Rigid, gas-permeable polymer as over-mold and sealant for adaptive ophthalmic lens
View Patent ↗An eye-mountable device is provided that includes electronics encapsulated within a rigid, gas-permeable polymeric material. The eye-mountable device includes an electroactive lens that can be operated to control an overall optical power of the eye-mountable device to restore an amount of visual accommodation of an eye to which the device is mounted. A method for fabricating the eye-mountable device is provided that includes applying an adhesive to secure lenses of the electroactive lens together and to maintain an amount of liquid crystal in the space between the lenses. The rigid, gas-permeable polymeric material can then be formed around the electroactive lens, electronics, or other elements of the eye-mountable device. The rigid, gas-permeable polymeric material can be mountable to a corneal surface of an eye or can be disposed on or within a soft polymeric material that is mountable to the corneal surface of the eye.
1. A method comprising:
forming an electroactive lens assembly, wherein the electroactive lens assembly comprises an amount of liquid crystal disposed between a first lens and a second lens, and wherein the electroactive lens assembly comprises first and second electrodes to which voltage can be applied to alter an optical power of the electroactive lens assembly;
applying an adhesive to the electroactive lens assembly, wherein the applied adhesive contacts the first lens and the second lens such that the amount of liquid crystal is contained within a combination of the first lens, the second lens, and the applied adhesive;
electrically coupling the first and second electrodes of the electroactive lens assembly to an electronic circuit;
disposing the electroactive lens assembly, the applied adhesive, and the electronic circuit within a precursor material;
curing the applied adhesive; and
curing the precursor material to form a rigid, gas-permeable polymer layer, wherein the applied adhesive and the electronic circuit are fully encapsulated by a combination of the rigid, gas-permeable polymer layer and one or more lenses of the electroactive lens assembly, wherein at least one of the lenses of the electroactive lens assembly comprises a rigid, gas-permeable polymeric material.
2. The method of claim 1 , further comprising:
forming a soft polymer layer such that the rigid, gas-permeable polymer layer is fully enclosed within the formed soft polymer layer, wherein the soft polymer layer is mountable to a corneal surface of an eye.
3. The method of claim 2 , wherein the soft polymer layer comprises a silicone hydrogel.
4. The method of claim 1 , wherein curing the applied adhesive and curing the precursor material at least partially overlap in time.
5. The method of claim 4 , wherein curing the applied adhesive and curing the precursor material comprise exposing the applied adhesive and the precursor material to ultraviolet light.
6. The method of claim 4 , wherein the applied adhesive and the precursor material are immiscible.
7. The method of claim 6 , wherein the applied adhesive comprises a silicone adhesive.
8. The method of claim 1 , wherein disposing the electroactive lens assembly, the applied adhesive, and the electronic circuit within a precursor material comprises:
disposing the electroactive lens assembly, the applied adhesive, and the electronic circuit within a mold; and
disposing the precursor material within the mold.
9. The method of claim 8 , wherein the precursor material comprises:
one or more di(meth)acrylate-derived monomeric units; and
one or more (meth)acrylate-derived monomeric units.
10. The method of claim 8 , wherein the mold comprises one or more support features, wherein disposing the electroactive lens assembly, the applied adhesive, and the electronic circuit within a mold comprises disposing the electroactive lens assembly, the applied adhesive, and the electronic circuit within the mold such that the electroactive lens assembly, the applied adhesive, and the electronic circuit are supported by the support features and the support features contact at least one lens of the electroactive lens assembly.
11. The method of claim 1 , wherein the applied adhesive is cured before disposing the electroactive lens assembly, the applied adhesive, and the electronic circuit within the precursor material.
12. The method of claim 1 , wherein the electroactive lens assembly further comprises:
a third lens; and
a further amount of liquid crystal, wherein the further amount of liquid crystal is disposed between the second lens and the third lens, wherein the applied adhesive contacts the second lens and the third lens such that the further amount of liquid crystal is contained within a combination of the second lens, the third lens, and the applied adhesive.
13. The method of claim 1 , wherein all of the lenses of the electroactive lens assembly comprise one or more rigid, gas-permeable polymeric materials.
14. The method of claim 13 , wherein the lenses of the electroactive lens assembly and the rigid, gas-permeable polymer layer comprise the same rigid, gas-permeable polymeric material.