Method of manufacturing hydrogel ophthalmic devices with electronic elements
The present invention provides methods for forming an ophthalmic lens that can include a media insert and/or electronic components. In particular, the present disclosure provides for adhesion promoting functionalization steps for a biocompatible coating to bind a hydrogel material to a plastic surface or electronic component prior to the polymerization of the hydrogel. In some aspects, the media insert can be used to contain energy sources and/or functional electronic components which may be, for example, in a stacked integrated component configuration to permit a generally arcuate shape that can conform to the anterior surface of an eye.
1. A method of forming an energized ophthalmic device, the method comprising:
pre-dosing a first mold part with a pre-dose amount of a reactive monomer mixture;
forming a media insert including at least one of energization or functional electronic components formed in a stacked integrated component device configuration, the media insert being a separate component that is configured to mount and encapsulate the at least one energization or functional electronic component;
functionalizing the media insert so that an adhesion promoter can bind to a surface of said media insert;
applying an adhesion promoter to the functionalized media insert;
coating said media insert including the adhesion promoter;
placing the media insert on said pre-dose of reactive monomer mixture;
pre-curing the pre-dosed reactive monomer mixture to fixedly hold the media insert proximate to the first mold part;
post-dosing the first mold part with a post-dose of a reactive monomer mixture;
placing a second mold part proximate to the first mold part, wherein the placing forms a ophthalmic device mold assembly with a lens forming cavity; and
curing at least the post-dosed reactive monomer mixture to form the ophthalmic lens, wherein the media insert is encapsulated in the ophthalmic lens.
2. The method of claim 1 , wherein the functionalizing step includes providing a plasma treatment in an oxygen environment.
3. The method of claim 1 , wherein the functionalizing step includes exposing the media insert to an ozone environment.
4. The method of claim 1 , wherein the functionalizing step includes crosslinking a chemical with the media insert.
5. The method of claim 4 , wherein the functionalizing step further includes exposing the media insert to a radiation to crosslink said chemical with the media insert.
6. The method of claim 1 , wherein the adhesion promoter includes a methoxy-silane chemical.
7. The method of claim 6 , wherein the methoxy-silane can include one of more of a vinyldimethylethoxysilane, a methoxysilane, a trimethoxysilane, a styrylethyltrimethoxysilane, a bis(trimethoxysilyl)hexane, and a vinylmethoxysiloxane homopolymer.
8. The method of claim 1 , wherein the coating is a parylene coating.
9. The method of claim 1 , wherein the coating is a polymerizable hydrogel coating.