WO2011097133A1

WO2011097133A1 - Cosmetic color contact lenses and printing methods thereof

Info

Publication number: WO2011097133A1
Application number: PCT/US2011/022979
Authority: WO
Inventors: Gerardo Ocampo; John Mulvihill
Original assignee: Gerardo Ocampo; John Mulvihill
Priority date: 2010-02-02
Filing date: 2011-01-28
Publication date: 2011-08-11

Abstract

Embodiments of the invention comprise a method for printing a cosmetic color contact lens. The method comprises printing an opaque iris pattern on the lens and printing a colored transparent pattern on the lens over the opaque iris pattern, such that the colored transparent pattern at least partially overlaps the opaque iris pattern.

Description

COSMETIC COLOR CONTACT LENSES AND PRINTING METHODS THEREOF

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to co-pending U.S. Provisional Patent Application Serial No. 61/300,604, filed February 2, 2010, the contents of which are incorporated herein by reference in their entirety. This application is related to U.S. Provisional Patent Application Serial No. 61/172,890, filed April 27, 2009, the contents of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

[0002] The present invention relates to contact lenses, and more particularly to cosmetic color contact lenses.

BACKGROUND

[0003] A cosmetic color contact lens is designed to change the appearance of the eye, by changing the appearance of the color of the wearer's iris. This is accomplished by coloring the iris portion of the lens. The colored iris portion obscures the wearer's iris, thereby causing the wearer's iris to appear to have the color of the contact lens.

[0004] However, known cosmetic color contact lenses often appear unrealistic due to the strongly pixilated or smeared nature of many prints, the smeared nature of many prints where the aim is to gain more coverage of the lens, the sharp junctions between colors on lenses (contrary to that of a natural iris where there are often many colors heavily blended), and very poor consistency of color appearance of cosmetic lenses when applied to different eyes.

BRIEF SUMMARY

[0005] A method for printing a cosmetic color contact lens comprises printing an opaque iris pattern on the lens and printing a colored transparent pattern on the lens over the opaque iris pattern, such that the colored transparent pattern at least partially overlaps the opaque iris pattern. The colored transparent pattern may completely overlap the opaque iris pattern.

[0006] The method may further comprises printing a second colored transparent pattern on the lens over the opaque iris pattern, such that the second colored transparent pattern at least partially overlaps the first colored transparent pattern and at least partially overlaps the opaque iris pattern.

[0007] The method may further comprise printing an opaque outer pattern on the lens having an outer diameter that is greater than an outer diameter of the opaque iris pattern and greater than an outer diameter of the colored transparent pattern. The opaque iris pattern may be printed after the opaque outer pattern is printed such that a portion of the opaque iris pattern covers a portion of the opaque outer pattern. The printed opaque iris pattern may comprise a plurality of indentions along an outer perimeter of the opaque iris pattern thereby enabling corresponding portions of the opaque outer pattern to be visible in the indentions.

[0008] The method may further comprise printing an opaque inner pattern on the lens having an inner diameter that is smaller than an inner diameter of the opaque iris pattern and smaller than an inner diameter of the colored transparent pattern.

[0009] The printed opaque iris pattern may cover at least 50% of an iris portion of the lens. The printed colored transparent pattern may cover at least 80% of an iris portion of the lens.

[0010] Any of the patterns may be printed on the lens using a halftone printing process. The halftone printing process may use between 120 and 300 lines per inch and an angle of 45 to 150 degrees.

[0011] In addition to the method of printing cosmetic color contact lenses, as described above, other aspects of the present invention are directed to cosmetic color contact lenses.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0012] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0013] FIG. 1 illustrates a main pattern of an improved cosmetic color lens, in accordance with embodiments of the present invention;

[0014] FIG. 2 illustrates an inner pattern of an improved cosmetic color lens, in accordance with embodiments of the present invention;

[0015] FIG. 3 illustrates a base (outer) pattern of an improved cosmetic color lens, in accordance with embodiments of the present invention;

[0016] FIG. 4 illustrates a topcoat pattern of an improved cosmetic color lens, in accordance with embodiments of the present invention; [0017] FIG. 5 illustrates an alternative main pattern of an improved cosmetic color lens, in accordance with embodiments of the present invention;

[0018] FIG. 6 illustrates an alternative inner pattern of an improved cosmetic color lens, in accordance with embodiments of the present invention;

[0019] FIGS. 7 A and 7B illustrate alternative base (outer) patterns of an improved cosmetic color lens, in accordance with embodiments of the present invention; and

[0020] FIG. 8 illustrates an alternative topcoat pattern of an improved cosmetic color lens, in accordance with embodiments of the present invention.

DETAILED DESCRIPTION

[0021] Described below are novel and non-obvious methods that may be used, separately or in combination, to create contact lenses (especially colored contact lenses). The concepts can be combined as appropriate in the preparation of new lens print designs. These inventive concepts are strong advances on the current state of the art. The two invention embodiments are: (1) a composite cosmetic lens pattern based on an opaque main coat/print (along with other more minor opaque patterns) with subsequent colored transparent overprints; and (2) improvement in the development of lens print patterns.

[0022] Embodiments of the invention comprise the application of a transparent topcoat (which will typically be colored, as discussed in detail below) over an opaque main coat. In one embodiment of the invention, there is only one transparent color overcoat in the first application. However, alternative embodiments of the invention can have two or more (partial or high coverage) transparent top coats that yield different color effects as they overlap each other and the underlying colors (the underlying colors being either the opaque main coat or the original eye color).

[0023] Typically, embodiments of the invention have one high coverage main coat of an opaque color, and one or two other patterns (termed "inner print" and "base print") to complete the cosmetic pattern. The inner and based prints are also referred to herein as the "other more minor opaque patterns" ("minor" meant only in terms of the coverage). While it is preferable to put these other minor opaque patterns (the inner print and the base print) under the main opaque coat, these other minor opaque patterns can also be placed on top of the main opaque coat and conceivably (but not preferably) on top of the transparent coat. [0024] The cosmetic patterns (as opposed to the colors) that appear on the lens are generally determined by the opaque patterns (coverage, opacity, dot size, dot arrangement, ink effects (viscosity, color intensity, etc), cliche effects (cliche material, dot depth and resolution), printer effects (cliche material, cup pressure, speed of movement, pad material, pad movement etc.) and the order in which they are printed. Because of the opacity of inks, whatever print is applied first will be covered by subsequent prints and will only show where there are gaps in the subsequent print.

[0025] Embodiments of the invention may use a printed patterned opaque main coat (along with other opaque prints) in combination with a transparent topcoat, which has the effect of improving the effective blending of the colors and the background color of the original eye. Both prints typically (but not necessarily) have substantial coverage, typically greater than 50% in the case of the main coat and typically greater than 80% in the case of the transparent print.

[0026] Embodiments of the invention may use advanced image processing, enabling conversion of images into print patterns that are easier to print and yielding patterns more closely replicating those seen in a real eye.

[0027] As demonstrations of the invention embodiments, two lenses (termed "Cooleyes" and "Tones") have been developed as prototypes.

[0028] The prototype "Cooleyes" lens involves the printing of a light colored opaque main coat (can be any lightly tinted color based on white opaque ink, including but not limited to white, yellow, grey, pale blue, pale green, pale almond, light violet, etc.) along with other opaque patterns, over which transparent colored coats are printed that serve to significantly alter the color of the opaque prints and that of the original eye color.

[0029] The prototype "Tones" lens involves printing of a more substantially or intensely colored opaque main coat (green, blue, grey, almond etc.) along with other opaque patterns, over which transparent colored coats can be printed to subtlety change the main coat color.

[0030] The terms "Cooleyes" and "Tones" as used herein designate two different but related embodiments of the invention. Both the "Cooleyes" and "Tones" lenses are produced by printing a transparent topcoat over an opaque main coat. "Cooleyes" is used to designate a lens with the overall color impression being mainly dictated by the transparent color(s) over the light colored opaque basecoat, because the opaque basecoat is light colored. "Tones" is used to designate a lens with the overall color impression being mainly dictated by the main coat (because the main coat is more intensely colored) and the transparent color altering the color effect slightly but perceptibly.

[0031] Embodiments of the invention may comprise four print layer lenses, but depending on requirements and practical technical capabilities, any number of print layers can be used. This has become feasible as an industrial process with the introduction of the multiple head circular or linear pad printing equipment. Lenses of embodiments of the invention may have only a single transparent topcoat that covers a significant (>80%) portion of the iris zone. However, the transparent print need not be limited to a single print, color, or pattern, and can be used as a partial cover print or a multiple color print.

[0032] In an example embodiment of a lens that might have more than four layers, two different transparent topcoats may be used on top of the opaque basecoat. For example, two different top transparent topcoats having two different patterns and two different colors allow for the gradual (and irregular) change of the intensity of the topcoat color from the outer to inner edge of the print pattern and vice versa to give a two color topcoat that blends to yield a very useful effect.

[0033] Most of the Cooleyes and Tones lenses prepared to date have used only a closed topcoat pattern. For example, a Tones lens was prepared with the transparent blue topcoat applied with a cliche (#7-118-6) with heavier application of ink from the outer to inner iris edge. The effect of such an application is that the lens has a two-tone effect with a stronger aqua (blue transparent over green opaque main coat) effect near the edge and a more green tone towards the inner part of the iris. This demonstrates the flexibility of altering patterns and colors of the topcoat transparent print.

[0034] It is suggested that the coverage of the combined topcoat print(s) will still be greater than 50% of the total area available unless an effect is required where the color of the main coat is deliberately allowed through.

[0035] Finally, while embodiments of the invention have been demonstrated on lenses using polyurethane heat cure technology, samples of UV cured prints on lenses have also been prepared using a formulation with UV curable resin, diluents, and pigment. These have the advantages of very quick cure and elimination of the limited pot life problem of the standard technology.

[0036] Definition of Terms [0037] Paste - The carrier liquid made from a resin solvent base, another solvent for evaporation purposes and pigment, milled to a fine dispersion.

[0038] UV cured system - prepared from a UV curable binder, diluents, initiator and pigments. Yields comparable print quality to that using the standard thermal cure technology.

[0039] Activation solution - The reactive component of an ink. Generally contains a diisocyanate (e.g. HDI, TMI, TMXDI) yielding an ink with a limited pot life, a protected crosslinker (e.g., those materials from the Trixene range from Baxenden chemicals) with a longer pot life, or a UV cure system with an unlimited pot life. It is added to the paste to make an ink.

[0040] Ink - Mixture of paste and activation solution. Can have a limited pot life depending on the activation system

[0041] Opaque ink - Blocks all light coming through. Generally it will contain an opaque pigment like titanium dioxide (a white pigment) in combination with another pigment that colors the system.

[0042] Transparent ink - Allows light through. In this case the pigment particle size is so small as not to allow it to interact with and scatter light. When applied to a lens will allow the base color of the eye to come through. A transparent ink applied over an opaque print will appear opaque.

[0043] Uniform print - A consistent print color over a print area.

[0044] Closed/solid pattern - Pattern where the ink print spots are close together over an area of the lens. This is difficult to do with pad printing due to the way the ink is trapped in the cliche and carried across to the lens on the pad. Embodiments of the invention (described below) have overcome this problem.

[0045] Open pattern - Pattern where the spots are spaced apart and allows a lot of the pattern/color of the underlying print or eye color through.

[0046] Halftone - A technique by which a continuous tone image such as a photograph can be converted into a monochrome image and then, though a process called dithering, different shades of grey are simulated by generating different densities, size and shape, and patterns of colored dots. Using modern commercial software, the process is simulated electronically using a screen frequency, the higher used generating smaller closer packed dots.

[0047] Base print (or base coat or base pattern) - The (typically) first print pattern placed on the front curve of the lens. Normally the black pattern provides masking to the underlying original eye color and is typically slightly wider than the main pattern and the eye's underlying original iris pattern. It provides some protection to the cosmetic function of the lens, preventing the underlying original eye color from showing if there is slight movement of the lens on the eye.

[0048] Main print (or main coat or main pattern) - Opaque iris patterned print normally with high coverage (often with titanium dioxide) that provides opacity and partial masking of the underlying eye color.

[0049] Inner print (or inner coat or inner pattern) - A print covering the inner area of the iris pattern adding to the composite color pattern of the finished cosmetic lens. Normally brown in color but not exclusively. This pattern (as can any of the patterns) can also be extended very slightly into the inner pupil portion of the lens. This gives a good blending effect with the underlying iris and once not interfering with visual acuity can be a very effective addition to the lens.

[0050] Topcoat (or top print or top pattern) - The (typically ) topmost print, normally with high coverage and of transparent color that serves to tint the underlying opaque prints, and to blend in these prints together with the underlying eye color. Can be a composite of more than one transparent print. While the topcoat will typically have a transparent color, the topcoat may optionally be clear.

[0051] Embodiments of the invention comprising a cosmetic lens pattern based on opaque prints with subsequent colored transparent overprints will now be described in more detail. In these embodiments, an opaque eye pattern is printed on the lens or mould (except for the optical portion of the lens) (the area of the lens on which the patterns are printed may be termed the "iris area"). As an example, on a 14.5mm diameter lens, the pattern may have an outer diameter of 12.5mm and a 4.5mm diameter optical zone in the center (dependent directly on the lens or mould being printed). On a mould the prints are placed in a reverse order.

[0052] The main print is an opaque iris pattern, illustrated in Figures 1 and 5. This pattern can be varied to cover as much or as little of the wearer's natural iris as desired. In general, the higher the coverage the less of the original eye color or any prints placed under it are allowed to show through. Figure 1 illustrates a comparatively low coverage main print, while Figure 5 illustrates a comparatively high coverage main print. Higher coverage will yield better consistency of appearance on different eyes. Where coverage is high the inner and base (outer) patterns (Figures 2/6 and 3/7A/7B, respectively) may also not show through, so one or both may be placed over the main coat pattern.

[0053] In general the coverage of the prints is high in embodiments of the invention. As an example, in one embodiment of the invention the base coat may have approximately 67% coverage, the main print may have approximately 53% coverage, the inner pattern may have approximately 25% coverage, and the topcoat may have approximately 80-90% coverage.

[0054] Other opaque patterns of variable coverage (e.g., inner pattern (Figures 2 and 6) or outer/base pattern (Figures 3, 7 A and 7B)) can be printed either under or over the main coat to yield other features. Optionally, the base pattern could have an inversion mark embedded in it as illustrated in Figure 7B. Inversion marks have been previously used to enable the wearer to distinguish the inside of the lens from the outside (which is more important now due to the use of structurally weaker daily disposable lenses than was historically the case) and to enable orientation of a toric lens or a lens that has a "vertical" print (e.g. novelty print) that only looks good when its orientated one way (e.g. a smiley face). Using an inversion mark in the base pattern of embodiments of the invention will be superior to the prior art because the high coverage of subsequent coats (e.g., the main pattern) used in embodiments of the invention will cause the inversion mark to only be visible/obvious from the back of the lens. In theory, the inversion mark may be embedded in other layers, such as the inner or main pattern. However, it is desirable to embed the inversion mark in the base pattern because the base pattern is at least partially covered with other opaque prints such that the inversion mark does not show when viewed from the front. The inversion mark can be any desired mark, e.g., letter, symbol, logo, etc. The inversion mark is typically printed in mirror image format, so that when viewed through the lens from the back the inversion mark will appear correct. Figure 7B shows an inversion mark (the "R" mark) that is created by omitting pixels from a portion of the pattern. The mark can be created by a) omission of pixels, as in Figure 7B (which may be more appropriate for a relatively closed pattern); b) by adding pixels (which may be more appropriate for a relatively open pattern like that of Figure 3 (which essentially produces same effect); or c) by placing an additional print under all the other opaque prints in a contrasting color. Finally, the extra print could also be a fluorescent print as a potential security mark.

[0055] A transparent color layer (i.e., the topcoat), as illustrated in Figure 4 and 8, may be printed over all these patterns (i.e., over the main, inner, and base patterns). The topcoat may comprise a substantially complete pattern of very small dots making up a transparent cover over the lens except for the optical zone. A halftone process may be used, but it may also be possible to do it without it. Other embodiments of the invention may use a more open topcoat or even partial or overlapping partial topcoats which give very novel effects. Again this pattern can be as closed or open as desired to allow the underlying colors to show through. The transparent coat can be uniform (such that the transparent coat completely covers the main pattern) (e.g., Figure 8), patterned (using any desirable pattern) (e.g., Figure 4) (such that the transparent coat does not completely cover the main pattern), or even varied in intensity (from one side to another or rather from the inner to the outer diameter of the pattern or vice versa, with a second transparent coat put on top of the first transparent coat with intensity varying in the opposite direction).

[0056] Where the two colors are superimposed (i.e., where the transparent color is over an opaque pattern) the transparent color becomes opaque and more intense in appearance. Any other opaque prints (e.g., inner or black base prints) will also similarly be tinted/enhanced. These are important components to the lens appearance.

[0057] Between the opaque pattern lines/dots, the transparent color serves to change and subtlety enhance the original eye color just enough to merge with the adjacent strong opaque color.

[0058] Typically, only the top color layer is both transparent and of a high level of coverage. The main print, the base (outer) print, and the inner print are opaque patterned prints. The effect of the different print layers overlap and the order in which the different print layers are applied is a key to the invention. The opaque coats must go on first, and the transparent color layer must be put on top of the base coat for the effect to be apparent. If a transparent blue is put on first for example, a subsequent white opaque pattern would only appear white as it would cover the transparent color with its opacity and would defeat the purpose.

[0059] The halftone process in this case is important to the transparent print as, without it, it is extremely difficult to print the substantially closed uniform print without smearing of the ink.

[0060] The transparent color acts as a filter over the main opaque color and makes the merging effect of the colors far more effective than the current state of the art cosmetic color lenses.

[0061] The main color can be any opaque color prepared by, for example, mixing white opaque paste and another pigment paste (yellow, green, blue, etc.). In practice, for the Cooleyes lens a white background worked well for a blue transparent topcoat and the yellow worked well as a background for a green transparent topcoat. In another example, a desirable effect may be obtained by printing a blue or green transparent topcoat over an almond main print. The color enhancer (transparent layer) can be, for example, green, blue, violet, red, yellow, orange or mixtures thereof, e.g. aqua. Other transparent colors can be used as they become available.

[0062] In many instances the combination of colors generates new and useful effects. For example, in the Tones lens the superimposition of a transparent color (e.g., green) over a blue opaque main pattern has a significant effect in the color resulting in an aqua color. As mentioned above, the Cooleyes lens generally has a transparent color topcoat(s) placed over a light colored main coat and the Tones lens generally has a light transparent topcoat placed over a more intensely colored main coat, however embodiments of the invention are not limited to such color combinations.

[0063] The order of application of the base (outer) and inner ring patterns is less critical, but when printed under the transparent coat there is a benefit that there is a reduction in the illusionary effect of these ring patterns appearing to "float" over the entire pattern.

[0064] The pattern used to produce the main print on either lens type (Figures 1 and 5) can have deliberate indents in the outer edge allowing the black base print (outer) (Figures 3, 7 A, 7B) to appear in a more random fashion as it is in an actual eye. This also serves to blend the black color into the colors of the main pattern. The dark base (outer) ring pattern is highly cosmetically desirable. It is conceivable that the inner and base (outer) prints can be put on top of the transparent coat without significant loss of effect.

[0065] The indents in the outer edge of the main opaque print are aimed at allowing the black from the base print to show through. These indents serve to blend the black into the main print pattern contributing a more natural effect. The fact that the black pattern extends out beyond the colored patterns is also a desirable effect. When larger than the eye's iris, the base print also serves to cover the iris when there is any slight movement of the lens.

[0066] A significant extension of the use of the transparent topcoat is that it can be used as a partial coat where less than the whole main pattern is covered. This allows some of the opaque color of the main pattern to show through as printed, which may be more appropriate to the "Tones"-type lens. [0067] The coverage of the topcoat(s) and main coat may vary significantly based on the desired effect. Generally, the topcoat(s) and the main coat will likely have high degrees of coverage. For example, the topcoat(s) and the main coat will each likely have >40% coverage and preferably >75% coverage. This allows the main coat to act as a mask for the original eye color and provide new opaque color and the topcoat(s) to tint the opaque color, the minor color patterns (inner and base prints), and the original eye color, and importantly to blend all these colors into a more natural cosmetic lens pattern.

[0068] Multiple transparent prints, either overlapping or not, may be used to yield new colors where prints of transparent colors overlap over the opaque prints. This shows its greatest impact where the transparent prints are placed over the opaque light colors as in the Cooleyes-type lens.

[0069] The final appearance of the individual prints have a significant influence on the cosmetic effects of the lenses with colored patterns (e.g., lines (inner to outer) or diffuse rings (radial patterns) being emphasized either to a greater or lesser extent. The patterns still appear to blend together without the strong opaque junctions currently observed in the prior art lenses. It is also possible to mimic and improve substantially the blending and appearance of inner and base patterns by appropriate overlap of the transparent colors by this method.

[0070] Embodiments of the invention may use two or three or more different transparent colors on two or more cliches (three being unlikely but possible), or different patterns (e.g., different color tones from one side of the lens to the other). There are potentially any number of possibilities of patterns and colors. The aim is always more "natural-looking", so irregular and radial lines are desirable.

[0071] Embodiments of the invention provide numerous advantages over current cosmetic color lenses. Embodiments of the invention provide more natural cosmetic look when on an eye. The severe junctions between the colors of existing prior art printed lenses are a significant problem resulting in the unrealistic appearance of lenses.

[0072] Embodiments of the invention also enable blending and softening of the edges of the colored patterns where the colored patterns and the original eye colors meet. One example of this effect is where a chestnut inner pattern (often very stark and obvious) is used in the prior art lens. In embodiments of the present invention, the chestnut print blends into the others as an integral part of the final pattern and results in a significant visual improvement in the "depth of color" to the lens. This effect can be created either as an opaque chestnut pattern or as a transparent color placed over the colored opaque print.

[0073] The use of the transparent prints with substantial composite coverage (perhaps up to 95% over the iris) results in the creation of new colors. (On the low end, the coverage would probably not be below 25%, as the effect would be minimal at this coverage level.) With regard to the color appearance on the eye, the transparent prints over the eye's original color (where it is allowed through) serves to yield many more colors than just those printed. For example with the Cooleyes lens, theoretically one should observe: (a) the three printed opaque colors where they are dark (and therefore are not really affected if covered by the transparent coat) or not covered by each other or the transparent coat; (b) the combined color effects where the transparent coat covers lighter colored opaque printed colors; (c) the original eye colors where they are not covered by either the opaque printed coats or the transparent coat; and (d) the original eye colors tinted with the transparent color where they are not covered by the opaque colors. Still more colors are created where two or more different transparent prints overlap with each other, the opaque prints, or the original eye color.

[0074] In contrast to embodiments of the invention, the existing prior art (with only opaque prints) shows only the printed colors and the original eye colors with no softening/blending of the color junctions. This has the effect of making the color junctions look very stark (when contrasting strongly with the original eye color) and often to appear to float across the surface of the eye. This is a significant problem.

[0075] In lenses of embodiments of the invention, the colors are well blended and there is a far lower evidence of the pixilation evident on the prior art product. In prior art lenses, at close range the dot matrix pattern is also very strongly apparent. Also, in prior art lenses, at a distance the cosmetic color change on the eye is diminished.

[0076] With prior art lenses, there is a very real disadvantage that variably shaded or colored eyes will always give variable results. The lenses of embodiments of the invention yield a more consistent result. This is because the opaque main coat will substantially hide the eye's original color and the transparent print will always serve to tint/blend the original eye color to a more (if the eye color s light) or lesser (if the eye color is dark) extent.

[0077] Current techniques for making cosmetic color lenses result in patterns that are highly pixilated, and in which blending of colors is difficult. Prints with substantial coverage (for example greater than 50%) are difficult to print and very often yield variable or undesirable (e.g. smeared) results. Current techniques typically use dot matrix patterns, although some use solid (no dots) prints. Current dot matrix techniques do not produce lifelike patterns well. Solid prints smear easily.

[0078] Current techniques print the main pattern first and then the inner pattern and a dark ring on the outer part of the lens. This is the standard order of print application for the industry. The effect of this current technique is that the inner pattern appears very often to "float" across the surface of the lens and is quite unnatural. Especially when the eye is dark, the inner pattern appears to "jump" out and look very stark.

[0079] Embodiments of the invention comprising improvements in print technique using both an improved patterned cliche and changes in the order of application will now be described in more detail.

[0080] To create cosmetic color lenses, the primary color patterns are split from a photograph or other detailed picture of a desired eye pattern. In prior art techniques, this is then processed into a dot matrix pattern and the result is used to create the different color print cliches. In embodiments of the present invention, the color patterns from the image are treated with a halftone computer treatment of the image data. This has the effect of diffusing the edges of the color print spots and improving the visual quality of the finished lens when on a wearer.

[0081] Halftones are defined in terms of the screen frequency (# of lines per inch; e.g., 102 to 300 lpi) and the angle (e.g., 45, 90, 180 degrees), and dot shape (e.g., round, diamond, ellipse, square, or cross). These define the dot size and shape. (Halftone technology is described in detail below.) Any of the patterns (the main pattern, the base pattern, the inner pattern, or the topcoat pattern) may be printed using a halftone process.

[0082] For the patterns used to create the "Cooleyes" and "Tones" lenses the parameters used were 175 LPI, angle of 45 degrees, and round dot shape, although embodiments of the invention may use other parameters and combinations of parameters. These parameters were empirically determined by printing and assessing individual lenses.

[0083] The use of the halftone technology in embodiments of the invention allows the elimination of the very obvious large dot appearance evident in the prior art lenses by making the edges of the print patterns more diffuse. This effectively allows for the merging of the different color patterns. This treatment can be applied to a solid color, light shade image to produce a pattern that can be easily printed. By using a halftone technique (creating smaller and variable size dots), the pattern can be varied between a more open (lighter shades) or closed (more intense shades) pattern using commercial software and the visual appearance of the lens is far improved.

[0084] Secondly, the counterintuitive order of print coats in embodiments of the invention has a significant effect in the way an external observer sees the colors on a wearer's lens. As an example, the preference for the "Tones" lens is to print the black base (outer) pattern first, then the inner chestnut pattern, and subsequently the opaque main pattern and the transparent color printed on top. This buries to some extent the opaque colors and also has the effect of enabling the colors to merge better because the inner and outer dark colors do not appear to float at the top of the print. This also has the effect of better coverage of the underlying real eye color.

[0085] The indents in the outer edge are also a novel feature. The gaps in the main pattern print allow the underlying colors (i.e., the inner and base patterns and potentially the underlying eye color) to show through.

[0086] Halftone technology

[0087] Basically a halftone is a group of differing sized dots that when viewed from a distance has the appearance of continuous shades of grey or any color. This capability to generate different shades of a single color has always been a technical difficulty for the printing industry. Using the current lens pattern printing technology, when a color image of an eye is scanned the colors are separated as defined patterns of same sized dots of equal size. This gives a harsh delineated look to the printed color dots whether on paper or on a lens.

[0088] In the halftone process a solid shaded area is "rastered" and computer converted into different shaped dots with a particular size dictated by the shade required and the parameters entered into the image processing software program. These include the frequency or lines per inch and the angle of the ellipse formed. The angle of the dot is important to eliminate regular patterns that can occur superimposed on the printed image (Moires).

[0089] The printed halftoning has the effect of softening or merging the edges of the hard patterns in the print. The beneficial effect is apparent when the image is viewed on a large (real- life) scale, while the detailed effect of the image processing on the print can be seen only when the printed pattern is viewed microscopically or when the image is enlarged.

[0090] In embodiments of the invention, the image was created from a scanned photograph or other detailed picture. This yields a pattern with the continuous areas of grey or colors. Because printing techniques can only print solid colors (single color inks) a way is needed to produce the shades. This is traditionally been done by breaking the image into printable dots the density of which would determine the shade.

[0091] To improve the appearance of the image the halftoning processing is used. After rastering with a particular frequency and angle, the large dots in the image get deliberately diffused and the solid shades get similarly broken into smaller dot patterns that allow the pad printer to produce a far better quality print.

[0092] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0093] The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

Claims

THAT WHICH IS CLAIMED:

1. A method for printing a cosmetic color contact lens, the method comprising: printing an opaque iris pattern on the lens;

printing a colored transparent pattern on the lens over the opaque iris pattern, such that the colored transparent pattern at least partially overlaps the opaque iris pattern.

2. The method of claim 1, wherein the colored transparent pattern completely overlaps the opaque iris pattern.

3. The method of claim 1, further comprising:

printing a second colored transparent pattern on the lens over the opaque iris pattern, such that the second colored transparent pattern at least partially overlaps the first colored transparent pattern and at least partially overlaps the opaque iris pattern.

4. The method of claim 1, further comprising:

printing an opaque outer pattern on the lens having an outer diameter that is greater than an outer diameter of the opaque iris pattern and greater than an outer diameter of the colored transparent pattern;

wherein the opaque iris pattern is printed after the opaque outer pattern is printed such that a portion of the opaque iris pattern covers a portion of the opaque outer pattern, and wherein the printed opaque iris pattern comprises a plurality of indentions along an outer perimeter of the opaque iris pattern thereby enabling corresponding portions of the opaque outer pattern to be visible in the indentions.

5. The method of claim 4, wherein the opaque outer pattern is printed on the lens using a halftone printing process.

6. The method of claim 5, wherein the halftone printing process uses between 120 and 300 lines per inch and an angle of 45 to 150 degrees.

7. The method of claim 1, further comprising:

printing an opaque inner pattern on the lens having an inner diameter that is smaller than an inner diameter of the opaque iris pattern and smaller than an inner diameter of the colored transparent pattern.

8. The method of claim 7, wherein the opaque inner pattern is printed on the lens using a halftone printing process.

9. The method of claim 8, wherein the halftone printing process uses between 120 and 300 lines per inch and an angle of 45 to 150 degrees.

10. The method of claim 1, wherein the printed opaque iris pattern covers at least 50% of an iris portion of the lens.

11. The method of claim 1 , wherein the printed colored transparent pattern covers at least 80% of an iris portion of the lens.

12. The method of claim 1, wherein the opaque iris pattern and/or the colored transparent pattern is printed on the lens using a halftone printing process.

13. The method of claim 12, wherein the halftone printing process uses between 120 and 300 lines per inch and an angle of 45 to 150 degrees.

14. A cosmetic color contact lens comprising:

an opaque iris pattern printed on the lens;

a colored transparent pattern printed on the lens over the opaque iris pattern, such that the colored transparent pattern at least partially overlaps the opaque iris pattern.

15. The contact lens of claim 14, wherein the colored transparent pattern completely overlaps the opaque iris pattern.

16. The contact lens of claim 14, further comprising:

a second colored transparent pattern printed on the lens over the opaque iris pattern, such that the second colored transparent pattern at least partially overlaps the first colored transparent pattern and at least partially overlaps the opaque iris pattern.

17. The contact lens of claim 14, further comprising:

an opaque outer pattern printed on the lens having an outer diameter that is greater than an outer diameter of the opaque iris pattern and greater than an outer diameter of the colored transparent pattern;

18. The method of claim 17, wherein the opaque outer pattern is printed on the lens using a halftone printing process.

19. The method of claim 18, wherein the halftone printing process uses between 120 and 300 lines per inch and an angle of 45 to 150 degrees.

20. The contact lens of claim 14, further comprising:

an opaque inner pattern printed on the lens having an inner diameter that is smaller than an inner diameter of the opaque iris pattern and smaller than an inner diameter of the colored transparent pattern.

21. The method of claim 20, wherein the opaque inner pattern is printed on the lens using a halftone printing process.

22. The method of claim 21, wherein the halftone printing process uses between 120 and 300 lines per inch and an angle of 45 to 150 degrees.

23. The contact lens of claim 14, wherein the printed opaque iris pattern covers at least 50% of an iris portion of the lens.

24. The contact lens of claim 14, wherein the printed colored transparent pattern covers at least 80% of an iris portion of the lens.

25. The contact lens of claim 14, wherein the opaque iris pattern and/or the colored transparent pattern is printed on the lens using a halftone printing process.

26. The contact lens of claim 25, wherein the halftone printing process uses between 120 and 300 lines per inch and an angle of 45 to 150 degrees.