Hybrid contact lens system and method

Abstract

Methods of manufacturing hybrid contact lenses using a mold are provided. The methods include pouring liquefied resin of a substantially rigid material within an inner section, curing the substantially rigid material, pouring liquefied resin of a substantially flexible material within an outer section and curing the substantially flexible material. In some embodiments, a wall disposed between the rigid and flexible materials is angled and/or bent to increase bonding strength between the rigid and flexible sections. The curing steps involve the application of heat, UV light, or a combination of both heat and UV light.

1 - 55 . (canceled)  
   
   
       56 . A method of manufacturing a hybrid contact lens, comprising the steps of: 
 providing a block mold including a central void;    pouring liquefied resin of a substantially rigid material within the central void;    curing the substantially rigid material;    removing the substantially rigid material from the block mold;    attaching a guard to the substantially rigid material;    pouring a predetermined amount of liquefied resin of flexible material into an area between the substantially rigid section and the guard; and    curing the substantially flexible material.    
   
   
       57 . The method of  claim 56 , wherein the central void includes an upper section including an outer wall formed by an inside surface of the block mold halves.  
   
   
       58 . The method of  claim 57 , wherein the outer wall forms the shape of the junction between the substantially rigid material and the substantially material.  
   
   
       59 . The method of  claim 56 , wherein the outer wall is disposed at an angle with respect to a horizontal surface.  
   
   
       60 . The method of  claim 59 , wherein the angle is between 5 and 175.  
   
   
       61 . The method of  claim 59 , wherein the angle is selected to maximize the bonding strength between the rigid and flexible portions of the contact lens.  
   
   
       62 . The method of  claim 59 , wherein the angle is about 90 degrees.  
   
   
       63 . The method of  claim 59 , wherein the angle is acute.  
   
   
       64 . The method of  claim 59 , wherein the angle is obtuse.  
   
   
       65 . The method of  claim 58 , wherein the outer wall includes one or more bends for increasing the bonding strength between the rigid and flexible portions.  
   
   
       66 . The method of  claim 57 , wherein the central void further comprises a lower section.  
   
   
       67 . The method of  claim 66 , wherein the step of pouring liquefied resin of the substantially rigid material within the central void includes the step of pouring liquefied resin of the substantially rigid material within the lower section.  
   
   
       68 . The method of  claim 66 , wherein the lower section is dimensioned to produce a gripping area that conforms to the collet of a computer numerically controlled lathe or other machining apparatus.  
   
   
       69 . The method of  claim 56 , wherein the curing steps involve the application of heat, UV light, or a combination of both heat and UV light.  
   
   
       70 . The method of  claim 56 , wherein the step of removing the substantially rigid material from the block mold includes the step of breaking the block mold along a breaking plane.  
   
   
       71 . The method of  claim 56 , further comprising the step of removing the guard after curing the substantially flexible material.  
   
   
       72 . The method of  claim 56 , wherein the guard includes a horizontal lower surface and a cylindrical sidewall.  
   
   
       73 . The method of  claim 56  wherein the materials for the substantially flexible material are chosen from the group consisting of: hydroxyethylmethacrylate (HEMA); methyl methacrylate (MMA); Ethyl methacylate (EMA); aminoaklyl containing acrylate or methacrylate; N-vinyl pyrrolidone (NVP); 2-methoxyethyl methacrylate (MEMA); ethylene glycol methacrylate (EGMA); trifluoropropyl methacrylate; pentafluoropentyl methacylate; N,N-dimethylacrylamide (DMA); acrylamide; methacylamide; tetramethyldisiloxane ethylene glycol dimethacrylate; perfluorophenyl methacrylate; 2-(trimethylsiloxyl)ethyl methacrylate; N-fluoroalkyl methacylamide; bis(2-methacryloxyphenyl)-propane; (N,N-dimethylaminoethyl)methacrylate; and combinations of any of these monomers and/or silicone hydrogel formulations such Cibavision lotrafilcon.  
   
   
       74 . The method of  claim 56  wherein the materials for the substantially rigid material are chosen from the group consisting of: fluorosilicone acrylate; siliconated, styrene; 
 fluoroacrylate; fluorometharylate, perfluorianted acrylate and methacrylate; any high DK or Hyper DK gas permeable rigid contact lens bottoms with DK of 70 (ISO), such as Boston 7 Envision, Boston EO, Boston Equales, Boston Equalens 2, Boston XO, Fluoroperm  151 , Fluoroperm 92, Fluoroperm 92, Fluoro 700, Menicon SE-P, Menicon Z; any other high DK materials; and combinations thereof.    
   
   
       75 . The method of  claim 56 , wherein the mold includes a base curve that automatically forms a posterior surface of the hybrid contact lens.  
   
   
       76 . The method of  claim 56 , further comprising the step of lathing the cured lens materials to form anterior and posterior lens surfaces.  
   
   
       77 . The method of  claim 76 , wherein surface modifications to correct aberrations of the lens-eye system are provided on the anterior and/or posterior surfaces.  
   
   
       78 . The method of  claim 76 , wherein the surface profile of the anterior and/or posterior surfaces are modified to contain a multi-focal feature for the correction of presbyopia.