KR20060130066A - Eyeglass manufacturing method - Google Patents

Abstract

A method of making corrective eyeglasses is disclosed. One embodiment is a method of making corrective eyeglasses. The method includes obtaining vision parameters of a patient's eyes, obtaining an eyeglass frame comprising at least one mounted optical element, and programming the optical element to define a pattern of refraction that is associated with the vision parameters.

Description

How to make glasses {EYEGLASS MANUFACTURING METHOD}

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.

This application is directed to US Provisional Application No. 60 / 520,065, filed Nov. 14, 2003, US Provisional Application No. 60 / 546,378, filed Feb. 20, 2004, US Application No. 10, filed September 7, 2004. / 936,132, and U.S. Application No. 10 / 936,131, filed Sep. 7, 2004, which is incorporated herein by reference.

The human eye, in particular the cornea and lens, can exhibit various optical aberrations that reduce the optical performance of the eye and blur the vision. The method of correcting blurred vision by wearing a lens on a subject is typically limited to correcting only low order aberrations such as focus mismatch and astigmatism. In general, high order aberrations that can be represented by more than three orders of magnitude Zernike polynomial are not corrected by the use of lenses. In addition, due to lens manufacturing limitations and costs, focus mismatch and astigmatism are typically only corrected in a separate step, and all corrections are made close to 1/4 (0.25) diopters (D). Unfortunately, vision correction is incomplete because the resolution is 0.25 diopters.

The systems, methods, and apparatus of the present invention each have several aspects, of which only one does not play a significant role in the desired properties. Without limiting the scope of the invention, which is defined by the appended claims, the superior features of the invention will be described briefly. In reviewing the following description, and in particular in reviewing the detailed description of embodiments of the present invention, it will be appreciated that the advantages provided by the present invention include methods of conveniently and economically manufacturing custom multilayer lenses.

One embodiment is a method of manufacturing corrective glasses. The method includes obtaining a vision parameter of the subject's eye, obtaining a spectacle frame comprising at least one mounted optical element, and programming the optical element to define a refractive pattern associated with the visual parameter. It includes.

Yet another embodiment is a method of making a custom lens. The method includes obtaining a lens definition that includes correction of the visual parameters of the subject's eye and at least one optical aberration in the subject's eye. The method also includes obtaining a frame that includes at least one optical element. At least one optical element comprises a layer of curable material. The method also includes curing the curable material to define the refractive pattern. The refractive pattern at least corrects optical aberrations in the optical path through the optical element.

Yet another embodiment is a method of making a custom lens. The method includes obtaining lens resolution comprising corrections for the visual parameters of the subject's eye and at least one optical aberration in the subject's eye. The method also includes obtaining a frame that includes at least one optical element. The method includes attaching a layer of material on at least one optical element. The layer defines a refractive pattern that corrects at least one optical aberration in the optical path through the optical element.

Yet another embodiment is a method of making a custom lens. The method includes obtaining lens resolution comprising corrections for the visual parameters of the subject's eye and at least one optical aberration in the subject's eye. A layer of curable polymer is applied to the lens mounted to the frame. The method includes selectively curing the layer to change the volume of the layer to form a surface contour of the layer. Surface contours define a refractive pattern that corrects at least one optical aberration.

Another embodiment is an optical element. The optical element includes at least one lens configured to correct at least one high order aberration. The at least one high order aberration includes at least one of trefoil aberration, coma aberration, spherical aberration, or a combination thereof.

Yet another embodiment is a method of making a custom lens. The method includes obtaining lens resolution comprising corrections for the visual parameters of the subject's eye and at least one optical aberration in the subject's eye. The method also includes obtaining a frame that includes at least one optical element. At least one optical element comprises a layer of curable material. The method includes selectively curing the layer to change the volume of the layer to form a surface contour of the layer. The surface contour defines the refractive pattern associated with the lens resolution.

1 is a flowchart illustrating a process of manufacturing a spectacle lens.

FIG. 2 is a flow diagram illustrating an embodiment of a method of manufacturing a lens for correcting optical aberration as part of the process of FIG. 1.

FIG. 3 is a flow diagram illustrating yet another embodiment of a method for manufacturing a lens blank as part of a lens manufacturing method as shown in FIG. 1.

4A is an illustration of a lens blank at one step of the method shown in FIG. 3.

FIG. 4B is an illustration of the lens blank of FIG. 4A in another step of the method of FIG. 3.

4C is an illustration of the lens blank of FIG. 4A upon completion of the method of FIG. 3.

FIG. 4D is a schematic diagram showing another embodiment of a lens manufacturing method similar to the method shown in FIG. 3.

FIG. 4E illustrates an embodiment of a method of producing an optical element by injecting a mixture of low and high refractive index formulations between two molds in a manner similar to FIG. 4D.

FIG. 5 is a flowchart illustrating another embodiment of a method of manufacturing an optical lens as part of the process of FIG. 1.

FIG. 6 is a flow diagram illustrating an embodiment of a method of manufacturing a lens for correcting optical aberrations using a mold, similar to the method shown in FIG. 1.

7A to 7E are schematic diagrams illustrating steps of manufacturing a lens as in the method shown in FIG. 6.

7F-7J are similar to the method shown in FIGS. 7A-7E, but the layers are configured to have a nearly uniform thickness and to change the proportion of material to produce a lens with a varying refractive index across the lens surface. It is a schematic diagram showing the steps of the method.

FIG. 8 is a flow diagram illustrating an embodiment of a method of making a lens blank using an independent film-like gel of polymer material similar to the method shown in FIG. 6.

FIG. 9 is a flowchart showing an embodiment of manufacturing a lens blank using, for example, an independent film-like gel of polymer material in the lens blank used in the embodiment of the method of FIG. 1.

FIG. 10 is a block diagram schematically illustrating one embodiment of a system for manufacturing spectacle lenses using, for example, the embodiment of the method of FIG. 1.

FIG. 11 is a diagram illustrating an embodiment of a method of manufacturing glasses using the embodiment of the system as shown in FIG. 10.

12 is a diagram illustrating an embodiment of a method of manufacturing a custom lens mounted to a frame.

  FIG. 13 is a schematic view showing still another embodiment of a method of manufacturing a lens having a layer of varying thickness. FIG.

The following detailed description relates to specific embodiments of the present invention. However, the present invention may be implemented in various other ways as defined and encompassed by the claims. In the drawings referred to in the description below, the same reference numerals are given to the same members throughout the drawings.

Typically in forming spectacle lenses, the lens blanks are polished to correct the measured optical aberrations, and the edges of the lens blanks are machined and mounted on the spectacle frames. Such correction is typically limited to low order aberrations. Also, since polishing is typically performed up to a tolerance of 0.25D, this calibration is typically incomplete.

By using an apparatus for measuring wavefront aberration in the subject's eye, the eye of the subject can be measured more accurately. The measurement results can be used to calculate the optimized lens definition. In one embodiment the lens resolution is a refractive index pattern that corrects one or more optical aberrations in the optical path through a lens that typically corrects the wavefront aberration of the subject to more than possible precision when apparent within an optical lens such as an eyeglass lens. It can be limited. Thus, the subject can correct his vision to the extent that it is close to his maximum optical capability.

As used herein, "correction" of optical aberrations does not necessarily mean complete elimination of optical aberrations, and should be understood to mean generally reducing, minimizing or optimizing optical aberrations. In addition, since it has been found in some cases that visual acuity is improved by an increase in a particular high order aberration, “correction” of the aberration may include adding or increasing a specific optical aberration. Optical elements may include thick or thin lens blanks, plano lenses, corrective lenses such as spectacle lenses, contact lenses, optical coatings, intraocular lenses, or other combinations of other optical elements. It may also include a member. The plano optical element, i.e. the element having no refractive power, may be flat, or may be curved for example for decorative reasons to have an appearance similar to that of a conventional spectacle lens.

1 is a high level flow diagram illustrating a method 100 of manufacturing a custom lens. Beginning at step 110, the eye of the subject is measured. In one embodiment, an aberometer (eg, including a wavefront sensor) is used to measure the subject's visual parameters, such as low and / or high order aberrations. For example, Shack-Hartmann, diffraction gratings, gratings, Hartman screens, Fizeau interferometers, ray tracing systems, Tscherning aberrations, optometry phase difference systems, Aberration sensors can be measured using wavefront sensors such as the Twymann-Green interferometer and the Talbot interferometer. US Pat. No. 6,721,043 to Platt. B. et al., Entitled “Light-Controlled Aberration Coupler,” describes a representative aberration system in more detail, which is incorporated herein by reference in its entirety. . US patent application Ser. No. 10/076218, filed Feb. 13, 2002, entitled " Apparatus and Method for Determining Target Refraction Using Wavefront Sensing, " Another embodiment of aberration system is disclosed in US patent application Ser. No. 10/14037, filed 10, each of which is incorporated herein by reference in its entirety. In one embodiment, the viewing parameter may comprise data obtained by examining a subject's vision through a test lens or test lens configured to correct high or low optical aberrations.

In addition to aberration measurements, other viewing parameters such as the vertex distance, interpupillary distance, frame information, gaze or x-y slope of the subject can be obtained. Such measurements are described in more detail in US Pat. No. 6,682,195, entitled “Method for Manufacturing Customer Eyeglasses,” issued January 27, 2004, which is incorporated herein by reference in its entirety.

Proceeding to step 120, a refractive pattern in the optical lens is calculated to correct the measured aberration. For example, a refractive pattern within an optical element may be defined by limiting the refractive index of the two-dimensional pattern across the face of the optical element or by varying the thickness of the layer of material comprising the optical element to change the refractive index and thereby define the refractive pattern. Can be formed. For example, standard spectacle lenses typically define a refractive pattern by varying the curvature of the lens material and thus the thickness of the lens material over the surface of the lens. The curvature of the lens along with the refractive index of the lens material defines the refractive pattern of the standard spectacle lens. Such standard lenses typically correct one or more lower optical aberrations. In one embodiment, the refractive pattern is defined and expressed at least in part by spheres, cylinders, and axes. In such an embodiment, another refractive pattern for correcting residual aberrations such as high order aberrations and polishing errors may also be calculated and applied to the lens. In another embodiment, the refractive pattern is calculated with the low and high Zernike polynomials and applied to materials that can be treated or cured for refractive index changes.

In one embodiment, the viewing parameters can be used by visual acuity measurement for optimization of lens resolution. Lens resolution may include wavemaps, refractive patterns, specifications for spheres, cylinders, and axes, or other relationships to refractive patterns or corrections. In addition, the lens resolution is optical center, multiple optical center, single correction region, multiple correction region, transition region, mixed region, swim region, channel, add zone, inter-vertex distance, compartment height , Off-axis gaze zones, logos, invisible markings, and the like.

Next, in step 130, a lens is manufactured to correct both low and high optical aberrations. One embodiment of such a lens is disclosed in more detail in US patent application Ser. No. 10/218049, filed Aug. 12, 2002, entitled " Apparatus and Method for Correcting High Aberrations of Human Eye, " And incorporated herein. Embodiments of a method of making a lens may include a number of different methods for making a lens having a calculated pattern of refractive indices, and are calibrated to include the calculated refractive pattern, as described in more detail herein. Attached layers, polishing or freeform surfacing of the lens surface, pour molding, and combinations thereof.

2 is a flow diagram illustrating one embodiment of a method 130 of manufacturing an optical lens blank capable of receiving a refractive index pattern calculated based on wavefront aberration, for example, from a human eye. The method 130 begins at step 210 where a photosensitive gel layer is formed between the first and second optical elements. One embodiment is a thick and thin lens. Other embodiments may include two thick lenses or two thin lenses. The thick optical lens is generally referred to as an optical element, which can be thicker and plano lens, and can generally provide corrective force. While thick or thin lenses can be contoured to change the refractive power of the element, thick lenses provide a wider range for contouring. Such contouring may include polishing and fine polishing, laser ablation, or freeform surface treatment. Preferably, the anterior optical element into which the light into the eye initially enters is generally a thin lens with no refractive power. It should be noted that the radius of curvature of the front optical element generally defines the refractive power of the optical lens blank. Based on the target corrective force of the final optical blank, a thick or thin lens can be selected for each optical element. For example, if a high corrective force lens is required, two thick lenses can be used. Two thin lenses may be used if only minimal low order aberration correction is needed for a particular lens.

The photosensitive gel layer can be optionally cured for refractive index changes. For example, the photosensitive gel layer may be cured in a dot or in a stepwise or continuous manner to define a two-dimensional refractive pattern that corrects one or more aberrations of the optical path through the lens. As used herein, such curable materials can be said to have an optional variable refractive index. The refractive pattern of the layer can be generated to define the correction for one or more optical aberrations. Specific embodiments of these and other methods are discussed herein with respect to the photosensitive gel layer, and other embodiments may use layers of other materials having an optional variable refractive index that may be treated or cured, for example, to change the refractive index. It should be understood that there is.

In one embodiment, the photosensitive gel layer is formed of, for example, a polymer gel first formed in a large sheet. US Patent Application No. OPH.031A, entitled “Stabilizing Polymer Materials and Methods” and “Stabilizing Polymer Materials and Methods”, pending together with the same application, are hereby incorporated by reference in their entirety; Examples of photosensitive gel layers are disclosed. A preferred embodiment uses a composition comprising a matrix polymer in which a monomer mixture is dispersed, the matrix polymer being polyester, polystyrene, polyacrylate, thiol-cured epoxy polymer, thiol-cured isocyanate polymer and Selected from the group consisting of mixtures, the monomer mixture comprises a thiol monomer and at least one second monomer selected from the group consisting of ene and yne monomers.

In one embodiment, a sheet of such known polymer or gel is formed. Part of this sheet is disposed between two optical elements to form a lens blank. A large single sheet can be formed in bulk and used to cut into several parts to form multiple lens blanks. Two optical elements are attached to form a lens blank. The first and second optical elements may be plano lenses or may have corrective forces. In one embodiment, the lens blank is prepared to have a correcting force within a predetermined range, for example, 0.25 diopters or 1 diopter, within the first and / or second lens. In a preferred embodiment, one or both of the optical elements is a thick lens that can be contoured by, for example, polishing and fine polishing to provide at least partial correction of one or more low order aberrations. Next at step 215, in such an embodiment, the outer surface of one or both of the optical elements may be contoured. In another embodiment, the lenses may be contoured before they are attached to each other and formed into a lens blank. The lenses are contoured by conventional polishing and fine polishing, or by free-form surface machining using a 3-axis turning machine manufactured by Schneider Optics, LOH, Gerber Coburn Optical. Or may be shaped to provide at least partial correction of optical aberrations. As used herein, freeform surface finish refers to any method of point-to-point surface finish or machining.

Next, in step 220, a refractive pattern or refractive index as calculated in step 120 of the method 100 is formed in the photosensitive gel layer. This pattern is formed to correct optical aberrations in the human eye. In one embodiment, the refractive pattern formed in the photosensitive gel is calculated to correct the high and low aberrations, otherwise it is not corrected by, for example, the thinning of the lens blank or the surface processing of the thin lens from the lens blank. Do not.

In one embodiment, such a refractive index pattern may be formed by the use of a source of radiation such as, for example, ultraviolet light having a two-dimensional grayscale pattern. The two-dimensional grayscale irradiation pattern includes all irradiation patterns, for example, in which the intensity of the two-dimensional grayscale changes when directed to the surface of the optical element. In one embodiment, the radiation passes through the photomask to control the amount of radiation received at various sites within the optical element. The photomask includes areas that are essentially opaque to the radiation, areas that are essentially transparent to the radiation, and areas that transmit a portion of the radiation. The lens blank is exposed to irradiation for a predetermined time to cure and partially cure the photosensitive polymer, whereby a refractive index is formed in the lens blank. In another embodiment, a digital mask system such as a Digital Light Projector (DLP) may be used with an ultraviolet light source. The ultraviolet light source may include an ultraviolet vertical cavity surface emitting laser (VSCEL), a triple YAG laser or a UV-LED.

Proceeding to step 230, the edges of the blank are machined and mounted on a pair of frames to be used by the subject. In one embodiment, step 210 may be performed together to provide a stock of lens blanks that may be conveniently processed (eg, according to steps 210 and 230), and in some embodiments, for example, a subject May be performed together in other places, such as in the optometrist's office, where the eyeball is measured.

FIG. 3 is a flow diagram illustrating yet another embodiment of a method of forming a photosensitive gel layer between a lens blank and a lens cover, as in step 210 of FIG. 2. Beginning at step 310, a passage is formed in the lens blank. The lens blank is formed of CR-39 or other suitable material such as polycarbonate, Finalite ^™ [Sola], MR-8 monomer [Mitsui], or other materials known in the art. Can be. In one embodiment, such passages may be drilled or cut into the lens blank. In general, the lens blank is larger than the final lens fitted within the spectacle frame. Thus, the area where the passage is formed is removed from the final lens and does not interfere with the optical correction of the lens. In another embodiment, the passage is formed with the lens blank, for example in a mold or press. Although two passages are described here, for example, extra passages may be formed in the lens blank to enable rapid filling or uniform filling of the cavity between the lens blank and the lens cover.

Next, in step 320, the gap between the lens cover and the lens blank is maintained at a predetermined distance set by the spacer or gasket, so that the lens blank is combined with the lens cover. However, any method of maintaining a predetermined distance between the blank and the cover can be used. Proceeding to step 330, a seal is formed around the outer periphery of the lens blank and the lens cover to form a sealed cavity therebetween. In one embodiment, an adhesive spacer with a thickness in the range of 1 mil to 100 mils is inserted between the lens blank and the cover lens to form and seal the cavity. In one embodiment, the adhesive spacer is about 20 mils thick.

In another embodiment, the method of combining the lens blank and the lens cover to form a cavity therebetween comprises a taping method. The thickness of the cavity is controlled by forming a cavity, for example by mechanically separating and fixing the two lenses by a clamp or jig. A tape or similar material is attached around the edges of the combined lens blank and cover to form a sealed cavity by winding a deformable elastic tape or rubber gasket on the edges of the two lens blanks and securing each other with a clamp. Also, in one embodiment, rather than forming a passage through the lens blank in step 310, a passage is formed through the spacer or tape by inserting a syringe or other dispenser through the tape or gasket.

Proceeding to step 340, in one embodiment a curable material formulation, for example a photosensitive material consisting of Thiol-Ene or a composition as described above, is mixed in a clean environment, degassed, and syringe Transfer to. Using a fluid dispenser, such as a dispenser from EFD, Inc. (EFD, Inc.) or a mechanical dispenser, such as a syringe, a mixed formulation is injected into the cavity through one of the passages, while the passage vents air from the cavity. Let's do it. In some embodiments, the material may be dispensed through a passageway in the spacer or seal. In one embodiment, such passages may be formed by a syringe used to dispense the curable material. Next, in step 350, the injected lens blank is placed in an oven maintained at a high temperature (eg, about 75 ° C.) to cure the injection material to form a photosensitive film. In other embodiments, the curing process may be performed at room temperature, depending on the curing properties of the implanted material.

4A-4C show side views of the lens 401 at various stages of manufacture using the embodiment of the method of FIG. 3. In particular, FIG. 4A shows the lens 401 after the steps 310, 320, 330 of the method of FIG. 3 are completed. The lens cover 410 is spaced apart from the lens blank 412 by the adhesive support spacer 414. Spacer 414 acts as a gasket surrounding the edge of the lens assembly to form cavity 416. Two or more passages 418 are formed in the lens blank 412 to allow material to be introduced into the cavity 416.

4B shows the lens 401 of FIG. 4A when step 340 of FIG. 3 is complete, in which case a photosensitive material is introduced into the cavity 416 to form layer 420. 4C shows the lens 401 after step 350 of the method of FIG. 3. Other curing methods, such as heat or ultraviolet light, are applied to layer 420 to form photosensitive gel 422.

4D schematically illustrates another embodiment of a method of manufacturing a lens, which is similar to the method shown in FIG. 3 using the pouring method. As mentioned above, a low or high refractive index formulation is dispensed between the two optical molds. In one embodiment, the optical mold may define a shape, for example, a radius of curvature that forms a selected low correction in the lens formed by the mold. Beginning as shown at block 452, the formulation dispensed between the two optical molds is selectively irradiated to create a lower or higher correction region 453 as shown at block 454. In one embodiment, the formulation in the mold is irradiated in a two dimensional grayscale irradiation pattern. Two-dimensional grayscale irradiation patterns are formed by passing approximately uniform light rays through filters such as photomasks and liquid crystal display screens, or by generating light in the form of a DLP with a two-dimensional array of light emitting diodes or ultraviolet light sources. Can be. As shown in block 456, the formulation is then replaced with a second high or low refractive index formulation. As shown in block 458 below, the entire mold is irradiated for a second time to cure the second formulation. In one embodiment, the second formulation is irradiated by a two-dimensional grayscale pattern to correct residual low or high order aberrations. Proceeding to block 460, the lens is removed from the mold, the edges are machined, mounted to the frame, and provided to the subject. In one embodiment, the irradiation shown in blocks 452 and 458 is conducted at room temperature or high temperature.

Alternatively, the pour method controls and attaches two or more formulations of low and high refractive index on one of the optical molds to correct low order aberrations by filling the space between the two optical molds after correcting the high order aberrations. And the optical mold may provide a radius of curvature to correct the lower prescription with a low or high refractive index formulation. Polymerization by heat or light at room or high temperature allows the polymerization of the formulation between the molds. The cured optical element may then be removed from the mold, edged, mounted to the frame, and provided to the subject.

4E illustrates an embodiment of a method similar to the embodiment of FIG. 4D. As shown in block 470, the two formulations are dispensed between the two optical molds. The formulation may comprise a mixture of low and high refractive index formulations. In one embodiment, the high refractive index formulation comprises an acrylate component that undergoes rapid photopolymerization and the low refractive index formulation comprises a vinyl and allyl component that is relatively slow in photopolymerization relative to the acrylate component. Alternatively, the low refractive index formulation may comprise a fast reacting acrylate component and the high refractive index formulation may comprise a slow reaction vinyl or allyl component.

As shown in block 470, the formulation in the optical mold defines a curing volume with a refractive index that one side is exposed to spatially modified high intensity light irradiation to correct high aberrations, while the other side of the mold is to correct the low aberrations. Are exposed to spatially modulated low intensity light. Low intensity and high intensity modulated light crosslinks the fast and slow reactive formulations at different rates, in which case the fast cured formulations are selectively cured significantly compared to slow cured formulations where hardening rarely occurs. If it is necessary to control the degree of photopolymerization of one formulation with respect to another formulation, step-growth photopolymerization of thiols and ene components (high or low refractive index) may be included. One embodiment uses a frontal-polymerization method that can easily monitor the polymerization front to control the depth of photopolymerization of one of the two formulations. In addition, the depth of cure can be controlled based on the amount of photoinitiator, photoinitiator-additive (UV-absorber or blocker) present in the formulation. The hardening tip may be controlled to form a contour surface that corresponds to the control of the low or high aberrations required in this formulation. Block 472 represents the contour volume in the lens by curing. The uncured material can be removed from the mold and replaced with a second layer of curable material. This second material may be cured to create a lens and then removed from the mold as shown in block 474.

In order to resolve the physical phase separation between the two cured formulations, one of the components in the formulation can be chosen to be identical. In addition, a fiduciary mark may be engraved on the lens to arrange the partition height, the additional area, and the like. As shown in block 474, the fully calibrated lens can be detached from the optical mold, and after edge processing these lenses can be mounted to the frame and provided directly in an optics lab. The above-described casting process has the advantage of correcting the aberration region in the custom lens precisely and accurately because the aberration region is controlled during the casting process. In addition, the contour surface corresponding to the low and high aberration correction may be precisely controlled in the lens. Low intensity and high intensity modulated light can be directed into the lens from both sides. Blocks 480, 482, and 484 represent another embodiment of the method shown in blocks 470, 472, and 474. In the embodiment shown in block 480, the low intensity and high intensity irradiation directions are opposite to the embodiment shown in block 470.

5 illustrates one embodiment of a method 500 for performing step 210 of FIG. Beginning at step 510, a spacer material is prepared and placed between the thick lens blank and the thin lens blank. Beginning at step 510, a pair of optical elements, such as lens blanks, are cleaned. Each lens blank may be formed of CR-39, polycarbonate, finite (solar), MR-8 monomer (Mitsui), 1.67, 1.71, 1.74 material, or other suitable material known to those skilled in the art. . In one embodiment, the optical element comprises a thick and thin lens blank. In another embodiment, two thick lens blanks or two thin lens blanks may be used, depending on the corrective force of the lens to be manufactured. Since contaminants formed in the optical lens can cause aberrations, the materials used during the process must be kept very clean. Preferably a filtered gas such as argon, nitrogen or air can be blown onto the optical element to remove contaminants. Next at step 512, spacer material is applied to the thin lens. In one embodiment, the spacer material comprises two layers of two mil ceramic tape cut into small rectangular shapes to form a 20 mil gap. In other embodiments, other types of gaskets may be used, including tapes of different thicknesses or adhesive gasket materials.

Proceeding to step 520, the lens filling material is mixed. The material may include suitable photosensitive materials described herein. Proceeding to step 522, the amount of fill material of the given mass is metered and attached to the thin lens.

Bubbles in the filling material, along with other contaminants, may cause optical aberrations in the final lens. Thus, next in step 524, the thin lens is placed in a vacuum chamber to remove bubbles from the filling material. Proceeding to step 526, the vacuum chamber is depressurized, for example by use of argon gas. Proceeding to step 530, the filling material is inspected for residual bubbles. In one embodiment, residual bubbles can be removed from the surface by carefully tooling the material manually to move the air pockets to the surface.

Placing the thick lens blank over the thin lens blank may cause a tendency for air pockets to be introduced into the final lens. However, it has been found that by placing droplets of filling material on thick lenses, this tendency can be substantially reduced. Thus, the process proceeds to step 532 where the droplet of filling material is placed on the thick lens with the center slightly off center. Next, in step 534, the filling material on the thick lens is slowly pressed onto the main mass of the filling material on the thin lens before the final lens is formed. Proceeding to step 536, the filling material is changed to a photosensitive gel, for example by curing the lens with heat. The method 500 then ends by forming a lens blank with a photosensitive gel layer as used in the method of FIG. 2.

6 illustrates one embodiment of a method 600 of forming a lens configured with a refractive index pattern calculated to correct for low and high optical aberrations. Beginning at step 610, the substrate surface of the mold is coated with a scratch resistant coating. In step 612, a polymer layer is deposited on the mold surface to define a predetermined refractive index. Other embodiments of programming the lens are shown below in FIGS. 7A-7E and 7F-7J.

Proceeding to step 614, a mating member of the mold is disposed at a distance from the base of the mold to form a cavity. The shape of this cavity can be calculated for correction of one or more low order aberrations. Next, in step 616, the cavity is formed of a CR-39, polycarbonate, finite (solar), MR-8 monomo (mitsui), 1.67, 1.71, 1,74 material or a field that forms a substantially rigid lens body. It is filled with a suitable polymer or polymerizable material such as other suitable materials known in the art. Proceeding to step 618, the polymer material is cured. The lens is then removed from the mold and mounted to the spectacle frame.

7A-7E show schematic diagrams of a mold during various stages of one embodiment of the method 600. 7A shows mold base 710 centered at a known centerline along line 702. It should be noted that the layers shown in FIGS. 7A-7E are not necessarily proportional.

7B illustrates one embodiment of step 612 of the method 600. Head 712 attaches a droplet of spray 714 to form polymer layer 716. The thickness of the polymer layer 716 at a location on the layer determines the refractive index of the layer at that location. Head 712 attaches a layer having a varying thickness to define a predetermined refractive pattern. In other words, the surface profile of the attached polymer or the height difference between the acid and the valley corresponds to the targeted aberration correction.

7C shows mating member 720 disposed on base 710 to form a cavity as described for step 614 of method 600. A second layer of material can be formed in the mold to maintain optical quality and uniformity of the surface. 7D shows the mold after being filled with the polymer as described for step 616 of method 600. 7E shows the completed optical lens 724 after being removed from the mold. This optical lens can be mounted to the spectacle frame.

7F-7J illustrate steps of a lens manufacturing method similar to the method shown in FIGS. 7A-7E, but the proportion of the material is varied so that the layer has a nearly uniform thickness and changes the refractive index over the surface of the lens. The difference is that it is configured to do so. In another embodiment, programming of the lens, such as defining a refractive pattern, is effected by control attaching two or more compatible formulations with different refractive indices onto the lens 710 that has already been corrected for low order aberrations. The formulation is photopolymerized during or after attachment to correct for low and high order aberrations. A representative process of programming a lens by attachment includes the following steps.

(a) placing the first spray head and the second spray head 716 at a working distance from the base 710, as shown in FIG. 7G,

(b) in a pre-selected position on the base, spraying a first droplet comprising the first amount of the first polymer composition from the first spray head to form a first adherent droplet,

(c) spraying a second droplet from the second spray head, the second droplet comprising a second amount of the second polymer composition, onto the substrate adjacent the first adherent droplet,

(d) forming a first polymer pixel on the substrate comprising the first polymer composition and the second polymer composition in a first ratio,

(e) adjusting at least one of the first and second spray heads to inject additional droplets different from at least one of the first and second droplets,

(f) adjusting the positioning of the first and second spray heads relative to the substrate, and

(g) repeating steps (a) to (f), thereby forming a second polymer pixel adjacent to the first polymer pixel and including a first polymer composition and a second polymer composition in a second ratio to form a layer Steps.

The pixels together form the layer 716 of FIG. 7G. This process is also described in US Patent Application No. 10/253956, filed by Lai et al. On September 24, 2002, under the name "Optical Elements And Method Of Making Them." This patent application is incorporated herein by reference in its entirety. As in the method described with respect to FIGS. 7A-7E, the material of the second layer may be formed in the mold to maintain optical quality and uniformity of the surface.

FIG. 8 is a flow diagram illustrating one embodiment of a method 800 of manufacturing an optical lens blank using a mold process similar to the method 600 discussed with respect to FIG. 6. Beginning at step 810, a scratch resistant coating is applied to the mold base 710. Next, in step 812, a photosensitive gel layer is formed. In one embodiment, a sheet of photosensitive polymer gel may be formed in bulk to provide gel layers for various lenses as described above for step 210. Proceeding to step 814, a portion of the sheet is disposed on the mold base 710.

Proceeding to step 816, the mating member 720 of the mold is disposed above the mold base 710 such that the mating member 720 and the polymer gel layer (not shown in FIG. 7C, but similarly disposed in layer 716). Cavities). Next, in step 820, the cavity is filled with a predetermined volume of polymer 722, such as CR-39, forming the support of the lens. Next, at step 822, the volume of polymer 722 is cured to form an optical lens blank. The lens blank may have a predetermined refractive pattern formed in the gel layer, for example, by the masking method described above. To increase the stiffness of the layer to prevent damage from physical contact, the gel layer may be cured in bulk form. The cured gel may be coated with a scratch resistant film or a hard film for increased mechanical strength.

In another similar embodiment, a portion of the sheet may be vacuumed into a stock optical element to form a lens. The stock optical element may be formed of a polymer such as CR-39 or a similar material known in the art. The stock optical element may be flano, or may provide correction of one or more lower optical aberrations. In one embodiment, the sheet portion of the semi-cured material is attached to the stock optical element and a small amount of monomer, such as used to form the sheet, is disposed between the stock optical element and the portion of the sheet. The stack of sheet portions and optical elements can be disposed within the flexible mold. Vacuum pressure is applied to attract the stock optical element into the sheet portion against the flexible mold. By applying light or heat while the vacuum is in operation, the monomer can be cured. In yet another embodiment, the monomer material is introduced between the stock optical element and the mold. A vacuum is applied between the optical element and the flexible mold to press the monomer into a thin layer on the surface of the stock optical element. The monomer is at least partially cured to form the material of the semi-cured layer. The resulting lens blank can be edged and mounted to the frame. The lens blank may be cured to define a refractive pattern in the material that corrects one or more high order optical aberrations. More detailed processes are disclosed in US Pat. No. 6,319,433, which is incorporated herein by reference in its entirety.

In another embodiment, a lens with a mounted lens or frame may be used in place of the stock optical element. The layer of semi-cured material is thus formed on a lens that is prepared in advance or mounted to the frame. This layer may also be optionally cured to define a pattern that corrects one or more high order aberrations. In addition, one or more low-order aberrations may be corrected in the lens. For example, small low-order aberrations, such as 0.25 diopters or less, that are not corrected by the stock lens, may be corrected in the layer. Higher correction may also be added to an existing lens mounted to a frame provided by the subject. For example, to correct residual low or high aberrations that are not corrected by an unmodified lens, an existing or previously obtained optical lens may be modified.

9 is a flowchart of an embodiment of another method 900 of manufacturing a lens blank. Beginning at step 910, a sheet or layer of photosensitive gel is formed as described above. Next, in step 912, the sheet is cut to form a group of freestanding optical flats.

Proceeding to step 914, a refractive pattern calculated to correct optical aberration can be formed in the gel, for example by photocuring using the masking method discussed herein. In one embodiment, the optical plate is molded into a curved lens shape by stamping or other method or molded to correct at least some lower optical aberrations. In addition, the gel can be cured in bulk for increased rigidity.

Next at step 916, the method 900 is completed by coating one or more coatings on the optical plate. Such coatings may include coatings of scratch resistant materials. In other embodiments, such coatings may include materials that provide additional stiffness to the lens. The finished lens blank can be used to form a finished optical lens for correcting low and / or high optical aberrations as described herein.

Each method described above has the advantage that it can be carried out in the same or several places. In particular, the process of measuring the subject's refraction, grinding the semi-finished lens blanks, correcting the low and / or high order aberrations, and fitting the frame to the subject's eye can be performed at one or several locations. Thus, by visiting the optometrist only once, the vision prescription can be managed and a custom lens can be provided to the subject. In addition, the subject may complete the purchase of the lens and / or the inspection fee because the subject may pay by cash, other legal tender or credit transaction during the same visit at the same place.

In another embodiment, the low and / or high order aberration of the subject as measured by the aberometer may be corrected in a plano lens premounted in the frame. In one embodiment, the plano lens may be flat or curved, for example for aesthetic reasons to make it look similar to a conventional lens. The plano lens may be made of a refractive index change material or a carrier material suitable for controlled attachment. The entire method 100 of measuring the refraction of the subject, the selection of the planar lens mounted on the frame, the correction of the low and / or high aberrations, and the provision of the custom lens can all be done in one place. Correction of the low and / or high order aberration may include a selective refractive index change corresponding to the target calibration, a controlled attachment of the low and high refractive index formulations corresponding to the target calibration, or a layer that changes the height and thickness of the layer corresponding to the target calibration. It may include any of the programming methods described above, such as optional volume change of. In addition, other fiat money, such as cash, electronic transfer, or credit settlement, may be included in the process involved in manufacturing custom lenses.

FIG. 10 is a block diagram illustrating components of an exemplary system 1000 for eye measurement, correction data calculation, and fabrication of a lens that corrects for measured disorders. Each of these functions may be performed by component systems such as, for example, eye measurement system 1010, calibration calculation system 1020, manufacturing system 1030, and billing and payment system 1040. Various embodiments of system 1000 may include various embodiments of such component systems. In some embodiments, some of the component systems 1010, 1020, 1030, 1040 of the system 1000 may be combined to form an integrated system. For example, in one embodiment, measurement system 1010 may be integrated with calibration calculation system 1030. In one embodiment, each component may be located in the same place. In other embodiments, system components 1010, 1020, 1030, 1040 may be located in separate locations. The measurement system 1010 may preferably be located in an optometrist's office or in an office or storefront where customers may visit. Manufacturing system 1030 may be preferably located in an optical laboratory. In one embodiment, as described in more detail below, the computing system 1020 is disposed at a central location separated by a computer network or other data communication system to perform the functions of one or more measurement systems 1010.

Embodiments of the eye measurement system 1010 may include one of the various wavefront sensors described above for measuring visual parameters, such as abnormalities or aberrations of the subject's eye. The ocular measurement system 1010 may comprise a poropter, an autorefractor, or a trial lens. Embodiments of the measurement system 1010 may generate eye measurement data indicative of optical low and / or high aberrations.

The calibration calculation system 1020 receives the eye measurement data and determines the lens resolution used to manufacture the lens. Embodiments of calibration calculation system 1020 may include computer hardware, software, firmware, or a combination thereof.

In one embodiment, the calibration calculation system 1020 generates a wavemap that represents the calibration to compensate for high and / or low aberrations of the subject's eye. Lens resolution may include prescriptions represented by wavemaps, refractive patterns, spheres, cylinders, and axes, or other relationships with refractive or correction patterns. In addition, lens resolution includes optical center, multiple optical center, single correction area, multiple correction area, transition area, mixed area, swim area, channel, additional area, distance between vertices, compartment height, off-axis gaze area, logo, invisible marking, etc. Include.

In one embodiment, the lens resolution includes one or more numbers or symbols that identify the refractive or correction pattern. Such an identifier may serve as a "prescription" that can be easily transmitted electronically or physically, for example by a barcode.

In one embodiment, the calibration calculation system 1020 converts the wavefront map as another type of lens indicator optimized for the subject. Wavefront maps or other data indices of the lens that are optimized for the subject include, for example, the distance between the vertices of the subject, cavity size, intercavity distance, frame information, gaze, compartment height, widetascopic tilt, or xy tilt. It may be based in part on properties such as

To calculate the lens resolution, the correction calculation system 1020 can generate a conjugate of optical aberrations of the subject's eye. In one embodiment, the calculation of lens resolution may be made with reference to additional metrics for calculating lens resolution based on measurement of the subject's eye including measured optical aberrations. For example, US Pat. No. 6,511,180, issued Jan. 28, 2003 and incorporated herein by reference, discloses an image quality measurement method for determining calibration based on measured optical aberrations. Other embodiments may use other measurements to calculate lens resolution. Lens resolution may be optimized by selecting a measurement method to correct optical aberrations associated with improved personal measurements of the subject's vision. In another embodiment, to select which optical aberrations are desirable to correct or add, or to remain uncorrected, the measurement method uses a trained software neural network using data from the subject. It may also include. More details of such embodiments are disclosed in US Provisional Application No. 60/546378, filed February 20, 2004, which is incorporated herein by reference in its entirety.

In one embodiment, calibration calculation system 1020 may calculate a wavefront wavemap based on color preference. High order aberrations may vary depending on the color of light passing through the correction element. Color preference generally refers to the wavelength the subject prefers to optimize the high calibration. This allows, for example, the user to optimize the calibration at the wavelength most useful for a particular activity (eg green in the case of golf). In one embodiment, color preference is dependent on aberration measurements at 850 nm and conversion to 550 nm (green) or 400 nm to 800 nm for further color enhancement.

In one embodiment, the calibration calculation system may calculate lens resolution with reference to one or more subject preferences. Subject preferences include spectral tints or colors in the lens. The subject preference item may include whether to include features of a photochromic photosensitive color change in the lens specification. The calibration calculation system 1020 may also calculate lens resolution for other features such as ultraviolet coating preferences, antireflective coating preferences. In one embodiment, lens resolution may be calculated for a subject's wearing options, such as how much the subject prefers a high-level correction region in relation to the subject's frame and field of view.

The calibration calculation system may calculate the lens resolution to include one or more calibration areas. The calculation may include the calculation of the number and size of calibration areas. Each calibration region can correct high order, low order, both high and low order aberrations, as well as forward and rearward curvature radii. The correction region may comprise a wide core region or multiple optical cores, for example progressive or multifocal lenses. One embodiment of the calibration calculation system 1020 may calculate a curved area or transition area between one or more correction areas and other portions of the lens. The transition region allows for a gentle change of field of view from the correction region, which is generally only a part of the lens, to another region of the lens. The transition region may comprise a transition between calibration regions. The transition region is described in more detail in US Pat. No. 6,712,466, issued March 30, 2004, entitled “Method for Making Glasses Using Variable Refractive Index Layers,” which is incorporated herein by reference in its entirety.

In one embodiment, calibration calculation system 1020 includes a server computer that executes software to perform the functions of calibration calculation system 1020. The server is capable of communicating with other components of system 1000 via a network. The network may be a local area or broadband network using any data communication technology as is known to those skilled in the art. In one embodiment, the network includes the Internet. In one embodiment, calibration calculation system 1020 is co-located with other components of system 1000. In another embodiment, the calibration calculation system 1020 may be connected to other components of the system 1000 by a network, but is located in a different location than the other components of the system 1000. In an exemplary embodiment, the calibration calculation system 1020 is configured to support one or more systems 1000. In such embodiments, the calibration calculation system 1020 may include a billing module. The billing module may claim based on the use of the calibration calculation system 1020, for example whenever the lens resolution is calculated and downloaded.

Manufacturing system 1030 uses the calibration data from calibration calculation system 1020 and manufactures custom lenses for the subject. Manufacturing system 1030 may include a programmer for transferring lens resolution to the lens. The programmer may include the investigator and photomask described herein. The programmer may include an attachment device configured to perform controlled attachment of one or more materials.

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

In another embodiment, manufacturing system 1030 corrects substantially all low and high aberrations. In such an embodiment, the blank is selected such that all low or nearly all low aberrations are corrected when shaping or polishing the shape with the lens blank. High order aberrations and all residual low order aberrations in one embodiment are corrected by the use of a programmer. Programmer refers to an apparatus for performing one or more methods of defining a refractive pattern in an optical element disclosed herein.

In another embodiment, 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 attach a layer having a predetermined index of refraction for correcting high order aberration, and then forming a finished lens having a shaped shape calculated to correct low order aberrations. Molds for the use are used.

In another embodiment, manufacturing system 1030 corrects high order aberrations and then corrects low order aberrations. For example, as described herein, an embodiment of the method 600 is used to attach a layer having a predetermined variable thickness to correct high order aberrations, and then calculate the shaped shape calculated to correct low order aberrations. A mold for forming a finished lens having is used.

The manufacturing system manages the correction of low order aberrations and programming of at least one high order or residual low order or high order aberrations. The manufacturing system manages the left and right lenses and the calibration required for each of these lenses. The manufacturing system manages lens count, low-level polishing, fine polishing, programming, edge machining, coating, and frames.

Payment system 1040 includes hardware and / or software that allows a subject to pay for lens, inspection and / or other costs by cash, credit card or other payment means. Embodiments of payment system 1040 may be computer hardware, software, firmware, or a combination thereof. Such embodiments may include cash registers, smart card readers, or credit card readers.

In one embodiment, the eye measurement system 1010 and component systems 1020, 1030, 1040 are located in one place. Single location means a location such as an office, a store, or an optical laboratory. Thus, the examinee can obtain a custom lens prepared and prepared by a single release of the place at a single place. In other embodiments, component systems 1010, 1020, 1030 may be located in one, two, or more than three locations. Each component of system 100 may communicate by the use of media or protocols known in the art. For example, in one embodiment components of system 100 may communicate by the use of a network such as an intranet or the Internet. In one embodiment, the component may provide printed matter, for example, in tangible form of data. For example, calibration calculation system 1020 prints a barcode that describes the lens or identifies the lens resolution. In other embodiments, the component may transmit and receive data via removable computer disks, smart cards, or other physical electronic media. Such print media and electronic media may be replaced by physical or facsimile transmission. By placing each element in a separate location, it is possible to make each system optimally sized and shared between measurement system locations, for example, sales locations such as stores, for expensive equipment such as calculation systems or manufacturing systems. Is possible.

FIG. 11 is an embodiment of a method 1100 of manufacturing eyeglasses using the embodiment of the system 1000 as shown in FIG. 10. In step 1110 of method 1100, the subject's eye is measured, for example, by measurement system 1010. Next, in step 1120, the examinee selects the shape of the frame. This selection of frame type is received, for example, by calibration calculation system 1020 and manufacturing system 1030. Proceeding to step 1130, the spectacle frame, including the lens, is selected from the inventory of available frames. In one embodiment, this selection is based on eye measurement and / or frame shape selection. The lens of the frame inventory includes a polymer layer having a refractive index that is selectively changeable by programmable elements, for example additional point hardening. The lens also has a coating, for example an antireflection coating, a scratch resistant coating or a tint coating. In one embodiment, the calculation system 1020 selects a frame that includes a lens with some optical correction that may be selected based on eye measurements. The calibration system 1020 may make this selection based on inventory data. In one embodiment, manufacturing system 1030 manages inventory data and communicates with calibration system 1020. Proceeding to step 1140, the calibration is calculated based on the ocular measurements. In one embodiment, the calibration is calibrated based on the received frame selection. In one embodiment, the calibration calculation system 1020 performs the calculation. The calculation may also be carried out for the necessary residual correction in connection with the desired correction of the lens of the selected frame. In one embodiment, the frame may be measured to include a correction for the residual error introduced by the selected frame. The calculated correction may include correction for low order aberration, residual low order aberration, high order aberration, or other forms of correction disclosed herein. Next at step 1150, the calculated correction is applied to the lens of the frame selected by the use of a programmer as disclosed herein. For example, in one embodiment, the UV source selectively cures a thin layer of curable material to form a refractive pattern corresponding to the calculated calibration. Thereafter, the frame can be provided to the subject and paid.

12 is one embodiment of a method 1200 of manufacturing a custom lens mounted to a frame. Beginning at step 1210, the subject's visual parameters are measured using, for example, measurement system 1010. In another exemplary embodiment, the visual parameter is received via one or more computer networks, printed prescriptions, or bar codes associated with the visual parameter. Next, in step 1220, a lens mounted on a frame, such as a spectacle frame having a pair of lenses mounted thereon, is obtained. The mounted lens may be obtained from the subject or from an inventory of the mounting lens. In one embodiment, the subject provides a lens mounted on the frame, eg, a conventional pair of lenses. In one embodiment, the subject's vision is measured through the framed glasses at step 1210. In yet another embodiment, the spectacle lens with frame and visual parameters of the subject are measured separately. Proceeding to step 1230, the calibration is calculated by the calculation system 1020 based, for example, on time parameters. Proceeding to step 1240, the manufacturing system 1030 uses the calculated correction to program the lens. In one embodiment, a layer of material defining the surface contour is applied to the surface of the lens mounted to the frame to define the refractive pattern of one or both of the lenses corresponding to the calculated correction. The calculated correction may include correction for low order aberrations, residual low order aberrations, high order aberrations, residual high order aberrations, or a combination of both. Although this embodiment is similar to the embodiment described with respect to FIG. 7B, the difference is that the layer is not applied to the mold but to the lens with the frame. In another embodiment, a layer of mixed material is applied to a framed lens to define a refractive pattern corresponding to the calculated correction. Although this embodiment is similar to the embodiment described with respect to FIG. 7G, the difference is that the layer is applied to the lens with the frame, not to the mold. Another embodiment may include applying a photosensitive gel layer and programming a calibration as described with reference to FIG. 9.

Another embodiment includes an optical element that provides correction or introduces one or more high order aberrations. Certain embodiments may correct or introduce increments of one or more high order aberrations. Such aberrations include spherical aberration, trefoil aberration and coma aberration. In one embodiment, the optical element is configured for use in the pupil. The ophthalmologist or other user may place the optical element in the optical path of the subject. The subject may personally determine if the correction improves vision. In yet another embodiment, the optical element comprises a spectacle lens with a frame. High-correction lenses with such frames may be worn with optical elements that correct for one or more high-order aberrations with varying correction powers. The subject may select the frame and calibration from an inventory of the frame, such as reading glasses. Thus, the subject may readily obtain such a lens for use in a particular environment or task, for example.

Another embodiment includes applying a layer of material that is cured to define a refractive pattern that corresponds to the calibration for which the volume change difference during curing is calculated. One such embodiment is described with reference to FIG. 13.

If the polymer is cured properly, for example by the use of high intensity light, it shrinks and substantially decreases in volume, which is predictable. It has been found that a layer of such a high volume material can be selectively cured such that the resulting layer exhibits a refractive pattern that corrects for both high and low optical aberrations. 13 diagrammatically illustrates another embodiment of a method 1300 of manufacturing a lens having a layer of varying thickness. Beginning at block 1310, the lens assembly consists of an optical element 1302 and a high volume shrinking monomer layer 1304. In one embodiment, optical element 1302 with a high volume change monomer layer may be present in a framed or mounted lens. In one embodiment, optical element 1302 may be contoured, for example, by polishing and fine polishing, to correct for example low order aberrations. In another embodiment, the volume change of the monomer layer 1304 can correct for low order aberrations. Next, as shown in block 1320, layer 1304 is exposed to a two-dimensional grayscale pattern of high intensity radiation. The irradiation pattern can be generated using, for example, a light source and a photomask. This pattern of high intensity irradiation causes various shrinkages of the layer 1304 to change the refractive index across the layer 1304. The monomer composition may comprise a material as disclosed herein. In addition, the selection of a suitable composition for layer 1304 and the appropriate wavelength, time and intensity of irradiation can include selections known in the art. The two-dimensional grayscale pattern may be selected to form a layer 1304 that corrects one or more high or low aberrations. In addition, the irradiation pattern is used herein to include optical cores, multiple optical cores, single calibration zones, multiple calibration zones, transition zones, mixed zones, swim zones, channels, additional zones, distance between vertices, compartment heights, logos, and invisible markers. It can be calculated to include other features as described. Proceeding to block 1330, layer 1304 may be exposed to a substantially uniform low intensity radiation. The intensity, wavelength and time of such irradiation may be selected as known in the art to complete the curing of the polymer. Volumetric changes can correct low order aberrations. Block 1340 shows a cured lens. The cured lens may be further treated with optical coatings such as hard coatings, UV blocking coatings, antireflective coatings and scratch resistant coatings.

Depending on the embodiment, the implementation and procedures of the methods described herein may be performed in any order, added, merged, or omitted together, unless specifically stated otherwise. For example, not all implementations and results are necessary for the practice of the invention. In addition, the methods described above can be used to make spherical, aspheric, single vision, bifocal, multifocal, progressive addition lenses, ateric lenses, intraocular lenses, or other special lenses.

While certain embodiments have been described herein in terms of providing an individual's eyeglass correction vision, it will be appreciated that other embodiments may include providing on-demand optical correction within other optical systems such as optical instruments. will be. For example, optical instruments such as cameras, telescopes, binoculars, or microscopes may include custom optical elements. The custom optical element may be included as part of a configurable alternative lens as an element in the device, or with an alternative lens. The custom optical element may be configured to calibrate the optical path of the instrument, including the viewfinder or viewing path of the camera, telescope, binoculars, microscope or similar optical device and the primary optical path. The custom optical element is configured to provide custom calibration of the optical system as described herein. In one embodiment, the custom optical element is configured to realize lens resolution including one or more optical aberrations and viewing parameters of at least one eye of the user. In another embodiment, the custom optical element is configured to correct one or more optical aberrations in the optics. In another embodiment, the on-demand optical element is configured to include lens resolution for at least one eye of the user as well as correct optical aberrations of the optics. In one embodiment, a layer of material as described above is applied to the lens, such as in an alternative lens, and cured (if necessary) to define corrections such as lens resolution on the lens. In one embodiment, the custom element is configured to include custom lens resolution for use in one eye of a user. In yet another embodiment, the binoculars can be customized to fit each eye of the user.

  While the foregoing detailed description has shown, described, and disclosed novel features of the invention, which have been applied to various embodiments, it is to be understood by those skilled in the art without departing from the spirit of the invention in the form or details of the apparatus or process illustrated. It should be understood that various omissions, substitutions, and changes may be made. As will be appreciated, the invention should not be implemented in a form that provides all of the features and advantages described in the specification, as some features may be used or practiced separately from other features. The scope of the invention is expressed not by the foregoing description but by the appended claims. All modifications that fall within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims (66)

Obtaining the visual parameters of the subject's eye, Obtaining a spectacle frame comprising at least one mounted optical element, and Programming an optical element defining a refractive pattern associated with said viewing parameter. The method of claim 1, And the visual parameter comprises at least one of a distance between vertices of a subject, a cavity size, an intercavity distance, frame information, gaze, or an x-y tilt. The method of claim 1, The visual parameter includes at least one of a high aberration, a low aberration, a high aberration region, a transition region, a swim region, a channel, a mixing region, and an off-axis viewing region, or a reading power. . The method of claim 1, And said visual parameter comprises at least one of color preference, spectroscopic color preference, photochromic preference, ultraviolet coating preference, antireflective coating preference, or subject wear preference. The method of claim 1, Obtaining the viewing parameter comprises receiving data collected by at least one of an aberometer, an automatic refractometer, a propeller, or a test lens. The method of claim 1, The programming of the optical element defining the refractive pattern includes programming the optical element such that the refractive pattern corrects at least one high order optical aberration. The method of claim 1, Programming the optical element defining the refractive pattern includes programming the optical element such that the refractive pattern corrects at least one low optical aberration. The method of claim 1, At least one optical element comprises at least two elements with a layer of curable material disposed therebetween. The method of claim 8, Wherein said at least two elements comprise an optical coating. The method of claim 9, And the optical coating comprises a scratch resistant coating. The method of claim 1, Programming the optical element comprises selectively curing a layer of curable material to define a refractive pattern. The method of claim 1, At least one optical element comprises a film of curable material. The method of claim 12, Programming the optical element comprises selectively curing a film of curable material to define a refractive pattern. The method of claim 13, Selectively curing the film of curable material comprises exposing the curable material to a two-dimensional grayscale irradiation pattern. The method of claim 1, The programming of the optical element comprises attaching a layer of material defining the refractive pattern on the optical element. The method of claim 15, Attaching the layer of material comprises attaching a layer having a surface contour defining a refractive pattern. The method of claim 15, Attaching the layer of material comprises attaching a variable mixture of at least two component materials, Wherein said variable mixture of at least two component materials defines a refractive pattern. The method of claim 1, Programming the optical element is Applying a layer of curable material to the mounted optical element, Selectively curing the layer of curable material to vary the volume of the layer to form a surface contour of the layer defining the refractive pattern. The method of claim 1, The step of programming the optical element comprises laser ablation of the optical element. The method of claim 1, And said optical element comprises a plano element. The method of claim 1, And the optical element comprises a lens having a curvature selected to correct at least one low order aberration. The method of claim 1, And the optical element comprises an element having a decorative curvature. The method of claim 1, At least one optical element has a predetermined refractive power. Obtaining a lens resolution comprising correction of a visual parameter of the eye of the subject and at least one optical aberration of the eye of the subject, Obtaining a frame comprising at least one optical element comprising a layer of curable material, and Curing the curable material to define a refractive pattern that corrects at least one optical aberration in the optical path through the optical element. The method of claim 24, And said visual parameter comprises at least one of a distance between vertices of a subject, a cavity size, an intercavity distance, frame information, gaze, or an x-y tilt. The method of claim 25, Hardening is carried out with reference to the said viewing parameter. The method of claim 24, Obtaining lens resolution comprises receiving data collected by at least one of an aberometer, an automatic refractometer, a propeller, or a test lens. The method of claim 24, At least one optical aberration comprises at least one high order aberration. The method of claim 24, The at least one optical element comprises two elements with a layer of curable material disposed therebetween. The method of claim 24, And said optical element comprises a plano element. The method of claim 24, Wherein said optical element comprises a lens having a curvature selected to correct at least one low order aberration. The method of claim 24, And said optical element comprises an element having a decorative curvature. Obtaining a lens resolution comprising correction of a visual parameter of the eye of the subject and at least one optical aberration of the eye of the subject, Obtaining a frame comprising at least one optical element, and Attaching a layer of material on the optical element that defines a refractive pattern that corrects at least one optical aberration in the optical path through the optical element. The method of claim 33, wherein And said visual parameter comprises at least one of a distance between vertices of a subject, a cavity size, an intercavity distance, frame information, gaze, or an x-y tilt. The method of claim 33, wherein Obtaining lens resolution comprises receiving data collected by at least one of an aberometer, an automatic refractometer, or a propeller. The method of claim 33, wherein At least one optical aberration comprises at least one high order aberration. The method of claim 33, wherein The at least one lens has a predetermined refractive power. The method of claim 33, wherein Attaching the layer comprises attaching a layer forming a surface contour defining a refractive pattern. The method of claim 33, wherein Attaching the layer of material comprises attaching a variable mixture of at least two component materials, Wherein said variable mixture of at least two component materials defines a refractive pattern. The method of claim 33, wherein The measurement of the viewing parameter comprises the measurement of at least one optical aberration, Attaching the layer of material comprises correcting at least one optical aberration in an optical element mounted to the frame. The method of claim 33, wherein And said optical element comprises a plano element. The method of claim 33, wherein The optical element comprises a spectacle lens having a predetermined refractive power. The method of claim 33, wherein And calculating a refraction pattern from the measured viewing parameters. The method of claim 33, wherein Attaching the layer, Attaching a layer of curable material, Selectively curing the layer to change the volume of the layer to define a surface contour of the layer defining the refractive pattern, and And curing the layer substantially uniformly. The method of claim 44, Selectively curing the layer comprises exposing the layer to a two-dimensional grayscale pattern of high intensity radiation, Curing the layer substantially uniformly comprises exposing the layer to a substantially uniform low intensity radiation. Obtaining lens resolution including correction of the visual parameters of the subject's eye and at least one optical aberration of the subject's eye, Applying a curable polymer to a lens mounted to the frame, and Selectively curing the layer to vary the volume of the layer to define a surface contour of the layer that defines a refractive pattern that corrects at least one optical aberration. 47. The method of claim 46 wherein And said refractive pattern corrects at least one high order aberration. 47. The method of claim 46 wherein And said refractive pattern corrects at least one low order aberration. 47. The method of claim 46 wherein And said refractive pattern corrects at least one low order aberration and at least one high order aberration. 47. The method of claim 46 wherein Selectively curing comprises exposing the layer to a two-dimensional grayscale irradiation pattern. 51. The method of claim 50, The irradiation method of producing a custom lens, characterized in that it comprises a high intensity irradiation. 47. The method of claim 46 wherein And curing the layer substantially uniformly. The method of claim 52, wherein Curing the substantially uniformly comprises exposing the layer to a substantially uniform irradiation. The method of claim 53, The irradiation method of producing a custom lens, characterized in that it comprises a low intensity irradiation. 47. The method of claim 46 wherein Method for manufacturing a custom lens, characterized in that the lens mounted on the frame is a plano lens. At least one lens configured to correct at least one high order aberration comprising at least one of trefoil aberration, coma aberration, spherical aberration, or a combination thereof. The method of claim 56, wherein And a frame configured to mount at least one lens. The method of claim 56, wherein And a pupilr configured to place the at least one lens in the optical path of the subject. Obtaining lens resolution including corrections to the visual parameters of the subject's eye and at least one optical aberration of the subject's eye Obtaining a frame comprising at least one optical element comprising a layer of curable material, and Selectively curing the layer to vary the volume of the layer to define a surface contour of the layer that defines a refractive pattern associated with lens resolution. The method of claim 59, And said visual parameter comprises at least one of a distance between vertices of a subject, a cavity size, an intercavity distance, frame information, gaze, or an x-y tilt. The method of claim 1, Obtaining lens resolution comprises receiving data collected by at least one of an aberometer, an automatic refractometer, a propeller, or a test lens. The method of claim 59, At least one optical aberration comprises at least one high order aberration. The method of claim 59, The at least one optical element comprises two elements with a layer of curable material disposed therebetween. The method of claim 59, And said optical element comprises a plano element. The method of claim 59, Wherein said optical element comprises a lens having a curvature selected to correct at least one low order aberration. The method of claim 59, And said optical element comprises an element having a decorative curvature.

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