KR20050035263A - Method of manufacturing an electro-active lens - Google Patents

Abstract

A method of manufacturing an electro-active lens is disclosed. The lens is manufactured by providing a lens blank (10) having a front and back surface, a thickness, and an index of refraction. An electro-active element is placed on one of the front or back surfaces of the lens blank (20). A covering surface is then formed over the surface of the lens blank containing the electro-active element (30). In some embodiments, the electro-active lens may then be surfaced to provide a desired fixed optical power (1960) and edged to fit within a spectacles frame (1950).

Description

Method of manufacturing an electro-active lens

The present invention relates to an effective method of making an electro-active lens.

In 1998, about 9,200 million vision measurements were performed in the United States alone. Most of these measurements include global checks for internal and external eye pathologies, analysis of muscle balance and binocularity, corneal and in many cases pupil measurements, and finally objective and subjective refraction measurements. It was.

Refraction measurements are performed to understand / diagnose the magnitude and type of refraction errors in the eye. Generally, the types of refractive errors that can be diagnosed and measured are myopia, hyperopia, astigmatism and presbyopia. Current refractometers (poropters) attempt to correct vision with 20/20 distance and near and in some cases 20/15 distance vision; However, this is an exception.

It should be noted that the theoretical limit that the retina of the eye can process and define vision is about 20/08. This is much better than the visual acuity level usually obtained by both methods of current refractometers (poropters) and conventional spectacle lenses. Missing from this conventional design is the ability to detect, quantify, and correct non-traditional refractive errors such as aberrations, irregular astigmatism, or lens layer irregularities. Such aberrations, irregular astigmatism and / or lens layer irregularities may be a result of the visual system, aberrations caused by conventional eyewear, or a combination of the two.

Summary of the Invention

In an exemplary embodiment of the invention, a method of making an electro-active lens from a lens blank is disclosed. The lens blank includes the front surface, back surface, thickness and refractive index. The electro-active element lies on the front or back surface of the lens blank. The method also includes forming a covering layer over the surface of the lens blank comprising the electro-active element.

In another exemplary embodiment another method of making an electro-active lens is disclosed. The method includes molding a lens blank with a front surface, back surface, thickness and refractive index around the electro-active element.

Aspects of the invention will be described in more detail with reference to exemplary embodiments as shown in the appended drawings.

1 is a process diagram of a method of making an electro-active lens according to an exemplary embodiment of the present invention.

2 is a process diagram of a method of manufacturing an electro-active lens according to an exemplary embodiment of the present invention.

2A-2F illustrate lenses of various stages within the method shown in FIG. 2.

3 shows a top view of a semi-finished fly-away mold gasket in accordance with an exemplary embodiment of the present invention.

4 shows a cross-sectional view of the semi-finished fly-away mold gasket of FIG. 3.

5 is a process diagram of a method of making an electro-active lens according to another exemplary embodiment of the present invention.

5A-5F illustrate lenses of various stages within the method shown in FIG. 5.

6 is a process diagram of a method of making an electro-active lens according to another exemplary embodiment of the present invention.

6A-6E illustrate lenses of various stages within the method shown in FIG. 6.

7 is a process diagram of a method of making an electro-active lens according to an exemplary embodiment of the present invention.

FIG. 7A shows an electro-active lens made by the method shown in FIG. 7.

8A-8C illustrate a conductive bus arrangement in accordance with another embodiment of the present invention.

9A-9C show exemplary embodiments of electro-active lenses with conductive bus arrangements.

10A shows a rear view of a spectacle frame with an electro-active lens made in accordance with an exemplary embodiment of the present invention.

10B shows a top view of a spectacle frame with an electro-active lens made in accordance with an exemplary embodiment of the present invention.

11A and 11B show another embodiment of the spectacle frame of FIGS. 10A and 10B with an electro-active lens article according to an exemplary embodiment of the present invention.

12A and 12B show another embodiment of the spectacle frame of FIGS. 10A and 10B with an electro-active lens article according to an exemplary embodiment of the present invention.

13A-13D illustrate battery attachment secured to or near a frame hinge in accordance with an exemplary embodiment of the present invention.

14 illustrates an integrated electrical component for use in the manufacture of an electro-active lens in accordance with an exemplary embodiment of the present invention.

15 illustrates another embodiment of an integrated electrical component for use in the manufacture of an electro-active lens in accordance with an exemplary embodiment of the present invention.

16 is a process diagram of a method of finishing and securing an integrated electrical component in the manufacture of an electro-active lens according to another exemplary embodiment of the present invention.

16A-16E illustrate lenses of various stages within the method shown in FIG. 16.

17 is a process diagram of a method of finishing a lens with an electrical component in the manufacture of an electro-active lens according to another exemplary embodiment of the present invention.

17A-17E illustrate lenses of various stages within the method shown in FIG. 17.

In accordance with an exemplary embodiment of the present invention, a method of making an electro-active lens is disclosed. Electro-active lenses are used to provide vision correction for one or more focal lengths and further correct non-traditional refractive errors, including higher order aberrations.

Descriptions of various terms are provided to aid in understanding certain embodiments of the invention. "Adhesion" may include bonding, depositing, adhering, and other well-known methods of attachment. A “controller” may include or include a processor, microprocessor, integrated circuit, IC, computer chip and / or chip. A "conductive bus" serves to conduct data in the formation of an electrical signal from one location to another. "Near refraction errors" can include presbyopia and other refraction errors that need to be corrected for a clear view at close range. “Mid-range refractive error” may include other refraction errors that need to be corrected to look clean at presbyopia and medium distance. The "far refraction error" may include other refraction errors that need to be corrected to look clean from a distance. “Typical refractive error” may include myopia, hyperopia, astigmatism and / or presbyopia. “Non-normal refractive errors” can include irregular astigmatism, aberrations of the visual system, and other refractive errors not included in the usual refractive errors. "Optical refraction error" can include aberrations associated with lens optics.

In certain embodiments “glasses” may include one lens. In other embodiments the “glasses” may comprise one or more lenses. "Multi-focal" lenses may include bifocal, triplefocal, quadfocal and / or progressive additional lenses. A “finished” lens blank may include a lens blank that finishes the optical surface on both sides. A "semi-finished" lens blank has an optical surface with only one side finished, while the other side can have a non-optically finished lens and such lenses can be used, for example, to make the lens usable. And / or further modifications such as polishing. "Unfinished" lens blanks do not have a finished surface on any side. "Base lens" refers to the non-electro-active part of the finished lens blank.

"Surface" may include grinding and / or grinding extra material to finish an unfinished surface of a semi-finished or unfinished lens blank. Lens blanks are also finished using free-form machining techniques recently adopted by the ophthalmic lens industry. Freeform technology not only allows the completely arbitrary shape to lie on the lens blank used to complete conventional error correction, but also corrects higher order aberrations that provide non-traditional error correction leading to vision correction of 20/20 or more. Used. Lens blanks can also be fabricated by joining two or more lens wafers together to form a finished lens or semi-finished lens blank. The lens blank is produced using a free forming technique that first corrects one or both of conventional and non-traditional refractive errors, whether finished, unfinished or semi-finished.

A method of making an electro-active lens as shown in FIG. 1 is disclosed. The method includes providing a lens blank as shown in step 10. The lens blank can be any type of lens blank and has a front and back surface, thickness and refractive index. In step 20 the electro-active element is placed on the front or back surface of the lens blank. In step 30 a covering layer is formed over the surface of the lens blank comprising the electro-active element. This covering layer protects the electro-active element and fixes the electro-active element in position on the lens blank. The material used to create the covering layer also combines with the lens blank to provide distance vision correction fixed to the wafer of the lens.

The electro-active element comprises one or more electro-active materials, such as polymer gels and / or liquid crystals, which, when activated by an applied electrical voltage, provide a refractive index that varies with the amount of electrical voltage applied to the electro-active material. When the wearer views through the area of the electro-active lens including the electro-active element, the wearer achieves vision correction based on the refractive index of the electro-active element, which is dependent on the vision correction provided by the non-electro-active part of the lens. Is added. Suitable electro-active materials include various types of liquid crystals and polymer gels. These types include nematic, smetic and cholesteric liquid crystals, polymer liquid crystals, polymer dispersed liquid crystals and polymer stabilized liquid crystals as well as electro-optic polymers.

If a liquid crystal such as a nematic liquid crystal is used as the electro-active material, an alignment layer is required because nematic and many other liquid crystals are birefringent. That is, they display two different focal lengths upon exposure to unpolarized light with no voltage applied. This birefringence causes a double or blurry image on the retina. To mitigate this birefringence a second layer of electro-active material is used and aligned at right angles to the first layer of electro-active material. In this way both polarization of light is equally focused by both layers and all light is focused at the same focal length.

Alternatively, the use of cholesteric liquid crystals with large chiral components is used instead as the preferred electro-active material. Unlike nematic and other common liquid crystals, cholesteric liquid crystals do not have the polarity of nematic liquid crystals and avoid the need for multiple layers of electro-active materials.

Various electro-active layers for use in the electro-active elements of embodiments of the invention are described in PCT / US03 / 12528, filed April 23, 2003, which is incorporated herein by reference.

Lens blanks may be any type of lens blank and include, for example, semi-finished blanks, unfinished lens blanks, lens wafers, preformed optics or finished lenses. The covering layer is formed by conformal sealing by molding, surface-casting or covering the lens blank with the lens wafer.

In an exemplary embodiment of the invention the electro-active lens is made from a blank semi-finished with a covering layer formed by conformal sealing. The electro-active element lies on the front or back surface of the semi-finished blank. Conformal sealing forms a protective covering layer on the surface of the lens blank in which the electro-active element is located and deposits the electro-active element in the lens. 2 illustrates a method of making an electro-active lens using a conformally sealed semi-finished blank in accordance with an embodiment of the invention. 2A-E show the lenses of various stages within the method shown in FIG. 2. As shown in FIG. 2A, a semi-finished blank 230 having a back concave surface 202 and a front convex surface 204 is selected in step 100. As shown in FIG. 2B, in step 110 the recess 205 is cut in the front convex surface 204 of the semi-finished blank 230. In step 120 an electro-active element is placed in recess 205. Furthermore, conductive bus 210 connected to electro-active element 200 lies in recess 205. Preferably, conductive bus 210 is constructed of an optically transparent and flexible material, such as a molded or cast polymer film of an ophthalmic grade material coated with a transparent conductive material such as indium-tin-oxide and / or conductive polymer. The conductive bus 210 has a number of gaps, which promotes better bonding of the conductive bus to the lens blank 230.

As shown in FIG. 2D the electro-active element 200 and the conductive bus 210 using a mold 220 comprising a sealant such as a transparent resin, optionally with a refractive index, preferably at or near the refractive index of the lens blank. Silver may be conformally sealed into the semi-finished blank 230.

The electro-active element 200 and the conductive bus 210 are placed in the mold 220 and covered with the lens blank 230. The resin is cured only by thermal energy, light energy or a combination of the two. The light source includes one or a combination of visible, ultraviolet or infrared light sources.

The semi-finished blank 230 may be demolded as shown in FIG. 2E to provide a semi-finished electro-active lens blank 235 at step 140. The cured resin produces a covering layer 215 on the front surface 204, which has the effect of burying the electro-active element 200 and the conductive bus 210 in the electro-active lens. The electro-active lens blank 235 has a covering surface 208 with the same radius of curvature as the mold 220. The radius of curvature of the covering surface 208 is combined with the radius of curvature of the rear concave surface 202 to provide a fixed optical power.

A firm, scratch-resistant coating is applied to the lens as shown in step 150. Hard coating is achieved by dipping or spin coating the lens prior to finishing the semi-finished electro-active lens blank 235. The hard coating is applied to the interior surface of the mold 220 before filling the mold with resin against the front convex surface 204 of the lens blank and curing the resin so that when the resin is cured and the covering layer is formed, the hard coat is already on the covering surface 208. Should be recognized.

As shown in FIG. 2F, the semi-finished electro-active lens blank 235 can be finished with the desired prescription by surface-surfacing the electro-active lens blank 235 by a known technique for producing an electro-active lens 240 in step 160. The electro-active lens 240 is then edged to fit snugly within the spectacle frame.

It is to be appreciated that the front convex surface 204 and the rear concave surface 202 of the lens blank 230 may or may not have some degree of curvature, which will be applied later through various surfacing techniques. When the lens blank 230 is conformally sealed to bury the electro-active element 200 and the conductive bus 210, the final degree of curvature added to the rear lumber surface 202 and the covering surface 208 after finishing rather than the front convex surface 204 is the electro-active lens 240 Determine the optical properties of

In an exemplary embodiment of the present invention, the manufacture of electro-active lenses utilizes preformed optics, for example, but not limited to finished or single vision lenses. FIG. 6 shows a method of making an electro-active lens from a lens blank, which is a single vision lens using a conformal sealing approach similar to that described above with respect to FIG. 2 to create a covering layer comprising an electro-active element in the lens. However, unlike the semi-finished blanks described with respect to the method of FIG. 2, single vision lenses already have a prescription and do not require additional surfacing to provide the correct fixed optical power to the wearer of the lens. Thus in this embodiment preferably conformal sealing is performed in a manner that does not change the power of the original finished lens. This is achieved for example by using a mold which creates a radius of curvature on the covering surface of the covering layer which is identical to the front convex surface of the single vision lens. However, even if a finished single vision lens is used, the optical power is changed by using a mold that creates a covering layer with a covering surface with a desired curvature that is different from the front convex surface of the single vision lens, if desired.

As shown in FIG. 6, in step 700 the single vision base lens 800 may be selected as further shown in FIG. 6A. In step 710 the recess 810 is cut into the front convex surface 804 of the single vision base lens 800 shown in FIG. 6B. Alternatively, the single sight base lens 800 already has a recess 810 as the single sight base lens 800 is formed within the single sight base lens 800 during the original manufacture. In step 720 the electro-active element 200 and conductive bus 210 are placed in recess 810 as shown in FIG. 6C. In step 730 the electro-active element 200 and bus 210 are conformally sealed using resin-containing mold 820 as shown in FIG. 6D. In step 740 mold 820 is removed and a hard coating is optionally applied. In certain embodiments the hard coat is removed from the mold during conformal sealing. In this case the inner concave surface of the mold used to create the convex covering surface 808 of the covering layer was cured and pre-coated with the hard coat moved during conformal sealing. Since the single sight base lens described in this example is already finished to have the desired fixed optical power before conformal sealing, the inner surface of the mold 820 is preferably concave with the same radius of curvature as the front convex surface 804 of the single sight base lens 800. Do. This yields a concave covering surface 808 after removal of the single sight base lens 800 from the mold 820 after conformal sealing substantially equal to the curvature of the front convex surface 804 as shown in FIG. 6E, which is within the fixed optical power of the single sight base lens 800. It does not cause any change.

The use of conformal seals in the manufacture of electro-active lenses can reduce the number of stock-keeping-units (SKUs) to 539, compared to the number of SKUs typically required for conventional lenses. Significant decrease.

In order to understand the significance of these improvements, one should understand the number of typical lens blanks needed to process most prescriptions. About 95% of the calibration prescriptions include sphere power calibration within the range of -6.00 diopters to +6.00 diopters with a 0.25 diopter increase. Based on this range there are about 49 commonly prescribed spherical powers. About 90% of these prescriptions, including astigmatism correction, will be in the range of -4.00 diopters to +4.00 diopters with a 0.25 diopter increase. Based on this range there are about 33 commonly prescribed astigmatism (or cylindrical) powers. However, because astigmatism has an axial component, there is about 180 degrees in the direction of astigmatism, which is usually prescribed in 1 degree increments. Thus there are 180 different astigmatism prescriptions.

Moreover, many prescriptions include a bifocal component that corrects presbyopia. About 95% of these intestines with presbyopia correction are in the range of +1.00 to +3.00 with a 0.25 diopter increase resulting in about nine commonly prescribed presbyopia powers.

This leads to the possibility of prescribing 2,619,540 (49 x 33 x 180 x 9) different lenses and requires a large number of SKUs for lens manufacturers. Many of these SKUs are further augmented by a variety of raw materials useful for lens manufacture, as well as other specific features useful for inclusion in lenses such as photochromic shades. By providing most vision correction with electro-activity, the number of SKUs is greatly reduced.

In another exemplary embodiment of the present invention, an electro-active lens is made by attaching two lens wafers together to have an electro-active element sandwiched between the two lens wafers.

As shown in FIG. 7, in step 1000 the front and rear lens wafers are selected to have the desired optical properties of a fixed distance refractive power that matches the wearer's vision prescription. As shown in FIG. 7A, the concave back lens wafer 900 and the convex front lens wafer 930 are selected. The front lens wafer 930 has a radius of curvature of R1 and the rear lens wafer 900 has a radius of curvature of R2. The fixed optical power of the lens wafer is equal to (n-1) x (1 / R1-1 / R2) "n" equal to the refractive index of the material used to make the lens wafer. If both R1 and R2 are parallel to each other, the resulting base lens formed by attaching the lens wafer has a fixed optical power of zero.

Like other electro-active lenses described herein, optical power for near and medium vision correction is derived from the addition of fixed optical power, which is generally viewed through the area of the electro-active lens containing the electro-active element. In addition to the optical power provided, optical power is provided that provides far vision correction. However, it should be appreciated that the lens is manufactured to have a fixed optical power equal to zero so that all vision correction is provided by looking through the area of the electro-active lens including the electro-active element. Similarly, viewing through the area of the lens including the electro-active element provides correction of non-normal refractive errors, including correction of high order aberrations for all focal lengths.

Recognizing that it is possible to correct for non-traditional refraction errors using only base lenses or in combination with electro-active elements through the use of customized casting, free-form manufacturing or light induced refractive index changes or light induced refractive changes. Should be. In these embodiments the base lens provides correction of non-traditional refractive errors independent from the electro-active element, which corrects for errors associated with conventional refractive errors such as spherical power adjustment or presbyopia.

Again in FIG. 7A the recess is cut into one or both of the opposite surface of the convex surface of the front lens wafer 930 and the opposite surface of the concave surface of the back lens wafer 900. Alternatively, the recess is already present in the lens wafers 900, 930 and is created in advance as at the time of manufacture. 7A shows the front lens wafer 930 with a single recess 940 in the opposite surface of the convex surface of the front lens wafer 930. The electro-active element 910 and flexible conductive bus 920 are positioned between the rear lens wafer 900 and the front lens wafer 930, and the electro-active element 910 and flexible conductive bus 920 are positioned to fit within the recess 940. The front lens wafer 930 and back lens wafer 900 are bonded together with an index matched adhesive to produce an electro-active lens as described in step 1030.

In a particular embodiment the electro-active lens is made from a lens wafer laminated with a back lens wafer providing cylindrical power and a combination of back and front wafers completing the spherical power of the lens.

In a particular embodiment of the manufacture of the electro-active lens as shown in FIG. 7, it should be appreciated that step 1010 is optional and no recess is required for the conductive bus and the electro-active element. For example, in certain embodiments the electro-active element and the conductive bus are sandwiched between two lens wafers while maintaining a proper relationship of the two wafers so as not to generate prismatic power unless the particular vision needs of the wearer is to be addressed. Index matched ophthalmic grade resins are only positioned by the end gasket until applied and cured between the layers, at which point the gasket can be removed resulting in an electro-active lens.

In another exemplary embodiment of the present invention, an electro-active lens can be made by molding the entire lens around an electro-active element disposed in the bulk of the final electro-active lens article. 3 shows a top view of a semi-finished fly-away mold gasket 610 having an electro-active element 200 and buses 410-413. The electro-active element 200 is electrically connected to four conductive buses 410, 411, 412, 413. Conductive buses 410, 411, 412 and 413 extend radially outwardly from electro-active element 200 with respect to mold gasket ring 420. 4 shows a cross-sectional view of the semi-finished fly-away mold gasket of FIG. 3, including electro-active element 200 and buses 410-413.

5 shows a method of making an electro-active lens using a fully molded semi-finished blank according to an embodiment of the invention. 5A mold assembly including upper mold 600 and lower mold 620 and gasket upper cavity 640, lower gasket cavity 650, fly-away gasket with electro-active element and conductive bus in step 500 610 is selected. As shown in FIG. 5B, in step 510 the gasket 610 overlies the lower mold 620. In step 520 resin 660 can be added to the mold assembly, which will form a lens upon curing. The resin passes through the lower gasket cavity 650 through a space between or a gap in the conductive bus. It should also be appreciated that the mold assembly shown in FIG. 5D may be filled with resin through a sealable gap in the side of the gasket 610.

Ophthalmic grade resins such as those used for conformal seals are used. These resins include diethilenglycol bisallycarbonate, high index polymers and other known ophthalmic resin materials such as PPG Industries, Pittsburgh, Pennsylvania, Inc. CR39 ^™ . As shown in FIG. 5D, in step 530 the upper mold 600 is positioned above the gasket upper cavity 640. As shown in FIG. 5E, the resin between the upper mold 600 and the lower mold 620 is cured in step 540. In step 550 the upper mold 600 and the lower mold 620 are removed together with the outer gasket ring 420 to produce a semi-finished electro-active lens blank, which is then subjected to various finishing techniques to produce a finished electro-active lens. .

It should be appreciated that while this embodiment describes the molding process for cast molding, injection molding is also used in the manufacture of electro-active lenses. In these embodiments a material such as polycarbonate is injection molded into the dye and cured around the conductive bus and the electro-active element included in the dye to produce the electro-active lens.

Various conductive bus arrangements are used in the manufacture of the electro-active lenses of the exemplary embodiments of the present invention. In general, the bus or bus group is located in any way that conducts electricity radially outwards from the electro-active element. As shown in FIG. 8A, the electro-active element 200 is electrically connected to a single conductive bus 1100. Bus 1100 extends radially outward from electro-active element 200. When the bus extends out of the electro-active element it is used as an electrical lead connecting the power source directly or indirectly to the electro-active element 200.

In another embodiment, as shown in FIG. 8E, the electro-active element 200 is electrically connected to a plurality of conductive buses, such as conductive buses 1110, 1111, 1112. In the single conductive bus of FIG. 7A, each bus 1110, 1111, 1112 is electrically connected to one end of the electro-active element 200 and extends radially outward from the electro-active element 200. Preferably, each bus 1110, 1111, 1112 is evenly spaced around the electro-active element 200. It should be understood that any number of buses are arranged to extend outwardly from the electro-active element 200 in whole or in some carriage-wheel shape. Many buses include the advantage of providing more locations where electrical components such as range finders, controllers, and power supplies are positioned to activate the electro-active elements and provide electro-active vision correction.

In another embodiment, as shown in FIG. 8C, the electro-active element 200 is electrically connected to a conductive bus 1120 in the form of a disk that at least partially surrounds the electro-active optical element 200. Conductive bus 1120 includes a number of perforations or gaps 1125. When an electro-active lens is manufactured using a lens wafer, these holes 1225 allow the resin to flow through and around the conductive bus 1120 which confines the electro-active element 200 into the lens blank during manufacture of the electro-active lens. There is and increases the junction between the conductive bus 1120 and the lens wafer. Conductive bus 1120 is electrically connected to the electro-active optical element 200 at the inner end of the disk.

9A shows an electro-active lens 1200 with a conductive bus arrangement connected to a range finder and controller. The conductive bus arrangement includes an electro-active element 1205, an electro-active substrate wafer 1210, an integrated controller / rangefinder 1220, a base lens 1230 and drive signal buses 1240.

The rangefinder is a chip that includes a transmitter, a microprocessor, an integrated circuit, or at least one memory component coupled to a controller. The controller stores information such as vision prescriptions, including the wearer's prescriptions for some other viewing distances. The controller may be a component of the range finder or its entirety. However, it should be appreciated that the controller and the range finder are separate components and do not need to be located at the same location, only the controller and the range finder are electrically connected. In addition, other field detectors, such as a micro tilt switch that measures the wearer's head tilt or an eye tracker that measures the wearer's sight line, allow the wearer to see what object the viewer is viewing and how the electro-active element provides proper vision correction to the wearer. It may be used in place of or in combination with a range finder to determine if it should be activated to provide a focal length corresponding to the object of view.

The range finder is in electrical communication with the electro-active element via a signal distributed via a conductive bus, directly or via a controller. If the rangefinder detects that the focal length generated by the electro-active element must be tm positioned to provide a different focal length, the rangefinder electrically signals the controller. In response to this signal, the controller adjusts the voltage applied to the electro-active element to produce a refractive index change, either alone or in combination with other refractive index changes, such as provided by the fixed optical power of the base lens to provide the desired vision correction. do. This refractive index change is generated in a pattern in which the refractive index change is prescribed using a pixylated electro-active element or a combination of conventional and non-traditional error corrections, one or both of which are prescriptions stored in the memory of the controller. If used, it is used to correct conventional refractive error, unusual refractive error. The new refractive index produces a suitable optical power in the electro-active lens that corresponds to the change in focal length.

Pixylated electro-active elements are used when non-traditional refractive errors are corrected only by electro-activity, not through the use of free-form lens technology. Non-traditional refraction errors are corrected by applying a voltage to the electro-active element, which creates a refractive index change in a number of pixels contained within the electro-active element and thus combines to provide a correction for the non-traditional refraction error. Create a grid or pattern with a refractive index.

Rangefinders use a variety of sources such as lasers, light emitting diodes, radio-frequency wavelengths, microwave or ultrasonic impulses to locate objects and determine their distance. Vertical cavity surface-emitting lasers (VCSELs) can be used as the light transmitters. The small size and compact shape of these devices make them very attractive for this application. In another embodiment, an organic light emitting diode or OLED is used as the light source for the range finder. The advantage of such a device is that the OLED can be made very transparent. It can therefore be a good rangefinder that aesthetically satisfies the lens since the OLED can be incorporated into a lens or frame without any noteworthy features.

In FIG. 9B, which is a cross-sectional view from the top of the lens shown in FIG. 9A, the controller / rangefinder 1220 is included within the electro-active substrate 1250 processed to produce the electro-active lens. Vias 1290 are used to provide electrical connections to the circuitry embedded within the base lens 1230. The outer surface of the base lens 1230 is then coated with transparent conductors 1293, 1296, which can be used to make electrical contact with the positive and negative terminals of the external power source, electro-active by applying a potential across the two outer surfaces of the lens. Power may be applied to element 1205 and controller / rangefinder 1220.

The controller / rangefinder 1220 is connected to the electro-active element 1205 by a series of conductive buses of any type described herein. Preferably the bus is a carriage wheel structure in which the bus forms spokes with electro-active elements acting as hubs. The wagon wheel structure provides a choice of controller / rangefinder 1220 fixed on the lens 1200 in many different locations. The controller / ranger 1220 is connected to any position on any conductive bus 1240, preferably at the lens end near the frame, or alternatively the controller / rangefinder 1220 is attached to a frame connected to the conductive bus 1240 via leads. This carriage-wheel conductive bus formation also provides multiple locations for applying voltage across the electro-active element 1205 from the power source.

Alternatively, in certain embodiments an electrically conductive surface is used as shown in FIG. 9C. In these embodiments a conducting through mechanism such as a clamp with a first jaw 1282 and a second jaw 1284 is used, with each jaw attached to the opposite terminal of the power source. The jaws 1282, 1284 are clamped such that a portion of the jaws penetrates the surface of the lens 1200 or otherwise contacts the surfaces of the transparent conductors 1293, 1296 to conduct electrical power from the power source. In Figure 9C the conductive jaws 1282, 1284 are shown on the opposite side of the lens. However, it should be recognized that both the jaws 1282 and 1284 penetrate the same side of the lens if proper insulation separates the positive and negative leads.

In another embodiment of the present invention, contact with a power supply such as a battery is secured on or near the frame hinge 1305 of the spectacle lens, including the electro-active lens 1200 manufactured according to the method described herein. . 10A shows a rear view of a spectacle frame in contact with a fixed power supply on or near a frame hinge in accordance with an exemplary embodiment of the present invention. 10B shows a rear view of a spectacle frame in contact with a battery fixed on or near a frame hinge in accordance with an exemplary embodiment of the present invention. In some embodiments, a power supply, such as battery 1320, is connected to the lens through the front of the lens by drilling holes 1330 in power terminals 1380, 1385 in the lens.

In some embodiments controller / rangefinder 1220 is secured within lens 1200 and power to controller / rangefinder 1220 and electro-active element 1205 is supplied by battery 1320 attached to frame 1300. 10A and 10B illustrate embodiments in which contact 1310 to battery 1320 is secured on or near frame hinge 1305, such as on the eyeglass region of the frame. Alternatively, as shown in FIGS. 11A and 11B, contact 1310 with battery 1320 may be through the rear of lens 1200. Contact 1310 consists of a transparent conductive material or from a transparent conductive material such as ITO or other conductive oxide.

12A and 12B show an alternative embodiment of contact 1310 with battery 1320 fixed on or near frame hinge 1305. Contact 1310 extends into the side of 1200 of the lens through the side of frame 1300. In this case it is advantageous to coat the outer edge of the lens 1200 with two conductive strips electrically isolated from each other to disturb the current supplied to the device. These conductive strips provide better surface contact and reduce the impedance to the voltage supplied to the electro-active element 1205.

It is also possible to use screws and frame hinges to frame secure the external power supply. In some embodiments the controller is also secured to the frame in this manner. 13A-13D show a fixed battery attachment on the frame hinge. Battery attachment includes a battery 1320 with an attached support ring 1420, frame screw 1410 and frame hinge 1305. The battery support ring 1420 is inserted into the frame hinge 1305 to receive the screws 1410. Screw 1410 is inserted through frame hinge 1305, which is sewn to retain screw 1410. FIG. 13D illustrates an alternative embodiment in which the battery 1320 includes a battery cradle 1322 in which the battery 1320 is removed or replaced without loosening the screw 1410 from the battery support ring 1420.

The controller, range finder and power supply of the electro-active lens are individual components placed on the lens or spectacle frame or integrated into a single module. 14 illustrates an integrated battery, controller and range finder forming a single control module for use in accordance with an exemplary embodiment of the present invention. The control module includes a semi-circular photo-detector 1700 and a semi-circular light emitting diode 1710 together forming the rangefinder as the first component of the module. The controller 1720 is placed behind the range finder to form a second component, and the disk-shaped battery 1730 is placed behind the controller 1720. As shown in FIG. 15, these components are connected to the electro-active element 1830 via a conductive bus 1820 to switch the focal length of the lens 1800 to provide power to the electro-active element 1839 and provide the vision correction required by the wearer of the lens. Form a single control module 1810 that can be attached.

16 shows a method of finishing and securing a control module integrated in a lens. In step 1900 the layout is selected for the desired eyeglass frame taking into account the lens blank size, the pupil position of the wearer and the distance between them. In step 1910 lens blank 1975, which is generally a pre-formed optical or semi-finished blank, is decentered based on the lens blank size and the wearer's pupil alignment. Also in some cases off-center is desirable to produce the desired prism effect. The lens blank is also rotated when astigmatism correction is provided by the non-electro-active part of the lens. In step 1920 the lens blank 1975 is surface cast or polished to provide the wearer with the necessary distance prescription. In step 1930 the recess is cut or molded into the surface to receive the electro-active element 1977 and the conductive bus 1979. It should be recognized that step 1930 is optional and that the recess has been created in advance. In step 1940 a controller / rangefinder 1981 as well as an electro-active element and a conductive bus, are inserted into the recess and conformally sealed to bury these components in the lens. The bus is preferably directed to a position where the range finder and controller can be placed near the edge of the spectacle frame and preferably near the wearer's leg.

However, as in other embodiments, the controller and rangefinder do not need to be buried in the lens and one or both of them may be added later, such as disposed on the eyeglass frame or on the lens surface, and then electrically connected to the conductive bus contained in the lens. Connected. In step 1950 the lens is edged in form for placement in the spectacle frame and then secured in the frame. When the lens is edged to fit snugly to the spectacle frame, the lens should be edged to remove only the portion of the lens that does not contain the electro-active element. Finally, in step 1960, the battery is connected to the conductive bus. If the controller has not been programmed before installation, it is programmed to include specific information about the wearer, such as the wearer's vision prescription for other focal lengths.

Alternatively, either or both of the range finder, controller and battery are secured on the spectacle frame and connected to the electro-active lens via leads passing through the electro-active element. 17 shows a method of finishing and preparing a lens with a range finder, battery and controller in a spectacle frame. In step 2000 the layout is selected. In step 2010 the pre-formed optical or semi-finished blank can be decentered and rotated as shown in FIG. 17B. If the lens has toric power and the electro-active element is above the optical center of the lens, the bus must be oriented in proportion to the toric axis. In step 2020 the lens is polished into toric and spherical shapes as shown in FIG. 17C. As in step 2030, the lens is edged for placement in the spectacle frame shown in FIG. 17D. The rangefinder, battery and controller represented by the control module 2060 integrated in step 2040 are secured onto the spectacle frame to complete the process as shown in FIG. 17E. Alternatively, it should be appreciated that the integrated control module is fixed on the spectacle frame during frame manufacture.

Prisms are added during various embodiments of electro-active lens fabrication as needed for the wearer's vision needs. For example, when a semi-finished blank is used, a prism may be added and surfaced into the lens as needed by vision prescription, or in some cases the prism may be created by the lens being out of center with respect to the pupil-to-pupillary distance. .

Similarly, another method of modifying an electro-active lens during manufacture is achieved by dyeing the lens after surfacing, preferably before hard coating. The lens can also be made of photo-chromium by conformal coating of the lens with a material that is readily absorbed by a photo-chromium layer or photo-chromium dye. Alternatively, the dyeing is produced by electrochromic dyeing produced by adding an electroactive element or an additional layer of electroactive material to the electroactive.

An optional anti-reflective coating is applied to the lens before or after edging. The electro-active element must be completely sealed in the lens to prevent gas-emissions that occur during application of the anti-reflective coating.

The invention is not limited by the scope of the particular embodiments described herein. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description and the accompanying drawings. Such modifications are therefore intended to fall within the scope of the appended claims below. Furthermore, although the invention is described within the context of a particular implementation within a particular environment for a particular purpose, those skilled in the art will recognize that its usefulness is not so limited and that the invention may be advantageously implemented in any environment for any purpose. Thus, the claims set forth herein should be construed in view of the full spirit of the invention as described herein.

Claims (32)

Providing a lens blank comprising a front and rear lens blank surface, a thickness and a refractive index; Positioning the electro-active element on either the front or back surface of the lens blank; And A method of making an electro-active lens comprising forming a covering layer on a surface of a lens blank comprising an electro-active element. The method of claim 1 wherein the lens blank is selected from the group consisting of semi-finished blanks, unfinished lens blanks, lens wafers, preformed optics and finished lens blanks. The method of claim 1, further comprising forming a recess in the front or rear surface of the lens blank to receive an electro-active element overlying the lens blank. 4. The method of claim 3, wherein the recess is formed by molding or molding the surface of the lens blank. The method of claim 1 wherein the electro-active element is connected to an electric bus. 6. The method of claim 5 wherein the bus is flexible. 6. The method of claim 5 wherein the bus is at least partially surrounding an electro-active element. 6. The method of claim 5 wherein the bus is connected to a transparent electro-active lead that reaches within the end of the electro-active lens. 6. The method of claim 5 wherein the bus comprises a plurality of transparent electrical leads radiating outward from the electro-active element. 6. The method of claim 5 wherein the bus comprises at least one hole. The method of claim 1 wherein said electro-active element is connected to a controller. The method of claim 1 wherein the electro-active element is connected to a power source. 13. The method of claim 12, wherein the power source is connected to a hinge of the spectacle frame. 13. The method of claim 12, wherein the power source is connected to the spectacles of the spectacle frame. 13. The method of claim 12, wherein the power source is connected to a hinge screw of the spectacle frame. 13. The method of claim 12, wherein the power source is included in an electro-active lens. The method of claim 1 wherein the covering layer is formed by molding. The method of claim 1 wherein the covering layer is formed by surface-casting. The method of claim 1 wherein the covering layer is formed by conformal sealing. The method of claim 1, wherein the covering layer is formed by a lens wafer. The method of claim 1, wherein the lens blank is a finished lens blank having the same optical power for the wearer's distance vision prescription. The method of claim 1 wherein the lens blank is a finished lens blank with an optical power equal to zero. The method of claim 1 wherein said electro-active element provides a change in refractive index. 24. The method of claim 23, wherein said refractive change corrects high order aberrations. 24. The method of claim 23, wherein the change in refraction corrects for non-traditional refraction errors. 24. The method of claim 23, wherein the refractive change corrects for conventional refractive errors. The method of claim 1, wherein the electro-active element is connected to a field of view detector. Lens manufactured according to the method of claim 1, characterized in that the lens blank corrects the wearer's usual and non-normal refractive errors and the electro-active element corrects the wearer's spherical error. Providing a lens blank comprising a front and back surface, a thickness and a refractive index, wherein the front or rear lens blank has a recess; Positioning the electro-active element in the recess of the lens blank surface; And A method of making an electro-active lens comprising forming a covering layer on a surface comprising an electro-active element. 32. The method of claim 31 wherein the covering layer is formed by a lens wafer. A method of making an electro-active lens comprising forming a lens blank having a front surface, a back surface, a thickness and refractive index, and a conductive bus around the electro-active element. A base lens; Electro-active elements; And Electro-active lens with front bend, back bend, thickness and refractive index with conductive bus