantially flat circular bottom surface and a cylindrical inner peripheral surface that rises substantially vertically therefrom. A slightly recessed optical part molding surface 36 is formed at the center of the flat bottom surface of the fitting recess 40 with a circular outer peripheral edge in plan view. The optical part molding surface 36 has a concave shape corresponding to one surface 38 of the optical part 24 in the target intraocular lens 28, for example, a substantially spherical concave shape.

Further, a stepped portion 42 is formed on the vertical cylindrical inner peripheral surface of the fitting recess 40 as a locking portion for locking the upper die 16 at an intermediate portion in the height direction. The opening side is slightly larger in diameter than the bottom with the portion 42 interposed therebetween. In short, the peripheral wall inner surface 44 on the bottom side across the stepped portion 42 is protruded inward in the radial direction by a predetermined amount: m from the peripheral wall inner surface 46 on the opening side. Although not particularly limited, in the present embodiment, the height of the peripheral wall inner surface 44 of the bottom side: h ₁ is the height dimension of the opening side of the inner surface of the peripheral wall 46: are greater than h ₂ , H ₁ > h ₂ . The inner diameter dimension of the fitting recess 40 is set in consideration of the outer diameter dimensions of the mold plate 14 and the upper mold 16, which will be described later, and the peripheral wall inner surface 44 on the bottom side of the step portion 42 is formed on the mold plate 14. Is formed with an inner diameter dimension in which the lower end portion of the upper die 16 is fitted.

  Further, the lower mold 12 is integrally formed with a leg portion 43 that projects downward at a constant height at the outer peripheral edge of the lower surface. The leg portion 43 may be anything that can be stably supported by placing the lower mold 12 on the upper surface of the substantially flat predetermined base 45. It may be continuously formed in an annular shape over the entire area, or may be divided into a plurality of parts in the circumferential direction. By forming the leg portion 43, a space 47 that opens downward is formed in the central portion of the lower surface of the lower mold 12. The void 47 is widened with a larger diameter than the bottom wall 30 of the fitting recess 40, whereby the bottom wall 30 is structured to float upward from the base 45. Further, the bottom surface of the bottom wall portion 30 has a curved surface shape corresponding to the top surface of the bottom wall portion 30 on which the optical portion molding surface 36 and the like are formed, and the top surface and the bottom surface of the bottom wall portion 30 substantially correspond to each other. It is made into a shape. Thereby, the entire bottom wall portion 30 has a substantially constant thickness dimension, and local deformation is suppressed even when a pressure accompanying polymerization shrinkage or the like is applied during polymerization molding to be described later. The shape of the molding surface 36 and the like is maintained with high accuracy.

  In addition, as a material of such a lower mold | type 12, various synthetic resin materials etc. other than a metal material and a glass material are employ | adopted suitably, for example. Examples of the synthetic resin material include polyolefins such as polyethylene, polypropylene, and polymethylpentene, polystyrene, polycarbonate, polymethyl methacrylate, ethylene-vinyl alcohol copolymer, polyacetal, nylon 6, nylon 66, nylon 610, nylon 612, and nylon. 11 and nylon 12 (polyamide), polyester, polysulfone, polytetrafluoroethylene and other fluororesins. Examples of the metal material include aluminum alloy, stainless steel, and brass. Also, as the material of the lower mold 12, the upper mold 16 and the middle mold 18 described later, any of the various materials exemplified for the lower mold 12 can be adopted. In particular, the lower mold 12, the upper mold 16, and the middle mold 18 are made of materials that are not easily affected by the polymerizable monomer 22 and that have excellent releasability when the intraocular lens 28, which is a molded product, is taken out after polymerization molding. It is desirable to do. Specific examples include nylon (polyamide) and polymethylpentene.

  Further, as shown in FIG. 6, the mold plate 14 has a thin and substantially disk shape as a whole. A molding hole 50 having a shape corresponding to the outer peripheral shape of the optical portion 24 and the support portion 26 of the target intraocular lens 28 is formed in the center portion of the mold plate 14 so as to penetrate in the plate thickness direction. Further, around the molding hole 50, the cutout hole 56 penetrates in the plate thickness direction, leaving the rim portion 52 constituting the outer peripheral wall portion of the molding hole 50 and the outer peripheral edge portion 54 of the mold plate 14. Is formed. Further, the rim portion 52 is integrally formed with a pair of connecting portions 58, 58 that extend outward in one radial direction across the central axis and reach the annular outer peripheral edge portion 54. Yes. Thereby, the cutout hole 56 is divided into two by the connecting portions 58, 58, and the mold plate 14 penetrates in the thickness direction on the outer peripheral side of the molding hole 50 and is independent from the molding hole 50. A pair of openings are formed.

The thickness dimension of the mold plate 14, the height of the peripheral wall inner surface 44 of the bottom side of the fitting recess 40 of the lower die 12: is reduced by a predetermined amount than h _1. Further, the outer diameter dimension of the mold plate 14, in other words, the outer diameter dimension of the outer peripheral edge portion 54 is slightly smaller than the inner diameter dimension of the peripheral wall inner surface 44 on the bottom side.

  Furthermore, the rim portion 52 in the mold plate 14 continuously extends over the entire circumference with a planar shape corresponding to the outer shape of the intraocular lens 28. In particular, in the present embodiment, the rim portion 52 is substantially constant over the entire circumference. The cross-sectional shape is as follows. Further, the upper end surface and the lower end surface of the rim portion 52 are gradually increased from the outer peripheral edge portion to the inner peripheral edge portion of the rim portion 52 as shown in FIGS. It is made into the taper shape inclined so that it may protrude toward the direction. That is, the upper end surface and the lower end surface of the rim portion 52 are inclined at a predetermined inclination angle: α with respect to the horizontal plane. Thereby, the opening edge part of the both sides of the plate | board thickness direction in the shaping | molding hole 50 of the type | mold plate 14 is comprised including the inner peripheral edge part of the rim | limb part 52 made into the acute-edged edge-shaped cross-sectional shape, The inner peripheral edge of the rim 52 is pressed against the opposing surface of the lower mold 12 and the opposing surface of the middle mold 18 during polymerization molding.

  The inclination angle α is not particularly limited, but is preferably 1 to 10 °, more preferably 2 to 8 °. When the inclination angle α is smaller than 1 °, the upper end surface of the rim portion 52 bites into the lower surface of the middle die 18 and the lower end surface of the rim portion 52 bites into the bottom surface of the lower die 12 when the mold is aligned later. However, it is difficult to effectively realize each, and there is a possibility that burrs or the like may occur in the molded product. On the other hand, when the inclination angle α is larger than 10 °, it is difficult to ensure the shape stability of the rim portion 52 during mold matching. This is because molding defects such as distortion and sink marks may occur in the molded product. The width dimension w of the rim portion 52 is not specified, but is preferably set to 0.2 to 1.0 mm, more preferably 0.4 to 0.6 mm. When the width dimension of the rim portion 52: w is smaller than 0.2 mm, the shape is difficult to be maintained due to polymerization shrinkage of the polymerizable monomer 22, while when the width dimension is larger than 1.0 mm, the inner liquid reservoir 60 is later described. This is because the supply of the polymerizable monomer 22 to the molding cavity 20 becomes insufficient, and molding defects such as sink marks are difficult to avoid.

  Note that the mold plate 14 of the present embodiment is not limited to the rim portion 52 as shown in FIGS. 7 to 8, and for example, as shown in FIG. 9, the molding hole 50 of the rim portion 52. A flat pressure contact surface having a predetermined width: b may be formed at the sharp edge-shaped apex portion formed on the side edge portion.

  Further, although not explicitly shown in the drawing, the inner peripheral surface of the molding hole 50 in the mold plate 14 is a rough surface or a ground glass-like rough surface as required, and at least the lower mold 12 and The surface of the middle mold 18 is rougher than the optical part molding surfaces 36, 68 and the like.

  Further, as shown in FIG. 10, the upper die 16 has a large-diameter, generally cylindrical shape, and has an annular-shaped ridge that extends radially outward at the upper end in the axial direction. The part 64 is integrally formed. Further, in the present embodiment, the central hole provided in the central portion of the upper mold 16 serves as a guide hole 66 and opens at both axial ends of the upper mold 16. Furthermore, the outer diameter of the upper mold 16 is slightly smaller than the inner diameter of the inner peripheral wall 46 on the opening side in the fitting recess 40 of the lower mold 12. In other words, the outer diameter dimension of the upper mold 16 is larger than the outer diameter dimension of the mold plate 14 by a predetermined amount (2 × m), and is locked by the step portion 42 to the bottom side of the fitting recess 40. The inner wall 44 of the peripheral wall is not allowed to enter.

  Further, as shown in FIG. 11, the middle mold 18 has a small-diameter thick disk shape, and a slightly concave optical part molding surface 68 is formed at the center of the lower surface. Yes. The optical part molding surface 68 has a concave shape corresponding to the other surface 70 of the optical part 24 in the target intraocular lens 28, for example, a substantially spherical concave shape. The outer diameter of the middle mold 18 is slightly smaller than the inner diameter of the guide hole 66 of the upper mold 16.

  Further, the lower surface of the middle mold 18 is provided with a tapered lower surface 72 that is gradually inclined downward in the axial direction as it goes from the outer peripheral edge of the optical part molding surface 68 formed in the central portion to the outer peripheral side. As shown in FIG. 12 in an enlarged manner, the tapered lower surface 72 is inclined at a predetermined inclination angle: β with respect to the horizontal plane, and has a tapered shape. Further, the inner peripheral edge portion of the tapered lower surface 72 is connected to the outer peripheral edge portion of the optical part forming surface 68, and the outer peripheral edge portion of the tapered lower surface 72 is an intermediate portion in the width direction of the lower surface of the middle die 18, particularly in the present embodiment. In the form, it is located near the outer peripheral edge. Furthermore, the lower surface of the middle die 18 is provided with a reverse tapered lower surface 74 that is gradually inclined upward in the axial direction toward the outer peripheral side in a region extending from the outer peripheral edge to the outer peripheral edge of the tapered lower surface 72. Yes. The reverse tapered lower surface 74 has a reverse tapered shape that is inclined upward at a predetermined inclination angle: γ with respect to the horizontal plane.

  The inclination angle β of the tapered lower surface 72 is not particularly limited, but is preferably set to 0.5 to 2 °, more preferably 1 to 1.5 °. When the lid is inclined and the inclination angle β is smaller than 0.5 °, depending on the molding material, conditions, etc., the edge is not cut off at the front end side of the support portions 26 and 26 positioned at the center portion of the middle mold 18. On the other hand, if the inclination angle β is greater than 2 °, depending on the molding material, conditions, etc., the base end side of the support portions 26, 26 positioned on the outer peripheral portion of the middle mold 18 or This is because the optical unit 24 may not be cut at the edge and may cause molding defects such as burrs. On the other hand, the inclination angle γ of the reverse tapered lower surface 74 is not particularly limited, but is preferably set to γ ≦ 2 °. When the cover is inclined and the inclination angle α exceeds 2 °, the reverse tapered lower surface 74 serves as a guide surface when aligning the mold, and the polymerizable monomer is placed in the gap between the outer peripheral surface of the middle mold 18 and the guide hole 66 of the upper mold 16. This is because it may be easy to enter. However, such β and γ are set to 0 °, and the tapered lower surface 72 and the reverse tapered lower surface 74 are formed with flat surfaces extending in the direction perpendicular to the axis over the whole, or β> 0 and γ = 0 °. A mode in which only the reverse tapered lower surface 74 is a flat surface extending in the direction perpendicular to the axis, or the width of the reverse tapered lower surface 74 is set to 0, and the tapered lower surface 72 extends to the outer peripheral edge of the lower surface of the middle die 18. Formed forms can also be employed in the present invention.

Further, although the width dimension B of the tapered lower surface 72 is not limited, the outer peripheral edge of the tapered lower surface 72 is positioned on the outer peripheral side with respect to the projecting tip of the support portion 26 of the target intraocular lens 28. Will be set to. Accordingly, when the maximum dimension in the projecting direction of the support portions 26 and 26 of the target intraocular lens 28 is L (see FIG. 6) and the outer diameter dimension of the optical portion 24 is D (see FIG. 6), such a tapered shape. The width dimension B of the lower surface 72 is set so as to satisfy the following expression.
B ≧ (LD) / 2
Specifically, in general, the maximum dimension of the intraocular lens 28: the value of L is 12.0 to 13.0 mm, and the outer diameter dimension of the optical unit 24: the value of D is 5.5 to 6.0 mm. Therefore, within that limit, the width dimension B of the tapered lower surface 72 is set to B ≧ 3.0 mm.

For the mold plate 14, the upper mold 16, and the middle mold 18, various synthetic resin materials, for example, in addition to the metal material and the glass material are appropriately employed as in the lower mold 12 described above. Therefore, in the present embodiment, the lower mold 12, the upper mold 16, and the middle mold 18 are composed of nylon (polyamide) such as nylon 6, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, or polymethylpentene. while being formed of a resin material, the mold plate 14, than the lower mold 12 and medium 18 are formed of a hard material, such as polypropylene, a metal material such as a synthetic resin material or an aluminum alloy such as polyethylene What is formed is adopted. The lower mold 12, the mold plate 14, the upper mold 16, and the middle mold 18 are formed by injection molding or cutting from a polymer block in the case of a synthetic resin material, and press processing in the case of a metal material. Or the like.

  The mold plate 14 is fitted into the inner peripheral surface 44 on the bottom side of the fitting recess 40 of the lower mold 12 so that the mold is matched. When the mold plate 14 is fitted in the fitting recess 40 of the lower mold 12, the outer peripheral edge 54 of the mold plate 14 substantially abuts over the entire circumference of the peripheral wall inner surface 44 on the bottom side. Thus, the central portion of the molding hole 50 having a shape corresponding to the outer peripheral shape of the optical part 24 of the target intraocular lens 28 is on the same central axis as the optical part molding surface 36 of the lower mold 12. It is arranged on the bottom surface of the fitting recess 40 so as to be positioned. As is clear from this, in the present embodiment, the outer peripheral abutting portion positioned on the bottom surface of the fitting recess 40 by being brought into contact with the inner peripheral surface of the fitting recess 40 of the lower mold 12 is: The outer peripheral edge portion 54 of the mold plate 14 is configured.

  Further, the lower end portion of the upper die 16 is fitted into the peripheral wall inner surface 46 on the opening side of the fitting recess 40 from the recess 34 of the lower die 12 and is locked to the step portion 42 of the fitting recess 40. .

  Further, the middle mold 18 is fitted into the guide hole 66 of the upper mold 16 so as to be matched with the lower mold 12 and the like. In particular, in the present embodiment, at the time of such assembly, the inner peripheral surface of the guide hole 66 and the outer peripheral surface of the middle mold 18 are so small that the polymerizable monomer 22 does not enter at least at the lower edge of the upper middle molds 16 and 18. They are fitted in such a state that they are substantially in close contact with each other and allow relative displacement in the axial direction. In this assembled state, the outer peripheral edge of the lower surface of the middle mold 18 and the lower end surface of the upper mold 16 are substantially flush.

  Thereby, as shown in FIG. 1, die matching using the lower die 12, the die plate 14, the upper die 16 and the middle die 18 according to the present embodiment is realized. In such a mold-matching state, the opening of the inner peripheral wall 44 on the bottom side of the fitting recess 40 is covered with the upper mold 16 and the middle mold 18, and is thus superimposed on the bottom surface of the fitting recess 40. A communication gap 76 having a substantially disk shape in a plan view is formed between the upper surface of the mold plate 14 and the lower surface of the upper mold 16 and the lower surface of the middle mold 18.

  Further, the middle die 18 is fitted into the guide hole 66 of the upper die 16 in a form in which the lower end surface of the upper die 16 and the lower end surface of the middle die 18 are substantially flush with each other, and the lower end of the outer periphery of the upper die 16 is the lower die. In the state of being fitted in the 12 fitting recesses 40, there is a gap between the upper surface of the mold plate 14 placed on the bottom surface of the fitting recess 40 of the lower mold 12 and the lower surface of the upper mold 16 and the lower surface of the middle mold 18. A communication gap 76 is formed over substantially the whole. Furthermore, the optical part molding surface 68 formed at the center of the lower surface of the middle mold 18 is positioned on the same central axis as the optical part molding surface 36 of the lower mold 12 and the central part of the molding hole 50 in the mold plate 14. The optical part molding surface 36 is opposed to the optical part molding surface 36 with a predetermined distance.

  Further, under the mold-matched state, on the inner peripheral side of the rim portion 52 of the mold plate 14, there is an outer peripheral wall surface between the opposing surfaces of the optical part molding surface 68 of the middle mold 18 and the optical part molding surface 36 of the lower mold 12. Is formed on the inner peripheral surface of the molding hole 50. On the other hand, on the outer peripheral side of the rim portion 52, the outer peripheral wall surface is the inner periphery of the outer peripheral edge portion 54 between the opposing surfaces of the bottom surface of the fitting recess 40 of the lower die 12 and the lower end surfaces of the middle die 18 and the upper die 16. An internal liquid reservoir 60 formed on the surface is formed. When the intraocular lens 28 is molded, the molding cavity 20 is not only filled with the polymerizable monomer 22 for molding, but the internal liquid reservoir 60 is also filled. Excess polymerizable monomer 22 is filled. Further, the internal liquid reservoir 60 of the mold plate 14 is communicated with the molding cavity 20 through a communication gap 76.

  Furthermore, in the above-described mold alignment state, the excess polymerizable monomer 22 is accommodated in the recess 34 of the lower mold 12 at the outer peripheral side of the upper mold 16 fitted in the fitting recess 40 during molding. The external liquid reservoir 78 is formed in an annular shape over substantially the entire circumferential direction. Further, in the present embodiment, although not clearly shown in the drawing, there is a minute gap between the overlapping surfaces of the lower peripheral edge of the upper die 16 and the stepped portion 42 of the lower die 12 in the fitting recess 40. The external liquid reservoir 78 is communicated with the communication gap 76 and the molding cavity 20 through the gap. In order to positively form a communication gap, for example, the lower end outer peripheral portion of the upper mold 16 fitted to each other, the stepped portion 42 of the fitting recess 40 of the lower mold 12 and the inner surface 46 of the peripheral wall, You may provide a ditch | groove etc. in at least one of them.

  Next, a specific example of the manufacturing method according to the present invention of the intraocular lens 28 using the molding die 10 having the above-described structure will be described, but the present invention is not limited to such a specific example.

  First, as shown in FIG. 13, the mold plate 14 is fitted into the fitting recess 40 of the lower mold 12, and the outer peripheral edge 54 abuts against the inner surface 44 of the peripheral wall on the bottom side of the fitting recess 40. Then, the positioning is superimposed on the bottom surface of the fitting recess 40 by positioning.

  Thereafter, or before the mold plate 14 is fitted, a predetermined amount of the polymerizable monomer 22 is supplied and injected into the fitting recess 40 of the lower mold 12 through an injection pipe or the like (not shown). This polymerizable monomer 22 is not only between the facing surface of the optical part molding surface 36 of the lower mold 12 and the lower surface of the mold plate 14 or the molding cavity 20 in the mold plate 14 but also to an internal liquid reservoir 60 and a communication gap 76 described later. The supply amount is set so as to be filled.

  As the polymerizable monomer 22, various known liquid monomer compositions used as a molding material for the target intraocular lens 28 are appropriately employed. For example, generally used conventionally. In addition to a compound in which one or two or more kinds of radically polymerizable compounds that are used are blended, a compound composed of a macromer or a prepolymer may be used. In particular, in this embodiment, an acrylic resin material can be advantageously employed for the polymerizable monomer 22. It should be noted that such an acrylic resin material may have an appropriate crosslinking agent or polymerization initiator such as a thermal polymerization initiator, a photopolymerization initiator, a sensitizer, a dye, an ultraviolet absorber, or the like, if necessary. An auxiliary agent is blended to form a liquid monomer composition.

  Next, as shown in FIG. 14, the upper die 16 in which the middle die 18 is fitted into the guide hole 66 as described above, with the lowermost end surfaces of both the die 18 and 16 being substantially flush with each other, The lower mold 12 is fitted from above, and the outer peripheral portion of the upper mold 16 is fitted into the fitting recess 40 of the lower mold 12. And the lower end outer peripheral part of the upper mold | type 16 is latched by the level | step-difference part 42 of the fitting recessed part 40, and is hold | maintained. It should be noted that an appropriate mold closing load may be applied from the outside between the lower mold 12 and the upper mold 16 in the axial direction during such mold matching. In this embodiment, the lower mold 12, the mold plate 14, the upper mold 16, and the middle mold 18 have respective central axes by fitting the lower end outer circumferential surface of the upper mold 16 into the peripheral wall inner surface 46 on the opening side of the lower mold 12. Are substantially matched and are kept in the matched state. Also from this, it is clear that the optical axis of the one surface 38 of the target optical unit 24 and the optical axis of the other surface 70 are aligned when matching the mold. In this embodiment, the mold closing force is applied between the upper mold 16 and the lower mold 12. However, in some cases, the mold closing force may be applied between the middle mold 18 and the lower mold 12. good.

The height dimension of the bottom side of the inner surface of the peripheral wall 44 of the fitting recess 40: The dimensions of substantially corresponding linking gap 76 to a value obtained by subtracting the thickness of the h ₁ type plate 14, although not particularly limited , Preferably 0.03 to 0.2 mm, more preferably 0.07 to 0.1 mm. When the height dimension of the communication gap 76 is shorter than 0.03 mm, sink marks, voids, etc. are formed on the intraocular lens 28 that has been polymerized without being sufficiently replenished with the polymerization monomer 22 to the molding cavity 20. However, when the thickness is larger than 0.2 mm, the edge of the molding cavity 20 is cut between the rim portion 52 of the mold plate 14 and the lower surface of the middle mold 18. This is because there is a risk that molding defects such as burrs may occur.

  As described above, by aligning the lower mold 12, the mold plate 14, the upper mold 16, and the middle mold 18, polymerization is performed between the opposed surfaces of the bottom surface of the lower mold 12, the lower surface of the middle mold 18, and the lower surface of the upper mold 16. The molding cavity 20 filled with the conductive monomer 22, the internal liquid reservoir 60, and the communication gap 76 are respectively formed. The excess polymerizable monomer 22 remaining after filling the molding cavity 20, the internal liquid reservoir 60, and the communication gap 76 is led to and stored in the external liquid reservoir 78, and is transferred from the molding die 10 to the outside. Spilling out is avoided (see FIG. 15).

  Thereafter, the lower mold 12, the mold plate 14, the upper mold 16, and the middle mold 18 are held in a matched state, and the polymerizable monomer 22 is subjected to polymerization treatment. In this polymerization process, a predetermined clamping force may be applied between the upper mold 16 and the lower mold 12 or between the middle mold 18 and the lower mold 12. Moreover, as a polymerization process, according to the polymerizable monomer 22 to be employed, a thermal polymerization process using an oven or a dryer, a photopolymerization process for irradiating electromagnetic waves such as microwaves, ultraviolet rays, γ rays, etc. Is appropriately adopted. Thermal polymerization conditions vary depending on the type of polymerizable monomer 22 employed and the like, and are not limited, but are generally 60 to 100 ° C. and 20 to 60 minutes. In addition, the polymerizable monomer 22 may be blended with a thermal polymerization initiator, a photopolymerization initiator, a sensitizer, a dye, an ultraviolet absorber, and the like as necessary.

  In such polymerization molding, the molding cavity 20 is formed in the external space even if a minute gap allowing a slight flow of the polymerizable monomer 22 is formed at the fitting portion of the upper mold 16 and the lower mold 12. It is maintained in a substantially sealed state. Therefore, when polymerization shrinkage occurs in the polymerizable monomer as the polymerization proceeds, a negative pressure is generated in the molding cavity 20, and this negative pressure approaches the opposing surfaces of the lower mold 12 and the middle mold 18. It is made to act in the direction to do. As a result, the middle mold 18 is displaced toward the mold plate 14 side, and the excess polymerizable monomer 22 filled in the external liquid reservoir 78 provided on the outer peripheral side of the upper mold 16 is moved into the fitting recess 40. A small gap between the overlapping surfaces of the upper mold 16 and the lower mold 12 is supplied to the internal liquid reservoir 60 and the molding cavity 20 in the mold plate 14 through the communication gap 76. Further, the polymerizable monomer 22 filled in the internal liquid reservoir 60 is introduced into the molding cavity 20 through the communication gap 76.

  In general, the polymerization of the polymerizable monomer 22 proceeds from the central portion of the molding cavity 20 during the polymerization molding, and the flow of the polymerizable monomer 22 for replenishing the polymerization shrinkage accompanying this proceeds from the outer peripheral portion to the central portion. It is thought to be born. Further, since the flow of the polymerizable monomer 22 is not sufficiently rapid to eliminate the negative pressure accompanying the polymerization shrinkage, a portion corresponding to the negative pressure that is not eliminated exerts as a mold clamping force between the lower mold 12 and the middle mold 18. Will be.

  Then, when the lower mold 12 and the middle mold 18 are clamped by the mold clamping force due to the negative pressure, the middle mold 18 is displaced toward the lower mold 12 as shown in FIG. The bottom peripheral portion is brought into contact with the mold plate 14, and then the mold clamping force due to the negative pressure is further increased, so that the middle mold 18 is deformed by a predetermined amount as shown in FIG. The middle die 18 is brought into contact with the entire periphery of the rim portion 52 formed on the die plate 14 not only at the outer peripheral portion but also at the central portion. In particular, in this embodiment, the inner peripheral edge of the rim 52 of the mold plate 14 has an edge shape, so that the mold clamping force is in contact with the inner peripheral edge of the rim 52 and the middle mold 18 and the lower mold 12. Intimately acting, the close state is advantageously expressed. Further, in this embodiment, the lower surface of the middle mold 18 that is brought into contact with the rim portion 52 of the mold plate 14 is the tapered lower surface 72 and the reverse tapered lower surface 74, so that the guide hole 66 of the upper mold 16 is used. The lower surface of the middle die 18 is stably brought into contact with the rim portion 52 of the die plate 14 in any region of the outer peripheral portion whose rigidity is increased by being supported and the central portion that is easily deformed. Thus, the edge cutting (division) at the outer peripheral edge of the molding cavity 20 can be performed satisfactorily.

  In this embodiment, the inner peripheral portion of the internal liquid reservoir 60 is formed between the opposing surfaces of the lower mold 12 and the middle mold 18, but the outer peripheral portion of the internal liquid reservoir 60 is the lower mold 12 and the upper mold 16. Are formed to extend to between the opposing surfaces. Therefore, even when the lower surface of the middle mold 18 is in close contact with the mold plate 14, the outer peripheral portion of the internal liquid reservoir 60 is a communication gap formed between the opposed surfaces of the upper mold 16 and the mold plate 14. The connection state to the external liquid reservoir 78 is maintained.

  Then, after the polymerization of the polymerizable monomer 22 in the molding cavity 20 is completed, the lower mold 12, the upper mold 16, and the middle mold 18 are opened. Thereafter, the mold plate 14 opened in a state of being attached to the lower mold 12 or the upper mold 16 is released from the lower mold 12 or the upper mold 16. The mold plate 14 is generally attached to the lower mold 12 and opened because the contact area is large, but the upper and lower molds 16 and 12 and the middle mold 18 can be formed by appropriately setting the material and molding surface. It is also possible to open the mold with the mold plate 14 attached to the mold 16 or the middle mold 18.

  Thereafter, the molded product is removed from the mold plate 14 using a solvent such as ethanol, methanol, acetone, etc., so that the optical unit 24 and the support unit 26 which are molded products as shown in FIGS. The inner lens 28 is obtained.

  In the intraocular lens 28 thus obtained, the entire outer peripheral surface is produced by polymerization molding in a molding cavity 20 defined by a single mold plate 14, and therefore the middle mold 18 and the lower mold 12 are molded. Even when the relative positioning in the circumferential direction is not set with high accuracy when aligning, the entire outer peripheral surface shape including the optical portion 24 and the support portions 26 and 26 is the inner peripheral surface of the molding hole 50 of the mold plate 14. Thus, it can be stably molded with high accuracy. Therefore, mold matching can be easily performed, and occurrence of molding defects such as burrs can be effectively prevented, and the target intraocular lens 28 can be manufactured with high accuracy.

  In addition, the shape and size of the support portion 26 can be easily changed and set by exchanging only the mold plate 14. Therefore, for example, a plurality of types of intraocular lenses 28 provided with support portions 26 and 26 having different shapes and sizes with respect to the same optical unit 24 are used while the upper, middle, and lower molds 16, 18 and 12 are left as they are. By changing only the plate 14, it is possible to prepare a small number of types of molds and efficiently manufacture a large number of types of intraocular lenses 28.

  In the present embodiment, when the polymerizable monomer 22 is polymerized and molded in the molding cavity 20, the negative pressure resulting from the polymerization shrinkage is caused by the displacement of the middle mold 18 toward the lower mold 12 and the molding cavity 20 of the polymerizable monomer 22. Therefore, it is possible to prevent molding defects such as sink marks and voids in the molded product, and to obtain the intraocular lens 28 of good quality more stably.

  In particular, in the present embodiment, the rigidity of the middle mold 18 and the lower mold 12 is made smaller than the rigidity of the mold plate 14, and the inner peripheral edge of the rim portion 52 of the mold plate 14 has an edge shape. In the polymerization molding, the inner peripheral edge portion of the rim portion 52 is brought into close contact with the cavity forming surface of the lower die 12 and the middle die 18. In addition, in this embodiment, the lower surfaces 72 and 74 of the intermediate mold 18 are tapered or reverse tapered inclined surfaces, so that the entire circumference of the rim portion 52 is relative to the lower surfaces 72 and 74 of the intermediate mold 18. Thus, the contact can be made more stably. Thereby, the sealing property of the molding cavity 20 can be expressed more highly and stably, and molding defects such as burrs in the intraocular lens 28 as a molded product can be prevented more advantageously, and the molding accuracy can be further improved. Can be achieved.

  Furthermore, in the molding die 10 of the present embodiment, not only the external liquid reservoir 78 but also the internal liquid reservoir 60 is formed at a position sufficiently close to the molding cavity 20, and can be stored. An internal liquid reservoir 60 that is relatively small in amount of the monomer 22 but close to the molding cavity 20 and an external liquid reservoir 78 that is separated from the molding cavity 20 but can store a sufficient amount of polymerizable monomer communicate with each other. The excess monomer reservoir of the molding cavity 20 is formed in an extremely efficient manner by communicating with each other in the gap 76 and working together, thereby allowing the molding cavity 20 to be subjected to polymerization molding with respect to the molding cavity 20. The replenishment of the polymerizable monomer 22 can be realized effectively and stably.

  In the present embodiment, among the molding surfaces of the optical part 24 of the intraocular lens 28, the optical part molding surface 36 and the middle mold 18 of the lower mold 12 for molding the optical surfaces 38 and 70 on both sides in the axial direction of the optical part 24. Compared to the optical part molding surface 68, the inner peripheral surface of the central circular part in the molding hole 50 of the mold plate 14 for molding the outer peripheral surface 79 of the optical part 24 is a rough surface. Thereby, in the optical part 24 of the obtained intraocular lens 28, generation | occurrence | production of a glare can be suppressed, ensuring the favorable optical characteristic in the optical surfaces 38 and 70. FIG.

  As mentioned above, although one embodiment of the present invention has been described in detail, this is merely an example, and the present invention is not limited to any specific description by this embodiment, and is based on the knowledge of those skilled in the art. The present invention can be implemented with various changes, modifications, improvements, etc., and all such embodiments are within the scope of the present invention without departing from the spirit of the present invention. Needless to say, there is.

  For example, the optical part molding surface 68 provided on the middle mold 18 and the optical part molding surface 36 provided on the lower mold 12 are specifically limited to be either the front surface or the rear surface of the target optical unit 24, respectively. Not a thing. Therefore, in the above-described embodiment, for example, an optical part molding surface having a fixed shape is formed on the lower mold 12, while different optical part molding surfaces are provided corresponding to different optical characteristics required for each intraocular lens 28. By preparing a plurality of types of formed middle molds 18, the lower mold 12 and the upper mold 16 are shared, and by replacing only the middle mold 18, a plurality of types having an optical unit 24 having different optical characteristics and shapes. It is possible to cope with the molding of the intraocular lens 28.

  In the above embodiment, for example, one or more fitting protrusions projecting toward the mold plate 14 are provided on the outer peripheral edge of the lower mold 12 and the outer peripheral edge of the middle mold 18, respectively. By providing fitting holes of a shape, size, and number corresponding to the protrusions in the mold plate 14 and fitting the fitting protrusions into the fitting holes, the middle mold 18 and the lower mold 12 are attached to the mold plate 14. In addition, it is possible to provide circumferential positioning means for relatively positioning in the circumferential direction.

  Furthermore, in the above-described embodiment, the guide hole 66 is formed so as to penetrate the upper mold 16 in the axial direction, but a guide hole that opens at a predetermined depth toward the mold plate 14 side may be adopted. Alternatively, a through hole for venting air may be formed in the upper bottom portion while adopting such a guide hole.

  Furthermore, by providing the guide hole 66 according to the above-described embodiment with a protruding portion or a step portion protruding radially inward, the displacement in the direction away from or approaching the mold plate 14 of the middle mold 18 is limited. Is also possible, thereby allowing the middle mold 18 and the upper mold 16 to be integrally handled.

  Further, as another aspect of the present invention, for example, a molding die in which the middle die 18 and the upper die 16 are integrally formed with the lower peripheral edge of the middle die 18 being substantially flush with the lower end portion of the upper die 16 is prepared. A pair of molds may be configured by the mold and the lower mold 12. Thus, the mold cavity 20 is defined by overlapping the pair of molds on the mold plate 14 from both sides in the thickness direction and covering the mold holes 50 of the mold plate 14 from both sides. It is also possible to employ a method for manufacturing the intraocular lens 28.

  Furthermore, the mold plate 14 shown in the above embodiment is not limited to the shape, size, structure and the like as illustrated, and for example, various mold plates 80 and 82 shown in FIGS. , 84, 86, 88 can also be adopted. In the following description, members and parts having substantially the same structure as those of the above embodiment are denoted by the same reference numerals as those of the above embodiment in the drawings, and detailed description thereof is omitted. . Moreover, since each type | mold plate 80,82,84,86,88 shown by FIGS. 18-22 is employ | adopted similarly to the said embodiment, and is used for shaping | molding of an intraocular lens. The illustration and description of the method of use and the overall structure of the mold using the method are omitted.

  That is, the mold plate 80 as another embodiment shown in FIG. 18 has a thin and substantially disk shape, and the outer peripheral shape of the optical part and the support part of the target intraocular lens at the center part thereof. Only the molding hole 50 having a shape corresponding to the above-described shape is provided, and the cutout hole (56) in the above-described embodiment is not formed. In addition, a mold plate 82 as another embodiment shown in FIG. 19 has a rim portion 52 that forms the outer peripheral wall portion of the molding hole 50 having a wide shape. Arc-shaped surfaces in which the outer peripheral surfaces 83 of the forming portions of the pair of support portions protruding outward are overlapped and positioned on the peripheral wall inner surface (44) on the bottom side of the fitting recess (40) of the lower mold (12). It is said that. Further, in the mold plate 84 as another embodiment shown in FIG. 20, the rim portion 52 that constitutes the outer peripheral wall portion of the molding hole 50 has a pair of support portions that protrude most outward. An arcuate portion 85 is integrally formed with each outer peripheral portion of the forming portion so as to be superimposed and positioned on the inner surface (44) of the peripheral wall on the bottom side of the fitting recess (40) of the lower mold (12). In addition, the mold plate 86 shown in FIG. 21 is cut off at an annular outer peripheral edge portion (54) of the mold plate (14) of the above embodiment at a portion opposed in one radial direction. The pair of outer peripheral edge portions 54a and 54a are integrally connected to the formation portion of the optical portion in the rim portion 52 by a pair of connecting portions 87 and 87. Furthermore, in the mold plate 88 shown in FIG. 22 as well, the annular outer peripheral edge (54) of the mold plate (14) of the above embodiment is cut off at a portion facing in one radial direction. The paired outer peripheral edge portions 54b and 54b are integrally formed by being connected to the forming portion of each support portion in the rim portion 52 by a pair of connecting portions 89 and 89.

  Hereinafter, the results of manufacturing an intraocular lens according to the method of the present invention by actually producing a molding die having the same structure as the embodiment and using them will be described as examples. Needless to say, the description of these examples is not intended to be construed as limiting.

  First, by cutting a polymer block made of polymethylpentene, the upper die 16, the middle die 18 and the lower die 12 as shown in the embodiment are formed, respectively, and the die plate 84 shown in FIG. Formed.

  In the same manner as in the above embodiment, after the mold plate 84 is fitted into the fitting recess 40 of the lower mold 12, a predetermined amount of the polymerizable monomer 22 is supplied to the fitting recess 40, and then the middle hole is inserted into the guide hole 66. The lower end portion of the upper mold 16 in which 18 is inserted so as to be displaceable is fitted into the inner surface 46 of the peripheral wall on the opening side of the fitting recess 40 and locked by the step portion 42. As a result, a mold for molding an intraocular lens that has been subjected to mold matching is obtained. In the molding die that has been matched in this way, not only the molding cavity 20 but also the internal liquid reservoir 60 is filled with the polymerizable monomer 22, and the excess polymerizable monomer 22 contains the communication gap 76. It is assumed that it is housed in

  Thereafter, the molding die was placed in a constant temperature dryer at 80 ° C. and allowed to stand for 40 minutes to polymerize the polymerizable monomer 22 in the molding cavity 20. Further, after the polymerization molding was completed, the mold was opened in the same manner as in the above embodiment, and the mold plate 84 was released in a state where the molded product was attached to the molding hole 50. Furthermore, the target intraocular lens 28 was obtained by removing the molded product from the mold plate 84 using a solvent.

  The results of observing the intraocular lens 28 thus obtained are shown below.

The composition of the polymerizable monomer used in this example is as follows.
Phenoxyethyl acrylate: 70 parts by weight Ethyl acrylate: 30 parts by weight 2-hydroxyethyl methacrylate: 20 parts by weight Butanediol diacrylate: 4 parts by weight 2,2′-azobis (2,4-dimethylvaleronitrile): 0.83 parts by weight Part

  The intraocular lens obtained in this example has a good surface shape corresponding to the outer peripheral shape of the molding hole 50, the shape of the optical part molding surface 36 of the lower mold 12 and the shape of the optical part molding surface 68 of the middle mold 18. confirmed. Further, it was confirmed that a rough surface (not shown) formed on the inner peripheral surface of the molding hole 50 was well transferred to the side surfaces of the optical portion 24 and the support portion 26 of the intraocular lens. Further, the generation of burrs was not observed not only in the optical part 24 but also in the pair of support parts 26 and 26. Furthermore, it was confirmed that such an intraocular lens satisfies a value required for optical characteristics such as refractive power, and there is no characteristic defect due to residual stress or the like.

It is a longitudinal cross-sectional explanatory drawing which shows the shaping | molding die of the intraocular lens as one Embodiment of this invention. FIG. 2 is an explanatory plan view showing a target intraocular lens molded using the molding die in FIG. 1. FIG. 3 is a sectional view taken along line III-III in FIG. 2. FIG. 2 is an explanatory plan view showing a lower mold that constitutes a part of the molding die in FIG. 1. FIG. 2 is a longitudinal cross-sectional explanatory view showing an enlarged main part of the lower mold in FIG. 1. FIG. 2 is an explanatory plan view showing a mold plate constituting a part of the molding die in FIG. 1. It is a longitudinal cross-sectional explanatory drawing which expands and shows the VII-VII cross section in FIG. It is longitudinal cross-sectional explanatory drawing which expands and shows the VIII-VIII cross section in FIG. FIG. 8 is a longitudinal cross-sectional explanatory view showing an enlarged main part of a mold plate as another specific example of the present invention, corresponding to FIG. 7. FIG. 2 is an explanatory plan view showing an upper die constituting a part of the molding die in FIG. 1. FIG. 2 is an explanatory plan view showing a middle die that constitutes a part of the molding die in FIG. 1. FIG. 2 is a longitudinal cross-sectional explanatory view showing an enlarged model of one main part of the middle mold in FIG. 1. It is a figure which shows one form as an example at the time of shape | molding an intraocular lens using the shaping | molding die in FIG. 1, Comprising: It is a XIII-XIII arrow line view of FIG. It is a longitudinal cross-sectional explanatory drawing which shows one form as a specific example at the time of shape | molding an intraocular lens using the shaping | molding die in FIG. FIG. 5 is an explanatory longitudinal cross-sectional view showing an enlarged form of another specific example when an intraocular lens is molded using the molding die in FIG. 1. FIG. 5 is an explanatory longitudinal cross-sectional view showing an enlarged form of still another specific example when an intraocular lens is molded using the molding die in FIG. 1. FIG. 5 is an explanatory longitudinal cross-sectional view showing an enlarged form of still another specific example when an intraocular lens is molded using the molding die in FIG. 1. It is plane explanatory drawing which shows the type | mold plate as another specific example of this invention. It is plane explanatory drawing which shows the type | mold plate as another specific example of this invention. It is plane explanatory drawing which shows the type | mold plate as another specific example of this invention. It is plane explanatory drawing which shows the type | mold plate as another specific example of this invention. It is plane explanatory drawing which shows the type | mold plate as another specific example of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Mold for intraocular lens 12 Lower mold 14 Mold plate 16 Upper mold 18 Middle mold 20 Molding cavity 24 Optical part 26 Support part 28 Intraocular lens 36 Optical part molding surface 38 One surface 40 of optical part Fitting recessed part 50 Molding Hole 66 guide hole 68 optical part molding surface 70 the other surface of the optical part

Claims (23)

A lower mold provided with an optical part molding surface for forming one surface of the optical part of the target intraocular lens at the center of the bottom surface of the fitting concave part.
A molding hole corresponding to the entire outer peripheral shape including the optical part and the support part of the target intraocular lens is penetrated in the center part, and has a substantially flat plate shape. A mold plate that fits into the mating recess and is superimposed on the bottom surface of the mating recess;
A guide hole that opens toward the mold plate is formed by being fitted into the fitting recess of the lower mold from above the mold plate, while being aligned with the lower mold. Upper mold,
The upper mold is slidably fitted into the guide hole of the upper mold, and the upper mold is superimposed on the upper surface of the mold plate so as to be displaceable in the approaching / separating direction in a state where the upper mold is fitted to the lower mold. And a middle mold provided with an optical part molding surface for forming the other surface of the optical part of the target intraocular lens at the center of the bottom surface superimposed on the mold plate. The entire mold cavity including the optical part and the support part of the target intraocular lens is formed so as to be defined by the mold plate between the opposed surfaces of the lower mold and the middle mold. A mold for molding an intraocular lens, characterized in that   A locking portion is formed on the inner surface of the outer peripheral wall of the fitting recess in the lower die, and the fitting die is locked by the locking portion in the mold matching direction with respect to the lower die. The mold for molding an intraocular lens according to claim 1, wherein a communication gap is formed between the upper surface of the mold plate superimposed on the bottom surface of the mold and the lower surface of the upper mold.   In the lower mold, an opening recess that spreads outward from the opening of the fitting recess is formed, and the upper mold is matched with the lower mold, and the inside of the opening recess 3. The intraocular lens molding device according to claim 1, wherein an external liquid reservoir for accommodating excess polymerizable monomer is formed on an outer peripheral side of the upper mold fitted in the fitting recess. 4. Type.   The inner peripheral surface of the guide hole of the upper mold and the outer peripheral surface of the middle mold are fitted in a substantially close state with a minute gap so that the polymerizable monomer does not enter at least at the edge portion on the mold plate side. The mold for molding an intraocular lens according to any one of claims 1 to 3, wherein the molds are combined.   In the mold plate, an opening that penetrates in the thickness direction on the outer peripheral side of the molding hole is formed independently from the molding hole, and the upper mold is matched with the lower mold, The intraocular lens according to any one of claims 1 to 4, wherein an internal liquid reservoir for accommodating excess polymerizable monomer is formed between the opposed surfaces of the lower mold and the middle mold in the opening. Mold for molding. The mold plate is
A rim portion extending in the circumferential direction on the outer peripheral wall portion of the molding hole;
An outer peripheral contact portion that is positioned on the bottom surface of the fitting recess by contacting the inner peripheral surface of the fitting recess of the lower mold;
The rim portion is formed to protrude from the rim portion toward the outer peripheral side, and is formed by a connecting portion that integrally connects the rim portion to the outer peripheral abutting portion. 6. The eye according to claim 5, wherein the molded cavity is formed on the inner peripheral side and the internal liquid reservoir is formed on the outer peripheral side with the rim portion interposed therebetween. Mold for molding inner lens.   In the mold plate, at least one opening edge in the thickness direction of the molding hole is formed as an acute edge-shaped cross-sectional shape, and the inner peripheral edge of the edge is opposed to the lower mold and / or the middle mold The mold for molding an intraocular lens according to any one of claims 1 to 6, wherein the mold is pressed against the mold.   The mold for molding an intraocular lens according to any one of claims 1 to 7, wherein an inner peripheral surface of the molding hole in the mold plate is rougher than at least molding surfaces of the lower mold and the middle mold.   9. The mold for molding an intraocular lens according to claim 1, wherein at least one of the lower mold and the middle mold forming the molding cavity is formed of a material having rigidity smaller than that of the mold plate.   On the bottom surface of the middle mold, an area extending further from the outer peripheral edge of the optical part molding surface to form the other surface of the optical part of the target intraocular lens is gradually increased toward the outer peripheral side. The mold for molding an intraocular lens according to any one of claims 1 to 9, wherein the mold is tapered so as to project toward the plate side.   On the bottom surface of the middle mold, the outer peripheral edge area outside the area forming the entire molding cavity including the optical part and the support part of the target intraocular lens is gradually separated from the mold plate side toward the outer peripheral side. The mold for molding an intraocular lens according to any one of claims 1 to 10, wherein the mold has an inversely tapered shape that is inclined in a straight line.   The lower mold is provided with a leg portion that is positioned at an outer peripheral edge portion thereof and projects downward, and is placed on a predetermined base by the leg portion, and the lower surface of the lower mold is placed on the fitting recess. The central portion located below the base is spaced apart from the base so that a space is formed below the bottom wall forming the fitting recess, and the bottom wall forming the fitting recess is formed. By projecting the central portion of the lower surface into the space corresponding to the molding surface of the molding cavity formed in the fitting recess, the wall thickness of the bottom wall forming the fitting recess is the molding. The mold for molding an intraocular lens according to any one of claims 1 to 11, wherein the mold is substantially constant over the entire molding surface of the cavity.   The eye according to any one of claims 1 to 12, further comprising circumferential positioning means for positioning at least one of the lower mold and the middle mold directly or indirectly relative to the mold plate in the circumferential direction. Mold for molding inner lens.   Using a mold plate in which a molding hole corresponding to the entire outer peripheral shape including the optical part and the support part of the target intraocular lens is penetrated, a pair of molding dies are inserted into the mold plate from both sides in the thickness direction. An intraocular lens in which a molding cavity is defined by overlapping and covering the molding hole from both sides, and a predetermined polymerizable monomer is polymerized and molded in the molding cavity so that a support part is integrally formed with the optical part. The manufacturing method of the intraocular lens characterized by obtaining.   The method for manufacturing an intraocular lens according to claim 14, wherein at the time of polymerization molding of the polymerizable monomer in the molding cavity, at least one of the pair of molding dies is displaced in an approaching direction with respect to the mold plate.   The method for producing an intraocular lens according to claim 14 or 15, comprising an acrylic monomer as the polymerizable monomer.   17. The polymer mold according to claim 14, wherein an inner peripheral edge portion of the molding hole in the mold plate is bitten into at least one of the pair of molds when the polymerizable monomer is polymerized in the molding cavity. Manufacturing method of an intraocular lens.   In the polymerization molding of the polymerizable monomer in the molding cavity, from the surplus polymerizable monomer reservoir provided outside the molding cavity, between the overlapping surfaces of the mold plate and at least one of the molding dies The method for producing an intraocular lens according to claim 14, wherein the polymerizable monomer is replenished through the molding cavity.   When opening the mold after polymerization molding of the polymerizable monomer, the molded product formed in the molding cavity is released from the pair of molds in a state of being attached to the mold plate, and then the mold plate removes the mold from the mold plate. The method for producing an intraocular lens according to any one of claims 14 to 18, wherein the molded product is removed from the mold.   The intraocular lens manufacturing method according to any one of claims 14 to 19, wherein a plurality of different types of intraocular lenses are formed by changing the mold plate by using the same one for at least one of the pair of molds. Method.   The intraocular lens according to any one of claims 14 to 19, wherein a plurality of different types of intraocular lenses are formed by using the same mold plate and changing at least one of the pair of molds. Method.   An intraocular lens in which a support part is integrally formed with an optical part by polymerizing and molding a polymerizable monomer in the molding cavity using the mold for molding an intraocular lens according to any one of claims 1 to 13. A method for producing an intraocular lens, comprising: obtaining an intraocular lens. An intraocular lens manufactured by the method for manufacturing an intraocular lens according to any one of claims 14 to 22, wherein a support portion is integrally formed with an optical portion.

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