JP2007511796A - Glasses manufacturing method - Google Patents

Abstract

High-order aberrations, i.e. aberrations expressed in the third or higher order of the Zernike polynomial, cannot be corrected by the lens, and defocus and astigmatism correction are usually gradual due to lens manufacturing limitations and costs. there were.
A method for correcting eyeglasses comprising: obtaining a visual parameter of a patient's eye; obtaining an eyeglass frame including one or more mounted optical elements; and programming an optical element defining a refraction pattern associated with the visual parameter. Providing manufacturing methods.
[Selection] Figure 1

Description

Related applications

  This application is based on US Provisional Application No. 60 / 520,065 filed on Nov. 14, 2003, U.S. Provisional Application No. 60/546378 filed on Feb. 20, 2004, and U.S. Patent Application filed on Sep. 7, 2004. Claims the benefits of application Ser. No. 10 / 936,132 and US patent application Ser. No. 10 / 936,131 filed Sep. 7, 2004, which are hereby incorporated by reference in their entirety.

  The present invention relates to systems and methods related to the manufacture of optical lenses for correcting aberrations in optical systems such as the human eye.

U.S. Patent No. 6,721,043 U.S. Patent No. 6,682,195 U.S. Patent No. 6,511,180 U.S. Patent No. 6,712,466 U.S. Pat.No. 6,319,433

  The human eye, and particularly the cornea and the lens, can exhibit various optical aberrations that impair the visual ability of the eye, resulting in blurred vision. Visual acuity correction by wearing glasses has usually been limited to correcting only low-order aberrations such as defocus and astigmatism. Conventionally, high-order aberrations, that is, aberrations expressed in the third or higher order of the Zernike polynomial, cannot be corrected by the lens. In addition, due to lens manufacturing limitations and costs, defocus and astigmatism corrections are usually corrected only in stages, and any correction is performed at the nearest quarter (0.25) diopter. (D) Unfortunately, vision correction is incomplete with the 1/4 diopter solution.

Summary of Certain Aspects of the Invention Each of the systems, methods, and apparatus of the present invention has several aspects, none of which alone can assure desirable characteristics. Without limiting the scope of the invention as expressed by the separate claims, its more prominent features will now be briefly described. In view of the discussion here, and especially after reading the “Detailed Description of Embodiments of the Invention”, the features of the present invention show how convenient and economical manufacture of custom-made (customized) multilayer lenses. It will be understood whether it provides benefits including statutes.

  One embodiment is a method of making corrective glasses. The method includes obtaining a visual parameter of a patient's eye, obtaining a spectacle frame that includes one or more mounted optical lenses, and programming an optical element that defines a refraction pattern associated with the visual parameter.

  Another embodiment is a method for manufacturing a customized lens. The method includes obtaining a lens definition (definition) that includes correction of a visual parameter of the patient's eye and one or more optical aberrations of the patient's eye. The method further includes obtaining a frame that includes one or more optical elements. The one or more optical elements include a curable material layer. The method further includes curing the curable material to define a refractive pattern. The refractive pattern corrects one or more optical aberrations in the optical path through the optical element.

  Yet another embodiment is a method of manufacturing a customized lens. The method includes obtaining a lens definition including correction of visual parameters of the patient's eye and one or more optical aberrations of the patient's eye. The method further includes obtaining a frame that includes one or more optical elements. The method includes laminating a material layer over one or more optical elements. The layer defines a refractive pattern that corrects one or more optical aberrations in the optical path through the optical element.

  Another embodiment is a method of manufacturing a single customized lens. The method includes obtaining a lens definition including correction of visual parameters of the patient's eye and one or more optical aberrations of the patient's eye. A cured polymer layer is applied to the framed lens. The method further includes selective curing of the layer, changing the volume of the layer to define the surface profile (shape) of the layer. The surface contour defines a refraction pattern that corrects one or more optical aberrations.

  Another embodiment is an optical element. The optical element includes one or more lenses configured to correct one or more higher order aberrations. The one or more higher order aberrations include one or more of trefoil, coma, spherical aberration, or combinations thereof.

  Another embodiment is a method for manufacturing a customized lens. The method includes obtaining a lens definition including correction of visual parameters of the patient's eye and one or more optical aberrations of the patient's eye. The method further includes obtaining a frame that includes one or more optical elements. The one or more optical elements include a curable material layer. The method further includes selective curing of the layer, changing the volume of the layer to define the surface profile of the layer. The surface contour defines the refraction pattern associated with the lens definition.

Detailed Description of Certain Embodiments The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be implemented in a number of different ways as defined and covered by the claims. In this description, like reference numerals refer to like parts throughout the views.

  A spectacle lens is usually manufactured by grinding a lens blank so as to correct a measured optical aberration, and processing the ends of the lens blank so as to fit a pair of spectacle frames. This correction is usually limited to low order aberrations. Furthermore, since grinding is usually done with a margin of 0.25D, the correction is usually incomplete.

  By using a device that measures the wavefront aberration of the patient's eye, a much more accurate measurement of the patient's eye is obtained. The resulting measurement can be used to calculate the optimum lens definition. In one embodiment, the lens definition determines a refractive index pattern that corrects one or more optical aberrations in the optical path through the lens, which when implemented in an optical lens, such as a spectacle lens, Aberrations are corrected much more accurately than before. Thus, the patient can see very close to the peak of his visual ability.

  As used herein, “correction” of optical aberrations is not necessarily the complete removal of optical aberrations, but generally reduces, minimizes, or optimizes optical aberrations. It should be understood that Furthermore, in some instances, “correction” of aberrations includes adding or increasing certain optical aberrations, as it has been found that increasing certain higher order aberrations improves vision. Optical elements include any component that transmits light, including thick or thin lens blanks, flat lenses, correction lenses such as eyeglass lenses, contact lenses, optical coatings, intraocular lenses or combinations with other optical elements Is included. The flat optical element, i.e. the element without refractive power, can be flat or curved for cosmetic reasons, for example to give it an appearance like a normal spectacle lens.

  FIG. 1 shows a top-level flowchart of a method 100 for making a customized lens. Starting from step 110, the patient's eye is measured. In one embodiment, visual parameters such as the patient's lower and / or higher order aberrations are measured using an aberrometer (eg, including a wavefront sensor). Aberrations include, for example, Shack-Hartmann, diffraction grating, grating, Hartmann Screen, Fizeau interferometer, ray tracing system, Tscherning aberrometer, detector. It can be measured using wavefront sensors such as a skiascopic phase difference system, a Twymann-Green interferometer, and a Talbot interferometer. More details of a typical aberrometer are described in US Pat. No. 6,721,043 “Light-Adjustable Aberration Conjugator” by Platt. B. et.al., which is incorporated herein by reference in its entirety. Other embodiments of the aberrometer are described in US patent application Ser. No. 10/076218 filed Feb. 13, 2002, entitled “Apparatus and Method for Determining Object Refraction Using Wavefront Sensing” and filed Dec. 10, 2001. US patent application Ser. No. 10/014037, entitled “Wavefront Measurement System and Method”, both of which are hereby incorporated by reference in their entirety. In one embodiment, the visual parameters include data obtained by examining a patient's visual acuity using a trial or examination lens configured to correct one or more high or low order optical aberrations.

  In addition to aberration measurements, information such as patient vertex distance, pupil diameter, pupil distance, frame information, gaze or xy tilt is obtained. More details on obtaining such measurements are described in US Pat. No. 6,682,195, issued January 27, 2004, entitled “Custom Eyeglass Manufacturing Method”, which is incorporated herein by reference in its entirety.

  Moving to step 120, a refraction pattern (lens specification, specification) of the optical lens for correcting the measured aberration is calculated. The refractive pattern is defined in the optical element, for example, by defining a two-dimensional refractive index pattern over the entire surface of the optical element, or by changing the refractive index to change the thickness of the material layer containing the optical element to define the refractive pattern Can be achieved. For example, standard spectacle lenses typically determine the refraction pattern by changing the curvature of the lens material, or the thickness of the lens material, across the lens surface. The curvature of the lens, along with the refractive index of the lens material, defines the refractive pattern of a standard spectacle lens. Such standard lenses typically correct one or more lower order optical aberrations. In one embodiment, the refraction pattern is defined at least in part by the expressions sphere, cylinder, and axis. In such an embodiment, additional refractive patterns can be calculated for application to the lens for correction of higher order aberrations and residual aberrations, for example due to grinding errors. In other embodiments, the refraction pattern can be calculated with low and high order Zernike polynomials for application to materials that can be processed or cured to change the refractive index.

  In one embodiment, the visual parameters are used for visual metrics to optimize lens definition. The lens definition may include a relationship with a prescription in terms of wavemaps, refraction patterns, spheres, cylinders, and axes, or any other refraction pattern or correction. In addition, lens definition can be optical center, multiple optical centers, single correction zones, multiple correction zones, transition zones, blend zones, swim zones. It may include swim regions, channels, add zones, inter-vertex distances, segment heights, off-axis gaze zones, logos, invisible marks, and the like.

  In the next step 130, the lens is manufactured to correct both low and high order optical aberrations. One embodiment of such a lens is disclosed in detail in US patent application Ser. No. 10/218049, filed Aug. 12, 2002, entitled “Apparatus and Method for Correcting Higher Order Aberrations in the Human Eye”. Are fully incorporated herein by reference. Embodiments of the lens manufacturing method, as described in detail herein, include lamination of layers that are cured to include a calculated refractive pattern, grinding or free-form surface finishing of the lens surface, casting and these Many different methods of forming a lens with a calculated refractive index pattern, such as a combination, can be included.

  FIG. 2 is a flowchart illustrating one embodiment of a raw optical lens manufacturing method 130 that can accommodate, for example, a refractive index pattern calculated based on the wavefront aberrations of the human eye. The method 130 begins at step 210 and forms a photosensitive gel layer between the first and second optical elements. In one embodiment, a thick lens and a thin lens. In other embodiments, it may include two thick lenses or two thin lenses. A thick optical lens is usually thick and may be a flat plate, but usually refers to an optical element having refractive power. Both thick and thin lenses can be surface contoured (or contoured) to change the refractive power of the element, while thicker lenses have a wider range of surface contours. Such surface contouring may include grinding and polishing, laser ablation or freeform surface finishing. Desirably, the front optical element, i.e., the element on which the light entering the eye first enters, is usually a thin lens without refractive power. Note that the radius of curvature of the front optical element typically determines the refractive power of the optical lens blank. Thick or thin lenses on individual optical elements can be selected based on the desired correction power of the final optical blank. For example, if a high refractive power lens is required, two thick lenses can be used. If a special lens requires only a minimal low-order correction, two thin lenses can be used.

  The photosensitive gel layer can be selectively cured to change the refractive index. For example, it defines a two-dimensional refraction pattern that can be cured in dots, steps or continuously and corrects one or more optical aberrations in the optical path through the lens. As used herein, a material that can be cured in this manner is referred to as “having a refractive index that can be selectively changed”. The refractive pattern of the layer can be made to define a correction for one or more optical aberrations. Certain embodiments of this or other methods are discussed herein in connection with the photosensitive gel layer, but in other embodiments, selective, such as can be processed or cured to change the refractive index. It should be noted that any other material with a refractive index that can be changed to

  In one embodiment, a photosensitive gel layer of polymer gel is first formed, for example, formed into a large sheet. US patent application entitled “Stabilized Polymer Materials and Methods”, attorney case number OPH.031A, titled “Stabilized Polymer Materials and Methods”, having the same filing date, discloses an embodiment of a photosensitive gel layer. And incorporated herein by reference in its entirety. In a preferred embodiment, formed using a composition comprising a matrix polymer having a mixture of monomers dispersed therein, the matrix polymer being polyester, polystyrene, polyacrylate, thiol cured epoxy polymer, thiol cured isocyanate polymer, and mixtures thereof. The monomer mixture is selected from the group consisting of thiol monomers and ene (ene, triunsaturated) monomers and in (yne, triunsaturated) monomers; Contains monomer.

  In one embodiment, a sheet of this matrix polymer or gel is formed. A portion of this sheet is placed between two optical elements to form a lens blank. One large sheet can be formed as a bulk, and the cut (diced) portion is used to make many lens blanks. Two optical elements are bonded together to make a lens blank. The first and second optical elements can be flat lenses or have corrective power. In one embodiment, the lens blank is prepared to have a correction force within a range of correction forces of the first and / or second lens, ie, 0.25 diopters or 1 diopter away. In a preferred embodiment, one or both optical elements are thick lenses that are contoured, for example by grinding and polishing, so as to correct at least part of one or more lower order aberrations. In a next step 215, in such an embodiment, one or both surfaces of the optical element may be contoured. In other embodiments, the lens can be contoured prior to lamination to form a lens blank. The lens is contoured by conventional grinding and polishing methods, or by free-form surface finishing using a triaxial lathe as manufactured in Schneider Optics, LOH, Gerber Coburn Optical. Or can be formed so as to correct at least part of the optical aberration. As used herein, free-form surface finish means any point-to-point surface finish or any method of machining.

  In the next step 220, a pattern of refraction or refractive index is formed in the photosensitive gel layer as calculated in step 120 of method 100. This pattern is configured to correct optical aberrations in the human eye. In one embodiment, the refractive pattern in the photosensitive gel corrects higher and lower order aberrations that cannot be corrected by other methods such as thin lens blanks or surface finishing of thin lenses from lens blanks. Calculated for.

  In one embodiment, the refractive index pattern can be formed using an illumination source, such as ultraviolet light, having a two-dimensional gray scale pattern. A two-dimensional grayscale illumination pattern includes any illumination pattern that changes intensity in a two-dimensional pattern such as, for example, a grayscale when directed to the surface of an optical element. In one embodiment, the light is irradiated through a photomask to control the dose at each point in the optical element. The photomask can be composed of a region that substantially does not pass the irradiation line, a region that substantially passes the irradiation line, and a region that partially passes the irradiation line. The lens blank is irradiated for a predetermined time such that the photosensitive polymer is cured and partially cured to form a refractive index pattern in the lens blank. In other embodiments, a digital mask system such as a digital light projector (DLP) can be used with a UV light source. The UV light source may include a UV vertical hole surface emitting laser (VSCEL), a triple YAG laser, a UV-LED.

  Proceeding to step 230, the lens blank may be edge processed and fitted to the spectacle frame for use by the patient. In one embodiment, step 210 is performed collectively to supply an inventory of lens blanks, and in some embodiments, conveniently processed at an optometrist's office that also takes measurements at different locations, such as a patient's eye ( For example, according to steps 210 and 230).

  FIG. 3 is a flowchart illustrating another embodiment of a method for forming a photosensitive gel layer between a lens blank and a lens cover as in step 210 of FIG. The first step 310 forms the passage (s) in the lens blank. The lens blank is made of CR-39 or other suitable material such as polycarbonate, Finalite® (Sola), MR-8 monomer (Mitsui), or other materials well known to those skilled in the art. It is formed. In one embodiment, these passages are created by drilling or cutting into the lens blank. In general, the lens blank is larger than the final lens placed in the spectacle frame. For this reason, the region where the passage is present is removed by the final lens and does not hinder the optical correction of the lens. In other embodiments, the passageway is formed with the lens blank, for example, by casting or die cutting. Although two passages are discussed here, it is understood that additional passages can be formed in the lens blank, for example to fill the space between the lens blank and the lens cover faster and more uniformly. The

  In the next step 320, the lens blank is combined with the lens cover at a predetermined interval using a spacer or gasket. In one embodiment, the spacer is a hard material placed between the lens blank and the cover. However, any method that maintains a predetermined distance between the lens blank and the cover can be applied. Moving to step 330, the outer periphery of the lens blank and lens cover is sealed to form a sealed space therebetween. In one embodiment, an adhesive spacer having a thickness in the range of 1 to 100 mils is sandwiched between the lens blank and the cover lens to form and seal the space. In one embodiment, the adhesive spacer is about 20 mils thick.

  In another embodiment, a taping method is included in combining the lens blank and the lens cover to form a space. The space is formed by mechanically fixing two lens blanks apart, for example by clamps or jigs, in order to adjust their thickness. Tapes or similar materials are combined to form a sealed space by wrapping the ends of two lens blanks with a deformable elastic tape or rubber gasket and fixing them with clamps. Applied to the lens blank and the edge of the cover. In yet another embodiment, instead of forming a passage in the lens blank in step 310, the passage is formed through a spacer or tape such that a syringe or other dispenser is inserted through the tape or gasket, for example.

  Proceeding to step 340, in one embodiment, a prepared curable material, eg, a photosensitive material comprising Thiol-Ene or the composition described above, is mixed, degassed, and syringe in a clean environment. Moved to. Using a liquid distributor such as a dispenser from EFD, Inc. or a mechanical distributor such as a syringe, the mixed preparation material is injected into the space from one passage and the other passage from the space. Used for air venting. In certain embodiments, the material is supplied through a spacer or seal passage. In one embodiment, such a passage may be formed with a syringe for supplying a curable material. In the next step 350, the injected lens blank is placed in an oven kept at a high temperature (eg, about 75 ° C.) so that the injected material cures into a photosensitive film. In other embodiments, the curing process can be performed at room temperature depending on the curing characteristics of the injected material.

  4A-4C are side views of lens 401 at various manufacturing steps using the method embodiment of FIG. In particular, FIG. 4A shows the lens 401 after completion of steps 310, 320 and 330 of the method of FIG. A lens cover 410 is placed at a distance from the lens blank 412 by spacers 414 with an adhesive. The spacer 414 serves as a gasket that surrounds the edge of the lens component so as to form a space 416. Two or more passages 418 are formed in the lens blank 412 so that material can be fed into the space 416.

  FIG. 4B shows the lens 401 of FIG. 4A after step 340 of FIG. 3 is completed, with photosensitive material being supplied to the space 416 to form the layer 420. FIG. 4C shows the lens 401 after step 350 of the method of FIG. Heat or a curing method such as UV light is applied to layer 420 to form photosensitive gel 422.

  FIG. 4D illustrates another embodiment of a manufacturing method using casting means, similar to the method shown in FIG. As described above, a low or high refractive index preparation material is provided between the two optical molds. In one embodiment, the optical mold defines an outline that forms a selected low order prescription of the lens formed by the mold, such as, for example, a radius of curvature. Initially at block 452, the prepared material supplied between the two optical molds is selectively illuminated to produce a lower or higher order corrected aberration region 453, as shown at block 454. In one embodiment, the prepared material in the mold is irradiated with a two-dimensional grayscale pattern. In the two-dimensional gray scale pattern irradiation, a substantially uniform light beam is passed through a filter such as a photomask or a liquid crystal display screen, or a light source diode or a two-dimensional array of DLP is combined with a UV light source. It can be generated by creating a dimensional pattern. As shown in block 456, the prepared material is then replaced with a second high or low refractive index prepared material. As shown in the next block 458, the entire mold is irradiated to cause the second preparation material to cure a second time. In one embodiment, the second preparation material is also irradiated with a two-dimensional grayscale pattern to correct residual lower or higher order aberrations. Moving to block 460, the lens is removed from the mold, edge processed and attached to the frame and passed to the patient. In one embodiment, the irradiation of blocks 452, 458 is performed at room temperature or elevated temperature.

  Alternatively, the casting method places two or more low and high refractive index prepared materials in a controlled manner on one of the optical molds for correction of high order aberrations, and then for correction of low order aberrations. It also includes filling a low or high refractive index preparation material between two optical molds to obtain a radius of curvature that corrects the low order prescription. Polymerization of the prepared material between the molds is carried out by a polymerization reaction at room temperature or elevated temperature caused by heat or light. The cured optical element is removed from the mold, edge processed and attached to the frame and delivered to the patient.

  FIG. 4E is a diagram of one method embodiment similar to the embodiment of FIG. 4D. As shown in block 470, two preparation materials are provided between the two optical molds. The plurality of preparation materials may comprise a mixture of low and high refractive index preparation materials. In one embodiment, the high refractive index preparation material includes an acrylate component that undergoes fast photopolymerization, whereas the low refractive index preparation material comprises a vinyl or allyl component that undergoes slow photopolymerization as compared to the acrylate component. Including. Alternatively, the low refractive index preparation material may include a fast reaction rate acrylate component and the high refractive index preparation material may include a slow reaction rate vinyl or allyl component.

  As shown in block 470, the prepared material in the optical mold is irradiated from one side with spatially modulated high intensity light that defines (or defines) a cured portion having a refractive index that corrects higher order aberrations, The opposite surface can be illuminated simultaneously with low intensity light that is spatially modulated to correct low order aberrations. Low and high intensity modulated light crosslinks fast and slow reaction rate preparation materials at different rates, and fast cure preparation materials are selectively predominantly compared to low cure preparation materials that rarely cure. Is cured. If it is necessary to control the rate of photopolymerization of one prepared material relative to the other, stepwise photopolymerization of thiol and ene components (low and high refractive index) can be incorporated. In one embodiment, a frontal-polymerization that allows easy monitoring of the polymerization front is used to control the depth of photopolymerization of one of the two prepared materials. Similarly, the depth of cure can be controlled based on the amount of photoinitiator, photoinitiator-additive (UV-absorption or inhibitor) in the prepared material. The curing tip (front) is controlled to produce a contour surface that corrects the lower or higher order aberrations required for this prepared material. Block 472 shows the shape of the hardened part in the lens. Uncured material can be removed from the mold and replaced with a second cured material. This second material is further cured to form a lens and removed from the mold as indicated at block 474.

  In order to prevent physical phase separation of the two cured preparation materials, one component of the preparation material can be selected to be the same. Furthermore, a reference mark for arranging a segment height, an additional zone, or the like can be engraved on the lens. As shown in block 474, the fully corrected lens is removed from the optical mold, edge processed and mounted on the frame, and passed in place in the optical test room. The mold molding method described above is managed in the mold molding process to advantageously correct the aberration region of the customized lens with high accuracy and accuracy. Furthermore, contoured surfaces corresponding to low and high order aberration correction can be accurately controlled within the lens. Low and high intensity modulated light can be irradiated from both lens surfaces. Blocks 480, 482 and 484 are other embodiments of the method shown in blocks 470, 472 and 474. In the embodiment shown in block 480, the low and high intensity illumination light is in the opposite direction compared to the block 470 embodiment.

  FIG. 5 illustrates one embodiment of a method 500 for performing step 210 of FIG. Beginning at step 510, a spacer is prepared for placement between two thick and thin lens blanks. Beginning at step 510, two optical elements such as lens blanks are cleaned. All lens blanks are CR-39, polycarbonate, Finalite® (Sola), MR-8 monomer (Mitsui), 1.67, 1.71, 1.74 material or other suitable obvious to those skilled in the art It can be formed of a material such as a simple material. In one embodiment, the optical element includes a thick lens blank and a thin lens blank. In other embodiments, two thick or two thin lens blanks can be used depending on the correction power of the lens to be manufactured. Since contaminants formed inside the optical lens can cause aberrations, the material used in the process must be kept very clean. The optical element can be blown to remove contaminants, preferably with a filtered gas such as argon, nitrogen or air. Step 512 then applies a spacer to the thin lens. In one embodiment, the spacer includes two layers of 10 mil ceramic tape cut into small rectangles for a 20 mil gap. In other embodiments, other types of gaskets can be used, including other thicknesses of tape or adhesive gasket material.

  Moving to step 520, the lens filler is mixed. This material may include any suitable photosensitive material described herein. Proceeding to step 522, the amount of filler of the determined weight is measured and applied to the thin lens.

  In addition to other contaminants, air bubbles in the filler can also cause aberrations in the final lens. Therefore, in the next step 524, the thin lens is placed in a vacuum chamber to remove bubbles from the filler. Moving to step 526, the vacuum chamber is depressurized (incorrectly pressurized) with, for example, argon gas. Moving to step 530, it is inspected for bubbles remaining in the filler. In one embodiment, bubbles can be removed by carefully manipulating the material by hand, moving the pocket to the surface and breaking it.

  By placing a thick lens blank on a thin lens blank, air pockets tend to enter the final lens. However, it has been found that placing a drop of filler on a thick lens significantly reduces this trend. Therefore, it moves to step 532 and puts one drop of the filler on the place a little away from the center of the thick lens. In the next step 534, the filler on the thick lens is pressed against the main part of the filler on the thin lens to form the final lens. In the following step 536, the lens is cured, for example by heat, and the filler becomes a photosensitive gel. The method 500 thus ends with the formation of a lens blank having a photosensitive gel layer as used in the method of FIG.

  FIG. 6 illustrates one embodiment of a method 600 of manufacturing a lens formed with a refractive index pattern calculated to correct high and low order optical aberrations. The first step 610 coats the base surface of the mold with a scratch resistant coating to prevent scratching. In the next step 612, a polymer layer is laminated on the mold surface to define a predetermined refractive index. Other embodiments of lens programming are described below in connection with FIGS. 7A-7E and 7F-J.

  Proceeding to step 614, one side of the mold pair is placed a predetermined distance from the base of the mold to form a space. The shape of this space can be calculated to correct for one or more low order aberrations. In the next step 616, this space is added to CR-39, polycarbonate, Finalite® (Sola), MR-8 monomer (Mitsui), 1.67, 1.71, 1.74 material or to those skilled in the art. Filled with a suitable polymer or material that can be polymerized, such as obvious other suitable materials, to form a sufficiently rigid lens body. Moving to step 618, the polymer material is cured. The lens is removed from the mold and attached to the spectacle frame.

  FIGS. 7A through 7E show simplified diagrams of the template at various stages of the method 600 embodiment. FIG. 7A shows a base mold (lower mold) 710 placed at the center of a line 702 along a known central axis. Note that the layers shown in FIGS. 7A through 7E are not necessarily to scale.

  FIG. 7B illustrates one embodiment of step 612 of method 600. Head 712 stacks droplets by spray 714 to form polymer layer 716. The thickness at a location of the polymer layer 716 determines the refractive index at that location of the layer. The head 712 is laminated by changing the thickness of the layers so as to define a predetermined refraction pattern. In other words, the surface contour or height difference of the laminated polymer corresponds to the desired aberration correction.

  FIG. 7C shows the mold pair member 720 placed over the base 710 to create a cavity as described in connection with step 614 of the method 600. A second material layer can be formed inside the mold to maintain optical quality and surface uniformity. FIG. 7D shows the mold after it has been filled with the polymer as described in connection with step 616 of method 600. FIG. 7E shows the completed optical lens 724 removed from the mold. This optical lens can be attached to a spectacle frame.

7F-7J illustrate the steps of a lens manufacturing method similar to the method shown in FIGS. 7A-7E, but the layer has a uniform thickness and the ratio of the material is varied over the entire surface. The difference is that the refractive index is changed in the direction crossing. In other embodiments, lens programming, e.g., refraction pattern determination, can be performed on two or more compatible (or mutual affinity) adjustments with different refractive indices on a lens 716 that has already been corrected for lower order aberrations. This is achieved by laminating while controlling the materials. The prepared material (s) is photopolymerized during or after lamination to fix the corrected lower and higher order aberrations. A typical lens programming process by the laminating method includes the following steps:
(A) as shown in FIG. 7G, the first spray head and the second spray head 712 are arranged at an operable distance from the base 710;
(B) discharging a first droplet from the first spray head to a pre-selected position of the base to form a first stacked droplet, the first droplet being a first polymer composition Including a first amount of matter;
(C) ejecting a second droplet from the second spray head proximate to the first stacked droplet on the base, the second droplet delivering the second polymer composition to the second Including only the amount of
(D) forming a first polymer pixel on the base, the first polymer pixel comprising a first polymer composition and a second polymer composition in a first proportion;
(E) adjusting at least one of the first and second spray heads to emit additional droplets, the additional droplets being at least one of the first and second droplets; Is different;
(F) adjusting the position of the first and second spray heads with respect to the base; and (g) repeating steps (a)-(f) to position the second polymer pixel next to the first polymer pixel. And the second polymer pixel comprises the first polymer composition and the second polymer composition in a second proportion so as to form a layer. Together the pixels form layer 716 of FIG. 7G. This process is described in detail in US patent application Ser. No. 10/253956 filed Sep. 24, 2002 by Lai, et al., Entitled “Optical Elements and Methods for Producing the Same”, which is incorporated by reference in its entirety. Incorporated into this document. Similar to the method described in connection with FIGS. 7A-7E, a second material layer can be formed within the mold to maintain optical quality and surface uniformity.

  FIG. 8 is a flowchart illustrating one embodiment of a method 800 for producing a raw optical lens using a mold process, similar to the method 600 discussed in connection with FIG. The first step 810 applies a scratch resistant coating to the base mold 710. In the next step 812, a photosensitive gel layer is formed. In one embodiment, as described in connection with step 210 above, a photosensitive polymer gel sheet can be formed in bulk to provide multiple lens gel layers. Moving to step 814, a portion of the sheet is placed on the base mold 710.

  A subsequent step 816 is that the mold pair part (pair mold) 720 is between the polymer gel layer (not shown in FIG. 7C, but includes a layer placed similar to layer 716) and the pair part 720. It is placed on the base mold 710 so as to form a space. In the next step 820, the space is filled with a polymer body 722 that forms a support for the lens, such as CR-39. In the next step 822, the polymer body 722 is cured to produce a raw optical lens. The lens blank can have a predetermined refraction pattern formed on the gel layer by the above-described masking method, for example. The gel layer can be further fully cured to increase the stiffness of the layer and prevent damage from physical contact. The cured gel can be scratch or hard coated to increase mechanical strength.

  In other similar embodiments, a lens can be formed by vacuum molding with a portion of the sheet and an inventory of optical elements. The optical inventory element can be formed of polymers well known to those skilled in the art, such as CR-39 or similar materials. The optical inventory element can be a flat plate or one or more low order optical aberrations can be corrected. In one embodiment, a portion of a sheet of semi-cured material can be applied to the optical inventory element with the same small amount of monomer as the monomer used to make the sheet sandwiched between the sheet and the optical inventory element. Place a thin layer of part of the sheet and an optical inventory element in a flexible mold. Depressurize and press the optical inventory element into a portion of the sheet toward the flexible mold. While the pressure is reduced, the monomer can be cured by applying light or heat. In other embodiments, the monomer material is placed between the optical inventory element and the mold. Depressurizing and pressing the monomer causes the monomer to form a thin layer on the surface of the optical inventory element between the element and the flexible mold. The monomer is at least partially cured to form a semi-cured layer. The finished lens blank is edge processed and applied or attached to the frame. The lens blank can be further cured to define an in-material refraction pattern that corrects one or more higher order optical aberrations. One more detail of such a process is disclosed in US Pat. No. 6,319,433, which is incorporated herein by reference in its entirety.

  In other embodiments, a mounted or framed lens may be used in place of the optical inventory element. A semi-cured material layer is formed on a lens prepared in advance or with a frame. This layer can be further selectively cured to define a refraction pattern that corrects one or more higher order aberrations. Furthermore, one or more low order aberrations can also be corrected in the lens. For example, a weak low-order aberration correction of less than 0.25 diopters that cannot be corrected with a stock lens can be corrected in the layer. Furthermore, higher order correction can be added to the framed lens provided by the patient. For example, an existing or previously obtained optical lens may be modified to correct residual low-order or higher-order aberrations that cannot be corrected with an uncorrected lens.

  FIG. 9 is a flowchart of an embodiment of another method 900 for manufacturing a lens blank. Beginning at step 910, a sheet or photosensitive gel layer is formed as described above. In the next step 912, the sheet is cut (diced) into a group of self-supporting optical flat plates.

  Moving to step 914, a refraction pattern calculated to correct for optical aberrations is formed by photocuring in the gel, eg, using the masking method discussed herein. In one embodiment, the optical plate can be pressed or otherwise shaped and curved into the shape of the lens, or can be formed to correct at least some lower order optical aberrations. Furthermore, the gel can be totally cured to increase its strength.

  A next step 916 completes the method 900 by applying one or more coatings to the optical plate. These coatings can include scratch resistant coatings. In other embodiments, these coatings may include materials that further increase the strength of the lens. The completed lens blank can be used to form a complete optical lens to correct lower and / or higher order optical aberrations as described herein.

  Any of the methods described above can be conveniently performed at one or more locations. More specifically, patient refractive index measurement, semi-finished lens blank grinding, low and / or high order aberration correction, and frame alignment to hold the lens in the patient's line of sight in one or more locations Can be implemented. Thus, with a single visit to the optometrist, a vision prescription is issued and a customized lens is handed to the patient. Furthermore, lens purchases and / or payments for examination costs may be completed at the same location and at the same visit by allowing the patient to pay cash or other legal or credit payments.

  In yet another embodiment, patient lower and / or higher order aberrations measured with an aberrometer can be corrected in a flat lens pre-mounted on the frame. In one embodiment, the flat lens may be flat or curved for cosmetic reasons, such as making it look like a normal lens. Planar lenses can be made from materials that change the refractive index or carrier materials suitable for controlled lamination. The entire method 100, measuring the refractive index of the patient, selecting a framed flat lens, correcting for low and / or high order aberrations, and providing a customized lens can all be performed in one place. The correction of low and / or high order aberrations corresponds to a selective refractive index change corresponding to the desired correction, a controlled stack of low and high refractive index preparation materials corresponding to the desired correction, or a desired correction. Any of the programming methods described above can be included, such as selective volume changes of the layer that change the layer height and thickness. In addition, legal or credit payments such as cash, telegraphic money orders can be included in processes related to customized lens manufacturing.

  FIG. 10 is a block diagram illustrating components of an exemplary system 1000 for eye measurement, correction data calculation, and manufacturing of a lens that corrects the measured anomalies. Each of these functions is performed by a component system. For example, an eye measurement system 1010, a correction calculation system 1020, a manufacturing system 1030, and a billing and payment system 1040. Various embodiments of the system 1000 can include various embodiments of these component systems. In some embodiments, several component systems 1010, 1020, 1030 and 1040 of system 1000 may be combined to create an integrated system. For example, in one embodiment, measurement system 1010 can be integrated with correction calculation system 1020. In other embodiments, the measurement system 1010 can be integrated with the manufacturing system 1030. In one embodiment, each component can be co-located. In other embodiments, system components 1010, 1020, 1030 and 1040 can be in separate arrangements. The measurement system 1010 may preferably be located in an optometrist office or an office or store where other consumers can go. Manufacturing system 1030 may desirably be located in an optical test chamber. In one embodiment, computing system 1020 can be integrated with measurement system 1010. In other embodiments, the computing system 1020 is separated and centrally located by a computer network or other data communication system and corresponds to one or more measurement systems 1010, as discussed in detail below.

  Embodiments of the eye measurement system 1010 can include any one of the various wavefront sensors described above to measure visual parameters such as abnormalities or aberrations in the patient's eye. Measurement system 1010 may also include a phoropter, autorefractor, or trial lens. Embodiments of the eye measurement system 1010 produce measurement data that represents optical lower and / or higher order aberrations.

  The correction calculation system 1020 receives the eye measurement data and determines the lens definition used for lens manufacture. Embodiments of the correction calculation system 1020 can include computer hardware, software, firmware, or a combination thereof.

  In one embodiment, the correction calculation system 1020 generates a wavemap showing corrections that compensate for higher and / or lower order aberrations of the patient's eye. Lens definition may include any relationship with wavefront, refraction pattern, prescription in terms of spheres, cylinders, and axes, or other refraction patterns or corrections. In addition, lens definition includes optical center, multiple optical centers, single correction zone, multiple correction zone, transition zone, blend zone, swim area, channel, additional zone, vertex distance, segment height, off-axis point of view. Zones, logos, invisible marks, etc. can be included.

  In one embodiment, the lens definition includes one or more numbers or symbols that identify a refraction pattern or correction. Such an identification mark can serve as an easy-to-transmit “prescription” that is transmitted, for example, electrically or physically via a bar code.

  In one embodiment, the correction calculation system 1020 converts the wavefront view into another lens display format that is optimized for the patient. Wavefront diagrams or other optimized lens display data for patients include, for example, patient apex distance, pupil diameter, pupil distance, frame information, gazing point, segmental height, pantascopic tilt, Alternatively, it can be based in part on features such as xy tilt.

  In order to calculate the lens definition, the correction calculation system 1020 can generate a conjugate of the optical aberrations of the patient's eye. In other embodiments, the lens definition calculation may be performed in conjunction with additional metrics used to calculate the lens definition based on the patient's eye measurements including the measured optical aberrations. For example, US Pat. No. 6,511,180 issued Jan. 28, 2003 discloses image quality metrics for determining corrections based on measured optical aberrations, which are incorporated herein by reference in their entirety. In other embodiments, other metrics may be used to calculate the lens definition. Metrics may optimize lens definition by selection for correction of optical aberrations associated with improved subjective measurement of patient vision. In other embodiments, the metrics are software distributed information processing trained with data obtained from the test subject to select which optical aberrations should be corrected, added, or uncorrected. It may include a software neural network. More details of such an embodiment are described in US Provisional Application No. 60 / 546,378, filed February 20, 2004, which is incorporated herein by reference in its entirety.

  In one embodiment, the correction calculation system 1020 can also calculate a wavefront diagram based on color preference (preference). Higher order corrections can vary depending on the color of light passing through the correction element. Color preference usually refers to the wavelength that the patient prefers to optimize higher order corrections. For example, this allows the user to optimize the correction at the wavelength that is most useful for a particular activity, such as green for golf. In one embodiment, the color preference is converted to 550 nm (green) by 850 nm measurement on the aberrometer, or 400 to 800 nm to enhance other colors.

  In one embodiment, the correction calculation system 1020 can also calculate lens definitions associated with one or more other preferences of the patient. Patient preferences may include lens tint, or color. Patient preferences may also include whether lens definition includes photochromic properties (photochromic), ie, changing color in response to light. Further, the correction calculation system 1020 can also calculate lens definitions related to features such as UV coating and anti-reflection coating preferences. In one embodiment, the lens definition may be calculated in relation to the patient's usage preferences, such as how the patient prefers to use a higher order correction zone in relation to the frame and field of view.

  The correction calculation system can calculate the lens definition to include one or more correction zones. The calculation may include calculating the number and size of correction zones. Each correction zone can correct high order aberrations, low order aberrations, both low order and high order aberrations, and front and back radii of curvature. The correction zone may include an optical center zone or multiple optical centers such as progressive refraction or multifocal lenses. In one embodiment, the correction calculation system 1020 can calculate a blending or transition zone between one or more correction zones or other parts of the lens. The transition zone smoothly shifts the gaze of the eye from the correction zone, which is usually part of the lens and other part of the lens. Transition zones can also include transitions between correction zones. The transition zone is described in more detail in US Pat. No. 6,712,466, issued March 30, 2004, entitled “Method of Manufacturing Eyeglasses Using Variable Refractive Index Layer”, which is incorporated herein by reference in its entirety.

  In one embodiment, the correction calculation system 1020 includes a server computer that executes software that performs the functions of the correction calculation system 1020. The server can communicate with other components of the system 1000 via the network. The network can be a local or wide area network using any data communication technology obvious to those skilled in the art. In one embodiment, the network includes the Internet. In one embodiment, the correction calculation system 1020 is co-located with the other components of the system 1000. In other embodiments, the correction calculation system 1020 may be coupled to other components of the system 1000 via a network, but is located at a location different from the other components of the system 1000. In one exemplary embodiment, the correction calculation system 1020 is configured to support one or more systems 1000. In such an embodiment, the correction calculation system 1020 may include a billing module. The billing module can charge based on usage of the correction calculation system 1020, for example, lens definition calculations or downloaded times.

  The manufacturing system 1030 uses the correction data from the correction calculation system 1020 to manufacture a customized lens for the patient. The manufacturing system 1030 may include a programmer that transfers the lens definition to the lens. The programmer can include an illumination source and a photomask as described herein. The programmer may also include a stacking device configured to control and stack one or more materials.

  In one embodiment, the manufacturing system 1030 corrects low and high order aberrations simultaneously. For example, a lens blank is programmed to cure the photosensitive material using, for example, an illumination source and a photomask to change the refractive index to correct both low and high order aberrations.

  In other embodiments, the manufacturing system 1030 corrects substantially all low order aberrations and then corrects high order aberrations. In such an embodiment, the green product is corrected for all or substantially all low-order aberrations by molding or grinding, resulting in a lens blank. Higher order aberrations and, in one embodiment, residual lower order aberrations are corrected using, for example, a programmer. A programmer means any apparatus that performs one or more methods of defining a refractive pattern of an optical element as disclosed herein.

  In other embodiments, the manufacturing system 1030 corrects high order aberrations and then corrects low order aberrations. For example, an embodiment of the method 600 may be used to laminate a layer having a predetermined refractive index to correct higher order aberrations and then have a cast shape calculated to correct lower order aberrations. A mold is used to form a simple lens.

  In other embodiments, the manufacturing system 1030 corrects high order aberrations and then corrects low order aberrations. For example, as described herein, an embodiment of the method 600 may be used to stack a layer having a predetermined varying thickness to correct higher order aberrations, followed by correcting lower order aberrations. A mold is used to form a complete lens having a calculated casting shape.

  The manufacturing system corrects low order aberrations and programs at least one higher order or residual lower order or higher order aberration. The manufacturing system performs the necessary corrections for both the left and right lenses. The manufacturing system performs lens number, low-order polishing, polishing, programming, edge processing, coating, frame, etc.

  Payment system 1040 includes hardware and / or software that addresses payment of patient lens costs, exam costs and / or other costs in cash, credits, or any other manner. Embodiments of payment system 1040 can be computer hardware, software, firmware, or a combination thereof. Such embodiments may include a cash register, smart card reader, or charge or credit card reader.

  In one embodiment, the measurement system 1010 and each component system 1020, 1030, and 1040 are located in one place. One place means a place such as an office, a storefront, or an optical test room. Thus, the patient can receive the prescription and receive the manufactured customized lens at a single location and only once there. In other embodiments, component systems 1010, 1020 and 1030 may be located in 1, 2, 3 or more locations. Each component of the system 1000 can communicate using well-known transmission media and procedures. For example, in one embodiment, the computers of system 1000 can communicate using a network such as an intranet or the Internet. In other embodiments, the component can provide data in a tangible material, such as a printed material. For example, the correction calculation system 1020 can print a barcode that describes the lens or identifies the lens definition. In other embodiments, the components can exchange data via a removable computer disk, smart card or other physical electronic medium. Such prints and electronic media can be exchanged by physical delivery or fax transmission. By placing each element in a different location, each system can be optimally sized, and for expensive equipment such as computing or manufacturing systems, between measuring system locations that are sales locations such as storefronts. It becomes possible to share.

  FIG. 11 is one embodiment of an eyeglass manufacturing method 1100 according to an embodiment of a system 1000 as shown in FIG. The method 1100 begins at step 1110 and measures the patient's eye, for example, by the measurement system 1010. In the next step 1120, the patient selects a frame style. This selected frame style is received by the correction calculation system 1020 and the manufacturing system 1030, for example. Moving to step 1130, a spectacle frame including a lens is selected from the frame inventory. In one embodiment, this selection is made based on eye measurements and / or a selected frame style. Frame stock lenses include programmable elements such as, for example, a polymer layer having a refractive index, and the refractive index can be further selectively changed, for example, by point curing. The lens can be antireflective, scratch resistant or tinted, for example. In one embodiment, the computing system 1020 selects a frame that includes a flat lens. In other embodiments, the computing system 1020 selects a frame that includes a lens with a predetermined optical correction that can be selected based on eye measurements. Correction system 1020 may perform this selection based on inventory data. In one embodiment, the manufacturing system 1030 maintains inventory data and communicates it to the correction system 1020. Moving to step 1140, a correction is calculated based on the eye measurements. In one embodiment, the correction is also corrected based on the received frame selection. In one embodiment, the correction calculation system 1020 performs the calculation. Calculations can be made for residual corrections that are required in connection with a predetermined correction of the lens of the selected frame. In one embodiment, the frame may be measured such that the correction includes a correction for residual error caused by the selected frame. The calculated corrections may include corrections for low order, residual low order aberrations, high order aberrations, or any type of correction disclosed herein. Moving to step 1150, the calculated correction is applied to the lens of the selected frame using a programmer as disclosed herein. For example, in one embodiment, the UV source selectively cures a thin layer of curable material so as to define a refraction pattern corresponding to the calculated correction. The frame is then handed over to the patient to receive payment.

  FIG. 12 shows one embodiment of a method 1200 for manufacturing a customized lens with a frame. Beginning at step 1210, the patient's visual parameters are measured using, for example, the measurement system 1010. In other exemplary embodiments, the visual parameters are received by one or more computer networks, printed recipes or barcodes associated with the visual parameters. In the next step 1220, a framed lens is received, such as glasses with two lenses. The wearing lens can be obtained from the patient or from a stock of wearing lenses. In one embodiment, the patient provides a framed lens, such as existing eyeglasses. In one embodiment, the patient's visual acuity is measured in step 1210 through framed eyeglasses. In other embodiments, the patient's visual parameters and framed eyeglasses are measured separately. Moving to step 1230, the correction is calculated based on the visual parameters, for example, by the calculation system 1020. In one embodiment, the correction can also be made based on a framed lens. Proceeding to step 1240, the manufacturing system 1030 programs the lens with the calculated correction. In one embodiment, a material layer that defines the contour of the surface is applied to the surface of one or both lenses of the framed lens so as to define a refraction pattern corresponding to the calculated correction. The calculated corrections may include corrections for low order aberrations, residual low order aberrations, high order aberrations, residual high order aberrations, or a combination of both. This embodiment is similar to that described in connection with FIG. 7B, except that the layer is applied to the framed lens rather than to the mold. In other embodiments, a layer of material consisting of a different mixture of materials is applied to the framed lens so as to define a refraction pattern corresponding to the calculated correction. This embodiment is similar to that described in connection with FIG. 7G, except that the layer is applied to the framed lens rather than to the mold. Other embodiments may include programming the correction applied to the photosensitive gel layer as described in connection with FIG.

  Other embodiments include optical elements that correct or introduce one or more higher order aberrations. In some embodiments, one or more higher order aberration values may be introduced that are corrected or incrementally increased. Desirably such aberrations may include spherical aberration, trefoil or coma. In one embodiment, the optical element is configured for use with a phoropter. An optometrist or other user places the optical element in the optical path of the patient. The patient can then subjectively determine whether the correction has improved visual acuity. In other embodiments, the optical element comprises a framed spectacle lens. Such a framed higher order correction lens can be stored with an optical element that corrects one or more higher order aberrations at various magnifications. The patient may select a frame and correction from the frame inventory, for example with reading glasses. Thus, for example, a patient can readily obtain a lens for use in a particular environment or task.

  In other embodiments, the refraction pattern corresponding to the calculated correction may include application of a material layer that is defined by the difference in volume change during curing. One such embodiment is described in connection with FIG.

  For example, when properly cured using high intensity light, the polymer shrinks, i.e., substantially reduces its volume, as expected. It has been found that such high volume layers are selectively cured and the resulting layer exhibits a refractive pattern that corrects both higher and lower order optical aberrations. FIG. 13 illustrates another embodiment of a method 1300 for manufacturing a lens having layers with varying thickness. Beginning at block 1310, a lens member is made from an optical element 1302 and a high volume shrinkage monomer layer 1304. In one embodiment, the optical element 1302 with the high volume change monomer layer 1304 can be a framed or attached lens. In one embodiment, the optical element 1302 can be contoured, eg, to correct low order aberrations, eg, by grinding or polishing. In other embodiments, low order aberrations can be corrected by volume changes in the monomer layer 1304. Next, as shown in block 1320, layer 1304 is exposed to high intensity irradiation of a two-dimensional grayscale pattern. The irradiation pattern can be generated using, for example, a light source and a photomask. This high intensity irradiation pattern causes various contractions in the layer 1304 and changes the refractive index throughout the layer 1304. Monomer compositions can include the materials disclosed herein. Further, selection of the appropriate composition of layer 1304, the appropriate wavelength, time and intensity of irradiation may include selections well known to those skilled in the art. The two-dimensional grayscale pattern can be selected to form a layer 1304 that corrects one or more higher or lower order aberrations. Furthermore, the irradiation pattern is optical center, multiple optical centers, single correction zone, multiple correction zones, transition zone, blend zone, swim area, channel, additional zone, distance between vertices, segment height, logo, invisible mark Can be calculated to include other features as described herein. Moving to block 1330, the layer 1304 may be exposed to approximately uniform low intensity irradiation. The intensity, wavelength and time of irradiation can be selected well known to those skilled in the art to complete the curing of the polymer. The change in volume can also correct low order aberrations. Block 1340 shows the cured lens. The cured lens can be further treated with optical coatings such as hard coatings, UV protection coatings, antireflection and scratch resistant coatings.

  Depending on the embodiment, acts or events of any method described herein may be performed in any order, unless otherwise specified, and may be added, merged, or removed entirely (eg, not necessarily all for performing the method). It is also understood that no act or event is necessary). Furthermore, the above method can also be used to manufacture spherical, aspherical, monocular, bifocal, multifocal, progressive refractive lenses, atoric, intraocular lenses, or other special lenses.

  Although certain embodiments are described herein for providing customized vision with eyeglasses, other embodiments may include providing customized optical corrections for other optical systems, such as optical instruments. For example, optical instruments such as cameras, telescopes, binoculars or microscopes can include customized optical elements. Customized optical elements may be included as part of a configurable eyepiece, a device element, or as an addition to the eyepiece. The customized optical element can be configured to correct the optical path of the instrument, including the viewfinder or path of view and the main optical path of cameras, telescopes, binoculars, microscopes or similar optical devices. The customized optical element is configured to provide customized corrections for the optical system as described herein. In one embodiment, the customized optical element is configured to provide a lens definition that includes one or more optical aberrations and other visual parameters of the user's at least one eye. In other embodiments, the customized optical element is configured to correct one or more optical aberrations in the optical instrument. In yet another embodiment, the customized optical element is configured to include correction of optical aberrations of the optical instrument and lens definition for at least one eye of the user. In one embodiment, a material layer as described above is applied to a lens, such as an eyepiece, and cured (if necessary) so as to define a correction, such as lens definition, in the lens. In one embodiment, the customization element is configured to include a customized lens definition for use with one eye of the user. In other embodiments, binoculars can be customized for the user's eyes.

  While the novel features of the invention have been illustrated, described, and pointed out in the foregoing detailed description, as applied to various embodiments, various omissions in the form and details of the depicted apparatus and processes are shown. It will be understood that substitutions and modifications may be made by those skilled in the art without departing from the spirit of the invention. As will be appreciated, the invention may be practiced in a form that does not provide all of the features and benefits described herein, that is, one feature may be utilized or practiced separately from another. The scope of the invention is indicated by the claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within the scope of the invention.

It is a flowchart which shows the manufacturing process of an eyeglass lens. 2 is a flowchart illustrating an embodiment of a lens manufacturing method for correcting optical aberrations as part of the process of FIG. It is a flowchart which shows other embodiment of the lens blank manufacturing method as a part of lens manufacturing method as shown in FIG. FIG. 4 shows a lens blank in one step of the method shown in FIG. 4B shows the lens blank of FIG. 4A in another step of the method of FIG. 4B shows the lens blank of FIG. 4A upon completion of the method of FIG. It is a figure of other embodiment of the lens manufacturing method similar to FIG. 4D is a diagram of one embodiment of a method of manufacturing an optical element by injecting a mixture of low and high refractive index preparation materials between two molds, similar to the embodiment of FIG. 4D. 6 is a flowchart showing another embodiment of a method for manufacturing an optical lens as part of the process of FIG. 2 is a flowchart illustrating an embodiment of a lens manufacturing method for correcting optical aberrations, similar to the method of FIG. 1 except that a mold is used. FIG. 7 illustrates steps for manufacturing a lens by a method as shown in FIG. FIG. 7 illustrates steps for manufacturing a lens by a method as shown in FIG. FIG. 7 illustrates steps for manufacturing a lens by a method as shown in FIG. FIG. 7 illustrates steps for manufacturing a lens by a method as shown in FIG. FIG. 7 illustrates steps for manufacturing a lens by a method as shown in FIG. A lens similar to the method shown in FIGS. 7A-7E, except that the layer is usually of a uniform thickness and is made of a material that has a ratio changed to change the index of refraction across the lens surface. The steps of the manufacturing method are illustrated. A lens similar to the method shown in FIGS. 7A-7E, except that the layer is usually of a uniform thickness and is made of a material that has a ratio changed to change the index of refraction across the lens surface. The steps of the manufacturing method are illustrated. A lens similar to the method shown in FIGS. 7A-7E, except that the layer is usually of a uniform thickness and is made of a material that has a ratio changed to change the index of refraction across the lens surface. The steps of the manufacturing method are illustrated. A lens similar to the method shown in FIGS. 7A-7E, except that the layer is usually of a uniform thickness and is made of a material that has a ratio changed to change the index of refraction across the lens surface. The steps of the manufacturing method are illustrated. A lens similar to the method shown in FIGS. 7A-7E, except that the layer is usually of a uniform thickness and is made of a material that has a ratio changed to change the index of refraction across the lens surface. The steps of the manufacturing method are illustrated. FIG. 7 is a flow chart illustrating an embodiment of a method for manufacturing a lens blank using a self-supporting polymer film membranous gel, similar to the method of FIG. 2 is a flowchart illustrating an embodiment of a method for producing a lens blank used in the embodiment of the method of FIG. 1 using a self-supporting film-like gel of polymer material. FIG. 2 is a simplified block diagram illustrating one embodiment of a spectacle lens manufacturing system using, for example, one embodiment of the method of FIG. FIG. 11 illustrates one embodiment of a method for manufacturing eyeglasses using an embodiment of the system as shown in FIG. It is one embodiment of a lens manufacturing method with a customized frame. FIG. 6 illustrates another embodiment of a method for manufacturing a lens having a layer with varying thickness.

Claims (66)

In the production of corrective glasses;
Obtaining vision parameters of the patient's eyes;
Obtaining a spectacle frame comprising one or more mounted optical elements; and programming the optical element to define a refraction pattern with respect to the visual parameter;
Including methods.   The method of claim 1, wherein the visual parameters include one or more of vertex distance, pupil diameter, pupil distance, frame information, gaze point or xy tilt of the patient's eye.   The method of claim 1, wherein the visual parameters include one or more of high order aberrations, low order aberrations, high order correction zones, transition zones, swim zones, channels, blend zones, and off-axis gaze zones or reading capabilities. .   The method of claim 1, wherein the visual parameters include one or more of a color preference, a hue preference, a light coloring preference, an ultraviolet coating preference, an anti-reflective coating preference, or a patient use preference.   The method of claim 1, wherein obtaining the visual parameter comprises receiving data obtained from one or more of an aberrometer, an automatic refractor, a phoropter, or a trial lens.   The method of claim 1, wherein programming the optical element to define the refractive pattern includes programming the optical element such that the refractive pattern corrects one or more higher order optical aberrations.   The method of claim 1, wherein programming the optical element to define the refractive pattern includes programming the optical element such that the refractive pattern corrects one or more lower order optical aberrations.   The method of claim 1, wherein the one or more optical elements include the two or more elements having a layer of curable material disposed between the two or more elements.   The method of claim 8, wherein at least one of the two or more elements comprises an optical coating.   The method of claim 9, wherein the optical coating comprises an abrasion resistant coating.   The method of claim 1, wherein programming of the optical element includes selective curing of a layer of curable material to define the refractive pattern.   The method of claim 1, wherein the one or more optical elements comprise a film of curable material.   The method of claim 12, wherein programming of the optical element includes selective curing of a film of the curable material to define the refractive pattern.   14. The method of claim 13, wherein the selective curing of the film of curable material comprises exposing the film of curable material to a two-dimensional gray scale pattern radiation.   The method of claim 1, wherein programming the optical element comprises laminating a layer of material defining the refractive pattern on the optical element.   The method of claim 15, wherein laminating the layers comprises laminating the layers to have a surface contour that defines the refractive pattern.   The method of claim 15, wherein the stack of material layers comprises a stack of different mixtures of two or more material compositions defining the refractive pattern. The programming of the optical element is;
Applying a layer of curable material to the mounted optical element; and selectively curing the layer of curable material to change the volume of the layer to form a surface contour of the layer defining the refractive pattern;
The method of claim 1.   The method of claim 1, wherein programming of the optical element comprises laser ablation of the optical element.   The method of claim 1, wherein the optical element comprises a flat element.   The method of claim 1, wherein the optical element comprises a lens having a curved surface selected to correct one or more lower order aberrations.   The method of claim 1, wherein the optical element comprises an element having a cosmetic curvature. The method of claim 1, wherein the one or more optical elements have a preset correction force. In the manufacturing method of customized lenses;
Obtaining a lens definition including visual parameters of the patient's eye and correction for one or more optical aberrations of the patient's eye;
Obtaining a frame comprising one or more optical elements comprising a layer of curable material; and curing the curable material defining a refractive pattern that corrects the one or more optical aberrations in an optical path through the optical element;
Including methods.   25. The method of claim 24, wherein the visual parameters include one or more of inter-apex distance, pupil diameter, inter-pupil distance, frame information, gaze point or xy tilt of the patient's eye.   26. The method of claim 25, wherein the curing is performed in relation to the visual parameter.   25. The method of claim 24, wherein obtaining the lens definition comprises receiving data from one or more of an aberrometer, an auto refractor, a phoropter, or a trial lens.   25. The method of claim 24, wherein the one or more optical aberrations include one or more higher order aberrations.   25. The method of claim 24, wherein the one or more optical elements comprise the two elements having the curable material layer disposed between two elements.   25. The method of claim 24, wherein the optical element comprises a flat element.   25. The method of claim 24, wherein the optical element comprises a lens with a curved surface selected to correct one or more lower order aberrations.   25. The method of claim 24, wherein the optical element comprises an element having a cosmetic surface. In the manufacturing method of customized lenses;
Obtaining a lens definition including visual parameters of the patient's eye and correction for one or more optical aberrations of the patient's eye;
Obtaining a frame comprising one or more optical elements; and on top of the one or more optical elements, a material layer defining a refractive pattern that corrects the one or more optical aberrations in an optical path through the optical elements Lamination,
Including methods.   34. The method of claim 33, wherein the visual parameters include one or more of inter-apex distance, pupil diameter, inter-pupil distance, frame information, gaze point or xy tilt of the patient's eye.   34. The method of claim 33, wherein obtaining the lens definition comprises receiving data obtained from one or more of an aberrometer, an automatic refractor, or a phoropter.   34. The method of claim 33, wherein the one or more optical aberrations include one or more higher order aberrations.   34. The method of claim 33, wherein the one or more lenses (optical elements) have a preset correction force.   34. The method of claim 33, wherein the layer stack includes a layer stack to form a surface contour that defines the refractive pattern.   34. The method of claim 33, wherein the stack of material layers comprises a stack of different mixtures of two or more material compositions that define the refractive pattern.   34. The method of claim 33, wherein the measurement of the visual parameter includes measurement of one or more optical aberrations, and the stack of material layers includes correction of the one or more optical aberrations in the framed optical element.   34. The method of claim 33, wherein the optical element comprises a flat element. 34. A method according to claim 33, wherein the optical element comprises a spectacle lens with a preset correction force.   34. The method of claim 33, further comprising calculating the refraction pattern from the measured visual parameters. The lamination of the layers is;
Lamination of the layers of curable material;
Selectively curing the layer, changing the volume of the layer to define a surface profile of the layer defining the refractive pattern; and substantially uniform curing of the layer;
34. The method of claim 33, comprising:   The selective curing includes exposing the layer to high intensity radiation in a two-dimensional gray scale pattern, and substantially uniform curing of the layer exposes the layer to substantially uniform low intensity radiation. 45. The method of claim 44, comprising: In the manufacturing method of customized lenses;
Obtaining lens definition including visual parameters of the patient's eye and correction of one or more optical aberrations of the patient's eye;
Applying a cured polymer layer to the framed lens; and selectively curing the layer to change the volume of the layer to define a surface profile that defines a refractive pattern that corrects the one or more optical aberrations;
Including methods.   The method of claim 46, wherein the refractive pattern corrects one or more higher order aberrations.   The method of claim 46, wherein the refractive pattern corrects one or more low order aberrations.   47. The method of claim 46, wherein the refractive pattern corrects one or more low order aberrations and one or more high order aberrations.   47. The method of claim 46, wherein the selective curing includes exposing the layer to a two-dimensional grayscale pattern radiation.   51. The method of claim 50, wherein the radiation includes a high intensity radiation. 48. The method of claim 46, further comprising a substantially uniform cure of the layer.   53. The method of claim 52, wherein the substantially uniform curing comprises exposing the layer to substantially uniform radiation.   54. The method of claim 53, wherein the radiation comprises a low intensity radiation.   47. The method of claim 46, wherein the framed lens comprises a flat lens. In the optical element;
Including one or more lenses configured to correct one or more higher order aberrations, wherein the one or more higher order aberrations include one or more of trilobal, coma, spherical aberration, or combinations thereof;
Optical element.   57. The optical element of claim 56, further comprising a frame configured to mount the one or more lenses.   57. The optical element of claim 56, further comprising a phoropter configured to place the one or more lenses in a patient's optical path. In the manufacturing method of customized lenses;
Obtaining lens definition including visual parameters of the patient's eye and correction for one or more optical aberrations of the patient's eye; and obtaining a frame including one or more optical elements including a layer of curable material; and relating to lens definition Selective curing of the layer, changing the volume of the layer to define a surface profile that defines a refraction pattern to
Including methods.   60. The method of claim 59, wherein the visual parameters include one or more of inter-apex distance, pupil diameter, inter-pupil distance, frame information, gaze point, or xy tilt of the patient's eye.   60. The method of claim 59, wherein obtaining the lens definition comprises receiving data from one or more of an aberrometer, an auto refractor, a phoropter, or a trial lens.   60. The method of claim 59, wherein the one or more optical aberrations include one or more higher order aberrations.   60. The method of claim 59, wherein the one or more optical elements comprise the two elements having the curable material layer disposed between two elements.   60. The method of claim 59, wherein the optical element comprises a flat element.   60. The method of claim 59, wherein the optical element comprises a lens with a curved surface selected to correct one or more lower order aberrations.   60. The method of claim 59, wherein the optical element comprises an element having a cosmetic surface.

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