RU2774572C1 - Method for making artificial eyes for robots and dolls - Google Patents

Abstract

FIELD: artificial eyes production.

SUBSTANCE: invention relates to the manufacture of artificial eyes for robots and dolls. A method for manufacturing artificial eyes includes forming an eyeball using a silicone mold, first a substrate for the iris of the eyeball is made from photographic paper by photo printing, an iris is formed on the substrate by applying drops of liquid aliphatic polyurethane, then it is dried, subjected to vacuum degassing and holding on a horizontal surface at room temperature, then the iris is placed deep into the silicone mold, and a portion of the liquid polymer mixture based on aliphatic polyurethane is poured over the iris, after degassing, the next portion of the liquid polymer mixture is added, an insert is placed into the silicone mold, forming imitation of the protein of the eyeball and thin sclera of the eye, then the entire structure is subjected to vacuum degassing, after which the workpiece is removed from the mold and placed in an oven, then cleaned of burr and polished.

EFFECT: invention can be used as training simulators for medical purposes.

2 cl, 2 dwg

Description

The invention relates to the manufacture of artificial eyes for robots and dolls, including those used as training simulators for medical purposes.

There are various methods for casting prostheses and eyeball simulators that are used in medicine and were intended only for people (RU 2612594, publ. 03/09/2017; RU 2649449, publ. 04/03/2018; RU 2683109, publ. 03/26/2019; RU 47694 , published on September 10, 2005).

However, for safety reasons, the resulting product must meet certain requirements, including the use of biologically inert expensive materials, and in the manufacturing process, individual selection and fitting are required, as well as hand-painting of the iris, which complicates and increases the cost of manufacturing artificial eyes.

There are also various methods for manufacturing artificial eyes for dolls, toy animals and stuffed animals (RU 9382, publ. 16.03.1999; RU 2179876, publ. 02.27.2002; RU 2164432, publ. 03.27.2001; KR102050171, publ. 11.28.2019; JP2012024382, published 02/09/2012; CN204319752, published 05/13/2015).

However, the known methods do not allow to obtain realistic artificial eyes with a three-dimensional effect, as close as possible to real ones.

Closest to the claimed is a method for manufacturing an ocular prosthesis for a person, which consists in forming the base by casting from polymethyl methacrylate (PMMA) painted in a light matte color, on the front of the base and the mating part of the coating, flat areas are made to image the iris, using a digital camera an image of the iris with the pupil, sclera and blood vessels of a healthy eye is obtained and the specified image is applied directly to the base by pad printing or piezo-jet UV curable printing (RU 2612594, publ. 03/09/2017).

The disadvantage of the known method is the complexity of manufacturing, the fragility of the product as a result of the use of rigid amorphous polymethyl methacrylate as a polymer, which has the property of cracking over time, as well as insufficient volume and realism of the eyeball.

The technical result is a simplification of the manufacturing method, an increase in the durability and realism of the resulting product.

The technical result is achieved by the fact that the method of manufacturing artificial eyes consists in the phased formation of the eyeball using a polymer-based material - aliphatic polyurethane Crystal clear 202 (https://www.smooth-on.com/products/crystal-clear-202/) , which is an optically transparent polyurethane with a hardness of SHOR D 80 and is intended for thin-walled casting, with a thickness of not more than 1.27 cm. Pot life 9 minutes, curing time 90 minutes. The viscosity of the mixture is 600 cP. The shrinkage is 3.175%, the refractive index is 1.49888. The material is used at 23 degrees Celsius. Two-component polymer, consisting of component A and component B, ratio A:B = 100A : 90B. Component A - 4,4'-methylenedicyclohexyl diisocyanate (CAS 5124-30-1). Component B - Phenylmercury neodecanoate (CAS 26545-49-3).

The formation of the eyeball is carried out using a silicone mold with a recess that repeats the outer contours of the eyeball and a metal insert to form the inner cavity of the eyeball.

At the same time, a substrate for the iris of the eyeball is preliminarily made by photoprinting, an iris is formed on the substrate by applying drops of liquid two-component aliphatic polyurethane, creating a lens effect, then the iris is dried, subjected to vacuum degassing and holding on a horizontal surface at room temperature.

Then the iris is placed deep into the silicone mold, and a portion of the liquid polymer mixture based on aliphatic polyurethane is poured over the iris, and after degassing, the next portion of the liquid polymer mixture is added. An insert is placed into the silicone mold, forming an imitation of the protein of the eyeball and thin sclera of the eye, then the entire structure is subjected to vacuum degassing, after which the blank is removed from the mold and placed in an oven, then it is cleaned of burr and polished.

It is known that aliphatic polyurethane is a polymeric material that does not have aromatic structures (https://ru.strephonsays.com/aliphatic-and-aromatic-polyurethane-2302). It is used as a coating in industry and construction, because. is durable and flexible and can be added to many products to give a durable finish. Most often, this material is used for sealants and coatings intended for outdoor use. However, its use for the manufacture of proteins in artificial eyeballs, including for dolls and robots, is not known from the prior art.

In addition, this material is highly resistant to water and UV rays, does not yellow when exposed to sunlight, has high tear strength, and is slow flowing, so it can be used as a thick film.

Using the method of photo printing to make a substrate on photographic paper for the iris of the eyeball and applying drops of liquid aliphatic polyurethane Crystal clear 202 allows you to form a convex iris with maximum reliability and realism.

The iris is placed deep into the silicone mold, and a liquid polymer mixture is poured over the iris in such an amount that the iris does not shine through, after degassing, the next portion of the liquid polymer mixture is added to form an imitation of the protein and sclera of the eyeball, placing the insert in the silicone mold. At the same time, an imitation of the protein of the eyeball and thin sclera of the eye was formed.

The entire structure is subjected to vacuum degassing, after which the blank is removed from the mold and placed in an oven, then it is cleaned of burr and polished, obtaining a realistic artificial eye blank.

Additional realism and similarity with a natural eye is provided by applying a layer of yellow acrylic paint to the workpiece to give a slight yellowness, as well as gluing red silk threads that imitate blood vessels (clause 2 of the formula).

In Fig.1, a section shows a device with which the artificial eyeball blank is manufactured by the claimed method, where:

1 - silicone mold;

2 - insert;

3 - substrate for the iris of the eyeball;

4 - transparent lens of the iris;

5 - sclera of the protein of the eyeball;

6 - silk threads imitating the blood vessels of the eyeball;

7 - an opaque polymer layer that mimics the protein of the eyeball.

Figure 2 shows a photograph of the finished product obtained by the claimed method.

The implementation of the proposed method is shown in a specific example.

Substrate file 3 for the formation of the iris of the eyeball was prepared on an electronic medium (PNG JPG, etc.) and the substrate was printed with a diameter of 12 mm by photo printing on photographic paper, then it was extruded using a punch (can be cut manually).

A small amount of Crystal clear 202 aliphatic polyurethane from Smooth-on (https://www.smooth-on.com/products/crystal-clear-202/) was applied to the dried substrate with a syringe, creating the effect of a lens that, under the action of the surface tension is held on the surface of the substrate. Next, drying was carried out at room temperature for 6 hours, vacuum degassing in a mono-vacuum pressure chamber MV 325-400 -degazacii-mv-325-400/) for 1 hour 30 minutes at 0.2 atm. and exposure on a horizontal surface at room temperature for 24 hours.

Then the finished iris (substrate 3 with lens 4) was placed in the recess of the silicone mold 1 for casting an imitation of the white of the eye.

A mixture was prepared on the basis of two-component (components A and B) aliphatic polyurethane Crystal clear 202 in the following order: 2 drops of white dye were added to 4 ml of the component, 1 drop of yellow dye + 5 ml of component B + black dye on the tip of a toothpick + 1 drop of red dye + 5 ml of component B + on the tip of a blue dye toothpick + 4.5 ml of component A.

The filling of the mixture took place as follows:

A large portion of the mixture was poured into a syringe and poured through the syringe needle into the recess of the silicone mold 1 until the iris 3.4 sinks. This was done so that the iris did not shine through under a dense, white layer of polymer.

The second portion of the liquid mixture was prepared as follows:

Previously, 1 ml of component B and 1.1 ml of component A of Crystal clear 202 polymer were mixed and placed in an A160-180 vacuum degassing chamber (http://v-sota.ru/katalog-produkcii/vakuumnoe-oborudovanie/vakuumnye-kamery/ -kamera-dlja-degazacii-a160-180/) at 0.08 atm for 4 minutes, stirred, and poured into silicone mold 1 using a syringe.

This mixture was poured into a silicone mold 1, so that when the stainless steel insert 2 was placed in the recess of the mold 1, the polymer mixture was displaced, forming an opaque layer 7, imitating the protein of the eyeball and the thin walls of the sclera 5.

Next, insert 2 was placed in silicone mold 1 and then placed in a pressure chamber MB 325-400 at 0.2 atmospheres for 1 hour and 30 minutes.

Next, the entire structure was subjected to vacuum degassing; placed in chamber A160-180 at 0.08 atm for 4 minutes. The next operations were applying a layer of yellow Ladoga acrylic paint (https://www.nevskayapalitra.ru/brands/#ladoga) to the blank of the eyeball on the surface of the protein with a brush to give a slight yellowness and drying for 1 hour. Next, red silk threads 6 32 µm wide, imitating blood vessels, were glued with transparent glue.

Before polishing, the product blank was removed from insert 2 and placed in an oven for 4 hours at a temperature of 50 degrees. The flash was cleaned with STS-60-R ABRO sandpaper for 10 seconds, then with STS-40-R ABRO sandpaper for 10 seconds and polished to a mirror state using a Bosch cordless drill - screwdriver, on which a Matrix mounting mandrel was put on. d125 with spindle, as well as a Fitter pad. Used abrasive polishing paste Fast Cut Plus ZM 50417 (https://www.insafe.ru/product/pasta-abrazivnaya-fast-cut-plus-3m-50417/).

Another variant of grinding is also possible with the help of a SHM - 1 grinder and a 70 mm “fluff” nozzle. (https://www.sapphire.ru/vcd-476-1-5331/goodsinfo.html). In this case, no abrasive paste was used.

In practice, the manufacturing time for a pair of artificial eyes was 3 days, of which 4 hours were spent on work, the rest of the time was spent on solidifying the Crystal clear 202 polymer.

The resulting product, shown in figure 2, looks voluminous and realistic, practically does not differ from a real eyeball. Production does not require expensive equipment and special conditions. The product has sufficient durability and reliability.

Claims (2)

1. A method for manufacturing artificial eyes for robots and dolls, which consists in the phased formation of an eyeball using a polymer-based material, characterized in that Crystal clear 202 aliphatic polyurethane is used as a polymer, the eyeball is formed using a silicone mold with a recess repeating external contours of the eyeball and inserts for forming the inner cavity of the eyeball, while preliminarily a substrate for the iris of the eyeball is made from photographic paper by photo printing, the iris is formed on the substrate by applying drops of liquid aliphatic polyurethane, then it is dried, subjected to vacuum degassing and exposure to horizontal surface at room temperature, then the iris is placed deep into the silicone mold, and a portion of the liquid polymer mixture based on aliphatic polyurethane is poured over the iris, and after degassing, the following is added 10th portion of the liquid polymer mixture, an insert is placed in a silicone mold, forming an imitation of the protein of the eyeball and thin sclera of the eye, then the entire structure is subjected to vacuum degassing, after which the workpiece is removed from the mold and placed in an oven, then cleaned of burr and polished. 2. A method for manufacturing artificial eyes for robots and dolls according to claim 1, characterized in that a layer of yellow acrylic paint is applied to the blank of the eyeball and allowed to dry, and red silk threads imitating blood vessels are glued to the surface.

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