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 mold comprising an inner section and an outer section that are separated by an inner wall;    pouring liquefied resin of a substantially rigid material within the inner section;    curing the substantially rigid material;    pouring liquefied resin of a substantially flexible material within the outer section; and    curing the substantially flexible material.    
   
   
       57 . The method of  claim 56 , wherein the inner wall comprises a pre-form optical grade divider that divides the substantially rigid material and the substantially flexible material.  
   
   
       58 . The method of  claim 56 , wherein the inner wall is bondable with the substantially rigid material and the substantially flexible material.  
   
   
       59 . The method of  claim 56 , wherein the mold is made from a material chosen from the group consisting of polypropylene, polyethylene, polyethylene terephthalate, polycarbonate and optical grade plastics.  
   
   
       60 . The method of  claim 56 , further comprising the step of coating the inner wall with a UV curable adhesive to promote bonding with the substantially rigid material and the substantially flexible material.  
   
   
       61 . The method of  claim 56 , wherein the inner wall remains part of the finished contact lens.  
   
   
       62 . The method of  claim 56 , further comprising the step of removing the outer wall after the step of curing the substantially flexible material.  
   
   
       63 . The method of  claim 56 , wherein the mold further comprises a lower section.  
   
   
       64 . The method of  claim 63 , wherein the step of pouring liquefied resin of the substantially rigid material within the inner section includes the step of pouring liquefied resin of the substantially rigid material within the lower section.  
   
   
       65 . The method of  claim 63 , 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.  
   
   
       66 . The method of  claim 56 , wherein the inner wall is disposed at an angle with respect to the horizontal surface.  
   
   
       67 . The method of  claim 66 , wherein the angle is between 5 and 175.  
   
   
       68 . The method of  claim 66 , wherein the angle is selected to maximize the bonding strength between the rigid and flexible portions of the contact lens.  
   
   
       69 . The method of  claim 66 , wherein the angle is about 90 degrees.  
   
   
       70 . The method of  claim 66 , wherein the angle is acute.  
   
   
       71 . The method of  claim 66 , wherein the angle is obtuse.  
   
   
       72 . The method of  claim 56 , wherein the inner wall includes one or more bends for increasing the bonding strength between the rigid and flexible portions.  
   
   
       73 . 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.  
   
   
       74 . 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-dimethylamino-ethyl)methacrylate; and combinations of any of these monomers and/or silicone hydrogel formulations such Cibavision lotrafilcon.  
   
   
       75 . 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.  
   
   
       76 . The method of  claim 56 , wherein the mold includes a base curve that automatically forms a posterior surface of the hybrid contact lens.  
   
   
       77 . The method of  claim 56 , further comprising the step of lathing the cured lens materials to form anterior and posterior lens surfaces.  
   
   
       78 . The method of  claim 77 , wherein surface modifications to correct aberrations of the lens-eye system are provided on the anterior and/or posterior surfaces.  
   
   
       79 . The method of  claim 77 , wherein the surface profile of the anterior and/or posterior surface is modified to contain a multi-focal feature for the correction of presbyopia.