CN1981233A - Method for producing a transparent optical element, an optical component involved into said method and the thus obtained optical element - Google Patents

Method for producing a transparent optical element, an optical component involved into said method and the thus obtained optical element Download PDF

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Publication number
CN1981233A
CN1981233A CNA2005800224779A CN200580022477A CN1981233A CN 1981233 A CN1981233 A CN 1981233A CN A2005800224779 A CNA2005800224779 A CN A2005800224779A CN 200580022477 A CN200580022477 A CN 200580022477A CN 1981233 A CN1981233 A CN 1981233A
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China
Prior art keywords
micropore
optical module
manufacture method
optical
array
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CNA2005800224779A
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Chinese (zh)
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CN100543518C (en
Inventor
让-保罗·卡诺
克里斯蒂安·博韦
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EssilorLuxottica SA
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Essilor International Compagnie Generale dOptique SA
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    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/10—Filters, e.g. for facilitating adaptation of the eyes to the dark; Sunglasses
    • G02C7/102—Photochromic filters
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/02—Lenses; Lens systems ; Methods of designing lenses
    • G02C7/08—Auxiliary lenses; Arrangements for varying focal length
    • G02C7/081—Ophthalmic lenses with variable focal length
    • G02C7/083—Electrooptic lenses
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/10—Filters, e.g. for facilitating adaptation of the eyes to the dark; Sunglasses
    • G02C7/101—Filters, e.g. for facilitating adaptation of the eyes to the dark; Sunglasses having an electro-optical light valve
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/12—Polarisers
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C2202/00—Generic optical aspects applicable to one or more of the subgroups of G02C7/00
    • G02C2202/18—Cellular lens surfaces

Abstract

The inventive method for producing a transparent optical element (11) consists in producing an optical component (10) provided with at least one transparent cell arrangement (15) juxtaposed in a parallel direction to the surface thereof, wherein each cell is tightly closed and contains a substance exhibiting an optical property, in cutting said optical component along a contour which is defined on the surface and corresponds to the determined shape of the optical element. In a preferred embodiment, the cell arrangement forms a layer whose height perpendicular to the component surface is less than 100 m.

Description

Make the optical element of the method for transparent optical element and the optical module of using and its acquisition
Background technology
The present invention relates to a kind of production with transparent element of optical function, it is applied in the production of the lens (ophthalmic lenses) with different optical characteristic especially.
Technical field
Traditional ametropia correcting lens is to make by the transparent material that its refractive index that is shaped is higher than the refractive index of air.Lens shape is made a choice, thereby make the refraction at material/air interface place can on wearer's retina, form suitable focusing.Thereby eyeglass will cut the appropriate location of the pupil of required relatively correction ocular in the picture frame that is fit to pack into usually.
As everyone knows, change the refractive index in the lens materials scope, can limit geometrical constraint (for example referring to EP-A-0728572) thus.Said method at first proposes at contact lenses.In the process of the whole object lens (solid object) that make to constitute eyeglass, refractive index gradient can be by such as diffusion, and selectivity radiation or selectivity heat and obtain.Although this method is done to produce for each medicable ametropia case and prepared, this method can not be fit to large-scale production well.In addition, this method can be made a series of object lens with multistage refractive index on industrial scale, select object lens that are fit to treat correction ocular the most approaching therein, and by machine work and polishing it is shaped once more, so that it is fit to these eyes.In this case, the step that needs to be shaped once more on lens device makes traditional manufacture method lose attractive force widely.
The ink gun adjustment that proposes used type in the use printer among the U.S. Patent application US 2004/0008319 is parallel to the refractive index of the lens surface of for example flexible focal length lenses group (spectacle lens).Control the drop that these ink guns are used for having the polymer solution of different refractive indexes and be deposited on the surface of object lens, so just the refractive index variable quantity of the objective lens surface that can obtain to want.Polymkeric substance solidifies by radiation or removal of solvents then.In deposition and solidification process, the control of the physical phenomenon of drops and substrate interphase interaction makes this method be difficult to put into practice.In addition, say again at this, the adjustment of refractive index is to obtain in the process of whole object lens that make to form eyeglass, and the subsequent user customization need reshape eyeglass, so whether this method can be applicable to and also be worth discussion in the large-scale production.
Another field that the present invention uses is about color-changing lens (photochromic lenses).The structure of those eyeglasses is associated with skim, and the absorption spectrum of this layer depends on the light that receives.The photochromic dyestuff of this layer is the solid shape normally, although liquid and gelinite have first-class characteristic, especially in the characteristic aspect the reaction velocity of luminance change.
Yet the light-sensitive coloring agent in the known eyeglass is liquid or gelinite, is provided with sept (spacer) and is used for limiting by the shared space of the dyestuff of adjacent transparent interlayer in the thickness of described layer, has aquiclude in this periphery, space.Such eyeglass manufacturing is used for special spectacle-frame.When eyeglass being assembled on another picture frame, can not cut it.But also be difficult to it is adjusted into rectification ametropia eyeglass.
Also maybe advantageously, change the absorption of the light be parallel to described lens surface and/or make such absorption be decided by the light polarization phenomenon.
In the lens of other type that the present invention may use, may mention effective system (active system), in this system, cause changes in optical properties owing to electro photoluminescence.Here it is electrochromism eyeglass, or other has the situations (referring to for example US-A-5359444 or WO 03/077012) of the eyeglass of different refraction performances.These technology are utilized liquid crystal or electrochemical system usually.
In the middle of above-mentioned various types of eyeglasses, or in the middle of the eyeglass in other lens (ophthalmicoptics) scope that is not necessarily limited to, people wish a kind of structure can be provided, its permission can be introduced one or more optical functions with modular mode flexibly with a kind of, simultaneously, consider optical element pack into the specific picture frame or the place of other any selection, or pack into described optical element is remained in any other device of correct position, still keep the cutting possibility eyeglass of resulting optical element.
Summary of the invention
One object of the present invention is to satisfy above-mentioned requirements.Another purpose is to produce optical element on a large scale in industrial scale under suitable condition.
For achieving the above object, the invention provides a kind of method of producing transparent optical element, comprise the steps:
-producing a kind of optical module with the transparent array micropore of at least one row (array of cells), the surface that this micropore is parallel to assembly is set up in parallel, and each micropore is sealed and hold the material with an optical characteristics; And
-delineate on the described surface, corresponding to the profile cut optical module of the reservation shape of optical element.。
Micropore can be inserted various materials, and the material of being inserted depends on their optical property, refractive index for example, and absorptivity or polarization phenomena, and they are to reaction of electricity or light stimulus or the like.
Therefore such structure can have a plurality of application, especially relates to the structure of variable optical function (variableoptical functions).It means optical element surface is divided into discrete pixel, therefore gives very big dirigibility in design, and flexible similarly in the utilization of element.
Especially, it should be noted that optical module can be cut into the outer contour shape of being wanted, enable to make up and be installed together with the various for example frames or the fixed support of the helmet.The technological process of its manufacturing generally includes, and under the situation that does not influence structural intergrity, boring is so that the step that optical element and fixed support tighten together on optical module.
The height that the described layer that is formed by above-mentioned array micropore preferably has is less than 100 μ m.According to a plurality of embodiment of the present invention, this highly is preferably 10～5 μ m, or is preferably 1～10 μ m.Especially best, highly be about 5 μ m.
In context of the present invention, the array micropore that is set up in parallel is distributed rationally, thereby fill factor τ is filled with the shared area of micropore of described material greater than 90% on this fill factor unit of being defined as assembly area.In other words, microwell array accounts for 90% of whole assembly area at least, is at least in the device region that is provided with the array micropore.Preferably, fill factor is between 90%～99.5% and comprise 90% and 99.5%, more preferably, and between 96%～98.5% and comprise 96% and 98.5%.
The diffraction effect of not expecting for dot structure is caused, the size that can set micropore is to mate the wavelength of the spectrum of being discussed.The geometric configuration that micropore is arranged is feature with the dimensional parameters, this dimensional parameters is usually directed to the size of the micropore parallel with the optical module surface, with with the corresponding height of height h of the wall of separating micropore, and the thickness d that is parallel to these walls of optical module surface measurement.The size of the micropore parallel with the optical module surface has determined the area σ of a micropore.Lift a simple case, micropore is foursquare, and its side edge length is D (as Fig. 4), and then area is σ=D 2, fill factor τ can pass through formula D approx 2/ (D+d) 2Obtain.The formula of σ and τ can easily be derived from any other space structure of micropore.
Major defect in the array micropore may be made up of the spaced walls of lattice-shaped.These spaced walls are to cause optical module that the main cause of transparency defect is arranged.The intent of the present invention is, described optical module is transparent, when an image observation signal during by optical module, there not be obviously to reduce perceived arriving under the situation of contrast, that is to say that the image by optical element formation does not weaken picture quality.Therefore, separate the wall of optical module micropore by diffraction of light and only interactional.From context of the present invention, when diffraction of light can be defined as light wave and runs into barrier, the phenomenon that a kind of light that observes scatters.(“Optique-Fondement?et?applications”-J.P.Perez-Dunod-7 eme?edition-Paris?2004-Page?262)。More clearly, the luminous energy that impacts on wall is concentrated in the solid angle.Because so, be a point when the light launching site no longer is observed when passing the optical module with this wall.This microscopic diffraction phenomena macroscopic view looks as if diffusion.The diffusion phenomenon of macroscopic view, or incoherent diffusion phenomenon, the dot structure of its optical module shows as unintelligible, and the contrast that can observe by this structure reduces.This contrast reduces to can be regarded as the defined transparency in front and reduces.According to the present invention, the diffusion phenomenon of this macroscopic view can not be accepted and be used for the optical element that obtains from the optical module of pixelation, especially can not be used for being transparent and can not having any weakening to wear the glasses of decorative defects of these glasses person's eyesight.By the pore size of passing judgement, can effectively reduce the diffraction energy of setted wavelength.
Therefore, in the context of the present invention, the pore size that is parallel to the optical module surface can be greater than 1 μ m.Especially, these pore sizes that are parallel to the optical module surface can be at 5 μ m between the 100 μ m.In the application of lens, can expectation avoid the excessive micropore of area, otherwise can form a visual structure at lens surface.Preferably, the size of micropore at 10 μ m between the 40 μ m.
Be parallel between the micropore on optical module surface and preferably isolate by the spaced walls of thickness between 0.10～5 μ m.In embodiments of the invention 1, septal wall thickness is between 0.10～5 μ m, and preferred thickness makes that these spaced walls do not produce the diffraction effect of in fact not expecting in visible spectrum between 0.10～0.35 μ m.These thin spaced walls have formed very high fill factor τ at the optical surface that is filled with material, have better optical effect.
In embodiments of the invention 2, septal wall thickness is between 0.40～2.00 μ m.For example, thickness is 1.00 μ m.In embodiments of the invention 3, septal wall thickness is between 2.00～3.5 μ m.For example, thickness is 3.0 μ m.The structured material of described micropore spaced walls can be selected as follows, and the material and the micropore that promptly are packed in the described micropore can distinguish that no longer the meaning of here " can't distinguish " is not have visible scattering, do not have visible diffraction and do not have passive reflection.Especially, this mode can obtain in practice by suitably regulating refractive index and absorptivity.
Microwell array can directly form on the transparency carrier of rigidity, or forms in the transparent film layer of flexibility, and this transparent film layer is transferred on the transparency carrier of rigidity subsequently.The transparency carrier of described rigidity can be convex surface, concave surface or plane on the side that holds described arrangement micropore.
Implement in a kind of method of above-mentioned steps, the material with optical property that is contained at least some micropores is liquid or gel.Described material can have following at least a kind of optical property especially: promptly painted, and variable color, polarization and refractive index.
The material that comprises in the micropore especially is liquid or gel, and it can incorporate photochromic dyestuff into, and therefore having very the photochromic element of rapid-action can produce expediently.
For the application of making correcting lens, need each micropore of optical module to include the material of different refractivity.Typically, the ametropia for the treatment of correction ocular by inference, refractive index will correspondingly be adapted at changing on the optical module surface.
Have the application of the optical mirror slip of polarization optics performance for manufacturing, in the micropore of optical module, especially can contain liquid crystal dyestuff or that do not make up dyestuff that has capable of being combined.
An object of the present invention is also to provide a kind of production method of above-mentioned optical module, this optical module is included in the formation of the lattice-shaped spaced walls that is used for limiting each micropore parallel with described assembly surface on the substrate, concentrate or fill separately micropore with having material optical property, liquid or gel form, and at the side-closed micropore opposite with substrate of micropore.
The array micropore of optical module comprises several groups of micropores with different material.Similarly, the material that is held in each micropore has one or more above-mentioned optical properties.And can on the thickness of optical module, insert a few row's micropores.In the present embodiment, the array micropore also can have identical or different performances in each layer, or each micropore in every row also can have different optical properties.Therefore just can see that the one deck in the array micropore has the material that can obtain variations in refractive index like this, another layer or array micropore then have the material of discoloration.
Another aspect of the present invention is the optical module that is used in the above-mentioned steps about a kind of.This optical module comprises that at least one is parallel to the juxtaposed transparent array micropore of assembly surface.Each micropore is closed and comprises according to the material that optical property is arranged.Preferably, each micropore is spaced apart wall to be separated, and the spaced walls height more preferably is less than 50 μ m less than 100 μ m, and can have the size greater than the 1 μ m that is parallel to the optical module surface.
In addition, the present invention also will introduce a kind of transparent optical element, and particularly a kind of flexible focal length lenses group is made this eyeglass by cutting described optical module.
Description of drawings
To become clear in the description to non-limiting example with reference to the accompanying drawings below about other characteristic and advantage of the present invention, wherein:
Fig. 1 is the front elevation according to optical module of the present invention;
Fig. 2 is the front elevation by the optical element of this optical module acquisition;
Fig. 3 is the schematic cross sectional views according to optical module of the present invention;
Fig. 4 and Fig. 5 are two types dot matrix synoptic diagram of the micropore in the optical module that can be used to arrange according to the present invention;
Schematic cross sectional views when Fig. 6 and Fig. 7 are two stages in its manufacture process of display optical assembly;
Fig. 8 is the schematic cross sectional views according to the another kind of manufacture method of optical module of the present invention.
Embodiment
As shown in Figure 1, optical module 10 is for being used for a blank (blank) of flexible focal length lenses group.Flexible focal length lenses group comprises lens.Term " lens " can be understood that it is a kind of eyeglass of picture frame to protect eyes and/or to correct defects of vision that be assembled to.These eyeglasses can be the eyeglasses of afocal, single focus, bifocal, trifocal and varifocal.
Although preferred application of the present invention field is a lens, but be to be understood that, the present invention also may be used on going in the transparent optical element of other type, optical instrument lens for example, light filter, optics eyesight lens, safety goggles (eye visors) is used for eyeglass (optics for lighteningdevices) of lighting device or the like.The lens that is included in the scope of the present invention is ophthalmic lens (ophthalmiclenses), contact lenses and ocular implants.
Fig. 2 is an eyeglass 11, and it obtains by cutting blank 10 around the predetermined profile line, and this outline line shows with dotted line in Fig. 1.In principle, the setting of outline line is arbitrarily, as long as it falls within the scope of blank.The blank of producing in enormous quantities can be used to obtain eyeglass, and this eyeglass can be fit to diversified picture frame.The edge of the eyeglass that cuts down can be repaired without any problem ground by traditional mode, so that lens shape can and be buckled on the picture frame firmly and/or meets aesthetic with the picture frame coupling.Also can bore hole 14 on the eyeglass 11, the screw of can screwing on aperture 14 is to be fixed in eyeglass 11 on the picture frame.
The general shape of blank 10 can for example have the circular contour that diameter is 60mm according to industrial standard, the front surface 12 of projection and recessed rear surface 13 (as shown in Figure 3).Produce eyeglass 11 by traditional cutting, deburring and boring bar tool from blank 10.
In Fig. 1 and Fig. 2, the eyeglass top layer is partly cut away to have shown the dot structure of blank 10 and eyeglass 11.This structure is that the dot matrix of small cavity 15 is formed by micropore, and this micropore is formed in the thin layer 17 of transparent components (Fig. 3).In these figure, relatively blank 10 with and the size of substrate 16, the size of layer 17 and micropore 15 is exaggerated, and can more easily study accompanying drawing like this.
The lateral dimensions D of micropore 15 (surface that is parallel to blank 10) is greater than 1 micron, to avoid that diffraction effect takes place in visible spectrum.In the reality, this dimension D at 10 μ m between the 100 μ m.The array micropore can use the technology of good control to produce in the field of microelectronics and micromechanism (micromechanical) equipment.
Therefore on eyeglass 11 and blank 10, this array micropore is can be invisible.
According to the present invention, the height h with above-mentioned layer 17 of array micropore 15 is preferably less than 100 μ m, more preferably between 1 μ m～10 μ m and comprise 1 μ m and 10 μ m.Best, this height h is about 5 μ m.
Spaced walls 18 is used for separating micropore 15, seals each other to guarantee each micropore, and the thickness of spaced walls is between 0.10 μ m～5.00 μ m and comprise 0.10 μ m and 5.00 μ m, makes its fill factor that can obtain high optical module (fill factor) especially.For example, the thickness of this wall can be 0.35 μ m.High fill factor provides the efficient of required optical function, and this optical function obtains by the material that is placed in the micropore 15.This fill factor is between 90%～99.5% and comprise 90% and 99.5%, preferably, and between 96%～98.5% and comprise 96% and 98.5%.If the thickness d of the spaced walls of the lateral dimensions D of reasonable combination micropore and isolation micropore and height h, the optical module that just can obtain to have high fill factor, it depends on a kind of optical property or the multiple optical property of the material that holds in the described micropore not obviously.
For example, with the micropore that square grid (Fig. 4) or hexagonal lattice (Fig. 5) are arranged, the thickness d of spaced walls 18=2 μ m, its Pixel Dimensions D=100 μ m only has 4% area absorbing (absorbing) (τ=96%).For thickness d=1 μ m, the spaced walls 18 of Pixel Dimensions D=40 μ m (or d=0.5 μ m, D=20 μ m), it is absorber (τ=95%) that 5% area is only arranged.Bottom line is about τ=90%.
As shown in Figure 5, cellular or hexagonal grid is preferred layout, because it has optimized the physical strength of the microwell array of given aspect ratio.Yet in context of the present invention, all are deferred to the possible grid of how much rules of crystal and arrange and can consider.Therefore, can produce rectangular grid, geometric configuratioies such as triangular lattice or octagon grid.From the present invention, the grid that can also make up different geometries forms microwell array, and its grid size as hereinbefore defined.
Comprise micropore 15 array described layer 17 can cover by some extra plays 19,20 (as Fig. 3), this point is general in lens.These extra plays provide for example anti-impact force, and scratch resistance is painted, antireflection, antidusting soil or the like function.In the example shown, the layer with microwell array 17 is positioned at the top of transparency carrier 16 just at the right time, can place between layer 17 and the substrate 16 but also can be regarded as one or more middle layers, for example can place to have shock resistance scratch resistance, the middle layer of function such as painted.
In addition, possible is that several microwell arrays appear in the multiple-level stack that is formed on the substrate.Therefore for example make that multiple-level stack comprises that the thin layer that especially has microwell array becomes possibility, the material that comprises in the micropore allows described element to have colour change function, and another layer then allows described element to have the function of variations in refractive index.These layers that comprise microwell array can alternately occur with above-mentioned extra play.
Owing to particularly produce the adaptability of the technology of transparent optical element, the various possibilities that are combined into.Thereby in context of the present invention, optical module can comprise microwell array, wherein insert the material with one or more optical properties in each micropore, or described micropore 15 arrays comprises several micropores that are assembled with different material.Optical module can also be by comprising that at least two piling up of thin layer of containing microwell array form, each microwell array all has identical optical property, or each microwell array all has different optical properties, or each micropore in each microwell array also has different optical properties.
Transparency carrier 16 can be made by glass or the various polymer material that is generally used on the lens.In these available polymer materials, below material can be used as quote as proof and and non-limiting purpose: makrolon material, polyamide, polyimide, polysulfones, the multipolymer of polycarbonate and polyethylene terephthalate, polyolefin, especially poly-bornylene (polynorbornens), the polymkeric substance and the multipolymer of two (allyl carbonate salt) binaryglycol ester, (methyl) acrylic polymers and multipolymer, especially derived from bisphenol-A (A-bisphenol), (methyl) acrylic polymers and the multipolymer of sulfo-(methyl) acrylic polymers and multipolymer, polyurethane and sulfo-polyether polyols with reduced unsaturation and multipolymer, epoxy polymer and multipolymer, episulfide polymkeric substance and multipolymer.
The above-mentioned layer 17 that includes microwell array is preferably placed on its protruding front surface 12, and recessed rear surface 13 keeps idle, to stand any by machining and polishing and once more necessary step of shaping operation.Yet, if transparent optical element is a correcting lens, the rectification of ametropia can reach by the refractive index of the material in ground, the space change micropore 15, so just can save the work that repeats on the rear surface, thereby and the different thin layers that must be provided with in design and/or on the eyeglass and the formation of coating all have better dirigibility.Optical module also can be positioned on the concave surface of eyeglass.Certainly, optical module also can be attached on the smooth optical element.
Fig. 6 and Fig. 7 have disclosed the first method of producing microwell array on substrate 16.The technology of when this used technology type is similar to the manufacturing electrophoretic display device (EPD), using.This technology is at for example WO00/77570, and WO 02/01281, and US 2002/0176963, introduces to some extent in the patent text of US 6327072 or US 6597340.Microwell array can also be produced by the manufacture craft that derives from microelectronics, and this method is well-known to those skilled in the art.Give an example as indefiniteness, the said method of mentioning can be a for example hot stamping brush, hot moulding, photoetching technique (photolithography), (hard, soft, positive, negative), microdeposit, micro-contact printing for example, screen printing, or ink jet printing.
In the embodiment that is discussed, but actinic radiation-curable, and as the solution film that UV solidifies, monomer is deposition on substrate 16 at first.This film is subjected to passing the action of ultraviolet ray of mask, this mask mask with grid distribute and with the corresponding square or sexangle in the position of small cavity 15.By optionally solidifying, the spaced walls 18 that upwards is erected at supporting layer 21 tops has just been stayed the appropriate location.Shift out monomer solution subsequently, described assembly is state as shown in Figure 6.
In order to obtain similar structure, another kind of possibility is to use photoetching technique.At first, begin deposition on the substrate 16 of the material layer of for example polymkeric substance, the thickness of material layer will highly adapt with the expection of desired spaced walls 18, for example is 5 μ m or 20 μ m.Then, photoresist film deposits on this layer, and this film carries out exposure by the mask of grid.When the development photoresist, not the zone of exposure removed so that mask about the position alignment of spaced walls, anisotropic etching material layer thus.This etching that has formed small cavity 15 arrives the conceivable degree of depth downwards always, then gets rid of this mask by chemical etching.
From state shown in Figure 6, small cavity 15 is full of the liquid or spawn with optical property.The processing in advance of the front surface of described optical module is optionally used, with the surface adhesional wetting of the bottom that promotes small cavity and described material walls.For the small cavity of all arrays, solution or suspending liquid that formation has the material of optical property can be identical, in this case, the injection of material can be by simple by being immersed in optical module in the suitable solution (bath), utilization screen printing technology, spin coating technology (spin coating process), the technology of using roller or doctor that material is coated with out, or finish with other spray technology.Also can use ink gun that material is injected in each small cavity partly.
When the material with optical property in each small cavity differed from one another, last technology can the typical case adopt, and promptly several ink guns move in above-mentioned surface, continuously small cavity are filled.
Yet, be under the situation about forming especially by selective etch at small cavity, another kind may be at first to dig out one group of small cavity, concentrate then and fill with first kind of material, should organize small cavity sealing then, when carrying out these operations, remaining assembly surface still keeps mask.Next, by Etching mask being covered the zone of the small cavity that at least had been filled, repeat above-mentioned selective etch, and in new small cavity, fill with different materials, then it is sealed in the extra-regional zone of spaced walls.When if the surface of this optical module will be packed into different materials, this process can repeat one or many.
Small array of cavities for sealing had been filled with above spaced walls 18, by the mode of hot weld or hot lamination (hot-laminated), covers the plastic film that one deck has adhesive coating.Also can be on zone to be isolated the curable materials of deposit solution form, this material does not mix with the material with optical property in the small cavity, and uses subsequently such as heating or radiation and solidify this material.
In case after small array of cavities forms (Fig. 7), described assembly can receive extra play or coating 19,20 to finish its manufacturing.Such optical module can be mass-produced and stores then, so that use in the future, and according to requirement of client each optical module is cut.
Can not keep liquid or gel state if having the material of optical property, then need it is implemented to solidify processing, for example adopt heating and/or sequence irradiation (irradiation sequence), a certain suitable stage behind electrodeposition substance carries out this curing to be handled.
In different embodiment shown in Figure 8, constitute by the form of the described optical module formed of the small cavity 25 of a row with the transparent membrane 27 of flexibility.A kind of like this film 27 can be made with being similar to technology above-mentioned.In the present embodiment, film 27 can be manufactured on the smooth substrate, just the also substrate of concave shape not of projection neither.
This film 27 is made in industrial scale for instance, and it has big relatively size, to accomplish to save in the combination of processing step is made, then this film is cut into suitable dimensions to transfer on the blank substrate 16.This transfer can be by glueing joint this fexible film, by this fexible film of thermoformed, or even sticks effect (physical adhesioneffect) by physics realize under vacuum environment.Subsequently, film 27 can maybe can be sent on the substrate 16 as receiving different coating in the embodiment previously described, and this substrate 16 itself is coated with one or more layers extra play as mentioned above.
In an application of the present invention, the optical property of introducing the material in the small cavity 15 mainly is its refractive index.The refractive index of material on assembly surface be change to obtain correcting lens.In first embodiment of the present invention, during the manufacture process of small cavity 15 arrays, the material that has different indexes by injection obtains above-mentioned variation.
In another embodiment of the present invention, the realization of change of refractive is that the refractive index of this material can be adjusted continuously by radiation by a kind of material of injection in small cavity 15.Correct the writing of optical function (writing) and be by blank 10 or eyeglass 11 are subjected to light be used for reach, the energy of light changes to obtain the index distribution of expection, the eyesight that finally can correct the patient at lens surface.Typically, this light can produce by laser, said write equipment and be used for etching CD-ROM or the equipment of other optical storage media is similar.Stronger or the more weak exposure of photonasty material can be caused by the variation of the exposure time of laser energy and/or selection.
In should be, for example can mention mesoporous material (mesoporousmaterials) and liquid crystal with the material that can use.Liquid crystal can be solidified by radiation-induced polyreaction by for example a kind of.Therefore, they can solidify in selected state, to postpone by introducing predetermined optical in their light wave.In the situation of mesoporous material, the refractive index of material is to control by the variation of its porosity.Another kind of possible situation is to utilize the well-known characteristics of photopolymer, i.e. the characteristic of change self refractive index in radiation-induced solidify reaction process.These change of refractive are to produce owing to having changed its density of material and having changed its chemical constitution.Be to utilize the photopolymer that in polymerization process, has only very little volume change better.
The polymerization of selected solution or suspending liquid is to carry out under radiation, and this radiation makes a distinction in spatial dimension with respect to the surface of described assembly, to obtain desired variations in refractive index.The estimation ametropia of the patient's eye that this variation can be corrected as required pre-determines.
In the further application of the invention, be formed in the small cavity be liquid or gelatinous material has photochromic characteristic.In should be with used these materials, can mention the photochromic potpourri that comprises core cell as an example, such as core cell such as spiral shell piperazine (spirooxazine), spiral shell-indoline [2,3 '] benzoxazine, chromene, the high azaadamantane of spiral shell piperazine (spiroxazine homoazaadamantane), Spirofluorene-based-(2H)-chromene, or naphtho-[2,1-b] pyrans nuclear, resemble describe in patent or the patented claim this: FR 2763070, EP 0676401, EP0489655, EP 0653428, and EP 0407237, FR 2718447, US 6281366 and EP1204714.
From content of the present invention, the material with optical property can be a kind of dyestuff, or a kind of pigment that can change the conveying degree.

Claims (63)

1. the manufacture method of a transparent optical element (11) comprises the following steps:
-produce an optical module (10), this assembly has the transparent micropore (15 of at least one array; 25), the surface that this micropore is parallel to assembly is set up in parallel, and each micropore is sealed and hold the material with optical characteristics; And
-cutting described optical module along the described lip-deep outline line that configures, this outline line is corresponding with the reservation shape of described optical element.
2. manufacture method as claimed in claim 1 is characterized in that: described microwell array cambium layer, this layer have a height less than 100 μ m perpendicular to described surface.
3. manufacture method as claimed in claim 2 is characterized in that: described by microwell array form the layer height be 10～50 μ m.
4. manufacture method as claimed in claim 2 is characterized in that: described by microwell array form the layer height be 1～10 μ m.
5. manufacture method as claimed in claim 4 is characterized in that: described by microwell array form the layer height be about 5 μ m.
6. the described manufacture method of arbitrary claim in the claim as described above is characterized in that: also comprise a step, promptly go up boring so that optical element (11) is fastened to fixed support at optical module (10).
7. the described manufacture method of arbitrary claim in the claim as described above is characterized in that: the manufacturing of described optical module (10) is included in rigidity transparency carrier (16) and goes up and form array micropore (15).
8. the described manufacture method of arbitrary claim in the claim as described above, it is characterized in that: the manufacturing of described optical module (10) is included in and forms array micropore (25) in flexible and transparent film (27) scope, subsequently with described film transfer to rigidity transparency carrier (16).
9. as claim 7 or 8 described manufacture methods, it is characterized in that: described rigidity transparency carrier (16) is at receiving array micropore (15; 25) side is a convex surface, concave surface, or plane.
10. the described manufacture method of arbitrary claim in the claim as described above is characterized in that: be contained at least some described array micropores (15; 25) material with optical characteristics in is liquid or gel form.
11. manufacture method as claimed in claim 10, it is characterized in that: the manufacturing of described optical module (10) is included in and forms grid spacings wall (18) is parallel to described optical module surface with qualification micropore (15) on the substrate, with the material with optical property of liquid or gel form described micropore jointly or is individually filled, and on the described micropore side opposite with substrate closed porosity.
12. the described manufacture method of arbitrary claim in the claim as described above, it is characterized in that: described optical property is selected from painted, photochromism, polarization or refractive index performance.
13. the described manufacture method of arbitrary claim in the claim is characterized in that: different micropores (15 as described above; 25) material with different refractivity is housed.
14. manufacture method as claimed in claim 13 is characterized in that: described material with different refractivity comprises photopolymer, liquid crystal or mesoporous material.
15. manufacture method as claimed in claim 14, it is characterized in that: the manufacturing of described optical module (10) is included in described substrate (16) and goes up the grid spacings wall (18) that forms is parallel to described optical module surface with qualification micropore (15), solution or suspending liquid with monomer or liquid crystal are jointly filled described micropore, closed porosity on the described micropore side opposite with substrate, and the surface that is parallel to described assembly is by disperseing described solution of electromagnetic radiation selective polymerisation or suspending liquid.
16. as the described manufacture method of one of claim 13 to 15, it is characterized in that: the refractive index of the material in the described micropore is adjustable, to change the lip-deep described refractive index of described optical module according to the ametropia of estimating for the treatment of correction ocular.
17. the described manufacture method of arbitrary claim in the claim is characterized in that: described array micropore (15 as described above; 25) comprise several groups of micropores that contain different material.
18. preparation method as claimed in claim 17, it is characterized in that: the manufacturing of described optical module (10) is included in substrate (16) and goes up formation grid spacings wall (18), this wall is used for limiting the micropore (18) that is parallel to described optical module surface, use ink gun to distinguish ground and fill micropore with material with optical property, and on the described micropore side opposite with substrate closed porosity.
19. the described manufacture method of arbitrary claim in the claim is characterized in that: pile up several array micropores on described component thickness as described above.
20. manufacture method as claimed in claim 19 is characterized in that: have same optical property in each display micropore, or have different optical properties in each array micropore, or each micropore in each array micropore has different optical properties.
21. the described manufacture method of arbitrary claim in the claim as described above, it is characterized in that: described fill factor τ is parallel to the surface of described assembly greater than 90%.
22. as claim 21 described manufacture method, it is characterized in that: described fill factor τ is between 90% to 99.5% and comprise 90% and 99.5%.
23. manufacture method as claimed in claim 22 is characterized in that: described fill factor τ is between 96% to 98.5% and comprise 96% and 98.5%.
24. the described manufacture method of arbitrary claim in the claim is characterized in that: described array micropore (15 as described above; 25) arrange with hexagonal lattice.
25. the described manufacture method of arbitrary claim in the claim is characterized in that: described micropore (15 as described above; 25) be parallel to the size of described assembly surface greater than 1 μ m.
26. manufacture method as claimed in claim 25 is characterized in that: described micropore (15; 25) be parallel to the size of described element surface between 5 μ m～100 μ m.
27. manufacture method as claimed in claim 26 is characterized in that: described micropore (15; 25) be parallel to the size of described element surface between 10 μ m～40 μ m.
28. the described manufacture method of arbitrary claim in the claim is characterized in that: described micropore (15 as described above; 25) separate by spaced walls (18), spaced walls is parallel to the size of described assembly surface between 0.10 μ m～5 μ m.
29. manufacture method as claimed in claim 28 is characterized in that: the size of described spaced walls (18) is less than 0.35 μ m.
30. manufacture method as claimed in claim 28 is characterized in that: described micropore (15; 25) separate by spaced walls (18), this spaced walls is made by reflectorized material not, and the size of this spaced walls is between 0.40 μ m～3.00 μ m.
31. manufacture method as claimed in claim 30 is characterized in that: described spaced walls (18) size is between 0.40 μ m～1.00 μ m.
32. optical module comprises the transparent micropore (15 of at least one array; 25), the surface that this micropore is parallel to described assembly is set up in parallel, and each micropore is sealed and hold the material with optical characteristics.
33. optical module as claimed in claim 32 is characterized in that: described array micropore constitutes layer, and this layer has the height less than 100 μ m perpendicular to described surface.
34. optical module as claimed in claim 33 is characterized in that: the height of the described layer that described array micropore forms is 10 μ m～50 μ m.
35. optical module as claimed in claim 33 is characterized in that: the height of the described layer that described array micropore forms is 1 μ m～10 μ m.
36. optical module as claimed in claim 35 is characterized in that: the height of the described layer that described array micropore forms is about 5 μ m.
37. as the described optical module of one of claim 32 to 36, it is characterized in that: comprise a rigidity transparency carrier (16), described array micropore (15) is formed on this substrate.
38. as the described optical module of one of claim 32 to 36, it is characterized in that: comprise a rigidity transparency carrier (16), the transparent membrane (27) with array micropore (25) is transferred on this substrate.
39. as claim 37 or 38 described optical modules, it is characterized in that: described rigidity transparency carrier (16) is at receiving array micropore (15; 25) side is a convex surface, concave surface, or plane.
40., it is characterized in that: at least some array micropores (15 as the described optical module of one of claim 32 to 39; 25) the described material with optical property in is liquid or gel.
41. as the described optical module of one of claim 32 to 40, it is characterized in that: described optical property is selected from painted, photochromism, polarization or refractive index performance.
42., it is characterized in that: different micropores (15 as the described optical module of one of claim 32 to 41; 25) comprise material with different refractivity.
43. optical module as claimed in claim 42 is characterized in that: described material with different refractivity is photopolymer, liquid crystal or mesoporous material.
44., it is characterized in that: described array micropore (15 as the described optical module of one of claim 32 to 43; 25) comprise several groups of micropores that contain different material.
45., it is characterized in that: on the thickness of described assembly, pile up a few row's array micropores as the described optical module of one of claim 32 to 44.
46. optical module as claimed in claim 45 is characterized in that: have same optical property in each row's micropore, or have different optical properties in each array micropore, or the micropore in each array micropore has different optical properties.
47., it is characterized in that as the described optical module of one of claim 32 to 46: described array micropore have the surface that is parallel to described assembly greater than 90% fill factor τ.
48. optical module as claimed in claim 47 is characterized in that: described fill factor is between 90% to 99.5% and comprise 90% and 99.5%.
49., it is characterized in that: described micropore (15 as the described optical module of one of claim 32 to 48; 25) become hexagonal lattice to arrange.
50., it is characterized in that: described micropore (15 as the described optical module of one of claim 32 to 49; 25) be parallel to the size of described assembly surface greater than 1 μ m.
51. optical module as claimed in claim 50 is characterized in that: described micropore (15; 25) be parallel to the size of described assembly surface between 5 μ m～100 μ m.
52. optical module as claimed in claim 51 is characterized in that: described micropore (15; 25) be parallel to the size of described assembly surface between 10 μ m～40 μ m.
53., it is characterized in that: described micropore (15 as the described optical module of one of claim 32 to 52; 25) separate by division wall (18), this spaced walls is parallel to the size of described assembly surface between 0.10 μ m～5 μ m.
54. optical module as claimed in claim 53 is characterized in that: described micropore (15; 25) separate by spaced walls (18), this spaced walls is parallel to the size of described assembly surface between 0.10 μ m～0.40 μ m.
55. optical module as claimed in claim 54 is characterized in that: the size of described spaced walls (18) is less than 0.35 μ m.
56. optical module as claimed in claim 53 is characterized in that: described micropore (15; 25) separated by described spaced walls (18), described spaced walls is made by reflectorized material not, and the size of this spaced walls is between 0.40 μ m～3.00 μ m.
57. optical module as claimed in claim 56 is characterized in that: the size of described spaced walls is between 0.40 μ m～1.00 μ m.
58. as the described optical module of one of claim 32 to 57, be used to make transparent optical element, be selected from: ophthalmic lens, optical instrument eyeglass, light filter, optics eyesight lens, safety goggles, and the eyeglass of light fixture.
59. be the manufacturing of transparent optical element as the purposes of the described optical module of one of claim 32 to 57, this transparent optical element is selected from ophthalmic lens, contact lenses, ocular implants, optical instrument lens, light filter, optics eyesight lens, safety goggles, and light fixture eyeglass.
60. lens, it is made as the described optical module of one of claim 32 to 57 (10) by cutting.
61. lens as claimed in claim 60 is characterized in that: on described assembly (10), drilled through a hole at least so that eyeglass (11) is fastened on the spectacle frame.
62. as claim 60 or 61 described lenses, it is characterized in that: described micropore (15; The optical property of the material that holds 25) is adjustable, changes on the surface of described eyeglass with the function according to the ametropia of assessing for the treatment of correction ocular.
63. as claim 60 or 61 described lenses, it is characterized in that: described micropore (15; 25) Nei material is photochromic material.
CNB2005800224779A 2004-07-02 2005-06-24 Make the optical element of the method for transparent optical element and the optical module of using and its acquisition Active CN100543518C (en)

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