HK1190199B - Method for forming a media substrate for an ophthalmic lens and media substrate for an ophthalmic lens - Google Patents

Description

Method for forming a media substrate for an ophthalmic lens and media substrate for an ophthalmic lens

Related patent application

The present patent application claims priority from U.S. patent application serial No. 13/401, 952, filed on day 22, 2, 2012, U.S. provisional application serial No. 61/447,469, filed on day 28, 2, 2011, and U.S. provisional application serial No. 61/454,205, filed on day 18, 3, 2011, the contents of each of which are incorporated herein by reference.

Field of use

The present invention describes a functionalized insert for an ophthalmic device formed from a plurality of stacked functional layers, and in some embodiments, methods and apparatus for manufacturing an ophthalmic lens having a functionalized insert formed from a plurality of stacked layers.

Background

Traditionally, ophthalmic devices such as contact lenses, intraocular lenses, or punctal plugs include biocompatible devices having corrective, cosmetic, or therapeutic properties. For example, a contact lens may provide one or more of the following functions: vision correction function, beauty enhancement function and treatment function. Each function is provided by a physical characteristic of the lens. Designs incorporating refractive properties into the lens can provide vision correction functionality. Pigments incorporated into the lens can provide cosmetic enhancement. The active agent incorporated into the lens can provide therapeutic functionality. These physical characteristics are achieved without having to place the lens in an energized state. Punctal plugs are traditionally passive devices.

Recently, there have been theories that active elements may be incorporated into contact lenses. Some of the elements may include semiconductor devices. Some examples show embedding a semiconductor device in a contact lens placed on an animal's eye. It is also described how the active elements can be energized and activated in various ways within the lens structure itself. The topography and size of the space defined by the lens structure creates a new and challenging environment for the definition of various functions. Typically, such disclosures have included discrete devices. However, the size and power requirements of available discrete devices are not necessarily conducive to inclusion in a device worn on the human eye.

Disclosure of Invention

Thus, the present invention includes a design of an assembly that can be made into an insert that can be energized and incorporated into an ophthalmic device. The insert may be formed from multiple layers, each of which may have a unique functionality; or have functionality that is mixed but in multiple layers. In some embodiments, these layers may have layers dedicated to product power-on or product activation, or may have layers for controlling various functional components within the lens body. Furthermore, the present invention proposes a method and an apparatus for forming an ophthalmic lens with an insert formed by stacking functionalized layers.

In some embodiments, the insert may include a layer in an energized state that is capable of powering a component capable of conducting electrical current. These components may include, for example, one or more of the following: variable optical lens elements and semiconductor devices that may be located in or otherwise connected to a stacked layer interposer. Some embodiments may also include cast-molded silicone hydrogel contact lenses, wherein the rigid or formable inserts of the stacked functionalized layers are contained in the ophthalmic lens in a biocompatible manner.

Accordingly, the present invention includes the following disclosure: an ophthalmic lens having a stacked functionalized layer portion, an apparatus for forming an ophthalmic lens having a stacked functionalized layer portion, and methods thereof. As discussed herein, the insert may be formed from multiple layers in various ways, and the insert may be disposed adjacent to one or both of the first mold member and the second mold member. The reactive monomer mixture is placed between the first mold part and the second mold part. The first mold part is disposed adjacent to the second mold part, thereby forming a lens cavity in which the energized media substrate and at least some of the reactive monomer mixture are disposed; the reactive monomer mixture is exposed to actinic radiation to form an ophthalmic lens. The lens can be formed by controlling the actinic radiation to which the reactive monomer mixture is exposed.

Drawings

FIG. 1 shows a mold assembly apparatus according to the foregoing embodiments.

Fig. 2 illustrates an exemplary embodiment of an exemplary form factor of an insert that may be placed in an ophthalmic lens.

Figure 3 illustrates a three-dimensional representation of an insert formed of stacked functional layers incorporated in an ophthalmic lens mold member.

Figure 4 shows a cross-sectional representation of an ophthalmic lens mold section with an insert.

Fig. 5 shows an exemplary embodiment comprising a plurality of stacked functional layers on a support and alignment structure.

Figure 6 illustrates different shapes and embodiments of components used to form layers in a stacked functional layer insert.

Detailed Description

The present invention includes a dielectric substrate device formed by stacking a plurality of functionalized layers. In addition, the present invention also includes methods and apparatus for manufacturing ophthalmic lenses having such stacked functionalized layered media substrates. Further, the present invention includes an ophthalmic lens wherein the stacked functionalized layered media substrate is incorporated into an ophthalmic lens.

The following sections will describe embodiments of the present invention in detail. The preferred and alternative embodiments described herein are exemplary embodiments only. And it is to be understood that variations, modifications and changes may be apparent to those skilled in the art. It is to be understood, therefore, that the exemplary embodiments are not to be considered as limiting the scope of the invention on which they are based.

Glossary

In the description and claims relating to the present invention, the terms used are defined as follows:

electrifying: this document refers to a state in which it is possible to supply electric current or in which electric energy is stored.

Energy: as used herein refers to the capacity of a physical system to perform work. Multiple uses in the present invention may relate to the capacity to perform electrical actions during work.

An energy source: as used herein refers to a device that is capable of powering or placing a biomedical device in an energized state.

An energy collector: as used herein refers to a device capable of extracting energy from the environment and converting it into electrical energy.

Functionalized: as used herein refers to enabling a layer or device to perform functions including, for example, powering on, activating, or controlling.

Lens: refers to any ophthalmic device that resides in or on the eye. These devices may provide optical correction or may be decorative. For example, the term lens may refer to a contact lens, intraocular lens, overlay lens, ocular insert, optical insert, or other similar device for correcting or improving vision or for enhancing the physiological beauty of the eye (e.g., iris color) without affecting vision. In some embodiments, preferred lenses of the invention are soft contact lenses made from silicone elastomers or hydrogels, including but not limited to silicone hydrogels and fluorohydrogels.

Lens forming mixture or "reactive mixture" or "RMM" (reactive monomer mixture): as used herein refers to monomeric or prepolymer materials that can be cured and crosslinked, or can be crosslinked to form an ophthalmic lens. Various embodiments may include a lens forming mixture having one or more additives, such as ultraviolet blocking agents, colorants, photoinitiators or catalysts, and other additives that may be desired in an ophthalmic lens, such as a contact lens or intraocular lens.

Lens forming surface: refers to the surface used to mold the lens. In some embodiments, any such surface 103-104 can have an optical quality surface finish, meaning that it is sufficiently smooth and shaped so that the lens surface has acceptable optical properties. The lens surface is shaped by polymerization of a lens-forming material in contact with the mold surface. Further, in some embodiments, the lens forming surface 103-104 can have a geometry necessary to impart desired optical properties to the lens surface including, but not limited to, spherical, aspherical, and cylindrical powers, wavefront aberration correction, corneal topographic feature correction, and the like, and any combination thereof.

A lithium ion battery: refers to an electrochemical cell in which lithium ions move through the cell to generate electrical energy. Such electrochemical cells, commonly referred to as batteries, may be re-energized or recharged in their typical fashion.

A dielectric substrate: as used herein refers to a formable or rigid substrate capable of supporting a source of energy within an ophthalmic lens. In some embodiments, the media substrate also supports one or more components.

A mould: refers to a rigid or semi-rigid object that can be used to form a lens from an uncured formulation. Some preferred molds include two mold parts that form a front curve mold part and a back curve mold part.

Optical zone: as used herein refers to the area of an ophthalmic lens that is visible through the ophthalmic lens by the wearer of the ophthalmic lens.

Power: as used herein, refers to the work done or energy transferred per unit time.

Rechargeable or re-energizable: can be restored to a state of operating with higher performance. A variety of uses within the scope of the present invention may be associated with a restoring capability that enables current to flow at a particular rate for a particular period of restoring time.

Re-power or recharge: refers to a return to a state with a higher capacity to do work. A variety of uses within the scope of the present invention may be associated with a restoring capability that enables the device to flow current at a particular rate for a particular period of restoring time.

And (3) releasing from the mold: it is meant that the lens is either completely separated from the mold, or is only loosely attached so that it can be removed by gentle agitation or pushed off with a swab.

Stacking: as used herein, refers to placing at least two component layers in close proximity to each other such that at least a portion of one surface of one of the layers contacts a first surface of a second layer. In some embodiments, a film, whether for adhesion or other functions, may reside between the two layers that are in contact with each other through the film.

Description of the invention

The powered lens 100 with embedded media substrate 111 may include an energy source 109, such as an electrochemical cell or battery of an energy storage assembly, in some embodiments, encapsulating and isolating the material includes an energy source from the environment in which the ophthalmic lens is placed.

In some embodiments, the media substrate further comprises a circuit pattern, components, and an energy source 109. Various embodiments may include a media substrate that positions the circuit patterns, components, and energy source 109 at the periphery of the optical zone through which the lens wearer can view. While other embodiments may include such circuit patterns, components, and energy sources 109 that are small enough not to adversely affect the field of view of the contact lens wearer so the media substrate can position them inside or outside of the optical zone.

Generally, according to the embodiments described above, the media substrate 111 is embedded in an ophthalmic lens by an automated device that places an energy source at a desired location relative to the mold parts used to make the lens.

Die set

Referring now to fig. 1, an exemplary mold 100 for an ophthalmic lens is shown having a media substrate 111. As used herein, the term mold includes a configuration 100 having a cavity 105 into which a lens forming mixture 110 can be dispensed such that when the lens forming mixture reacts or cures, a desired shaped ophthalmic lens is produced. The mold and mold part 100 of the present invention is comprised of more than one "mold part" or "mold piece" 101 and 102. The mold parts 101-102 can be brought together such that a cavity 105 is formed between the mold parts 101-102, in which the lens can be formed. Preferably, this combination of mold parts 101-102 is temporary. After the lens is formed, the mold parts 101 and 102 can be separated again to remove the lens.

At least a portion of the surface 103 104 of the at least one mold member 101-102 is contacted with the lens forming mixture such that upon reaction or curing of the lens forming mixture 110, the surface 103-104 provides the desired shape and form to the portion of the lens contacted therewith. The same is true for at least one other mold part 101-102.

Thus, for example, in one preferred embodiment, the mold assembly 100 is formed from two parts 101-102, a female part (front part) 102 and a male part (back part) 101, forming a cavity therebetween. The portion of the concave surface 104 that contacts the lens forming mixture has the curvature of the front curve of the ophthalmic lens to be produced in the mold assembly 100 and is sufficiently smooth and formed so that the surface of the ophthalmic lens formed by polymerization of the lens forming mixture that contacts the concave surface 104 is optically acceptable.

In some embodiments, the anterior mold member 102 may also have an annular flange surrounding and integral with the circular peripheral edge 108, the anterior mold member 102 extending from the flange in a plane perpendicular to the axis and extending from the flange (not shown).

The lens forming surface may comprise a surface 103 having an optical quality surface finish 104, meaning that it is sufficiently smooth and shaped so that the lens surface formed by polymerization of the lens forming material in contact with the mold surface is optically acceptable. Further, in some embodiments, the lens forming surface 103-104 can have a geometry necessary to impart desired optical properties to the lens surface including, but not limited to, spherical, aspherical, and cylindrical powers, wavefront aberration correction, corneal topographic feature correction, and the like, and any combination thereof.

The energy source 109 can be disposed on a dielectric substrate shown as 111. The dielectric substrate 111 may be any receptive material upon which the energy source 109 may be disposed, and may also include circuit paths, components, and other aspects for using the energy source in some embodiments. In some embodiments, the media substrate 111 can be a clear coating of a material that is incorporated into the lens at the time of lens formation. The clear coat may comprise, for example, pigments, monomers, or other biocompatible materials as described below. Additional embodiments may include a medium containing an insert, which may be rigid or formable. In some embodiments, the rigid insert may include optical zone and non-optical zone portions that provide optical properties, such as those used for vision correction. The energy source may be disposed on one or both of the optical zone and the non-optical zone of the insert. Still other embodiments may include an annular insert that may be rigid or formable, or some shape that surrounds the optical zone through which the user sees.

Various embodiments further include disposing the energy source 109 on the media substrate 111 and then disposing the media substrate 111 within a mold portion for forming a lens. The media substrate 111 may also include one or more components capable of receiving an electrical charge via the energy source 109.

In some embodiments, a lens with a media substrate 111 may include a hard-center soft-edged design (rigidcentterstoffkirtdesign), wherein a central rigid optical element is in direct contact with the atmosphere and corneal surface on the anterior and posterior surfaces, respectively, and wherein a soft skirt of lens material (typically a hydrogel material) is attached to the periphery of the rigid optical element, which also serves as a media substrate to provide energy and functionality to the resulting ophthalmic lens.

Other embodiments include a media substrate 111 that is a rigid lens insert fully encapsulated within a hydrogel matrix. The media substrate 111 as a rigid lens insert may be manufactured, for example, using microinjection molding techniques. Embodiments may include, for example, a poly (4-methyl-1-pentene) copolymer resin having a diameter between about 6mm and 10mm, a front surface radius between about 6mm and 10mm, a back surface radius between about 6mm and 10mm, and a center thickness between about 0.050mm and 0.5 mm. Some exemplary embodiments include such inserts having a diameter of about 8.9mm, a front surface radius of about 7.9mm, a rear surface radius of about 7.8mm, a center thickness of about 0.100mm, and an edge profile within a range of about 0.050 radius. One exemplary micro-molding machine may include Microsystem50 five ton system available from Battenfield ltd.

The media substrate may be disposed within a mold part 101 and 102 for forming an ophthalmic lens.

The mold part 101-102 material may include, for example, one or more of the following polyolefins: polypropylene, polystyrene, polyethylene, polymethyl methacrylate, and modified polyolefins. Other molds may include ceramic or metallic materials.

A preferred alicyclic hydrocarbon copolymer comprises two different alicyclic hydrocarbon polymers sold under the trade name ZEONOR by japan ruisbane company (zeon chemicals l.p.). There are several different grades of ZEONOR. The different grades may have glass transition temperatures ranging from 105 ℃ to 160 ℃. A particularly preferred material is ZEONOR 1060R.

Other mold materials that may be combined with one or more additives to form an ophthalmic lens mold include, for example, Zieglar-Natta polypropylene resin (sometimes referred to as znPP). An exemplary Zieglar-Natta polypropylene resin is sold under the trade name PP9544 MED. PP9544MED is a clear random copolymer for clean forming (clean molding) according to FDA regulation 21CFR (c)3.2, supplied by ExxonMobileChemicalcompany. PP9544MED is a random copolymer with vinyl groups (znPP) (hereinafter 9544 MED). Other exemplary Zieglar-Natta polypropylene resins include: atofina polypropylene3761 (Atofina polypropylene3761) and Atofina polypropylene3620WZ (Atofina polypropylene3620 WZ).

In addition, in some embodiments, the molds of the present invention may further comprise polymers such as polypropylene, polyethylene, polystyrene, polymethyl methacrylate, modified polyolefins containing alicyclic moieties in the main chain, and cyclic polyolefins. The blend may be used on either or both mold halves, where it is preferred that the blend be used on the back curve, while the front curve contains the alicyclic co-polymer.

In some preferred methods of making mold 100 according to the present invention, injection molding is performed according to known techniques, however, embodiments may also include molds shaped by other techniques including, for example, lathe machining, diamond turning, or laser cutting.

Stacked functionalized layer interposer

Referring now to FIG. 2, an exemplary design of one embodiment of a dielectric substrate 111 formed as a stacked functionalized layer insert is shown. The present invention relates to a novel method of making and forming a media substrate that can be used and formed in an ophthalmic lens in a manner consistent with the foregoing techniques. For clarity of illustration, an exemplary media substrate 210 is shown and described that includes a fully annular ring with an optical lens area 211, but this is not intended to limit the scope of the invention. It may be apparent to those skilled in the art that the inventive techniques described in this specification are similarly applicable to the various shapes and embodiments that are generally described for various media substrates.

Referring now to fig. 3, a three-dimensional representation of some embodiments of a fully formed ophthalmic lens using a stacked layer media substrate is shown, wherein item 210 is illustrated as item 300. The representation shows a partially cut away portion of the ophthalmic lens to understand the different layers present within the device. Item 320 shows a cross-section of a host material of an encapsulation layer of a media substrate. This item surrounds the entire perimeter of the ophthalmic lens and can be envisaged for an insert of the type in item 210. It will be clear to those skilled in the art that the actual insert may comprise a full annular ring or other shape that is still capable of being within the size limitations of a typical ophthalmic lens.

Items 330, 331, and 332 are intended to illustrate three layers of the plurality of layers that may be present in a media substrate formed as a functional layer stack. In some embodiments, a single layer may include one or more of the following: active and passive components and portions having structural, electrical or physical characteristics that serve a particular purpose.

In some embodiments, layer 330 may include a power source, such as one or more of the following: a battery, a capacitor, and a receiver within layer 330. Thus, in a non-limiting exemplary sense, item 331 can include a microcircuit in a layer that detects an actuation signal of an ophthalmic lens. In some embodiments, a power regulation layer 332 may be included that is capable of receiving power from an external source to charge the battery layer 330 and control the use of battery power from the layer 330 when the lens is not in a charging environment. The power conditioning source may also control signals to an exemplary active optic, shown as item 310 in the central annular cut of the media substrate, and identified as 211 in fig. 2.

Figure 4 illustrates a closer cross-sectional view of some embodiments of a stacked functional layer insert 400. In some embodiments, the body of the ophthalmic lens 410 has embedded therein a functionalized layer insert 420 that surrounds and connects to the active lens component 450. It may be clear to those skilled in the art that this example shows only one of many embodiments of embedded functionality that may be placed in an ophthalmic lens.

Multiple layers are shown in the stacked layer portion of the insert. In some embodiments, the layer may include a plurality of semiconductor-based layers. For example, item 440, the bottom layer in the stack, may be a thin silicon layer having circuitry defined thereon for various functions. Another thin silicon layer may be found in the stack as item 441. In a non-limiting example, such a layer may vary with the power-up condition of the device. In some embodiments, the silicon layers may be electrically insulated from each other by an intermediate insulating layer shown as item 450. The portions of the surface layers of items 440, 450, and 441 that overlap each other may be bonded to each other by using an adhesive film. It will be apparent to those skilled in the art that a variety of adhesives may have the characteristics required to adhere and passivate a thin silicon layer to an insulator, such as an epoxy.

The plurality of stacked layers may include an additional layer 442, which may include, in a non-limiting example, a thin silicon layer having circuitry capable of activating and controlling the active lens components. As described above, when the stacked layers need to be electrically insulated from each other, a stacked insulating layer may be included between the electroactive layers, and in this example, item 451 may represent such an insulating layer, including a portion of the stacked layer interposer. In some examples described herein, reference has been made to a layer formed from a thin silicon layer. The scope of use of the general techniques can be extended to different embodiments where the material definition of the thin stacked layers includes, in a non-limiting manner, other semiconductor, metal or composite layers. The function of the thin layer may include circuitry, but may also include other functions such as signal reception, energy processing and storage, and energy reception, to name a few. In some embodiments including different material types, it may be desirable to select different adhesives, encapsulating materials, and other materials that interact with the stack of layers. In an exemplary embodiment, a thin layer of epoxy may bond three silicon layers, shown as 440, 441, and 442, with two silicon oxide layers 450 and 451.

As described in some examples, the thin stack of layers may include circuitry formed in a silicon layer. There are many ways of fabricating such layers, however, the standards and state of the art semiconductor processing equipment can utilize general processing steps to form electronic circuits on silicon wafers. After the circuits are formed in place on the silicon wafer, the wafer may be thinned from several hundred microns to a thickness of 50 microns or less using wafer processing equipment. After thinning, the silicon circuits can be cut or "diced" from the wafer into the appropriate shape for an ophthalmic lens or other application. In the following, different exemplary shapes of the stacked layer invention disclosed herein are shown in fig. 6. As will be explained in detail below, however, the "slicing" operation may use various technical options to cut out laminae having curved, circular, rectilinear, and other more complex shapes.

In some embodiments, it may be desirable to provide electrical contact between stacked layers when the stacked layers perform a function related to electrical current. In the general technical field of semiconductor packaging, such electrical connections between stacked layers have a general solution comprising: wire bonding, solder bump, through silicon via, and wire deposition methods. Some embodiments of wire deposition may use a printing method in which a conductive ink is printed between two connection pads. In other embodiments, the wire may be physically defined by an energy source (e.g., a laser) that interacts with a gaseous, liquid, or solid chemical medium capable of creating an electrical connection where the energy source impinges. Still other interconnect definition embodiments may be obtained from photolithographic processing, either before or after deposition of the metal film by various means.

In the present invention, one or more of the layers may have metal contact pads that are not covered by a passivation and insulating layer if they need to communicate electrical signals to the outside thereof. In many embodiments, these pads will be located on the periphery of the layer where subsequent stacked layers do not cover the area. In an example of this type of embodiment, in fig. 4, interconnect wires 430 and 431 are shown as electrically connecting peripheral regions of layers 440, 441 and 442. It may be apparent to those skilled in the art that there may be a variety of layouts or designs for locating the electrical connection pads and ways to electrically connect the various pads together. Furthermore, it may be apparent that different circuit designs may result from the selection of which electrical link pads are connected and which pads are connected to which other pads. In addition, the function of the wire interconnection between pads may vary in different embodiments, including the following functions, to name a few: electrical signal connections, receiving electrical signals from external sources, electrical power connections, and mechanical stabilization.

In the previous discussion, it was proposed that the non-semiconductor layer may comprise one or more of the stacked layers in the present technique. It may be apparent that there may be a wide variety of applications that originate from the non-semiconductor layer. In some embodiments, the layer may define an electrical power source, such as a battery. In some cases, this type of layer may have a semiconductor that serves as a support substrate for the supporting chemical layer, or may have a metal or insulating substrate in other embodiments. Other layers may be derived from layers that are primarily metallic in nature. These layers may define an antenna, a thermal conduction path, or other functions. There may be many combinations of semiconductor and non-semiconductor layers, including suitable applications within the spirit of the present techniques.

In some embodiments where there is an electrical connection between the stacked layers, the electrical connection needs to be sealed after the connection is defined. There are a variety of methods that may be consistent with the technology herein. For example, an epoxy or other adhesive material used to hold the various stacked layers together may be repeatedly applied to the areas having electrical interconnections. Additionally, in some embodiments, a passivation film may be deposited over the entire device to encapsulate the regions for interconnection. It may be apparent to those skilled in the art that a variety of encapsulation and sealing schemes may be used in the art to protect, reinforce and seal stacked layer devices and their interconnections and interconnection areas.

Assembling stacked functionalized layer inserts

With continued reference to fig. 5, a close-up view of an exemplary apparatus for assembling a stacked functionalized layer insert is illustrated (item 500). In this example, a stacking technique is shown in which the stacked layers are not aligned on either side of the layers. Items 440, 441, and 442 may likewise be silicon layers. On the right side of the figure, it can be seen that the right side edges of items 440, 441, and 442 are not aligned with one another, which may be the case in alternative embodiments. Such a stacking method may allow the insert to take on a three-dimensional shape similar to the overall contour of the ophthalmic lens. Also in some embodiments, such stacking techniques may allow the layers to be made with the largest surface area possible. Such surface area maximization can be important in layers that function for energy storage and circuitry.

In general, many of the features of the foregoing stacked inserts can be observed in fig. 5, fig. 5 including stacked functional layers 440, 441 and 442; stacked insulating layers 450 and 451; and interconnects 430 and 431, which may include through silicon vias. Additionally, a support fixture for supporting the stacked functionalized layer insert when assembled may be observed (item 510). It may be apparent that the surface profile of item 510 may take on a number of shapes that would alter the three-dimensional shape of the insert on the surface.

Generally, the clamp 510 may be provided with a predetermined shape. The fixture 510 may be coated with different layers (item 520) for many purposes. In some embodiments, in a non-limiting manner, the coating may first include a polymer layer that enables easy incorporation of the insert into the substrate of an ophthalmic lens, and may even be formed from a silicone polymer material. Next, an epoxy coating may be deposited over the silicone polymer coating to adhere the bottom thin functional layer 440 to the coating 520. The bottom surface of the next insulating layer 450 can be coated with a similar epoxy coating and then placed in its proper position on the fixture. It will be clear that in some embodiments the clamp may have the function of aligning the correct arrangement of the various stacked layers with respect to each other when the device is assembled. The remainder of the insert may then be assembled in an iterative manner, defining the interconnects, and then encapsulating the insert. In some embodiments, the encapsulated insert is subsequently coated with a silicone polymer coating from top to bottom. In some embodiments using a silicone polymer coating for item 520, the assembled insert may be separated from the fixture 510 by hydration of the silicone polymer coating.

The clamp 510 may be formed from a variety of materials. In some embodiments, the fixture may be formed and fabricated from similar materials used to fabricate molded parts when fabricating standard contact lenses. Such use can support the flexible formation of a variety of clip types for different insert shapes and designs. In other embodiments, the clip may be formed from: the material does not adhere to the chemical mixture used to bond the different layers to each other by itself or when provided with a special coating. It will be apparent that there are many options for the configuration of such a clamp.

Another aspect of the fixture shown as item 510 is its shape to physically support the layer located thereon. In some embodiments, the interconnections between layers may be formed by wire bonded connectors. During wire bonding, significant force is applied to the wire to ensure that a good bond is formed. Structural support of the layers may be important in such a bonding process and may be performed by the support fixture 510.

Yet another function of the fixture shown as item 510 is to have alignment structures on the fixture that enable the components of the functionalized layer to be aligned not only linearly with respect to each other, but also radially along the surface. In some embodiments, the fixture may align the azimuthal angles of the functional layers relative to each other about a center point. Regardless of the final shape of the manufactured insert, it may be apparent that the component fixture may be adapted to ensure that the components of the insert are properly aligned for their function and proper interconnection.

With continued reference to FIG. 6, a more general discussion of the shape of the stacked layer insert may be found. In a subset of general shapes in accordance with the present technique, some substantial shape variation is shown. For example, item 610 shows a top view of a stacked insert formed from substantially circular laminae. In some embodiments, the cross-hatched regions 611 may be annular regions in which layer material is removed. However, in other embodiments, it will be apparent that the assembly used to form the stacked layers of the insert may be a disk without an annular region. While the utility of such non-annular insert shapes in ophthalmic applications may be limited, the nature of the inventive technique herein is not intended to be limited by the presence of an internal annulus.

In some embodiments, item 620 may show different embodiments of stacked functional layer inserts. As shown in item 621, in some embodiments, the layer may not only be discontinuous in the stacking direction, but also discontinuous around an azimuthal direction perpendicular to the stacking direction. In some embodiments, the insert may be formed using a semi-circular assembly. It will be apparent that in a shape having an annular region, the local shape may be adapted to reduce the amount of material that needs to be "sliced" or cut away after the layer material is formed to have its function.

Further, item 630 illustrates definable non-radial, non-elliptical, and non-circular insert shapes. A rectilinear shape may be formed, as shown in item 630, or other polygonal shapes may be formed, as described in item 640. In a three-dimensional perspective cone, the different shapes of the various layers used to form the insert may produce a cone or other geometric shape. In a more general sense, it will be apparent to those skilled in the art that a wide variety of shapes can be formed into shapes and products to discuss the more general case where shapes can be made that are functional, electrically conductive, active, and the like.

Conclusion

As described above and further defined by the following claims, the present invention provides devices and methods for stacking functional layer inserts, apparatus for implementing such methods, and ophthalmic lenses formed to include stacked layers.

Claims (17)

1. A method of forming a media substrate for an ophthalmic lens, the method comprising:

forming a plurality of substrate functional layers having electrical functionality;

assembling the substrate functional layers into one of: a portion of the annular shape and a donut shape;

adhering the substrate functional layer to an insulating layer to form a stacked feature;

forming electrical interconnections between the functional layers of the substrate;

encapsulating the stacked features with one or more materials that can be incorporated into the body of a molded ophthalmic lens,

wherein each of said insulating layers is sandwiched between two of said substrate functional layers.

2. The method of forming a media substrate for an ophthalmic lens of claim 1 wherein at least one of the substrate functional layers of the media substrate comprises a solid state energy source.

3. The method of forming a media substrate for an ophthalmic lens of claim 2 wherein the media substrate comprises an annular shape.

4. The method of forming a media substrate for an ophthalmic lens of claim 2 wherein the media substrate comprises a silicon substrate.

5. The method of forming a media substrate for an ophthalmic lens of claim 2, further comprising securing a zoom lens to the media substrate.

6. The method of forming a media substrate for an ophthalmic lens of claim 2 further comprising the step of forming an integrated circuit on the substrate functional layer.

7. The method of forming a media substrate for an ophthalmic lens of claim 6 further comprising forming through-silicon vias in at least one substrate functional layer.

8. The method of forming a media substrate for an ophthalmic lens of claim 2 further comprising the steps of: a step of stacking a plurality of substrate functional layers into a three-dimensional shape comprising an overall contour of an ophthalmic lens.

9. A stacked functionalized media substrate for an ophthalmic lens, the substrate comprising:

a first thin silicon layer shaped as a ring;

a first adhesive film on a first surface of the first thin silicon layer; and

a second thin silicon layer shaped as a ring having an outer radius smaller than that of the first thin silicon layer, and

an insulating layer sandwiched between the adhesive film on the first thin silicon layer and the second thin silicon layer.

10. The stacked functionalized media substrate of claim 9, wherein:

the first thin silicon layer comprises a semiconductor substrate having electronic circuitry near a first surface thereof.

11. The stacked functionalized media substrate of claim 9, wherein:

the second thin layer includes a substrate having a layer including an electrochemically energized component.

12. The stacked functionalized media substrate of claim 9, wherein:

the stacked functionalized media substrate is encapsulated in a silicone polymer-based polymer.

13. An ophthalmic lens, comprising:

(1) a stacked functionalized media substrate comprising:

a first thin silicon layer shaped as a ring;

a first adhesive film on a first surface of the first thin silicon layer;

a second thin silicon layer shaped as a ring, the outer radius of the ring being smaller than the outer radius of the first thin silicon layer; and

an insulating layer sandwiched between the adhesive film on the first thin silicon layer and the second thin silicon layer; and

(2) a polymeric lens form having the stacked functionalized media substrate embedded therein.

14. The ophthalmic lens of claim 13, further comprising at least one layer comprising one or more electrochemical cells.

15. The ophthalmic lens of claim 14, further comprising at least one layer comprising semiconductor electronic circuitry capable of controlling current from the electrochemical cell.

16. The ophthalmic lens of claim 15, wherein:

the electronic circuit is electrically connected to the electro-active lens component in the lens.

17. The ophthalmic lens of claim 16, further comprising a metal layer capable of functioning as an antenna.