US20130297057A1 - Contour form control - Google Patents

Contour form control Download PDF

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Publication number
US20130297057A1
US20130297057A1 US13/854,877 US201313854877A US2013297057A1 US 20130297057 A1 US20130297057 A1 US 20130297057A1 US 201313854877 A US201313854877 A US 201313854877A US 2013297057 A1 US2013297057 A1 US 2013297057A1
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United States
Prior art keywords
lens
instruction
data
dmd
dmd show
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Abandoned
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US13/854,877
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English (en)
Inventor
Christopher Wildsmith
Michael Widman
Jonathan P. Adams
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Johnson and Johnson Vision Care Inc
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Johnson and Johnson Vision Care Inc
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Application filed by Johnson and Johnson Vision Care Inc filed Critical Johnson and Johnson Vision Care Inc
Priority to US13/854,877 priority Critical patent/US20130297057A1/en
Publication of US20130297057A1 publication Critical patent/US20130297057A1/en
Priority to US15/693,424 priority patent/US10377096B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
    • B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F9/00—Methods or devices for treatment of the eyes; Devices for putting-in contact lenses; Devices to correct squinting; Apparatus to guide the blind; Protective devices for the eyes, carried on the body or in the hand
    • A61F9/007—Methods or devices for eye surgery
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B15/00—Systems controlled by a computer
    • G05B15/02—Systems controlled by a computer electric
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M11/00—Testing of optical apparatus; Testing structures by optical methods not otherwise provided for
    • G01M11/02—Testing optical properties
    • G01M11/0242—Testing optical properties by measuring geometrical properties or aberrations
    • G01M11/025—Testing optical properties by measuring geometrical properties or aberrations by determining the shape of the object to be tested
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00951—Measuring, controlling or regulating
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F9/00—Methods or devices for treatment of the eyes; Devices for putting-in contact lenses; Devices to correct squinting; Apparatus to guide the blind; Protective devices for the eyes, carried on the body or in the hand
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0888—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using transparant moulds
    • B29C35/0894—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using transparant moulds provided with masks or diaphragms
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M11/00—Testing of optical apparatus; Testing structures by optical methods not otherwise provided for
    • G01M11/02—Testing optical properties
    • G01M11/0242—Testing optical properties by measuring geometrical properties or aberrations
    • G01M11/0278—Detecting defects of the object to be tested, e.g. scratches or dust
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B26/00—Optical devices or arrangements for the control of light using movable or deformable optical elements
    • G02B26/08—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light
    • G02B26/0816—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light by means of one or more reflecting elements
    • G02B26/0833—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light by means of one or more reflecting elements the reflecting element being a micromechanical device, e.g. a MEMS mirror, DMD
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F17/00—Digital computing or data processing equipment or methods, specially adapted for specific functions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0833—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using actinic light

Definitions

  • a contour forming apparatus may be controlled based upon a Convergence Process to manufacture a series of Contour Form Lenses until a Lens Design meets an Acceptance Criteria.
  • one aspect of this invention provides for implementing a Convergence Process to create a contour form contact Lens that meets an Acceptance Criteria of a Lens Design.
  • a DMD Show may create a Lens that does not meet an Acceptance Criteria wherein a Convergence Process may be initiated for a subsequent Iteration.
  • there may be a variety of one or more of a masking technique, a Convergence modality, and a thickness correction method used during a Convergence Process.
  • a masking technique may include one or more of a radial masking technique, a sector masking technique, a segment masking technique, and an area masking technique, wherein Blend Zones may be applied if necessary.
  • a modality may include one or more of a one-sided Convergence modality and a two-sided Convergence modality. Accordingly, in related embodiments, one or both of an apex-locking technique and a piston-shifting technique may be used when performing one or both of a one-sided Convergence Modality and a two-sided Convergence modality.
  • a thickness correction method may include one or more of a percentage thickness correction method, an arithmetic thickness correction method, and a secant thickness correction method.
  • one of either of a uniform spatial gain method and a non-uniform spatial gain method may be applied when utilizing a thickness correction method.
  • there may be multiple types of a non-uniform spatial gain method including a function-based non-uniform spatial gain method and a direct mapping non-uniform spatial gain method.
  • FIG. 1 illustrates methods steps that may be used to implement some embodiments of the present invention.
  • FIG. 2 a illustrates an example of a radial masking technique that may be used to implement some embodiments of the present invention.
  • FIG. 2 b illustrates an example of a sector masking technique that may be used to implement some embodiments of the present invention.
  • FIG. 2 c illustrates an example of a segment masking technique that may be used to implement some embodiments of the present invention.
  • FIG. 2 d illustrates an example of an area masking technique that may be used to implement some embodiments of the present invention.
  • FIG. 2 e illustrates an example of Blend Zones that may be used to implement some embodiments of the present invention.
  • FIG. 3 illustrates a graphical representation in flat space of a two-sided Convergence modality that may be used to implement some embodiments of the present invention.
  • FIG. 4 illustrates a graphical representation in flat space of a one-sided Convergence modality utilizing a thickening ratchet procedure that may used to implement some embodiments of the present invention.
  • FIG. 5 illustrates a graphical representation in flat space of a one-sided Convergence modality utilizing a thinning ratchet procedure that may be used to implement some embodiments of the present invention.
  • FIG. 6 and FIG. 7 illustrate graphical representations in flat space of an apex locking technique that may be used to implement some embodiments of the present invention.
  • FIG. 8 illustrates a graphical representation in flat space of a piston-shifting technique that may be used to implement some embodiments of the present invention.
  • FIG. 9 illustrates a display of data generated by utilizing an arithmetic thickness correction method with application of various gain magnitude factors that may be used to implement some embodiments of the present invention.
  • FIG. 10 illustrates a display of data generated by utilizing a percentage thickness correction method with application of various gain magnitude factors that may be used to implement some embodiments of the present invention.
  • FIG. 11 illustrates a processor that may be used to implement some embodiments of the present invention.
  • the present invention provides for methods and apparatus for one or both of creating and modifying a DMD show to create a Lens that Converge a Lens Design.
  • “Acceptance Criteria” as used herein, refers to one or both of specified parameter ranges and specified parameter values, such that if measured parameters of a fabricated Lens or Lens Precursor fall within a range or meet a value of one or both a Lens Design and a Desired Target File, the fabricated Product may be deemed acceptable.
  • “Blend Zone” as used herein means a contiguous area that blends one or both of a portion of a Lens to another adjoining portion of a Lens, and a portion of a DMD Show to another adjoining portion of a DMD Show.
  • Catalog Item refers to a file, feature, component, design, data or descriptor that may temporarily or permanently stored in various embodiments, such as libraries or databases, and may be recalled for use without having to recreate them.
  • Contour Forming Device refers to equipment and methods for fabricating one or more of a Lens Precursor Form, a Lens Precursor, and a Lens wherein the device may involve, for example, the use of actinic radiation, Reactive Mixture, and DMD devices.
  • Convergence refers to the process of modifying DMD Files and using the modified DMD Files in an Iterative Loop until subsequent fabricated Lens parameters satisfy one or both of a specified Acceptance Criteria and a Desired Target File.
  • Computer Space refers to a coordinate mapping space (e.g., Cartesian, polar, spherical, etc) where curvature of a design has not been removed.
  • Custom Product refers to a Product including one or more parameters that may be available in other than incremental steps. Custom Product parameters allow for more precise sphere power, cylinder power, and cylinder axis (e.g., ⁇ 3.125D/ ⁇ 0.47D ⁇ 18°) than Standard Product parameters, and may include base curves, diameters, and stabilization profiles, and thickness profiles based upon a particular use of a Product offered.
  • Desired Target File refers to data that may represent one or more of a Lens Design, a Thickness Map, a Lens Precursor design, a Lens Precursor Form design, a Lens Precursor Feature design, and combinations of the above.
  • a Desired Target File may be represented in either a hydrated or un-hydrated state, in Flat or Curved Space, in 2-dimensional or 3-dimensional space, and by methods including but not limited to, geometric drawings, power profile, shape, features, thicknesses etc. Desired Target Files may contain data on a regularly or irregularly spaced grid.
  • Digital Core Break refers to a range of Product where select Lens Precursor Features or control parameters or other features may be identical and may remain constant within a specified Product range.
  • DMD refers to a digital micromirror device that is a bistable spatial light modulator consisting of an array of movable micromirrors mounted over a CMOS SRAM. Each mirror may be independently controlled by loading data into the memory cell below the mirror to steer reflected light, spatially mapping a pixel of video data to a pixel on a display. The data electrostatically controls the mirror's tilt angle in a binary fashion, where the mirror states are either +X degrees (“on”) or ⁇ X degrees (“off”). For example, with current devices, X may be either 10 degrees or 12 degrees (nominal); future devices may have different tilt angles. Light reflected by the “on” mirrors is passed through a projection Lens and onto a screen.
  • Each mirror may receive a number of instructions from one, none, or a plurality of DMD Shows. Select mirrors may be turned “on” during the Lens fabrication process. DMDs (digital micromirror device) may be found in DLP projection systems.
  • DMD Control Software refers to software that organizes and utilizes DMD Files and DMD Shows that may enable fabrication of Lens Precursors, or Lens Precursor Features.
  • DMD Show refers to a collection of one or both of time based instructional data points and thickness based instructional data points that may be used to activate mirrors on a DMD, and enable a Lens or Lens Precursor or Lens Precursor Form or Lens Precursor Feature(s) to be fabricated.
  • a DMD Show may have various formats, with (x, y, t), and (r, ⁇ , t) being the most common where, for example “x” and “y” are Cartesian coordinate locations of DMD mirrors, “r” and “ ⁇ ” are Polar coordinate locations of DMD mirrors, and “t” represents time instructions controlling DMD mirror states.
  • DMD Shows may contain data on a regularly or irregularly spaced grid.
  • Fabrication Process Conditions refers to settings, conditions, methods, equipment and processes used in fabrication of one or more of a Lens Precursor, a Lens Precursor Form, and a Lens.
  • Frtering refers to the process including one or more of defining, detecting, removing, and correcting errors in given data, in order to minimize the impact of errors in input data on succeeding analyses.
  • Frat Space refers to coordinate mapping space (e.g., Cartesian, polar, spherical, etc) where curvature of a design being considered has been removed.
  • “Fluent Lens Reactive Media” as used herein, means a Reactive Mixture that is flowable in either its native form, reacted form, or partially reacted form and may be formed upon further processing into a part of an ophthalmic Lens.
  • Free-form refers to a surface that is formed by crosslinking of a Reactive Mixture via exposure to actinic radiation on a voxel by voxel basis, with or without a fluent media layer, and is not shaped according to a cast mold, lathe, or laser ablation.
  • Detailed description of Free-form methods and apparatus are disclosed in U.S. patent application Ser. No. 12/194,981 (VTN5194USNP) and in U.S. patent application Ser. No. 12/195,132 (VTN5194USNP1).
  • “Iteration” as used herein, refers to the creation of a subsequent DMD File/DMD Show that is subsequently, used in the Convergence Process to satisfy Acceptance Criteria.
  • “Iterative Loop” refers to one, or a series of process steps that may enable one or more of a Lens, a Lens Precursor, and a Lens Precursor Feature fabrication such that each time through a loop, one or more of a Lens, Lens Precursor, and a Lens Precursor Feature may be more conformal to a desired Lens Design, than its predecessor.
  • a Convergence Process may contain one or more Iterative Loops wherein one or both of DMD Shows and Fabrication Process Conditions may be modified.
  • Lens refers to any ophthalmic device that resides in or on the eye. These devices may provide optical correction or may be cosmetic.
  • the term Lens may refer to a contact Lens, intraocular Lens, overlay Lens, ocular insert, optical insert or other similar device through which vision is corrected or modified, or through which eye physiology is cosmetically enhanced (e.g., iris color) without impeding vision.
  • the preferred Lenses of the invention are soft contact Lenses and are made from silicone elastomers or hydrogels, which include but are not limited to silicone hydrogels, and fluorohydrogels.
  • Lens Design refers to form, function or both of a desired Lens, which if fabricated, may provide optical power correction, acceptable Lens fit (e.g., corneal coverage and movement), acceptable Lens rotation stability, etc.
  • Lens Designs may be represented in either a hydrated or un-hydrated state, in Flat or Curved Space, in 2-dimensional or 3-dimensional space, and by a method including one or more of, geometric drawings, power profile, shape, features, thicknesses etc. Lens Designs may contain data on a regularly or irregularly spaced grid.
  • Lens Precursor as used herein, means a composite object consisting of a Lens Precursor Form and Fluent Lens Reactive Media in contact with a Lens Precursor Form that may be rotationally symmetrical or non-rotationally symmetrical.
  • Fluent Lens Reactive Media may be formed in the course of producing a Lens Precursor Form within a volume of Reactive Mixture. Separating a Lens Precursor Form and Fluent Lens Reactive Media from a volume of Reactive Mixture used to produce a Lens Precursor Form may generate a Lens Precursor.
  • a Lens Precursor may be converted to a different entity by either the removal of an amount of Fluent Lens Reactive Media or the conversion of an amount of Fluent Lens Reactive Media into non-fluent incorporated material.
  • Lens Precursor Feature refers to a non-fluent substructure of a Lens Precursor Form, and acts as an infrastructure for a Lens Precursor.
  • Lens Precursor Features may be defined empirically or described mathematically by control parameters (height, width, length, shape, location, etc.,) may be are fabricated via DMD Show instructions. Examples of Lens Precursor Features may include one or more of the following: a Lens Edge feature, a Stabilization Zone feature, a Smart Floor Volumator feature, an Optic Zone feature, a Moat feature, a Drain Channel feature, etc.
  • Lens Precursor Features may be fabricated using Actinic Radiation Voxels and may be incorporated into an ophthalmic Lens upon further processing.
  • Lip Precursor Form refers to a non-fluent object, which may be consistent with being incorporated upon further processing into an ophthalmic Lens.
  • “Product” refers to one or more of a Lens, a Lens Precursor, and a Lens Precursor Form and may include either “Standard Product” or “Custom Product”.
  • PV Peak to Valley
  • RMS Root Mean Square
  • Standard Product refers to a Product with limited Product parameter availability, such as those offered in discrete steps.
  • sphere power parameters may only be available in 0.25D steps (e.g., ⁇ 3.00D, 3.25D, ⁇ 3.50D, etc.); cylinder power parameters may only be available in 0.50D steps (e.g, ⁇ 0.75D, ⁇ 1.25D, ⁇ 1.75D, etc.); and cylinder axis parameters may only be available in 10° steps (e.g., 10°, 20°, 30°, etc.).
  • Other Standard Product parameters and features offered in discrete steps include but are not limited to base curve radii, diameter, stabilization profiles and thickness profiles.
  • Substrate refers to a physical entity upon which other entities may be placed or formed.
  • “Surface Fitting” as used herein, refers to the process of constructing a surface or mathematical function that has the best fit to a series of data points, possibly subject to constraints. Surface Fitting can involve either interpolation, where an exact fit to the data is required, or smoothing, in which a “smooth” function is constructed that approximately fits the data.
  • Thickness Map refers to a 2-dimensional or 3-dimensional thickness profile representation of a desired Product, Lens Precursor Form, or Lens Precursor. Thickness Maps may either be in Flat or Curved Space coordinate space and may contain data on a regularly or irregularly spaced grid.
  • Training Region refers to one or both of a whole Lens, and one or more portions of a Lens, that may be iterated upon during a Convergence Process.
  • Voxel as used herein, also referred to as “Actinic Radiation Voxel” is a volume element, representing a value on a regular or irregular grid in 3-dimensional space.
  • a Voxel may be viewed as a three dimensional pixel, however, wherein a pixel represents 2D image data a Voxel includes a third dimension.
  • a Voxel is used to define the boundaries of an amount of actinic radiation reaching a particular volume of Reactive Mixture, thereby controlling the rate of crosslinking or polymerization of that specific volume of Reactive Mixture.
  • Voxels are considered in the present invention as existing in a single layer conformal to a 2-D mold surface wherein the Actinic Radiation may be directed normal to the 2-D surface and in a common axial dimension of each Voxel.
  • specific volume of Reactive Mixture may be crosslinked or polymerized according to 768 ⁇ 768 Voxels.
  • a Lens may be fabricated based upon a desired Lens Design, via the use of DMD Shows. Furthermore, a fabricated Lens may not conform to an Acceptance Criteria of a Lens Design wherein an Iteration of a previous DMD Show may have to occur. For example, an Iteration of a previous DMD Show may enable closer Convergence of a desired Lens Design.
  • a Lens surface may be examined for surface anomalies (e.g., blobs, dirt, etc), that may be present on a Lens surface.
  • a Lens may be discarded and a new Lens remade for example, by utilizing the same settings of a previous DMD Show.
  • a PV value may be determined.
  • a PV is not acceptable, at 104 , parameters for a subsequent Iteration of a DMD Show may be created and a new Lens made. If a PV is acceptable, at 105 , a determination may be made of whether a RMS is in a desired optic zone. If a RMS is not acceptable, at 104 , parameters for a subsequent DMD Show may be created and a new Lens made. If a RMS is acceptable, at 106 , a determination may be made of whether a measured Lens meets other thickness specifications (e.g., peripheral geometries). If other thickness specifications are not acceptable, at 104 , parameters for a subsequent Iteration of a DMD Show may be created and an Iteration of a Lens made. If other thickness specifications are acceptable, at 107 , a Lens may be released for post processing.
  • thickness specifications e.g., peripheral geometries
  • a subsequent DMD Show instruction for a subsequent Iteration may be one or both of an altered previous DMD Show instruction, a combination of a previous show instruction and one or more of another DMD Show instruction, and a combination of two or more DMD Shows.
  • two or more portions from one or multiple DMD Shows may be combined together for a subsequent Iteration.
  • an Iterative Loop of a Convergence Process may be continuously repeated until a Lens meets an Acceptance Criteria of a Lens Design.
  • a masking technique may be implemented during a Convergence Process.
  • a masking technique may include one or more of a radial masking technique, a sector masking technique, a segment masking technique, and an area masking technique.
  • one or more of a masking technique may be applied to either: one DMD Show, and two or more DMD Shows that may be used in a subsequent Iteration.
  • one or more of a masking technique may be applied to a Training Region of a Lens that may include one or both of a whole Lens, and one or more of a portion of a Lens.
  • performing a masking technique may be used to further Converge a Lens Design even if a measured Lens already meets a desired Acceptance Criteria. For example, a PV of a measured Lens may be acceptable, but performing a masking technique in a subsequent Iteration may cause Convergence of a Lens Design even more closely and therefore, enable better performance of a Lens such as improving vision with even more precision than it may have been without using a masking technique.
  • FIGS. 2 a - 2 d illustrate various examples of different masking techniques, in flat space.
  • a user may specify one or more of a boundary inside of which a DMD Show may be used, and outside of which a different DMD Show may be used.
  • FIG. 2 a illustrates an example of a radial masking technique applied to a DMD Show.
  • one or more portions of one or more DMD Shows may be specified to occur within a certain radius.
  • one or more portions of one or more different DMD Shows may be specified to occur within one or both of one or more radii of a Lens Design, and an entire remaining portion of a Lens Design.
  • FIG. 2 b illustrates an example of a sector masking technique applied to a DMD Show.
  • one or more portions of one or more DMD Shows may be specified to occur within a certain sector.
  • one or more portions, of one or more different DMD Shows may be specified to occur within one or both of one or more sectors of a Lens Design, and an entire remaining portion of a Lens Design.
  • FIG. 2 c illustrates an example a segment masking technique applied to a DMD Show.
  • one or more portions of one or more DMD Shows may be specified to occur within a certain segment.
  • one or more portions, of one or more different DMD Shows may be specified to occur within one or both of one or more segments of a Lens Design, and an entire remaining portion of a Lens Design.
  • FIG. 2 d illustrates an example an area masking technique applied to a DMD Show.
  • one or more portions of one or more DMD Shows may be specified to occur within a certain area.
  • one or more portions, of one or more different DMD Shows may be specified to occur within one or both of one or more areas of a Lens Design, and an entire remaining portion of a Lens Design.
  • one or more of a Blend Zone may be specified when using a masking technique.
  • one or more of a Blend Zone may be applied when implementing a masking technique and two or more portions taken from either one DMD Show or two or more DMD Shows, do not connect to one another when they are combined together in a subsequent DMD Show, as illustrated in FIG. 2 e.
  • a two-sided Convergence modality may be used when performing an Iteration of a previous DMD Show to Converge a Lens Design in a subsequent DMD Show.
  • a previous show may create parts of a Lens that may be either one or both of thicker than a Lens Design, and thinner than a Lens Design.
  • an Iteration for a subsequent DMD Show may occur by adjusting one or more of a parameter of both of an instruction that resulted in a Lens with both one or more thicker areas and one or more thinner areas, than called for in a Lens Design. Adjustments may occur at each pixel of a previous show for a subsequent show.
  • a one-sided Convergence modality may also be implemented to Converge a Lens Design in a subsequent DMD Show.
  • a one-sided Convergence modality when performing an Iteration of a previous DMD Show, may be performed by utilizing either one or both of a thickening ratchet instruction, and a thinning ratchet instruction.
  • a previous DMD Show may create areas of a Lens that may be either one or both of thicker than a Lens Design, and thinner than a Lens Design. Iterations for a subsequent show instruction may occur by one of either adjusting one or more parameters of an instruction that needs to be decreased in value, and of an instruction that needs to be increased in value. Accordingly, adjustments may occur at each pixel of selected areas for a subsequent show instruction.
  • FIG. 3 illustrates a graphical representation in flat space, of implementing a two-sided Convergence modality.
  • the previous DMD instruction 301 created the measured Lens 303 with areas of the Lens that were both thinner than the target thickness 302 , and thicker than the target thickness 302 of the desired Lens Design.
  • At 300 illustrates applying a two-sided Convergence modality to the subsequent DMD instruction 304 .
  • the subsequent DMD Show instruction 304 results in decreasing instruction in areas of the previous DMD Show instruction 301 that created regions that were too thick on the measured Lens 303 , in comparison to the target thickness value 302 .
  • the subsequent DMD Show instruction results increasing instruction in areas of the previous DMD Show instruction 301 that created regions that were too thin on the measured Lens 303 , in comparison to the target thickness value 302 .
  • FIG. 4 illustrates a graphical representation in flat space, of implementing a one-sided Convergence modality by utilizing a thickening ratchet instruction.
  • the previous DMD instruction 401 created the measured Lens 403 with areas that were both thicker than the target thickness and thinner than the target thickness 402 of the Lens Design.
  • At 400 illustrates applying a one-sided Convergence modality by utilizing a thickening ratchet instruction 405 in the subsequent DMD Show instruction 404 .
  • the subsequent DMD instruction 404 results in an increasing instruction only in areas of the previous DMD Show instruction 401 that created regions that were too thin on the measured Lens 403 , in comparison to the target thickness value 402 . Additionally, the subsequent DMD instruction 404 remains unchanged from the previous show instruction 401 that created regions of the measured Lens 403 that were too thick, in comparison to the target thickness value 402 . Therefore, for the subsequent Iteration, adjustments occur only to portions of the previous show that resulted in regions that were too thin on the measured Lens 403 while other areas remain unchanged in the subsequent DMD instruction 404 .
  • FIG. 5 illustrates a graphical representation in flat space, of a one-sided Convergence technique by utilizing a thinning ratchet instruction.
  • the previous DMD instruction 501 created the measured Lens 503 with areas that were both, thicker and thinner than the target thickness 502 of the Lens Design.
  • At 500 illustrates applying a one-sided Convergence modality by utilizing a thinning ratchet instruction 505 for in subsequent DMD Show instruction 504 .
  • the subsequent DMD instruction 504 results in only decreasing instruction of the previous DMD Show instruction 501 that created regions that were too thick on the measured Lens 503 , in comparison to the target thickness 502 . Additionally, the subsequent DMD instruction 504 remains unchanged from the previous show instruction 504 that created areas of the measured Lens 503 that were too thin, as compared to the target thickness value 502 . Therefore, for the subsequent Iteration, adjustments occur only to portions of the previous show that resulted in regions that were too thick on the measured Lens 503 while other areas remain unchanged in the subsequent DMD instruction 504 .
  • various techniques including one or both of an Apex locking technique and a piston-shifting technique may be applied when implementing one or more the aforementioned Convergence modalities.
  • an instruction at an apex from a previous DMD Show may be adjusted up to a target thickness value.
  • other selected areas of a previous instruction may be adjusted up uniformly by a same amount as an apex value and an apex may be locked so that it may be kept constant for other subsequent DMD Shows.
  • instruction at an apex may be adjusted up to a target thickness apex value and kept the same; this measured distance between an I CT and a target thickness apex is a lock CT value.
  • a lock CT value ( ⁇ th ) may be calculated by taking the difference between an I CT of a previous show and a target thickness apex value of that same show. Subsequently, ⁇ th may be added to every point of an entire measured Lens surface, and may become a “modified” Lens thickness file for a subsequent DMD Show. Consequently, a subsequent DMD Show instruction may create a “modified” measured Lens and subsequently, be compared to a Lens Design.
  • performing an apex locking technique may be used to further Converge a Lens Design even if a measured Lens already meets a desired Acceptance Criteria. For example, a PV of a measured Lens may be acceptable, but performing an apex locking technique in a subsequent Iteration may cause Convergence of a Lens Design even more closely and therefore, enable better performance of a Lens such as improving vision with even more precision than it may have been without using an apex locking technique.
  • FIG. 6 illustrates a graphical representation in flat space, of utilizing an apex locking technique when a Lens center thickness is too thin
  • FIG. 7 illustrates a graphical representation in flat space, of utilizing an apex locking technique when a Lens center thickness is too thick
  • both FIG. 6 and FIG. 7 are examples in flat space, of a comparison between a subsequent locked apex DMD instruction wherein the I CT remains the same as in the previous show instruction 601 and 701 , and a subsequent non-locked apex DMD instruction 606 and 706 , wherein the I CT may not remain the same as in the previous show instruction 601 and 701 .
  • the previous DMD instruction 601 created the measured Lens 603 , where the I CT is thinner than the target thickness 602 apex value of the desired Lens Design.
  • the previous DMD instruction 701 created the measured Lens 703 , where the I CT is thicker than the target thickness 702 apex value of the desired Lens Design.
  • the temporary adjusted measured Lens profile is created by comparing the difference between the I CT value of the measured Lens 603 and 703 , and the target thickness apex value 602 and 702 , and adjusting the subsequent instruction by ⁇ th .
  • the subsequent non-locked apex instruction is calculated by adding ⁇ th to every point on the entire measured Lens 603 and 703 , surface of a temporary adjusted measured Lens profile 605 and 705 , plus any selected additional amount and thereby, adjusting a subsequent instruction by that total amount.
  • the apex lock instruction is calculated by taking the difference of the non-locked apex instruction 606 and 706 , and the ⁇ th , and subsequently, adding the difference to every point on the measured Lens 603 and 703 , surface except to the I CT . Accordingly, the I CT remains the same as in the previous DMD instruction 601 and 701 , and is kept constant during subsequent Iterations when going through an Iterative Loop of a Convergence Process.
  • a uniform shift of a previous DMD Show instruction may be done to one or more selected portions of a previous instruction by a selected amount.
  • performing a piston shifting technique may be used to further Converge a Lens Design even if a measured Lens already meets a desired Acceptance Criteria. For example, a PV of a measured Lens may be acceptable, but performing a piston shifting technique in a subsequent Iteration may cause Convergence of a Lens Design even more closely and therefore, enable better performance of a Lens such as improving vision with even more precision than it may have been without using a piston shifting technique.
  • FIG. 8 illustrates a graphical representation in flat space, of utilizing a piston-shifting technique.
  • 800 is an example in flat space of a comparison between a subsequent piston shifted DMD instruction, wherein a uniform shift of one or more selected portions of the instruction of the previous show are adjusted by a same amount, and a subsequent non-piston shifted DMD instruction.
  • the previous DMD instruction 801 created the measured Lens 803 , with areas of the Lens that were both thicker and thinner than the target thickness 802 of the desired Lens Design.
  • the subsequent non-piston-shifting instruction results by non-uniformly adjusting one or more of a selected portion of the previous DMD instruction 801 by one or more of various selected amounts.
  • the subsequent piston-shift instruction results by uniformly shifting one or more of a selected portion of the previous DMD Show instruction 801 by a same selected amount.
  • various thickness correction methods may be utilized in a Convergence Process to calculate a subsequent DMD Show instruction including one or more of an arithmetic thickness correction method, a percentage thickness correction method, and a secant thickness correction method.
  • a thickness correction method may be selected based upon observation made by someone skilled in the art.
  • adjustments may be made at each pixel of a previous DMD Show using a selected thickness correction method to calculate a DMD Show instruction for a subsequent Iteration.
  • selected data points of a previous show may go through one or both of a Filtering process and a Surface Fitting process for a subsequent DMD Show prior to applying a thickness correction method.
  • a DMD Show may be Iterated to affect certain or specific areas of a Lens. Accordingly, for example, subsequent Iterations of a previous DMD Show may result in one or more of changing a whole Lens, one or both of reducing certain apertures of a Lens and increasing certain apertures of a Lens (e.g., optic zone, peripheral zone), and changing select regions of a Lens.
  • various gain magnitude factors may be applied to a calculation of a subsequent DMD Show instruction.
  • a gain magnitude factor may be changed mid-stream during subsequent Iterations. For example, a gain factor of 200% applied to Iteration 3 may be dropped down to 150% at Iteration 5.
  • an arithmetic thickness correction method may be used to calculate instructions for an Iterative DMD Show.
  • FIG. 9 illustrates a display of data generated by utilizing an arithmetic thickness correction method to calculate subsequent DMD Show instructions at different iterations and applying various gain magnitude factors.
  • a Delta thickness value may have to be calculated.
  • a Delta thickness value may be equal to a target thickness value of a target design minus a measured Lens thickness value created from a previous DMD Show.
  • a Delta thickness value may be multiplied with an applicable gain magnitude factor amount selected and divided by 100, to determine a scaled Delta thickness value.
  • a scaled Delta thickness value may be added to a value of a previous show instruction.
  • use of the aforementioned formula may occur at each pixel of a previous show to calculate a new value for each pixel for a subsequent DMD Show.
  • the target thickness value of the Lens Design is 0.0900 ⁇ m and the measured Lens thickness is 0.0750 ⁇ m.
  • the Delta thickness value is 0.0150 ⁇ m, which is calculated by subtracting the measured Lens thickness of 0.0750 ⁇ m from the target thickness value of 0.0900 ⁇ m.
  • the scaled Delta thickness value is 0.0300 ⁇ m, which is calculated by multiplying the Delta thickness value of 0.0150 ⁇ m by the gain magnitude factor of 200%, and dividing that value by 100. Subsequently, the scaled Delta thickness value of 0.0300 ⁇ m is added to the previous show value of 0.1250 ⁇ m, giving the subsequent show instruction value of 0.1550 ⁇ m.
  • a percentage thickness correction method may be used to calculate instructions for an Iterative DMD Show.
  • FIG. 10 illustrates a display of data generated by utilizing a percentage thickness correction method to calculate subsequent DMD Show instructions at different iterations and applying various gain magnitude factors.
  • a Delta instruction value may have to be calculated.
  • a Delta instruction value may be equal to taking a previous show value and multiplying it by an applicable gain magnitude factor followed by, multiplying the resulting value by a target thickness value minus a measured Lens value.
  • the preceding value is divided by a measured Lens value, followed by multiplying the resulting value by 100 and subsequently, adding the value to a previous show value.
  • use of the aforementioned formula may occur at each pixel of a previous show to calculate a new value for each pixel for a subsequent DMD Show.
  • the subsequent DMD Show instruction is calculated by multiplying the initial show value of 0.125 ⁇ m by 200%, followed by multiplying this value by 0.015 ⁇ m, which is value of the difference of the target thickness value of 0.090 ⁇ m, and the measured Lens value of 0.075 ⁇ m, equaling the value of 0.00375 ⁇ m.
  • the Delta instruction a value of 0.05 ⁇ m is calculated by dividing the value of 0.00375 ⁇ m by the measured Lens value of 0.075 ⁇ m. Furthermore, the previous show value of 0.125 ⁇ m is subsequently added to the Delta instruction value of 0.05 ⁇ m, resulting in the subsequent DMD Show instruction value of 0.175 ⁇ m.
  • an Iteration value for a subsequent DMD Show instruction set may be determined by utilizing a secant thickness correction method, which may be calculated by using a secant method algorithm.
  • a secant method is a root-finding algorithm that uses a succession of roots of secant lines to better approximate a root of a function ⁇ , and is known to those skilled in the art.
  • various spatial gain methods may be applied when using one or more of the aforementioned thickness correction methods.
  • spatial gain methods may include one or both of a uniform (linear) spatial gain method, and a non-uniform spatial gain method.
  • a non-uniform spatial gain method may consist of two types including one or both of a function based non-uniform spatial gain method, and a direct mapping spatial gain method.
  • a same thickness correction method when applying a uniform (linear) spatial gain method, be applied across a designated Training Region wherein a gain magnitude factor is equal at each pixel location. For example, all pixels within an optic zone may be modified by the arithmetic method using a 100% gain magnitude factor.
  • a same thickness correction method when applying a non-uniform spatial gain method, may be applied across a designated Training Region wherein a gain magnitude factor may be different at each pixel location. For example, pixels lying on a diameter of 4 mm may have a gain magnitude factor of 200% whereas pixels lying a diameter of 2 mm may have a gain magnitude factor of 150%.
  • a gain magnitude factor when applying a function based non-uniform spatial gain method, may be related to a radial location of a pixel.
  • corresponding data when applying a direct mapping non-uniform spatial gain method, corresponding data may be leveraged from a Training Region of one or more previous DMD Shows, a measured Lens, and a Lens Design, to calculate a desired gain magnitude at each pixel location.
  • FIG. 11 illustrates a controller 1100 that may be used to implement some aspects of the present invention.
  • a processor unit 1101 which may include one or more processors, coupled to a communication device 1102 configured to communicate via a communication network.
  • the communication device 1102 may be used to communicate, for example, with one or more controller apparatus or manufacturing equipment components.
  • a processor 1101 may also be used in communication with a storage device 1103 .
  • a storage device 1103 may comprise any appropriate information storage device, including combinations of magnetic storage devices (e.g., magnetic tape and hard disk drives), optical storage devices, and/or semiconductor memory devices such as Random Access Memory (RAM) devices and Read Only Memory (ROM) devices.
  • RAM Random Access Memory
  • ROM Read Only Memory
  • a storage device 1103 may store an executable software program 1104 for controlling a processor 1101 .
  • a processor 1101 performs instructions of a software program 1104 , and thereby operates in accordance with the present invention such as, for example, the aforementioned method steps.
  • a processor 1101 may receive information descriptive of a desired Lens Design.
  • a storage device 1103 may also store ophthalmic related data in one or more databases 1105 and 1106 .
  • a database may include one or more of files containing DMD Show instruction data, customized Lens Design data, metrology data, defined Lens parameter data for specific Lens Designs.
  • the present invention provides an apparatus for implementing a Convergence Process.

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