WO2011140043A2

WO2011140043A2 - Attachable electro-active lens systems

Info

Publication number: WO2011140043A2
Application number: PCT/US2011/034936
Authority: WO
Inventors: Robert Hall; Joshua Haddock; William Kokonaski
Original assignee: PixelOptics
Priority date: 2010-05-03
Filing date: 2011-05-03
Publication date: 2011-11-10
Also published as: WO2011140043A3

Abstract

Lens processing and testing systems are provided various forms of marking and/or holding lens components, such as lens substrates and the like including electro-active elements. A lens testing system may include, for example, a light source, a first polarizer, a second polarizer, and a camera. The device may be configured to hold a test lens between the first and second polarizers and to shine light from the light source through the first polarizer, through the test lens, and through the second polarizer, and to receive the light in the camera. Exemplary systems may also include various holding and/or marking features to properly align the lens component to be tested or processed. For example, a lens including an electro-active element may be marked according to a predetermined offset from the center of the electro-active element and may be aligned based on the offset marks.

Description

ATTACHABLE ELECTRO-ACTIVE LENS SYSTEMS

CROSS-REFERENCES TO RELATED APPLICATIONS This PCT application claims the benefit under 35 USC 119(e) to provisional application serial number 61/330,444 filed May 3, 2010, provisional application serial number 61/365,386 filed July, 2010, provisional application serial number 61/375,899 filed August 23, 2010, provisional application serial number 61/382,957 filed September 15, 2010, the contents of which are incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

The present subject matter deals generally with methods for processing and inspecting spectacle lenses, including electro-active lenses. Electro-active lenses can be any lenses capable of adjusting, changing or tuning a provided optical power, or other optical effect, through the application of electricity. For example, U.S. Pat. No. 5,712,721, U.S. Pat. No. 6,517,203 and U.S. Pat. App. Pub. No. 2009/0256977, each describe exemplary electro-active lenses and spectacles, and are hereby incorporated by reference in their entireties.

The front curvature of a semi-finished lens blank can be measured using a visual inspection device that uses reflection to measure surface power. An example of such a device is the Focovision SPV-1. Such devices can be used to measure surface power of semi-finished lens blanks that have been prepared with or without pad prints. Using conventional techniques to measure a front curvature of a semi-finished curvature using such a device typically requires steps to be implemented that are time consuming and risk damaging the semi-finished lens blank. Specifically, using conventional techniques, masking tape is first applied to the semi-finished lens blank. Second, if the semi-finished lens blank does not have a pad print, a technician conducting the surface power measurements must place marks on the lens with a marker to help locate and orient the major reference point or distance vision point of the lens. Next, the marked semi-finished lens blank is placed under the reflection measurement device. During this step the technician must carefully adjust the orientation of the lens to locate the precise point on the lens where the surface power measurement should be made. After making the measurement, the technician must clean the lens to remove the ink marks on the lens. Removing the ink marks can scratch or otherwise damage the semi-finished lens blank. Further, this cleaning step is time-consuming and can be burdensome when a large number of lenses are to be inspected for quality. Further, using conventional measurement techniques can result in inaccurate surface power measurements if the technician marks the lens poorly or fails to hold the lens in a steady and properly oriented manner to make the measurement.

In addition, the processing of electro-active lenses includes additional considerations such as, for example, protecting the electro-active area, which is typically comprised of a liquid crystal layer, from damage. Inspecting electro-active lenses may also require an additional assessment of the electro-active areas of the lens.

Accordingly, there are ongoing needs for improved procedures and devices for making surface power measurements of lens blanks, including those with electro-active elements, e.g. that reduce inspection time, increases the accuracy of the measurement and reduce the likelihood of damaging or scratching the lens. BRIEF SUMMARY OF THE INVENTION

Aspects of the present invention provide systems, methods and apparatus for improving processing and quality control inspections for lenses, particularly with respect to various marking and adjustment techniques that may be used in the processing of electro-active lenses.

According to first aspects of the invention, lens testing devices and methods may be provided including a light source; a first polarizer; a second polarizer; and a camera, wherein, the device is configured to hold a test lens between the first and second polarizers and to shine light from the light source through the first polarizer, through the test lens, and through the second polarizer, and to receive the light in the camera. In embodiments, the polarizers may be parallel to one another, perpendicular to one another, or offset from one another such that they are not oriented parallel or perpendicular with respect to one another.

Embodiments may also include a controller configured to detect at least one of, for example, a cell gap dimension and a liquid crystal volume for a electro-active areas of the test lens.

According to further aspects of the invention, a front curvature measurements (e.g., cylinder and spherical measurements or surface power measurements) of a semi-finished lens blank may be made quickly and precisely with a lens measurement device including a lower arm; an upper arm; and a lens holder disposed on the lower arm. In embodiments, the lens holder may include at least two adjustable pins that are configured to hold a lens under the upper arm, and to locate the lens under a visual inspection measurement point. In embodiments, the at least two pins may be adjustable in tracks that are disposed in the lens holder and that run substantially in a plane of the lens being measured.

In embodiments, the lens holder may include at least two markers a top surface of the lens holder. The at least two markers may be disposed at different locations for orienting a left lens and a right lens.

According to further aspects of the invention, methods of measuring a lens may include providing a semi-finished lens blank with marks on a periphery of the lens blank; placing the lens blank on a lens holder having at least two adjustable pins and at least two alignment markers; adjusting the lens blank to touch the at least two pins and to align with at least one of the alignment markers; and measuring a front curvature of the lens blank. Embodiments may also include adjusting the at least two pins to accommodate a second lens blank having a different size; placing the second lens blank on the lens holder; adjusting the second lens blank to touch the at least two pins and to align with at least one of the alignment markers; and measuring a front curvature of the second lens blank.

According to further aspects of the invention, methods of processing an electro-active lens substrate may include locating a center of an-electro-active diffractive zone; marking the lens substrate with a relative mark at a location measured from the located center of the diffractive zone; processing the lens substrate based on the relative mark; and removing the relative mark from a lens formed from the substrate. Embodiments may include wherein the relative mark is a geometric center of the lens substrate, and is measured based on a known X and Y offset from the center of the diffractive zone. The relative mark may be, for example, a horizontal guide mark that passes through the geometric center of the lens substrate. In embodiments, the diffractive zone may be on a convex side of the substrate and the relative mark may be placed on a concave side of the substrate.

According to further aspects of the invention, methods of processing a lens for a user may include determining a fitting height for the user; if the fitting height is in a first range, performing a first blocking procedure including marking the lens blank at a point approximately 4mm above a fitting point of the lens, and if the fitting height is in a second range, performing a second blocking procedure including marking the lens blank approximately the fitting point of the lens.

In embodiments, if the fitting height is in the second range, an offset may be calculated for dropping the lens while blocking. In embodiments, the lens may include an electro-active element, and the method may further include marking an approximate center of the electro-active area, and aligning the approximate center of the electro-active area of the lens with a template including corresponding marks.

Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention claimed. The detailed description and the specific examples, however, indicate only preferred embodiments of the invention. Various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention, are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the detailed description serve to explain the principles of the invention. No attempt is made to show structural details of the invention in more detail than may be necessary for a fundamental understanding of the invention and various ways in which it may be practiced. In the drawings:

FIG. 1 depicts aspects of an exemplary lens inspection system according to an embodiment of the invention. FIG. 2 depicts a related art lens including an electro-active area.

FIG. 3 depicts aspects of an exemplary lens inspection system according to an embodiment of the invention.

FIG. 4 depicts further aspects of the exemplary lens inspection system shown in FIG. 3. FIG. 5 is a top-down view depicting further aspects of the exemplary lens inspection system shown in FIG. 3.

FIG. 6 is a side view depicting further aspects of the exemplary lens inspection system shown in FIG. 3. FIG. 7 depicts aspects of an exemplary electro-active lens with markings according to an embodiment of the invention.

FIG. 8 depicts aspects of an exemplary electro-active lens pair with markings according to an embodiment of the invention.

FIG. 9 depicts a process flow for processing optical lenses according to an embodiment of the invention.

FIG. 10 depicts aspects of an exemplary lens with markings according to an embodiment of the invention.

FIG. 1 1 depicts further aspects of the exemplary lens as shown in FIG. 10, with additional markings according to an embodiment of the invention. FIG. 12 depicts positioning of an exemplary lens for blocking according to an embodiment of the invention.

FIG. 13 depicts an alternative positioning of another exemplary lens for blocking according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

It is understood that the invention is not limited to the particular methodology, protocols, etc., described herein, as these may vary as the skilled artisan will recognize. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the invention. It also is be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include the plural reference unless the context clearly dictates otherwise.

Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which the invention pertains. The embodiments of the invention and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well- known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments of the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those of skill in the art to practice the embodiments of the invention. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the invention, which is defined solely by the appended claims and applicable law. Moreover, it is noted that like reference numerals reference similar parts throughout the several views of the drawings.

As discussed herein, and in the incorporated references, electro-active lenses may include one or more electro-active layers, zones and/or regions. An "electro-active zone" can include or be included in an electro-active structure, layer, and/or region. An "electro-active region" can be a portion and/or the entirety of an electro-active layer. An electro-active region can be adjacent to another electro-active region. An electro-active region can be attached to another electro-active region, either directly, or indirectly with, for example, an insulator between each electro-active region. An electro-active layer can be attached to another electro-active layer, either directly, or indirectly with, for example, an insulator between each electro-active layer. "Attaching" can include bonding, depositing, adhering, and other well-known attachment methods.

A "controller" can include or be included in a processor, a microprocessor, an integrated circuit, an IC, a computer chip, and/or a chip. A "refractor" can include a controller. An "auto- refractor" can include a wave front analyzer. "Near distance refractive error" can include presbyopia and any other refractive error needed to be corrected for one to see clearly at near distance. "Intermediate distance refractive error" can include the degree of presbyopia needed to be corrected an intermediate distance and any other refractive error needed to be corrected for one to see clearly at intermediate distance. "Far distance refractive error" can include any refractive error needed to be corrected for one to see clearly at far distance. "Near distance" can be from about 6 inches to about 24 inches, and more preferably from about 14 inches to about 18 inches. "Intermediate distance" can be from about 24 inches to about 5 feet. "Far distance" can be any distance between about 5 feet and infinity, and more preferably, infinity. "Conventional refractive error" can include myopia, hyperopia, astigmatism, and/or presbyopia. "Non-conventional refractive error" can include irregular astigmatism, aberrations of the ocular system, and any other refractive error not included in conventional refractive error. "Optical refractive error" can include any aberrations associated with a lens optic.

In certain embodiments, a "spectacle" can include one lens. In other embodiments, a "spectacle" can include more than one lens. A "multi-focal" lens can include bifocal, trifocal, quadrafocal, and/or progressive addition lens. A "finished" lens blank can include a lens blank that has finished optical surface on both sides. A "semi-finished" lens blank can include a lens blank that has, on one side only, a finished optical surface, and on the other side, a non-optically finished surface, the lens needing further modifications, such as, for example, grinding and/or polishing, to make it into a useable lens. "Surfacing" can include grinding and/or polishing off excess material to finish a non- finished surface of a semi-finished lens blank.

As used herein, "attachment mechanisms" may include, without limitation, various mechanical, magnetic, electro-magnetic, and other adhesive means suitable to attach and/or detach attachable lens units, and the like, to and/or from a base lens unit, spectacle frame etc. In embodiments, various attachment mechanisms may provide for convenient joining of an attachable lens unit to a base lens unit, and may also provide for the detachment and/or rejoining of the units.

FIG. 1 illustrates an electro-active lens cell gap inspection system according to first aspects of the present invention. The inspection system can comprise a first polarizer, a second polarizer, a light source and a camera. As shown in FIG. 1, an electro-active lens can be positioned between the first and second polarizers during inspection. The light source can be positioned adjacent to a first side of the polarizer pair and the camera can be positioned adjacent to a second side (i.e., the opposite side) of the polarizer pair.

The camera can be an input device to a visual inspection system. That is, the camera can be coupled to a signal processing device (e.g., a computer or other processor, not pictured in FIG. 1 for simplicity) that can be used to process visual information provided by the camera.

The electro-active lens can comprise a liquid crystal material as will be appreciated by one skilled in the pertinent arts. The liquid crystal material may be contained within a designated reservoir or chamber of the electro-active lens. The area of the electro-active lens confining the liquid crystal material may be a space formed when bringing a first substrate (e.g., a front) of the electro-active lens into contact with a second substrate (e.g., a back) of the electro-active lens during fabrication.

The gap or space between the two substrates (i.e., the gap or space where the two substrates do not meet or touch) can define the area of liquid crystal confinement. FIG.2 provides a top view of an exemplary electro-active lens. As shown in FIG. 2, a cell gap region indicates an area where liquid crystal material is confined. The cell gap region may be a diffractive region. The depth of this cell gap, and how well it is uniformly filed with the liquid crystal material, may be determined using the electro-active cell gap inspection system and methods of the present invention.

For example, according to an aspect of the present invention, the first and second polarizers can be oriented parallel with respect to one another (such that the electro-active lens is placed between parallel polarizers). When oriented in this manner, the color of the cell gap (as viewed by the camera or by an individual positioned on the same side of the polarizer pair as the camera) can be used to determine the quality of the cell gap. Specifically, with a parallel polarizer configuration, a cell gap that has consistent depth and is filled uniformly with liquid crystal material will have a uniform color. Deviations in color uniformity (e.g., areas of darker or lighter coloring) can indicate a low quality cell gap, i.e., a cell gap that lacks uniform depth of formation as desired and/or lacks uniform liquid crystal confinement.

Based on a predetermined cell gap dimension and a predetermined liquid crystal volume, a known or target color indicative of acceptable cell gap depth and/or liquid crystal

confinement/uniformity can be determined and used in the inspection and quality analysis of the present invention such as, for example, by programming a controller to analyze signals from the camera and compare them to predetermined values.

According to an aspect of the present invention, the first and second polarizers can be oriented perpendicular with respect to one another (such that the electro-active lens is placed between perpendicular polarizers). When oriented in this manner, the transparency of the cell gap (as viewed by the camera or by an individual positioned on the same side of the polarizer pair as the camera) can be used to determine the quality of the cell gap. Specifically, with a perpendicular polarizer configuration, a cell gap that has consistent depth and is filled uniformly with liquid crystal material will have a uniform transparency. Deviations in transparency or transmission (e.g., areas of different brightness) can indicate a low quality cell gap, i.e., a cell gap that lacks uniform depth of formation as desired and/or lacks uniform liquid crystal confinement.

Transmission/transparency can also be used to indicate cell gap integrity using a parallel polarizer configuration. Further, color can also be used to indicate cell gap integrity using a perpendicular polarizer configuration.

According to further aspects of the invention, the first and second polarizers may be orientated to be offset from one another such that they are not oriented parallel or perpendicular with respect to one another (i.e., oriented at some offset between being perpendicular and parallel to one another). When oriented in this manner, the color and/or transparency of the cell gap (as viewed by the camera or by an individual positioned on the same side of the polarizer pair as the camera) can be used to determine the quality of the cell gap. Specifically, with an offset polarizer configuration, a cell gap that has consistent depth and is filled uniformly with liquid crystal material will have a uniform optical characteristic such as color and/or transparency. Deviations in this uniform optical characteristic can indicate a low quality cell gap, i.e., a cell gap that lacks uniform depth of formation as desired and/or lacks uniform liquid crystal confinement.

Inspection of the cell gap of an electro-active lens using a particular orientation of the first and second polarizers can be conducted by a person. Alternatively, or in addition thereto, inspection of the cell gap of an electro-active lens using a particular orientation of the first and second polarizers can be facilitated or aided by an automated vision system. The vision system can include the camera as mentioned above. The vision system can also include a processor to process optical information collected by the camera. As an example, the vision system can be programmed to detect color or brightness variation in the cell gap. The vision system may also compare any deviation from an expected color or level of transparency to a permissible threshold of deviation. The vision system may determine if the determined deviation exceeds a predetermined range of quality or falls within a permissible range of quality (e.g., above or below a determined quality threshold, respectively, as related to the measured color/transparency uniformity). As such, the vision system may be capable of determining color and brightness of the cell gap across an entire spatial region of interest. Further, the vision system may include the capability to process this information and compare it to a determined range of variability to aid a determination of acceptable cell gap quality. According to further aspects of the invention, apparatus and methods may also be provided for conducting reflection power measurement. FIG. 3 illustrates an exemplary measurement fixture 102 according to aspects of the invention that can be used to improve the measurements including, for example, reflection power measurement. The measurement fixture 102 can be designed to rest on a lower arm 104 of a visual inspection device also shown in FIG. 3. A lower portion of the measurement fixture 102 can be designed to have a shape that conforms to the shape of the lower arm 104 so as to be stabilized. Further, a locking pin or other mechanism and adjustment knob 106 can be used to ensure the measurement fixture 102 rests tightly against the lower arm 104. As further shown in FIG. 4, a semi-finished lens blank 108 can rest on top of the measurement fixture 102. The semi-finished lens blank 108 can be positioned under a lower arm 1 10 of the visual inspection device.

FIGS. 5-6 provide additional details on the measurement fixture 102. The measurement fixture 102 can include pins 202-A, 202-B, that can help precisely position and orient the semi-finished lens blank 108. Specifically, the pins 202 can be positioned such that when the semi-finished blank of a known diameter is placed on top of the measurement fixture 102 to rest, the distance vision point of the semi-finished lens blank 108 can be substantially directly underneath the visual inspection device measurement point. As a result, highly accurate power measurements can be made. The pins 202-A, 202-B can be rotated (that is, not rigid) so as to fall back (e.g., away from the lens 108 as shown in FIG. 4) to allow the semi-finished blank to be easily placed on top of and removed from resting on the measurement fixture 102. Further, the positioning of the pins 202- A, 202-B relative to the base of the measurement fixture 102 can be adjusted using pin positioning channels 204-A, 204-B, respectively. A locking pin or other mechanism can be used to hold the pins 202 in a particular position to accommodate measurements of lenses having a specified diameter. When a larger lens is to be measured (e.g., a semi-finished lens blank having a larger diameter L), the pins 202 can be moved in the channels 204 and set at a new position to accommodate precise measurements (such that the distance vision point of the larger lens is placed substantially directly underneath the visual inspection device measurement point). The top surface of the measurement fixture 102 can also include left and right orientation marks 206-A, 206-B. A technician may, for example, line up the orientation marks 202-A, 202-B with the left or right marks on a periphery of the lens 108 (such as discussed further herein) to make precise measurements for either right-eye or left-eye semi-finished lens blank. Marks on the lens 108 that can be used to match up to the orientation marks 206 may be made, for example, by mold when the lens 108 is fabricated, by automated laser techniques, and/or can be made by the technician using a marker. Marks made at the periphery of the semi-finished lens blank 108, unlike marks made closer to the center of the lens 108 using conventional measurement techniques, may not need to be removed by the technician after conducting the surface power measure since such marks may be removed during subsequent lens processing. By obviating the need to clean any orientation marks made by the technician, the measurement fixture 104 and techniques of the present invention reduce the likelihood of the lens 108 being damaged during or after a measurement is conducted.

According to further aspects of the invention, systems, methods and apparatus for laser marking ophthalmic lenses may also be provided. For example, a laser marking system including a vision system can be used to provide guide marks on an electro-active diffractive lens. The guide marks can be used to aid measuring, as well as the subsequent processing (e.g., edging and finishing), of the electro-active diffractive lens. The laser guide marks can be used as an alternative to conventional lens marking techniques such as ink stamping.

FIG. 7 shows an optical substrate 1100 that can be used to form, when combined with other components such as described in U.S. Pat. Appl. No. 12/408,973, filed March 23, 2009 (hereby incorporated by reference in its entirety), an electro-active diffractive lens. As shown in FIG. 7, the optical substrate 1100 may include a diffractive zone 1 102. A laser marking-vision system of the present invention can be used to locate the center 1 110 of the diffractive zone.

After locating the center of the diffractive zone, a laser mark or other feature can be made at any position on the substrate relative to the center of the diffractive zone (e.g., on the concave side of the substrate with the diffractive zone being on the convex side of the substrate). For example, the geometric center (GC) 1150 of the substrate can be marked based on adding a known horizontal offset 1120 (X direction) and vertical offset 1130 (Y direction) to the determined center 1110 of the diffractive zone 1102. Once the GC 1150 is determined and marked (e.g., by a point), a horizontal guide mark can be placed on the lens as also shown in FIG. 7. The horizontal guide mark and GC mark can be used to help subsequently measure and/or process the electro-active diffractive lens once assembled. During subsequent processing steps, the laser markings may be removed (e.g., as part of the material that is removed from the lens during processing into a final, finished lens).

In general, a laser marking-vision system of the present invention may be used, for example, to (1) find a reference point of significance on a substrate (e.g., the center of a diffractive pattern on the substrate) and to (2) make guide marks on the lens relative to the determined reference point.

Other marks, e.g., logos or trademarks, can be made on an ophthalmic lens using the lens marking-vision system of the present invention. Other types of lenses, e.g., conventional static lenses, can also be marked using the lens marking- vision system of the present invention. For example, a static lens comprising Trivex can be marked with guide marks using the lens marking-vision system of the present invention. Laser marking a Trivex lens may improve the quality of the lens since tinting of a Trivex lens using conventional ink marking can lead to marks that remain discernible after tinting.

According to further aspects of the invention, offset finishing of electro-active lenses may be used to reduce or eliminate the application of clamping pressure to the electro-active portion of the lens, thus reducing the occurrence of void defects. Offset finishing may use the optical blocking and edging modes of, for example, the National Optronics blocking and edging equipment to allow placement of the finish block outside the electro-active portion of the lens while allowing the optician to achieve the full range of allowable fitting heights and PDs.

Exemplary procedures for offset finishing may be fitting-height dependant. For example, the method may be different for fitting heights between 19.5 mm and 23 mm, than for fitting heights between 23.5 mm and 26.5 mm, as generally shown in FIG. 4.

Equipment that may be used include, National Optronics 4Ti tracer, 3B blocker, 7E HLP edger, marking template, Staedtler Lumocolor lens marking pen. It should be appreciated that, although the methods described below may be explained for clarity with reference to particular equipment and functions, the invention is not limited to such equipment and may find applicability in a wide variety of contexts.

In general, a template, such as shown in FIG. 8, including, for example, locations for fill ports, engravings, fit points, trace lines, diffractive center and/or offsets, may be used to place ink fiducial markings on the lenses for proper offset blocking. The template may allow the optician to accurately mark the location of the fit point, or a location 4 mm above the fit point, in relation to the other features of the lens. An exemplary process of using the template is depicted in FIG. 9, and will be described in detail below.

An exemplary process may begin with the following preparatory steps: Turn on 4Ti tracer.

Turn on 3B blocker, wait for the Job screen to appear, and then confirm blocker is set to block on optical center ("OC (3B Calc)" at screen center). If not, reconfigure the blocker for optical center blocking using the following steps: a. Press "Menu" softkey (F5) to access the 3B's main menu. b. Press "Setup" softkey (F4) to enter setup mode. c. Using the left and right arrow set "Default blocking" to "Opt. Ctr. (3B Calc)". d. Make sure "Prog. Blocking" is set to "Cross". e. Save changes and return to the Job screen by pressing the "Job" softkey (Fl). Turn on the 7E HLP edger. a. When prompted by the edger, chuck the calibration disk and run the probe calibration routine. b. Calibrate groove placement.

After the equipment has been prepared, a prescription may be reviewed as follows: Determine the fitting height for the patient's right eye. a. If the right-eye fitting height is between 19.5 mm and 23.0 mm, perform procedure

A. b. If the right-eye fitting height is between 23.5 mm and 26.5 mm, perform procedure

B.

Procedure A: Blocking for fitting heights between 19.5 mm and 23.0 mm.

Load job 667 into the blocker if not done so already.

Use the "Lens Type" softkey (F2) to change the lens type to "Progressive". Enter the appropriate frame DBL value. For example, one of two values may be entered: 18.0 mm (small black frame) or 20.0 mm (large silver frame).

Enter the patient's right eye, distance monocular PD value.

The input field designated as "Seg Ht" (segment height) shall be used to enter fitting height values as the two are equivalent. a. Enter a Seg Ht value of 19 mm. b. Do not enter any value for "OC Ht" (optical center height).

Using the lens marking pen, dot the center of the engravings 620, 630 and the center of the diffractive 610 on the right-eye lens as shown in FIG. 1 1. Place the marked lens on the marking template and align the pen marks and other visible features on the lens to their counterparts on the template as shown in FIG. 12. An important feature here to align between lens and template is the center of the diffractive 710 so as to avoid edging into the electro-active, secondary to that is to make sure the engravings are level. Mark the lens at location 720 (4 mm above the fit point 712) as shown in FIG. 11. Load a finish block into the blocker and press the green block key (lower right on key pad) to align the lens.

Align the mark 720 made at the location 4 mm above the fit point 712 with the cross hairs in the blocker alignment screen as shown in FIG. 12. Use the array of horizontal lines (1 mm vertical spacing) to make sure the pen marks on the engravings are level.

Press the green block key on the blocker a second time to block the lens. The blocker will automatically switch to the left eye, repeat steps in this section (Procedure A) if the fitting height for the left lens is between 19.5 mm and 23.0 mm, if greater than 23.0 mm, continue to Procedure B for the left lens.

Procedure B: Blocking for fitting heights between 23.5 mm and 26.5 mm.

Load job 667 into the blocker if not done so already. Use the "Lens Type" softkey (F2) to change the lens type to "Progressive".

Enter the appropriate frame DBL value. For example, one of two values may be entered: 18.0 mm (small black frame) or 20.0 mm (large silver frame). Enter the patient's right eye, distance monocular PD value.

At the blocker, the input field designated as "Seg Ht" (segment height) shall be used to enter fitting height values as the two are equivalent. a. Enter the desired fitting height value as the Seg Ht value. b. Do not enter any value for "OC Ht" (optical center height).

Using the lens marking pen, dot the center of the engravings and the center of the diffractive on the right-eye lens as shown in FIG. 10.

Place the marked lens on the marking template and align the pen marks and other visible features on the lens to their counterparts on the template as shown in FIG. 11. An important feature to align between lens and template is the center of the diffractive so as to avoid edging into the electro-active, secondary to that is to make sure the engravings are level.

Mark the lens at the fit point, e.g. at location 712 in FIG. 11.

Load a finish block into the blocker and press the green block key (lower right on key pad) to align the lens. Align the mark made at the fit point with the cross hairs in the blocker alignment screen. Use the array of horizontal lines (1 mm vertical spacing) to make sure the pen marks on the engravings are level, as was shown in Figure 12.

Based on the values shown in Table 1 below, and using the array of horizontal lines in the blocker alignment screen (1 mm vertical spacing), drop the lens by the required amount.

Table 1 Figure 13 shown a lens dropped by 3.0 mm to achieve a fitting height of 24.0 mm. Press the green block key on the blocker a second time to block the lens.

The blocker will automatically switch to the left eye, repeat steps in this section (Procedure B) if the fitting height for the left lens is between 23.5 mm and 26.5 mm, if less than 23.5 mm, return to Procedure A.

Procedure C: Edging for fitting heights between 19.5 mm and 23.0 mm.

Load job 667 into the edger if not already done so. a. Change "Frame" from "St Groove" to "W Groove". b. Change "Blocking" from "Geometric" to "Optical". c. For strong negative Rx's in 2.75 base, change "Bevel" from "Automatic" to "Base" with a value of "4.01".

Change the "Seg Height" value according to the chart below to achieve the desire fitting height in the edged lens as shown in Table 2.

_Ta le 1; Pitt ing height vs seg height 1

Table 2

Chuck the lens into the edger and press the green "Start" key to edge the lens.

For fitting heights of 22.5 and 23.0 mm, use the manual grooving machine in the surfacing lab to open up the region of the groove at the top of the lens that the edger bypassed.

Use the hand wheel in the surfacing lab to apply a safety bevel to the front and back edges of the lens. Unlike the blocker, the edger must be manually switched from right eye to left eye using the "Eye" softkey (Fl).

Procedure D: Edging for fitting heights between 23.5 mm and 26.5 mm. Load job 667 into the edger if not already done so. a. Change "Frame" from "St Groove" to "W Groove". b. Change "Blocking" from "Geometric" to "Optical". c. For strong negative Rx's in 2.75 base, change "Bevel" from "Automatic" to "Base" with a value of "4.01".

Change the "Seg Height" value to 27.0. Chuck the lens into the edger and press the green "Start" key to edge the lens.

Using the manual grooving machine in the surfacing lab, open up the region of the groove at the top of the lens that the edger bypassed.

As discussed herein, exemplary systems and methods may be particularly suited for use with lenses including electro-active elements. As discussed herein, electro-active lenses may include one or more electro-active layers, zones and/or regions. Electro-active lenses may be configured to correct for, for example, distance refractive error, intermediate distance refractive error, far distance refractive error, conventional refractive error, non-conventional refractive error, optical refractive error, and combinations thereof known to those of skill in the art. The electro-active lenses may be any lenses capable of adjusting, changing or tuning a provided optical power through the application of electricity. Electro-active lenses may be configured to provide a desired vision correction for a wearer or user (e.g., near, intermediate and/or far distance vision correction). By way of further example regarding various functions of electro-active lenses, in certain embodiments, a variable power electro-active field may be located over the entire lens and adjust as a constant spherical power change over the entire surface of the lens to accommodate one's working near vision focusing needs. In other embodiments a variable power field may be adjusted over the entire lens as a constant spherical power change while at the same time creating an aspherical peripheral power effect in order to reduce distortion and aberrations. In some of the embodiments mentioned above, the distance power may be corrected by way of either a single vision, multifocal finished lens blanks, or a multifocal progressive lens optic. An electro-active optical layer may be used to correct for working distance focusing, and/or other needs. It is also possible, in some cases, to utilize either a single vision, multifocal finished lens optic, or multifocal progressive lens optic for distance spherical power only and correct near vision working power and astigmatism through an electro-active layer or utilize either a single vision or multifocal lens optic to correct astigmatism only and correct the sphere power and near vision working power through an electro-active layer. Also, it is possible to utilize a piano, single vision, multifocal finished lens optic, or progressive multifocal lens optic and correct for distance sphere and astigmatism needs by way of an electro-active layer. It should also be noted that the power correction needed, whether prismatic, spherical or aspheric power as well as total distance power needs, mid range power needs and near point power needs, can be accomplished by way of any number of additive power components. These may include the utilization of a single vision, or finished multifocal lens, optic providing all the distance spherical power needs, some of the distance spherical power needs, all of the astigmatic power needs, some of the astigmatic power needs, all of the prismatic power needs, some of the prismatic power needs, or any combination of the above when combined with an electro-active layer, will provide for one's total focusing needs.

In addition to vision correction, an electro-active layer may also be configured to give a spectacle lens an electro-chromatic tint or shading. As used herein, electro-chromatic features may include and/or be provided by, for example only, electro-chromic, electronic tints, liquid crystal changeable tints, and/or dynamic tunable tints. For example, by applying a voltage to an appropriate gel polymer or liquid crystal layer, a tint or sunglass effect can be imparted to the lens, which may alter the light transmission through the lens. A reduced light intensity, or other chromatic change, may be used to give a "sunglass" or tint effect to the lens for the comfort of the user in bright, outdoor environment, or in other circumstances where a certain tint may be useful, e.g. low light conditions, or even aesthetically desirable. Liquid crystal compositions and gel polymers with high polarizability in response to an applied electric field are examples of suitable compositions for such applications.

The description given above is merely illustrative and is not meant to be an exhaustive list of all possible embodiments, applications or modifications of the invention. Thus, various

modifications and variations of the described methods and systems of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments.

Claims

WHAT IS CLAIMED IS:

1. A lens testing device comprising:

a light source;

a first polarizer;

a second polarizer; and

a camera,

wherein, the device is configured to hold a test lens between the first and second polarizers and to shine light from the light source through the first polarizer, through the test lens, and through the second polarizer, and to receive the light in the camera.

2. The device of claim 1, wherein the first and second polarizers are substantially parallel to one another.

3. The device of claim 1, wherein the first and second polarizers are substantially perpendicular to one another.

4. The device of claim 1, further comprising a controller configured to detect at least one of a cell gap dimension and a liquid crystal volume for a electro-active areas of the test lens.

5. The device of claim 1, further comprising a lens holder with at least two adjustable pins that are configured to locate the test lens under a visual inspection measurement point.

6. A lens measuring device comprising:

a lower arm;

an upper arm; and

a lens holder disposed on the lower arm,

wherein, the lens holder includes at least two adjustable pins that are configured to hold a lens under the upper arm, and to locate the lens under a visual inspection measurement point.

7. The device of claim 6, wherein the at least two pins are adjustable in tracks that are disposed in the lens holder and that run substantially in a plane of the lens being measured.

8. The device of claim 6, wherein the lens holder further comprises at least two markers on a top surface of the lens holder, the at least two markers disposed at different locations for orienting a left lens and a right lens.

9. The device of claim 6, wherein the lens holder has a lower surface that is shaped to conform to an upper surface of the lower arm.

10. A method of measuring a lens comprising:

providing a semi-finished lens blank with marks on a periphery of the lens blank;

placing the lens blank on a lens holder having at least two adjustable pins and at least two alignment markers;

adjusting the lens blank to touch the at least two pins and to align with at least one of the alignment markers; and

measuring a front curvature of the lens blank.

11. The method of claim 10, further comprising:

adjusting the at least two pins to accommodate a second lens blank having a different size;

placing the second lens blank on the lens holder;

adjusting the second lens blank to touch the at least two pins and to align with at least one of the alignment markers; and

measuring a front curvature of the second lens blank.

12. A method of processing an electro-active lens substrate comprising:

locating a center of an-electro-active diffractive zone;

marking the lens substrate with a relative mark at a location measured from the located center of the diffractive zone;

processing the lens substrate based on the relative mark; and

removing the relative mark from a lens formed from the substrate.

13. The method of claim 12, wherein the relative mark is a geometric center of the lens substrate, and is measured based on a known X and Y offset from the center of the diffractive zone.

14. The method of claim 13, wherein the relative mark is horizontal guide mark that passes through the geometric center of the lens substrate.

15. The method of claim 12, wherein the diffractive zone is on a convex side of the substrate and the relative mark is placed on a concave side of the substrate.

16. A method of processing a lens for a user comprising:

determining a fitting height for the user;

if the fitting height is in a first range, performing a first blocking procedure including marking the lens blank at a point approximately 4mm above a fitting point of the lens, and

if the fitting height is in a second range, performing a second blocking procedure including marking the lens blank approximately the fitting point of the lens.

17. The method of claim 16, wherein if the fitting height is in the second range, an offset is calculated for dropping the lens while blocking.

18. The method of claim 16, wherein the lens includes an electro-active element, the method further comprising:

marking an approximate center of the electro-active area and aligning the approximate center of the electro-active area of the lens with a template including corresponding marks.