Insert assembly for manufacturing intraocular lenses

An injection mold comprising:

• a first injection mold half in which an insert assembly is received, wherein the insert assembly comprises:
• an insert assembly end surface, which bounds an injection mold cavity of the injection mold for forming the first casting mold half and which extends substantially perpendicular to an axial centerline of the insert assembly;
• an outer part assembly which has an outer part assembly end surface which forms a part of the insert assembly end surface;
• an inner part which has an optically accurately defined end surface which in a mounted condition is substantially adjacent the outer part assembly end surface and which forms a part of the insert assembly end surface;
• and
• at least one notch in the insert assembly end surface which forms a bounding structure cavity for forming a bounding structure which is an integral part of the first casting mold half to be formed with the injection mold, such that, in a condition of the first and the second casting mold halves placed onto each other, the bounding structure abuts against the second casting mold half and bounds at least one haptics cavity which links up with the lens cavity, wherein the haptics cavity is so configured that in use of the casting mold, after curing of monomeric material deposited in the casting mold, an ophthalmic device in the implementation of an intraocular lens is formed which comprises a lens and integrally formed-on haptics;
• a second injection mold half which is movable relative to the first injection mold half from a closed to an opened position and vice versa;
• and
• a first injection mold cavity which is formed in the closed condition of the injection mold, which is at least partly bounded by the insert assembly end surface of the first insert assembly, and which is configured for manufacturing the first casting mold half.

A method for manufacturing a casting mold for manufacture of an ophthalmic device, wherein the casting mold comprises a first casting mold half and a second casting mold half which in a condition placed onto each other bound a lens cavity, wherein the method comprises:

• providing an injection mold comprising:
• a first injection mold half in which an insert assembly is received, wherein the insert assembly comprises:
• an insert assembly end surface, which bounds an injection mold cavity of the injection mold for forming the first casting mold half and which extends substantially perpendicular to an axial centerline of the insert assembly;
• an outer part assembly which has an outer part assembly end surface which forms a part of the insert assembly end surface;
• an inner part which has an optically accurately defined end surface which in a mounted condition is substantially adjacent the outer part assembly end surface and which forms a part of the insert assembly end surface;
• and
• at least one notch in the insert assembly end surface which forms a bounding structure cavity for forming a bounding structure which is an integral part of the first casting mold half to be formed with the injection mold, such that, in a condition of the first and the second casting mold halves placed onto each other, the bounding structure abuts against the second casting mold half and bounds at least one haptics cavity which links up with the lens cavity, wherein the haptics cavity is so configured that in use of the casting mold, after curing of monomeric material deposited in the casting mold, an ophthalmic device in the implementation of an intraocular lens is formed which comprises a lens and integrally formed-on haptics;
• a second injection mold half which is movable relative to the first injection mold half from a closed to an opened position and vice versa;
• and
• a first injection mold cavity which is formed in the closed condition of the injection mold, which is at least partly bounded by the insert assembly end surface of the first insert assembly, and which is configured for manufacturing the first casting mold half;
• and
• providing a second injection mold comprising:
• a second insert assembly provided with an optically accurately defined surface;
• and
• a second injection mold cavity which is formed in the closed condition of the injection mold, and which is at least partly bounded by the optically accurately defined surface of the second insert assembly, and which is configured for manufacturing the second casting mold half;
• injection molding the first casting mold half with an optically accurately defined surface part;
• and
• injection molding the second casting mold half with an optically accurately defined surface part;
• wherein in a condition of the first and the second casting mold halves placed onto each other, the bounding structure of the first casting mold half abuts against the second casting mold half and bounds at least one haptics cavity which links up with the lens cavity, wherein the haptics cavity is so configured that in use of the casting mold, after curing of monomeric material deposited in the casting mold, an ophthalmic device in the implementation of an intraocular lens is formed which comprises a lens and integrally formed-on haptics.

A method for manufacturing an intraocular lens, wherein the method comprises:

• providing a casting mold, the casting mold comprising:
• a first casting mold half with an optically accurately defined surface part, wherein the first casting mold half is manufactured with an injection mold comprising:
• a first injection mold half in which an insert assembly is received, wherein the insert assembly comprises:
• an insert assembly end surface, which bounds an injection mold cavity of the injection mold for forming the first casting mold half and which extends substantially perpendicular to an axial centerline of the insert assembly;
• an outer part assembly which has an outer part assembly end surface which forms a part of the insert assembly end surface;
• an inner part which has an optically accurately defined end surface which in a mounted condition is substantially adjacent the outer part assembly end surface and which forms a part of the insert assembly end surface;
• and
• at least one notch in the insert assembly end surface which forms a bounding structure cavity for forming a bounding structure which is an integral part of the first casting mold half to be formed with the injection mold, such that, in a condition of the first and the second casting mold halves placed onto each other, the bounding structure abuts against the second casting mold half and bounds at least one haptics cavity which links up with the lens cavity, wherein the haptics cavity is so configured that in use of the casting mold, after curing of monomeric material deposited in the casting mold, an ophthalmic device in the implementation of an intraocular lens is formed which comprises a lens and integrally formed-on haptics;
• a second injection mold half which is movable relative to the first injection mold half from a closed to an opened position and vice versa;
• and
• a first injection mold cavity which is formed in the closed condition of the injection mold, which is at least partly bounded by the insert assembly end surface of the first insert assembly, and which is configured for manufacturing the first casting mold half;
• and
• a second casting mold half with an optically accurately defined surface part, wherein the first casting mold half and the second casting mold half in a condition placed onto each other bound a lens cavity, which lens cavity is at least partly bounded by said optically accurately defined surface parts,
• wherein the casting mold is provided with:
• a bounding structure which is an integral part of the first casting mold half, such that in a condition of the first and the second casting mold half placed onto each other, the bounding structure abuts against the second casting mold half and bounds at least one haptics cavity which links up with the lens cavity, wherein the haptics cavity is so configured that in use of the casting mold, after curing of monomeric material deposited in the casting mold, an ophthalmic device in the implementation of an intraocular lens is formed which comprises a lens and integrally formed-on haptics;
• injecting an amount of monomeric material into the first casting mold half;
• placing the second casting mold half on the first casting mold half;
• and
• curing the monomeric material that is in the casting mold for forming in the casting mold an intraocular lens which comprises a lens and integrally formed-on haptics.