'METHOD FOR ORNAMENTING CONTACT LENSES"
BACKGROUND OF THE INVENTION
Field of the Invention
This invention generally relates to contact lenses. More specifically, the invention relates to contact lenses which are colored and methods for the creation of same, used to change the apparent color of the wearer's iris using a natural eye color pattern, or to generate original iris patterns that will be used in the film and television industry.Description of the Prior Art
Contact lenses have been known to the art for years. Initially, their use was for vision correction. Since then, contact lenses have been used, for example, to change the apparent color of the iris of the wearer. This color change has both cosmetic and theatric uses. Narious methods have been developed to create a colored lens with a realistic appearance.
U.S. Patent o. 3,712,718 to LeGrand et al. discloses a corneal contact lens with an irregular pattern of colored striations surrounding a transparent central zone. The striations are intended to highlight the natural color of the wearer's iris.
U.S. Patent No. 5,160,463 to Evans et al. discloses a method of manufacturing a contact lens with an iris simulating pattern. At least two differing designs are used to form an overall pattern, with the resulting pattern substantially covering the wearer's iris and producing a colored natural simulation of the iris.
U.S. Patent No. 5,414,477 to Jahnke discloses a colored contact lens. The lens has two shaded portions. The first portion has a first shade and is generally located on the outside of the iris section. The second portion has a second shade and is generally located on the inside of the iris section. A jagged border separates the two portions. An embodiment with a third iris section and second jagged border are also disclosed.
While the above references strive to create a colored contact lens which simulates a natural iris pattern, the instant invention achieves the goal of creating a colored contact lens which incorporates the wearer's actual iris pattern.
SUMMARY OF THE INVENTION In accordance with the present invention, there is disclosed a colored contact lens having a non-opaque pupil section and an at least partially opaque iris section surrounding
the pupil section. The iris section has a color pattern which is derived from a natural color pattern of an iris.In accordance with another aspect of the invention, the color pattern is applied to the lens as a plurality of sections of color, with each section being arranged adjacent to but not overlapping other sections of color to form a single composite layer of color. The pupil section may be between about 3 millimeters and 7 millimeters. This technique of applying entire sections of color adjacent to other sections of color without overlapping the adjacent sections is known as "block printing", the word "block" referring to each section of color. Heretofore no one known to the inventor has coated contact lenses in sections or blocks without overlapping the sections to minimize the thickness of the resulting lens. Previous attempts at coating lenses for special effects or cosmetic purposes have either utilized the transferring of dot patterns via dot pattern printing transfer techniques, which results in a pattern of dots visible to the observer, or hand painting of colors, an extremely undesirable solution given the time consuming nature of hand painting. Hand painting and techniques which result in overlapping layers of coloring materials result in lenses having unacceptably thick surface treatments, which severely impacts the permeability of the lenses with a consequent negative effect on the wearer's eye. This limitation is extremely critical not only to the health of the eye of the wearer, but it also severely limits the amount of time a wearer can wear a lens. In circumstances such as the motion picture industry where actors routinely wear colored/modified image contact lenses, limiting the time an actor can wear a particular pair of lenses limits the amount of filming that can be accomplished in a given day, which has a commensurate effect on the film's budget.
In accordance with another aspect of the present invention, there are disclosed methods for mass producing contact lenses with more than four colors, and, indeed, for mass producing contact lenses with photo-realistic images in sixteen or more color detail.
In accordance with another aspect of the invention, there is disclosed a contact lens which is capable of changing color according to the surrounding lighting condition. The lens is manufactured of a composition which includes a photochromic material, or is coated with a material having photochromic properties.
In accordance with yet another aspect of the invention, there is disclosed a contact lens on which any desired pattern, iris or otherwise, may be imparted using a photo sensitive
or phosphorescent material which will either glow in the dark or be sensitive to black light or any other radiant energy which will react with the material coated upon the lens.
In accordance with another aspect of the present invention, there is disclosed a method for creating a colored contact lens having a natural iris pattern comprising the steps of: taking a digital image of an eye of a subject, wherein the digital image is composed of a plurality of pixels; manipulating the pixels of the digital image to achieve a desired visual effect; dividing the digital image into a plurality of sections of colors; and, printing the sections of color onto a contact lens such that adjacent sections do not overlap. The step of manipulating the pixels of the digital image may be accomplished by changing the hue of the colors of the digital image, replacing pixels of substantially one color with pixels of a different color, and/or changing the overall color of the digital image while preserving the original gradation of the image.
In accordance with another aspect of the present invention, there is disclosed a method for creating a colored image on a contact lens in any combination of 12.7 million colors which are comprised of 4 colors of inks ( CMYK Off-Set Printing ), comprising the steps of: separating the colors of the image into CMYK format, using a digital photo editing system; creating CMYK positives for each of the 4 colors; finally printing the said image onto the surface of a contact lens or prosthetic eye via the transfer plate or halftone silk screen methods.
In accordance with another aspect of the present invention, there is disclosed a method for improving a contact lens comprising the steps of dividing any desired image to be placed onto a contact lens into a plurality of sections of colors or "blocks" and printing the sections or blocks of color onto a contact lens such that adjacent sections do not overlap. The benefit of using block printing is that, instead of using dots as with the dot transfer technique, sections or blocks of color of any desired shape can be used. In addition, areas of non-opaque sections can be left between blocks of sections of color, and half-tone printing using dots can be used to create a gradual transition from one section of color to another section of color.
In accordance with another aspect of the present invention, there is disclosed a method for creating a colored contact lens using both CMYK and block Screen processes so that maximum manufacturing efficiency can be reached while still maintaining the highest level of detail. Monochromatic lenses with high detail will be produced this way by using a
single halftone screen or plate to create the entire gray scale with one color of paint and using a block screen or plate for the color.
In accordance with still another aspect of the present invention, there is disclosed a method for creating an image on a prosthetic eye which matches the companion eye of a prosthetic eye wearer. The method comprises the steps of: taking a digital image of the functioning eye of the subject, wherein the digital images are composed of a plurality of pixels; optionally manipulating the pixels of the digital image to achieve a desired visual effect; dividing the digital image into a plurality of sections of color; and, printing the sections of color using either CMYK or block process, or combination, utilizing silk screen or plate printing, onto a prosthetic eye blank. In this way, both the natural and prosthetic eyes of the subject will be duplicates of each other, allowing the subject to feel more at ease.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 illustrates a colored contact lens known to the art.
Figure 2 is a flow diagram of the process used to derive the natural color pattern of the iris.
Figure 3 illustrates a predetermined special effect eye pattern of the iris.
Figure 4 is a flow diagram of the process used to print the colored contact lens in block process.
Figures 5A through 5G illustrate photo positives of the component layers used to create a seven-color contact lens of the present invention.
Figure 6 illustrates a predetermined special effect eye pattern of the iris.
Figure 7 is a flow diagram of the process used to print the colored contact lens by the CMYK process.
Figures 8 A through 8E illustrate photo positives of the component layers used to create a color contact lens of the present invention using any combination of 12.7 million colors.
DESCRIPTION OF A PREFERRED EMBODIMENT
Contact lenses in accordance with a preferred embodiment of this invention are generally known to the art. As shown in Figure 1, such lenses have a non-opaque pupil section 20 in the center of the lens and an annular iris section 21 surrounding the pupil section. For hydrophilic or soft contact lenses, a peripheral section 22 surrounds the iris section. A colored opaque or possibly translucent or intermittent pattern is located over the entire iris section apparently altering the color of the iris of the wearer.
An improvement of this invention is a method for deriving a natural looking colored pattern and the resulting lens. A flow diagram of the process is shown in Figure 2. Unlike the prior art, the lens of the present invention uses a natural or computer generated iris pattern as demonstrated in Figure 3. As can be appreciated, the color pattern of the iris will change depending on the customization desired. The depiction of a specific pattern should not be interpreted as a limitation of the claims or an attempt to claim a specific natural iris pattern. The reference numbers in Figure 3 correspond to colored sections noted by the same reference number in Figures 5A through 5G and is discussed below.
The pattern is obtained by obtaining a highly detailed photograph of the subject's eye. Typically, this is done by using a tripod clamp to attach a digital camera to the chin rest of a Kerotometer. This establishes a predetermined focal length which can be used each time by a technician and ensures that the photograph is taken from a correct angle and distance from the eye to produce a quality photograph. As can be appreciated, the subject's eye must be open as wide as possible to expose the entire iris while the photograph is taken. While a digital camera is preferred, a conventional film camera can also be used. The digital photograph, whether obtained from a digital camera or using an optical scanner, is then input into a photo editing computer program. Preferably, Adobe Photoshop 5.5 is used for photo editing, but any of a number of comparable programs could also be used. Photoshop allows for multiple image layers to be displayed at once.
The loaded image is edited so that only the iris portion of the eye remains. Initially, the digital image is on the first image layer. Small sections of color are selected from the original image, cut from the image, and pasted onto a new image layer. The process of selecting, cutting, and pasting is continued until all of the colored sections of the original image have been removed and placed on one of several image layers. The iris is then
reassembled by aligning the sections on each layer. With each colored section on its own layer, each section can be independently selected and moved without mistakenly selecting a portion of another section. This produces a quality final image. When aligning the sections, care should be taken to prevent adjacent sections from overlapping or having gaps of white space between the sections. The realigned image, when viewed through all layers, should look substantially like the original iris. The merge feature of Photoshop is used to reassemble all of the aligned layers onto a single layer for further processing.
This particular program has a "posterize" function, which is a shade limiter used to reduce the number of shades in the image to a more manageable level. For example, there are 256 shades or grey scale levels recognized by the printing industry. Since it is believed that the human brain is not capable of perceiving or differentiating differences in grey scale beyond 16 to 22 shades in a space that is 1.5 cm square, posterizing the image of the iris to 22 shades or fewer permits the use of fewer sections of color while still capturing a photorealistic duplication of the subject's natural iris, or the photorealistic production of an original iris pattern for a special effect. The use of 22 or more colors is mostly reserved for the film and television industry where closeup filming with magnification necessitates the need for higher amounts of detail. This process uses 4 to as many colors as necessary to achieve the desired effect.
Another aspect of the present invention is the use of the CMYK Off-Set process which is capable of producing all the shades, tints, and hues that the human eye can see with only 4 colors of ink. Since the eye can not perceive all of these colors at once, this process is used for streamlining production so that custom colors do not have to be pre-mixed each time for the more inexpensive lenses. Advancements in silk screen and plate printing technology have allowed new high detail producing micro mesh screens and plates to be produced. This new technology has been incorporated into the present invention. Now CMYK methods can produce equal detail to block process so any variable of designing methods can be used to produce a lens, Block, CMYK, or a fusion of any of them can be produced by the methods of this invention. Fewer shades (e.g.: 7) can be used as a compromise without losing the level of realism demanded by special effects experts and those wearing appliances such as prosthetic eyes. This feature is used in the next step. The color of the iris can be manipulated in several ways, and any or all of them can be used to achieve the desired visual effect. First, the overall
color of the lens can be changed while leaving the natural color gradation intact. For example, if the color of the iris changes from green in the center to brown on the outer region, the new lens would transition from a light hue to a darker hue as well. Second, a specific color in the iris could be replaced with another color without effecting the whole iris at one time. For example, color highlights could be added to the iris by replacing colors in different sections of the iris. The replacement colors could be lighter or darker shades of the original color, or an entirely different color. Third, the lens could be colorized with one hue in a monochromatic scale. For example, all of the colors of the original iris could be replaced with various shades of red. While the original colors are replaced, the natural iris pattern is preserved. All of these effects can be accomplished using different features of Photoshop or various other photo editing programs.
The size of the pupil section of the lens can also be changed. Colored contact lenses currently on the market have a clear pupil section which measures approximately 7 millimeters in diameter. As can be appreciated, the pupil of the eye changes diameter according to the amount of available light. With a comparatively large diameter, the wearer's natural eye color would be visible if the wearer is under bright lights. To compensate for this, the preferred contact lens of the instant invention uses a pupil section of about 3 millimeters. This eliminates the ring of natural color visible under bright light, but does not impair the wearer's ability to see. This dimension is merely a preferred one, and it is to be appreciated that other pupil sizes are contemplated, depending upon the particular application. For example, a wearer may desire to give off the effect of having heavily dilated or constricted pupils, in which case the pupil size will be created accordingly.
Printing these lenses requires the mixing of several techniques to maintain cost effectiveness during the manufacturing process. These techniques are novel and have been created to ensure the overall effectiveness and artistic quality of the final lens. CMYK Off-set and block methods can be used in combination with silk screen and plate printing methods. The techniques are new to the art and were created to be used to produce photo-realistic colored contact lenses and prosthetic eyes. Several different manufacturing devices are known to the art, but only one happens to be widely used in production of lenses and prosthetic eyes. This machine uses plates with a photo-etched image in which a rubber stamper is used to transfer the color pattern from the plate to the surface of the lens. A novel
method of plate production is described below. Another novel method of printing with the same type of machine is to use a silk screen as a stencil for color application.
Once an acceptable image of the iris has been produced, it may be printed on a contact lens. One method is the CMYK Off-Set printing process, which uses halftone screens or plates. In this process, dots (halftone pattern method of evenly sized dots) of the primary printing colors (cyan, magenta, yellow, and black) are applied to the lens. Once the desired iris pattern is made the colors must be separated for the CMYK process. Using Photoshop the image is converted to CMYK format by using the MODE function. The next step is to use the CHANNELS function to select the individual CMYK colors one at a time and print positives for each screen or plate. A new addition to this process is the addition of a white base coat that covers the total area of color to ensure that the colors are correct and opaque. The white layer of opaque ink also prevents the dulling of color when the lens is actually being worn. Different halftone pattern settings can be used with the white layer to help with the permeability of the lens. A solid layer of white is sometimes not necessary depending on the design of the lens pattern. The inks in CMYK are semi-transparent so that the hues truly mix to produce an outstanding color range. The dots vary in the angle of printing for each color so that the colors can be seen overlapping and off-set. The colors are vibrant and blended because of the slight off-set. This process takes advantage of the human brain's natural ability to optically mix colors, so that the discrete dots of ink are interpreted as a single, blended color. This process has two minor disadvantages. Overlapping colors tends to make the lens less permeable, and the mesh pattern from the screens used during printing can be detected when viewed in close proximity to the lens. This problem is easily overcome by varing the thickness of the white base coat by printing it with a halftone mesh or plate so that the micro spaces between the mesh help with oxygen transfer. Also using micro-mesh screens or plate printing can boost the detail level to 200 to 300 lines per inch which creates blending that can only be detected under magnification. This process also is capable of producing 12.7 million colors with only 4 colors of ink. This method is highly useful for dropping costs all the way across the manufacturing process, and the pre-mixing of 7 or more separate colors in not necessary, but making new master screens or plates must be made for each different overall color range. The same type of lens can not be made in a different color without having a different set of screens or plates.
The process used to produce the lens is shown in Figure 6. The printing process requires that five screens or plates be produced. As shown in Figures 8 A through 8E, each screen or plate contains an area of the iris, each of which uses a single color to blend with the other inks in the CMYK method to create the full 12.7 million color range. Figures 8A through 8E illustrate the positives for C-Cyan, M-Magenta, Y- Yellow, K-Black, and the Base coat White for the iris in Figure 6. When all of the screens or plates are combined, the composite produces the complete iris. The level of detail in this process is controlled by the output level "Lpi" lines per inch of the printed positives.
A second method of printing has been created. Using a block screen printing process multiple colored sections are applied to the lens. Unlike half-tone printing, the sections are printed adjacent to each other. This requires that the color being applied to the lens is mixed prior to application. Preferably, the differences in color tone between adjacent sections is subtle so that the eye, through optical mixing, interprets the change as a smooth rather than abrupt transition, and the lens has a natural appearance.
The process used to produce the lens is shown in Figure 4. The printing process requires that several screens be produced. As shown in Figures 5 A through 5G, each screen contains the areas of the iris which use a single color, with each screen preferably having a color. Reference numbers 30, 31, 32, and 33 are used to generally refer to colored sections in Figures 5 A tlirough 5D which generally correspond to similarly numbered colored sections in the original lens shown in Figure 3. As can be appreciated, the smaller colored sections not numbered in Figures 5E, 5F, and 5G also have corresponding sections in Figure 3. When all of the screens are combined, the composite produces the complete iris. The number of screens can be varied depending on the quality of the finished lens. Preferably, at least seven screens are used to produce a quality lens, with sixteen screens producing a lens which is virtually undetectable.
The screens or plates can be made using a photo-editor, such as Adobe Photoshop. Beginning with the image of the iris, the image is posterized to reduce the number of colors used in the image. For example, if a lens using seven screens is desired, the image is posterized to seven colors. The posterized image is saved to a computer file for future use.
Each color section of the posterized image must be printed separately. To accomplish this, the user must first decide which color is to be printed. The choice is arbitrary, as long as
all of the colors are ultimately printed. Once the choice is made, all of the other colors of the lens are replaced with white, until only the chosen color remains. The color replacement function is a feature of many photo-editors, including Adobe Photoshop. Alternatively, the unwanted colors could be replaced by editing the color palate of the image. Once all of the unwanted colors have been removed, the single color image is printed. The process is repeated until all of the colors have been printed. Each time, the original posterized image is used as the starting point.
The printed images are used as positives for the photo-transferring of said patterns to silk screens or transfer plates for the lens printing apparatus. Each image represents the region of the contact lens to which a particular color is to be applied. The lens printing apparatus required to produce the lens of the instant invention is known to the art and need not be modified to accomplish the task of printing the lenses.
Printing with CMYK method or block method in conjunction with silk screens is accomplished by printing a silk screen positive for the designated color for that particular screen, transferring the image to the screen by using the standard method of photo-transfer known to the silk screen art. After all the screens for a lens have been made the screens are placed over the lens so that they are directly between the lens and ink stamper so that the screens act as a stencil during the painting method.
Printing with CMYK method or block method in conjunction with plates is accomplished by printing a plate positive for the designated color for that particular plate, transferring the image to the plate by using the standard method of photo-transfer known to the plate printing art, after all the plates for a lens have been made the plates are used to hold the ink in the desired pattern and the rubber stamp is used to transfer to image to the surface of the lens.
Another use of the above-referenced process has been found to apply to the creation of color patterns on prosthetic eyes. In this aspect of the invention, not only can the natural iris pattern (and color of the eye) bes lavishly reproduced onto the prosthetic eye blank, but the entire patterning of the eye including scleral veins and other visible matter may be reproduced onto the prosthetic eye blank as well.
Another application of the instant invention is to the application using some or all of the steps disclosed herein of photochromic, photosensitive and/or phosphorescent material
onto the contact lens, such that the lens will create a dramatic visual effect under conditions which will be obvious to those skilled in the art.
The contact lens and prosthetic eyes, and the method steps to produce them, have been described in reference to, but not limited by, a single preferred embodiment. It is conceivable that numerous variations could be made by those skilled in the art and that these variations would be within the scope of the invention. For example, the method steps to produce the lens have been described as a sequence of manual operations. It is conceivable that a computer program could be written to automatically execute these steps. These and other variations are intended to be within the scope of the claims which follow.