WO2019209234A1 - Procédé de fabrication d'un élément optique et dispositif de sa mise en oeuvre - Google Patents

Procédé de fabrication d'un élément optique et dispositif de sa mise en oeuvre Download PDF

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Publication number
WO2019209234A1
WO2019209234A1 PCT/UA2018/000038 UA2018000038W WO2019209234A1 WO 2019209234 A1 WO2019209234 A1 WO 2019209234A1 UA 2018000038 W UA2018000038 W UA 2018000038W WO 2019209234 A1 WO2019209234 A1 WO 2019209234A1
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WO
WIPO (PCT)
Prior art keywords
optical element
polymer composition
manufacturing
optical
curing
Prior art date
Application number
PCT/UA2018/000038
Other languages
English (en)
Russian (ru)
Inventor
Олег Юрьевич ХАЛИП
Original Assignee
Khalip Oleg Yurevich
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Khalip Oleg Yurevich filed Critical Khalip Oleg Yurevich
Priority to PCT/UA2018/000038 priority Critical patent/WO2019209234A1/fr
Publication of WO2019209234A1 publication Critical patent/WO2019209234A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/14—Eye parts, e.g. lenses, corneal implants; Implanting instruments specially adapted therefor; Artificial eyes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/02—Lenses; Lens systems ; Methods of designing lenses
    • G02C7/04—Contact lenses for the eyes

Definitions

  • the invention relates to the field of optics, to the creation of general-use lenses, ophthalmic lenses, implantable ocular lenses and other optical elements, in particular, to methods for improving the quality and smoothness of the lens surfaces of glasses and other optical elements obtained with their use.
  • a known method of manufacturing an optical element, in particular an ophthalmic lens (see c. USA N ° 20160101573, priority WO2014FR51362 dated 06.06.2014, publ. 14. 04. 2016, IPC B29D 67/00, G02C 7/02 ), including:
  • the deposition process is adjusted by adding height in the construction zone by introducing at least one additional volumetric element without changing the parameters of the given geometric envelope,
  • the known method has the following disadvantages.
  • the measurement of the shape parameters of the lens area is carried out after applying the material to the specified area, therefore, if the parameters of the specified area are rejected, shape correction is possible only by adding material and / or calculating a new envelope and then applying additional material not only for the given area, but also for a large part of the surface. This increases the total manufacturing time and can lead to marriage, for example, due to exceeding the permissible mass or geometric dimensions of the manufactured lens.
  • the formation of the lens is carried out by applying a curable material in the form of individual elements.
  • a curable material in the form of individual elements.
  • This application process is usually long, the contact of each of these volumetric elements with the air of the surrounding space entails an increased risk of manufacturing defective products in the case of, for example, dust entering the product, changing the rheology of the material depending on temperature and imposing severe restrictions on production conditions , for example, the need to create a special atmosphere.
  • the known method provides the formation of only one side of the lens.
  • the shape of the other side must be defined either by the base, which subsequently must be separated, or by a prefabricated blank that becomes part of the manufactured lens. This leads to the need to perform additional operations and the need to manufacture additional components.
  • the optical elements are not of high enough quality, and the technological time required for their production is long.
  • the closest in technical essence and the achieved result to the claimed method is a method of manufacturing an optical element (see U.S. N ° 20170100903 of 09.10.15, publ. 13.04.17, IPC B29D 11/00, publ. Also WO2017062857 ), including the formation of the surface of this element of optical quality by placing a curable polymer composition in contact with the surface of at least one membrane of a flexible and / or elastic material, curing this composition by polymerization.
  • a lens which is pre-manufactured by three-dimensional printing and contains a surface that is not completely smooth, form a surface of optical quality.
  • a curable polymer composition is placed on the surface of the preform and distributed on the surface of the preform, pressing an elastic membrane against the indicated surface, then the polymerization of the curable polymer composition is initiated, and after completion of the polymerization and removal of the membrane, a smooth lens surface is obtained.
  • a vacuum is created to press the membrane to the surface of the optical element - the lens, as a result of which the curable polymer composition covers and smooths the surface of the lens.
  • the membrane is held evenly, stretched in the body.
  • the housing supports a membrane similar to a drum casing.
  • the lens preform prefabricated by three-dimensional printing, is held on a support platform that is connected to the support structure.
  • the concave surface of the lens is positioned so that it faces the membrane.
  • the housing has an adjustable volume, for which there is an output port, channel or other hole through which air can be removed from the housing to create a vacuum.
  • a pump or other vacuum device is connected to an opening in the housing.
  • a valve or other blocking or closing device is used to open and close the hole.
  • the optical elements are not of high enough quality, and the technological time required for their production is long due to the need for several operations performed in different devices.
  • the known method in order to obtain an optical quality surface, it is necessary to prefabricate an optical element preform by three-dimensional printing, then apply a curable polymer composition to the preform, distribute it over the surface of the preform using a membrane and cure, for example, by actinic radiation.
  • the refraction coefficients of the workpiece and the leveling layer may differ (including in different areas), which will lead to a deterioration in the optical characteristics of the finished product optical element.
  • the measurement of optical characteristics is possible only after the completion of the formation of the optical element, the correction of future optical characteristics of the product during the manufacturing process is impossible, since the shape of the optical element is determined by the shape of the workpiece, which also increases the likelihood of obtaining defective products.
  • a device for manufacturing an optical element is known (see c.US. N ° 20160101573, priority WO2014FR51362 dated 06/06/14, published on 04/14/16, IPC B29D 67/00, G02C 7/02), in particular an ophthalmic lens containing a node for forming the manufactured ophthalmic lens — a base holder, a curable polymer composition source, a curing source for the curable polymer composition, a control unit.
  • the curable polymer composition source comprises a nozzle or nozzle block for supplying the material from which the lens is made, controlled by the control unit.
  • the control unit is equipped with system elements configured to run a computer program containing commands configured to implement each of the stages of the manufacturing process.
  • the device also contains a unit for measuring the average curvature at least at a given point of at least one zone of the manufactured ophthalmic lens, which is equipped with a measuring pupil.
  • the measuring unit may, for example, function in accordance with the known principle of deflectometry.
  • the geometric characteristics of the production holder - the foundation is contained in a file that is stored or loaded into the control unit of a known device.
  • the hardware of the known device is configured to execute commands for applying the material, monitoring the curvature of the manufactured lens, and for polymerization devices of the applied material, which the specified device contains.
  • the device has the following disadvantages. Obtained on the known device, the optical elements are not of high enough quality, and the speed of their production is low, since the technological time required for the production of optical elements is long.
  • the measurement of the shape parameters of the lens area is carried out after applying the material to a given area. Therefore, if the parameters of a given section are deviated, shape correction is possible only by adding new batches of material and / or calculating a new envelope. Additional material is applied not only to a given area, but also to a significant part of the surface. This increases the total manufacturing time and can lead to marriage, for example, due to exceeding the permissible mass or geometric dimensions of the manufactured lens.
  • the formation of the lens is carried out by applying a curable material in the form of microdrops using nozzles, which, as a rule, is a long sequential process.
  • the contact of each microdroplet with air increases the likelihood of manufacturing defective products in the case of, for example, dust entering the product, changing the rheology of the material depending on temperature and imposing severe restrictions on production conditions.
  • the shape of the other side must be defined either by the base, which subsequently needs to be separated, or by a prefabricated blank that becomes part of the manufactured lens. This leads to the need to perform additional operations and the need to manufacture additional components.
  • a device for the manufacture of an optical element comprising a housing with an adjustable volume for accommodating liquid and / or gas in the form of at least one hollow cylinder, one of the bases of which is made in the form a flexible and / or elastic membrane, a container with an adjustable volume for accommodating a curable polymer composition in contact with the membrane, a curing source for the curable polymer composition, a control unit.
  • the known device comprises a housing in the form of a hollow cylinder, on the base of which a membrane is stretched, a support platform for locating the lens blank, a curing source for the curable polymer composition, a container with an adjustable volume for accommodating the curable polymer composition in contact with the membrane, which contains a channel for removing air - creating a vacuum, a vacuum pump or other device for removing air, a valve or other closing device, a cylinder with a piston.
  • the device may include a support structure for accommodating the lens blank, made with the possibility of vertical movement.
  • the cross section of the housing may be square, rectangular, round, oval or triangular in shape.
  • the housing may be made of metal or other material.
  • the curing source for the curable polymer composition is UV lamps that can be placed above and / or next to the membrane stretched across the cylinder.
  • the device has the following disadvantages. Obtained on a known device, the optical elements are not of high enough quality, and the speed of their production is low, since the technological time required for the production of optical elements is long due to the need for several operations separated by a technological cycle.
  • a prefabricated method is placed three-dimensional printing blank optical element.
  • a curable polymer composition is then applied to the preform and distributed onto the surface of the preform using a membrane. Then carry out curing, for example, by the action of actinic radiation.
  • the refraction coefficients of the preform and the alignment layer may differ (including in different areas), which will result low quality optical characteristics of the finished optical element. Correction of the optical characteristics of the product during the manufacturing process is impossible, since the shape of the optical element is determined by the shape of the workpiece, which also increases the likelihood of obtaining defective products.
  • the basis of the invention is the task of improving the method of manufacturing an optical element, in which new operations, their sequence and new operations allow to improve the quality of the optical element and the speed of its receipt due to the simultaneous formation of the optical element and its surface of optical quality, as well as by improving the accuracy of regulation modes by continuously monitoring the parameters of the formed optical element and providing the ability to control the curvature of rhnosti liquid lens, such that formed by the optical unit, during the formation of the optical element due to the introduction of feedback. This eliminates the likelihood of receiving defective products, reduces the cost of manufacturing an optical element.
  • the invention is also based on the task of improving the device for manufacturing an optical element, in which new elements, a new embodiment of the device elements and new connections between the elements of the device can improve the quality of the optical element and its production speed by enabling the simultaneous formation of the optical element and its optical quality surface continuous monitoring of the parameters of the formed optical element, as well as improving the accuracy of regulation by Providing the ability to control the curvature of the surface of a liquid lens, similar to the formed optical element, in the process of forming the optical element due to the introduction of feedback. This eliminates the likelihood of receiving defective products, reduces the cost of manufacturing an optical element.
  • the problem is solved in that in the known method of manufacturing an optical element, comprising forming the surface of this optical quality element by placing a curable polymer composition in contact with the surface of at least one membrane of a flexible and / or elastic material, curing this composition by polymerization, new, in accordance with the claimed technical solution, is that from the curable polymer composition form a liquid lens similar to an optical element, and measure its optical characteristics and, upon reaching the specified characteristics, cure the optical element or its fragments; in this case, a physically closed volume filled with liquid and / or gas is limited to the membrane, and optical quality surfaces are formed by changing the curvature of the surface of the membrane in contact with the cured polymer composition by controlling the amount of liquid and / or gas in a physically enclosed volume, wherein the formation of a liquid lens similar to an optical element and the formation of the surface of this optical quality element are performed simultaneously.
  • New in accordance with the technical solution, is also the fact that the curing of the polymer composition is produced by actinic radiation.
  • New is also the fact that at the same time produce the formation of two surfaces of the optical element.
  • the membrane in contact with the curable polymer composition adheres to the surface of the optical element upon curing.
  • the problem is solved in that in a known device for manufacturing an optical element containing a housing with an adjustable volume for accommodating liquid and / or gas in the form of at least one hollow cylinder, one of the bases of which is made in the form of a flexible and / or elastic membrane , a container with an adjustable volume for accommodating a curable polymer composition in contact with the membrane, a curing source for the curable polymer composition, a control unit, new, in accordance with the claimed
  • the device further comprises a unit for measuring the optical characteristics of the formed liquid lens similar to an optical element, the output of which is connected to the input of the control unit, the first output of which is connected to the input of the unit for measuring the optical characteristics of the formed liquid lens similar to an optical element, the second output the control unit is connected to the control unit for the amount of supplied liquid and / or gas, which is connected to the housing, and the third output of the control unit with one with the source of curing effect on the curable resin composition.
  • New in accordance with the technical solution, is the fact that at least one membrane is made in the form of a wavefront converter of actinic radiation.
  • New is also the fact that the housing for the placement of fluid and / or gas is additionally provided with a transparent window.
  • the housing for accommodating liquid and / or gas contains at least one flexible and / or elastic element that is permeable to actinic radiation and intended for contact with the curable polymer composition.
  • the container for the curable polymer composition is made of a flexible and / or elastic material.
  • the curing source for the curable polymer composition is made in the form of an actinic radiation source.
  • the curing source for the curable polymer composition is made in the form of an actinic radiation source with a function of spatial modulation of actinic radiation.
  • the curing source for the curable polymer composition is made in the form of a heating device.
  • the source of the curing effect on the curable polymer composition is made in the form of a source of ionizing radiation.
  • the source of the curing effect on the curable polymer composition is made in the form of a source of electromagnetic waves in the microwave range.
  • the unit for measuring the optical characteristics of a formed liquid lens similar to an optical element, contains optically coupled source of actinic and / or non-actinic radiation, a screen for projections of this radiation and J
  • At least one membrane is made in the form of a wavefront converter of actinic radiation.
  • a causal relationship between the set of essential features of the proposed method and the achieved technical result is that:
  • the optical element or its fragments are cured
  • a physically enclosed volume filled with liquid and / or gas is limited by a membrane
  • - and surfaces of optical quality are formed by changing the curvature of the surface of the membrane in contact with the curable polymer composition by controlling the amount of liquid and / or gas in a physically enclosed volume
  • the manufacture of an optical element is carried out in a single technological process, which ensures the constancy of the refractive index for various sections of the product, significantly improves the quality of the formed optical element and reduces the technological time required for production.
  • the claimed method provides the ability to measure optical characteristics for individual sections of the product in the manufacturing process - before curing the polymer composition in the areas. This provides the possibility of correction to accurately obtain the specified parameters of the formed optical element.
  • the curing of the polymer composition in different versions can be performed by actinic radiation, heating, ionizing radiation, microwave radiation, an arbitrary combination of all of the above.
  • the entire optical element can be cured either simultaneously, or various portions of the formed optical element can be cured in turn.
  • the optical characteristics of the obtained liquid lens similar to an optical element are measured using non-actinic radiation.
  • At least one correction of the curvature of the surface of the membrane is performed.
  • the intensity and / or duration of exposure of the curing agent to the polymer composition is controlled.
  • the membrane in contact with the cured polymer composition either separated from the manufactured optical element, or the membrane in contact with the curable polymer composition, when cured, adheres to the surface of the optical element.
  • the device further comprises a unit for measuring the optical characteristics of the formed liquid lens, similar to an optical element, the output of which is connected to the input of the control unit,
  • the first output of the control unit is connected to the input of the unit for measuring the optical characteristics of the formed liquid lens, similar to an optical element
  • the second output of the control unit is connected to the node for regulating the amount of liquid and / or gas supplied, which is connected to the housing,
  • control unit is connected to the source curing effects on the curable polymer composition
  • An additionally introduced unit for measuring the optical characteristics of the formed liquid lens similar to an optical element, the output of which is connected to the input of the control unit, allows you to continuously monitor the optical characteristics of the formed liquid lens, compare them with the specified required values and, if they diverge, adjust by changing the curvature of the membrane directly in the process of forming an optical element, adjust the curing modes and other variable parameters of the device.
  • the first output of the control unit is connected to the input of the unit for measuring the optical characteristics of the formed liquid lens, similar to an optical element
  • the second output of the control unit is connected to the unit for controlling the amount of liquid and / or gas supplied, which is connected to the housing
  • the third output of the control unit is connected to a curing agent for the curable polymer composition
  • FIG. 1 shows a diagram of a device for manufacturing an optical element
  • FIG. 2 shows a container for accommodating a curable polymer composition, made with a window of solid material
  • FIG. 3 shows a container for accommodating a curable polymer composition, made with a window in the form of a membrane;
  • FIG. 4 shows a container for accommodating a curable polymer composition made of an elastic material
  • FIG. 5 shows a diagram of a two-sided exposure of a formed optical element and an example of using a rigid insert
  • FIG. 6 shows the use of a direct projection screen
  • FIG. 7 shows a change in the position of the membrane in the process of correcting the curvature of a liquid lens, similar to the formed optical element
  • FIG. 8 shows an algorithm for manufacturing an optical element.
  • a device for manufacturing an optical element contains case 1 with an adjustable volume for accommodating liquid and / or gas, for example, in the form of at least one hollow cylinder, one of the bases of which is made in the form of a flexible and / or elastic membrane 2, a container 3 for accommodating a curable polymer composition in contact with a membrane 2, a curing source 4 for the curable polymer composition, control unit 5.
  • the device also includes a unit 6 for measuring the optical characteristics of the formed liquid lens 7, similar to an optical element.
  • the information output of the optical characteristics measuring unit 6 is connected to the information input of the control unit 5, the first control output of which is connected to the control input of the optical characteristics measuring unit 6 of the formed liquid lens 7, similar to an optical element, the second control output of the control unit 5 is connected to the supply quantity control unit 8 liquid and / or gas, which is connected to the housing 1 by a pipeline for the supplied liquid and / or gas, and the third control output of the control unit 5 is connected with the control input of the curing source 4 to the curable polymer composition.
  • At least one membrane 2 can be made in the form of a wavefront converter of actinic radiation.
  • the actinic radiation wavefront converter can be made in accordance with one of the options described in the description of WO2018 / 044249, for example, in the form of an array of microlenses formed on an embossed membrane 2 (not shown in the figures).
  • the housing 1 for accommodating liquid and / or gas may additionally be provided with a transparent window 9, made, for example, of silicate glass, quartz glass or a polymer material with suitable optical and mechanical characteristics.
  • the housing 1 for accommodating liquid and / or gas may be made of any suitable material, for example, metal, such as an aluminum-based alloy or stainless steel.
  • the housing 1 for accommodating liquid and / or gas can be made of composite materials based on polymer binders, or of durable thermoplastic plastics.
  • the housing 1 for accommodating liquid and / or gas may contain at least one flexible and / or elastic element - a membrane 2.
  • the membrane 2, which is permeable to actinic radiation and intended for contact with the curable polymer composition, can be made, for example, of silicone rubber, fluoropolymer, polyurethane, latex, polypropylene, polyethylene. Preferred for the manufacture of membrane 2 are optically transparent materials having suitable elongation ratios without permanent deformation within the working elongation.
  • the membrane 2 may have a thickness of 10 microns to 250 microns or 250 microns to 2 mm or more.
  • the specified membrane 2 can be multilayer, and the various layers can be made of various materials and can make up a permanent or temporary composition.
  • the material of which the layer of said membrane 2 is made, which has contact with the actinic radiation curable polymer composition, must be selected based on whether the membrane 2 will be removed after the formation of the optical element is completed. For example, materials having low surface energy, such as fluoropolymers, can be easily separated from the formed optical element, and films based on acrylic polymers or polyurethane will be firmly adhered.
  • the different layers of the membrane 2 can represent a single element, or separate layers membranes 2 can be easily connected and easily separated. This embodiment is especially convenient when using a container 3 made of elastic material (see Fig. 4).
  • the housing 1 for accommodating liquid and / or gas may include a drive 10 for moving the housing 1 and / or its elements.
  • a screw drive can be used as a drive 10 for moving the housing 1 gearbox connected to an electric motor.
  • the drive 10 of the movement of the housing 1 can carry out both longitudinal and transverse movement. This, for example, can be useful in the manufacture of an optical element in the form of a prism.
  • the container 3 for the curable polymer composition may be in the form of a bath having a solid bottom and / or bottom of an optically transparent material (see Fig. 2), and the bottom may have a flat, convex or concave shape (not shown in Fig. )
  • the container 3 for the curable polymer composition may be made in the form of a bath having a bottom in the form of a membrane 2 of elastic material intended for contact with the curable polymer composition (see Fig. 3).
  • the shape of the bottom, made in the form of a membrane 2 of an elastic material intended for contact with the curable polymer composition can be defined by a replaceable rigid insert 11 an arbitrary shape of a transparent material, which deforms the specified membrane 2 of an elastic material (see Fig. 5).
  • the container 3 for the curable polymer composition may be made of flexible and / or elastic material, for example, said container 3 may be a sealed bag of flexible and / or elastic material containing fasteners, spacer 12, fasteners for built-in elements (in the figures not shown), at least one nozzle 13 for filling with a curable polymer composition (see Fig. 4).
  • a container 3 can be installed and fixed between the parts of the housing 1, the fixation can be carried out, for example, by compressing the elements of the housing 1 with the help of the drive 10 or by vacuum.
  • the unit 8 for controlling the amount of liquid and / or gas supplied can be, for example, in the form of a hydraulic cylinder or a pneumatic cylinder, equipped with, for example, a mechanical piston displacement drive in the form, for example, of an electric stepper motor with a helical gearbox, equipped with control and monitoring means.
  • the node 8 for controlling the amount of liquid and / or gas supplied can be made in the form of a metering pump or in the form of a source of compressed gas equipped with controlled valves and controls.
  • the curing source 4 for the curable polymer composition can be made in the form of an actinic radiation source, for example, in the form of an ultraviolet radiation source.
  • Any actinic radiation source for example, an incandescent lamp, a mercury lamp, a fluorescent lamp, a laser, an LED, and other devices, including a combination of these devices, can also be used.
  • Curing Source 4 for Curable the polymer composition can be made in the form of an actinic radiation source with a function of spatial modulation of actinic radiation, for example, in the form of a DLP projector or in the form of a laser scanning device, or in the form of a device containing combinations thereof.
  • the curing source 4 for the curable polymer composition can be made in the form of a heating device, for example, in the form of a resistance heater or a Peltier element, or in the form of a heat exchanger with circulation of a liquid or gaseous heat carrier.
  • the curing source 4 for the curable polymer composition can be made in the form of an ionizing radiation source, for example, as a radioisotope source or an X-ray tube, and as a means of spatial modulation, contain, for example, a stencil and / or iris with a drive (not shown).
  • an ionizing radiation source for example, as a radioisotope source or an X-ray tube
  • spatial modulation contain, for example, a stencil and / or iris with a drive (not shown).
  • the curing source 4 for the curable polymer composition can be made in the form of a source of electromagnetic waves in the microwave range, and for supplying energy to the formed optical element may contain a waveguide and / or volume resonator (not shown in the figures).
  • the curing source 4 for the curable polymer composition can be made in the form of a device containing a combination of all of the above.
  • the device can be made in such a way that it is possible to expose a liquid lens 7, similar to the formed optical element, by curing on one side (see Fig. 1), or on both sides (see Fig. 5).
  • Block 6 measuring the optical characteristics of the formed a liquid lens 7, similar to an optical element, can be made in the form of optically coupled actinic and / or non-actinic radiation source 14, a screen 15 for projecting said radiation and a recording device 16.
  • a screen 15 for projecting said radiation and a recording device 16.
  • screen movement 15 for . projections associated with the recording device 16, relative to the formed optical element using the drive 17.
  • the drive 17 for example, can be used an engine with a helical gearbox (see Fig. 1).
  • a source 14 of non-actinic radiation of the optical characteristics measuring unit 6 for example, an incandescent lamp, a gas discharge lamp, an LED or devices combining them equipped with means for normalizing the light flux, such as a reflector, a diaphragm, diffusing, collecting and collimating lenses ( in Fig. not shown).
  • Spatially modulated radiation sources can also be used, for example, a non-actinic laser source equipped with a scanning system; or DLP projector.
  • an actinic radiation source is used as the curing source 4
  • spatial modulation devices combining actinic radiation sources intended for curing the polymer composition and non-actinic radiation intended to control the optical characteristics of a liquid lens similar to the formed optical element.
  • This can be, for example, a combination of two or more laser sources, one of which is a non-actinic radiation source combined with a common scanning system (not shown in the figures), or a DLP projector, equipped with sources of actinic and non-actinic radiation.
  • a common scanning system not shown in the figures
  • a DLP projector equipped with sources of actinic and non-actinic radiation.
  • a direct projection screen see Fig. 6
  • a rear projection screen see Fig. 1
  • the screen 15 of the direct projection can be used with any reflective material with a frosted surface. Usually these are polymer films and paint coatings.
  • any optically transparent surface with a scattering coating can be used, for example, glass frosted by etching or grinding, polymer films with scattering fillers, arrays of microlenses, arrays of diffraction elements, etc.
  • a recording device 16 for observing a projection of non-actinic radiation intended to measure optical characteristics on a screen for projections of said non-actinic radiation may be, for example, a photocell array or, preferably, a video camera mounted to observe the entire surface of the screen 15.
  • an optical filter 18 with spectral selectivity.
  • Such an optical filter 18 can either be combined with a screen 15 (see Fig. 1) for observing projections, or it can be mounted on the lens of a recording device 16 (see Fig. 6).
  • Block 6 measuring the optical characteristics can be built using the means and principles of interferometry or deflectometry (not shown in the figures), while recording can be subjected to both transmitted and reflected from the surface of the formed optical element electromagnetic radiation.
  • the composition of the unit 6 for measuring optical characteristics may include an analyzing device (not shown in the figures), which is, for example, a specialized computing device equipped with software and implementing the function of technical vision. In this case, data from this device is transmitted to the information input of the control unit 5.
  • an analyzing device not shown in the figures
  • data from this device is transmitted to the information input of the control unit 5.
  • the control unit 5 may be performed, for example, as a specialized computing device or may be a general-purpose computer equipped with special software.
  • the control unit 5 can also perform the functions of an analyzer of the vision system, in this case, the signal from the recording device 16 is transmitted to the information input of the control unit 5. In the case of using a video camera, this can be an analog video signal or digital data. Such devices are well known to those skilled in the art.
  • the inventive method is implemented as follows.
  • FIG. 8 shows an algorithm for manufacturing an optical element.
  • Membrane 2 is limited by a physically enclosed volume — a housing 1 for accommodating liquid and / or gas, and optical quality surfaces are formed by changing the curvature of the surface of the membrane 2 in contact with the curable polymer composition. To do this, regulate the amount of liquid and / or gas in physically enclosed volume - housing 1 for placement of liquid and / or gas.
  • the surface of the elastic membrane 2 changes curvature depending on the amount of liquid or gas that are in the physically enclosed volume of the housing 1.
  • the surface may take a convex shape, a concave shape, or be flat.
  • the surface takes the form of a paraboloid, part of which, located near the central axis, has a shape close to spherical.
  • the curable polymer composition under the influence of atmospheric pressure takes the form limited by said membrane 2.
  • the surface of the elastic membrane 2 should be so smooth as to provide an optical quality surface on the formed optical element, both after separation from the surface of the formed optical element and in the event that the film of the membrane 2 adheres to its surface during the manufacturing of the optical element. Thus, simultaneously with shaping the optical element, its surface of optical quality is formed.
  • a liquid lens 7, similar to an optical element, is formed from the curable polymer composition After a liquid lens 7, similar to an optical element, is formed from the curable polymer composition, its optical characteristics are measured and, when the desired characteristics necessary to obtain the manufactured optical element are achieved, the optical element or its fragments are cured.
  • the curing of the polymer composition is carried out by actinic radiation or heating, or ionizing radiation, or microwave radiation, or any combination of the above. In this case, the entire optical element is cured at the same time, or various parts of the formed optical element are cured alternately. Curing is carried out, for example, by exposing predetermined portions of a liquid lens 7, similar to an optical element, to actinic radiation using an actinic radiation source, by exposing the entire liquid lens 7 simultaneously or sequentially, section by section, using an actinic radiation source with spatial modulation.
  • a source may be, for example, a DLP projector or a laser scanning device.
  • the formed product after curing with actinic radiation, can be heated to conduct additional thermally initiated polymerization of the curable polymer composition.
  • the curing of the curable polymer composition is carried out by heating using curable liquids with a thermally initiated polymerization.
  • Curing of the curable polymer composition can also be carried out using ionizing radiation.
  • the optical characteristics of the obtained liquid lens 7, similar to an optical element, are measured using non-actinic radiation.
  • the collimated flux is directed safelight irradiation through the liquid lens-like optical element, the display 15 for observing and measuring the intensity of the projection light flux at predetermined points of the projections, collecting 'the data using the recording device 16 - camcorder. Then analyze and compare the result with the reference data that is stored in the memory of the control unit 5.
  • a laser beam is directed through a scanning system through predetermined points of a liquid lens 7 similar to optical element, on the screen 15, collecting data on the deflection of the beam using a recording device 16, for example, a video camera.
  • the screen 15 for observing projections and the recording device 16 can be, to facilitate observations, be moved a greater distance using the drive 17 to move the screen 15.
  • At least one correction of the curvature of the surface of the membrane 2 is carried out.
  • the optical properties of the lens are corrected by changing the amount of liquid or gas supplied to the physically enclosed volume of the housing 1.
  • the process of measurement and analysis continues.
  • the necessary optical parameters produce curing of this area, for example, using an actinic radiation source with spatial modulation.
  • the described correction and alternating curing algorithm is especially useful in cases where the manufacture of lenses having an aspherical surface and / or a surface that is not symmetrical about the central axis is required.
  • the approximation parameters when changing the surface curvature of the formed optical element from section to section are determined by the thickness of the membrane 2 and its adhesion to the already formed part of the optical element (see Fig. 7).
  • the procedure for further correction of the shape of the specified liquid lens is not carried out and exposure is performed by the curing effect of the specified liquid lens completely in the given geometry and in accordance with the selected mode curing.
  • the uncured polymer composition is removed from the container 3.
  • the finished optical element and the region around the optical element are cured, for example, by irradiating the indicated region with actinic radiation. In this way, contamination of the finished optical element with the uncured polymer composition can be avoided.
  • the intensity and / or duration of exposure of the curing agent to the polymer composition is controlled.
  • the curing parameters are determined by the requirements for a particular process, based on the properties of the cured polymer composition used.
  • optical element for example, when the housing 1 is made in the form of two symmetrical parts, each of which is equipped with a membrane 2.
  • the curvature of each of the surfaces of the liquid lens 7, similar to the formed optical element, is set separately (see Fig. 1, 2, 3, 4, 5).
  • the curing exposure of the liquid lens 7, similar to the formed optical element, can be carried out on one side (see Fig. 1), or on both sides (see Fig. 5).
  • At least one membrane 2 can be made in the form of a wavefront converter of actinic radiation. This, for example, can facilitate the easier separation of the membrane 2 from the surface of the formed optical element at intermediate stages of its manufacture (not shown in the figures).
  • the curable polymer composition may not contain actinic radiation absorbers, in which case the article is completely exposed to the actinic radiation through the entire thickness.
  • the curable polymer composition may contain an actinic radiation absorber, and when exposed on one side, a liquid lens 7, similar to the formed optical element, in this case only cures to a predetermined depth of penetration of actinic radiation.
  • complete polymerization can be subsequently carried out, for example, by another source of actinic radiation from a different wavelength for which the absorber does not work, or the same, but with a longer duration and / or specific exposure power.
  • the final polymerization will be carried out for the entire remaining thickness of the product.
  • the optical element is formed from the center to the edges, exposing the sections sequentially. It also provides compensation for the shrinkage of the curable polymer composition due to the influx of the polymer composition from areas where the curable polymer composition remains liquid.
  • a similar exposure method for compensating for shrinkage during curing in a transparent form is described in patent DE000003882957T2 ..
  • the membrane 2 forming the surface of the optical element can remain part of the products, adhering to them. Moreover, remaining subsequently a part of the product, it can perform protective functions, color filter functions, enlightenment functions, be part of the optical system, contain images, holograms, represent a diffractive optical element, etc.
  • the membrane 2 forming the surface of the optical element can be removed after completion of the construction process and at the same time serve as a means of transfer of protective and other functional coatings, means of transfer of microrelief, for example, to form a diffractive optical element, or serve as a means of image transfer.
  • the temperature of the hydraulic fluid or gas can be adjusted to maintain the necessary parameters, for example, to remove the heat of polymerization, to provide the desired properties of the membrane adhered to the product, to thermoset the cured polymer composition, to provide a given viscosity of the cured polymer composition.
  • built-in elements This may, for example, be required to be placed inside a diffractive optical element for use in, for example, virtual reality systems or for installing fixing fixtures in the manufacture of an eye lens implant (artificial lens).
  • the built-in element may also be a film separating the transversely arranged layers of the formed optical element, while the film material must provide adhesion to the curable polymer composition.
  • the film material must provide adhesion to the curable polymer composition.
  • a hologram can be recorded in the formed article.
  • a cured polymer the composition may be replaced by another curable polymer composition having, for example, a different refractive index or color, or other properties.
  • This will allow the formation of an optical element having different refractive indices in different areas, or, for example, a painted frame or shell, or areas with different mechanical properties.
  • Various combinations of the described operations are possible.
  • a useful function of the claimed device is the ability to register the parameters of the wavefront conversion from the optical element under study, save the received data in the device memory and use these data as a task in the manufacture of the optical element that reproduces the optical function of the investigated optical element.
  • the software used in the device provides the preparation of 3 D-models of the manufactured optical element, the selection of the modes of the manufacturing process of the manufacturing of the optical element, diagnostics and preparation of the device’s hardware, control of the formation of the optical element, its automatic correction, and technical control of the manufactured optical element.
  • the device software consists of the following systems: operator workstation, machine vision, automatic control.
  • the system of the operator’s workstation can use the ST-model of the optical element with the refractive index of the material as a task for the manufacture of the optical element; in the case of the manufacture of ophthalmic lenses - the prescription of the ophthalmologist or the specified conversion parameters of the optical element of the wavefront.
  • the Slic3r open source Slicer model and open source libraries for working with 3D-graphics OrePTK and OpenGL were used.
  • the machine vision system uses the OpenCV (Open Source Computer Vision Library) open-source computer vision library.
  • the operator’s workstation system and machine vision system are written in Microsoft Visual Studio software development environment using high-level programming languages C # and C ++.
  • the automatic control system was a distributed control system for the technical means of the device; automatic control system software - the control code is written using the PCTGOE.
  • the software implemented in the control unit 5 After the formation of the task in the parameters of the conversion by the optical element of the wavefront and the procedures associated with the preparation of the device, the software implemented in the control unit 5 generates commands and / or projections for non-actinic radiation sources with spatial modulation: projectors or laser beam scanning devices for measuring parameters of a liquid lens 7 similar the formed optical element.
  • the software implemented in the control unit 5 performs the functions of analysis and subsequent comparison of the parameters obtained during measurement with the task parameters for the generated optical element.
  • the software implemented in the control unit 5 generates instructions for changing the amount of hydraulic fluid or gas in the housing 1 to accommodate the fluid and / or gas, which leads to a change in the curvature of the membrane 2 and a change in the optical parameters of the fluid lens 7, similar to the formed optical element.
  • the software implemented in the control unit 5 If, after correction, the optical parameters corresponding to the task for a given section of the liquid lens 7, similar to the formed optical element, are achieved, the software implemented in the control unit 5 generates commands and / or projections for actinic radiation sources to expose the specified section of the specified liquid lens. After curing a predetermined portion of the liquid lens 7, similar to the formed optical element, the described operation is repeated for the next portion.
  • the software implemented in the control unit 5 If the optical parameters of the entire liquid lens 7, similar to the formed optical element, correspond to the task completely, the software implemented in the control unit 5 generates commands and / or projections for actinic radiation sources to expose the specified liquid lens completely in the given geometry, in accordance with the selected processing and curing algorithm. If, in accordance with a given technological regime, it is necessary to carry out exposure to a curing source, for example, to heat an formed or partially formed optical element, or to irradiate it with ionizing radiation, the software implemented in the control unit 5 generates commands for exposing the specified liquid lens and / or a partially formed optical element from a curing source 4.
  • the software implemented in the control unit 5 After the completion of the formation of the optical element, the software implemented in the control unit 5 generates commands and / or projections for non-actinic radiation sources with spatial modulation — projectors or laser beam scanners for measuring the parameters of the finished optical element and analyzes and compares the parameters obtained during measurement with job parameters stored in the memory of control unit 5 for the generated optical element. Based on the results of the comparison, the software gives a message about the quality of the finished optical element.
  • control unit 5 performs a number of automation and control tasks known to specialists in this field of technology.
  • the curing mechanism may be free radical polymerization or cationic initiation.
  • the monomer used may be a multifunctional monomer, such as, for example, acrylic resin, acrylates and methacrylates, which are well suited for UV curing reactive functional groups, including acrylate and methacrylate groups, can be included in oligomers with polyester, polyurethane, polyurea, etc. Multifunctional monomers can be used, which after curing give an insoluble, non-melting, transparent crosslinked network polymer.
  • Curable polymer compositions may include a mixture of photoinitiators to provide curing of the monomer using UV radiation, may contain heat-curing initiators, may contain monomers having the property of polymerization under the influence of ionizing radiation.
  • curable polymer compositions may be used comprising a radical polymerization photo-initiation system and additionally a radical polymerization thermal initiator. Examples of such curable liquids are discussed, for example, in patent RU2138070C1.
  • Curable polymer compositions containing nanoparticles can be used; examples of such compositions are discussed in US20170368742A1.
  • Curable polymer compositions for recording holograms can be used; examples of such compositions are discussed in WO2012 / 062658 A1.
  • US6309803 describes an active material that is sensitive to ultraviolet radiation. Such an active material can polymerize in two different phases, which are selected by the polymerization conditions applied to the optical component.
  • the first phase corresponds to an organic polymerization network. It is formed by irradiation of the active material.
  • the second phase corresponds to the lattice of mineral polymerization and is formed by heating the active material.
  • First phase refractive index lower than the rate of the second phase.
  • the claimed method and device that implements it it is possible to manufacture various lenses for constructing optical systems - spherical lenses, aspherical lenses, lenses that are not symmetrical about the central axis, lenses with special properties, for example, lenses containing a diffractive optical element, or lenses used in optical augmented reality devices.
  • Lenses containing a diffractive optical element are described in US20170075139A1. It is possible to manufacture lenses with selective filtering properties of radiation (some types of such optical filters are described, for example, in US20140300857A1), lenses with integrated elements, prism-like lenses, lenses with protective and antireflective coatings. It is possible to manufacture ophthalmic lenses for glasses, including composite lenses having different sections made of materials with different refractive indices.
  • actinic radiation means electromagnetic radiation, irradiation of which of the curable polymer composition leads to a curing process, or, in other words, initiates polymerization.
  • electromagnetic radiation from the ultraviolet range for example, from 350 nm to 420 nm, may be implied, although for a number of curable polymer compositions, radiation with a different wavelength may be actinic radiation.
  • the term “curing effect” means an effect that results in curing or polymerization of the curable polymer composition. Such exposure includes exposure to actinic radiation, thermal exposure, exposure to microwave radiation, exposure to ionizing radiation.
  • adhere means that surfaces are bound by adhesion forces or chemical bonds and cannot be separated without physical damage or impaired function.
  • adhere means that surfaces are temporarily bonded due to the absence of air or other fluid between them, without adhesion and formation chemical bonds. Such an effect, for example, occurs when attaching an elastic suction cup to the glass.
  • the term ’’ elastic material ’ means a material capable of complete restoration of shape within a given deformation.
  • the term “temporary composition” means such a combination of device elements when these elements can be separated during the device’s implementation of a given function.
  • the inventive device made in accordance with that shown in FIG. 1, tested for the manufacture of an optical element - a concave-convex lens symmetrical about the central axis.
  • a curing source we used a dynAXIS S laser scanning galvanometric device available from Laser 2000 Ltd, Great Britain, in which two 50mW lasers were combined: a RLTMPL -355-50-10 UV laser with a wavelength of 355nm, used as an actinic radiation and a visible laser with a wavelength of 532nm RLTMGL-532-50 used as a source of non-actinic radiation, available from ROITHNER LASERTECHNIK GmbH, Austria.
  • Air is used as a hydraulic gas.
  • the case has an internal diameter of 70mm.
  • the following software was used in the implemented device: the operator’s workstation uses the Slic3r open source Slicer model and open source libraries for working with 3D graphics of OrepTK and OpenGL.
  • the machine vision system is based on the OpenCV (Open Source Computer Vision Library) open-source computer vision library.
  • the operator's workstation and machine vision system are written in Microsoft Visual Studio software development environment using high-level programming languages C # and C ++.
  • the automatic control system is a distributed control system for the technical means of the device.
  • the automatic control system software - control code - is written using the PCSHE.
  • the manufactured optical element is a concave-convex lens with a diameter of 55 mm symmetrical about the central axis.
  • the wavefront transformation parameters obtained by measuring the parameters of the prototype lens — the negative concave-convex -3D ophthalmic lens — were used.
  • composition NOA88 available from Norland Product, USA, was used as a curable polymer composition.
  • the lens corresponding to the task was made within 8 minutes.
  • the membrane is removed after finishing polymerization.
  • Both surfaces of the manufactured lens are of optical quality.
  • the parameters of the manufactured lens are additionally monitored by an automatic CLM-3100P diopter tester manufactured by Huvitz Co. Ltd, Korea, and it was found that the optical function of the manufactured lens is consistent with the task.

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  • General Physics & Mathematics (AREA)
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  • Optics & Photonics (AREA)
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Abstract

Le procédé de fabrication d'un élément optique consiste à former la surface de cet élément de qualité optique en plaçant une composition de polymère durcissable en contact avec la surface d'au moins une membrane en matériau souple et/ou élastique et en assurant le durcissement de cette composition par polymérisation. On forme à partir de la composition de polymère durcissable une lentille liquide semblable à l'élément optique, on mesure ses caractéristiques optiques et, lorsque les caractéristiques désirables sont atteintes, on effectue le durcissement de l'élément optique ou de ses fragments, et ce faisant, on limite par la membrane le volume physiquement englobant rempli de liquide et/ou de gaz. La surface de qualité optique est formée en modifiant la courbure de surface de membrane en contact avec la composition de polymère durcissable par la régulation de la quantité de liquide et/ou de gaz dans un volume physiquement englobant. La formation d'une lentille liquide semblable à un élément optique et la formation d'une surface de cet élément de qualité optique sont réalisés simultanément. Le résultat technique consiste à améliorer la qualité de l'élément optique et la vitesse de sa fabrication.
PCT/UA2018/000038 2018-04-23 2018-04-23 Procédé de fabrication d'un élément optique et dispositif de sa mise en oeuvre WO2019209234A1 (fr)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021126552A1 (fr) 2019-12-20 2021-06-24 Brentwood Industries, Inc. Feuilles de remplissage et ensembles de supports de remplissage associés
CN114885605A (zh) * 2019-12-09 2022-08-09 元平台技术有限公司 制造透镜组件

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US4701288A (en) * 1985-06-05 1987-10-20 Bausch & Lomb Incorporated Method of making articles of dissimilar polymer compositions
US5462700A (en) * 1993-11-08 1995-10-31 Alliedsignal Inc. Process for making an array of tapered photopolymerized waveguides
RU2503541C2 (ru) * 2007-08-21 2014-01-10 Джонсон Энд Джонсон Вижн Кэа, Инк. Устройство формирования заготовки офтальмологической линзы и линзы
RU2532507C2 (ru) * 2009-03-31 2014-11-10 Джонсон Энд Джонсон Вижн Кэа, Инк. Линзы свободной формы с варьируемым показателем преломления

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Publication number Priority date Publication date Assignee Title
US4701288A (en) * 1985-06-05 1987-10-20 Bausch & Lomb Incorporated Method of making articles of dissimilar polymer compositions
US5462700A (en) * 1993-11-08 1995-10-31 Alliedsignal Inc. Process for making an array of tapered photopolymerized waveguides
RU2503541C2 (ru) * 2007-08-21 2014-01-10 Джонсон Энд Джонсон Вижн Кэа, Инк. Устройство формирования заготовки офтальмологической линзы и линзы
RU2532507C2 (ru) * 2009-03-31 2014-11-10 Джонсон Энд Джонсон Вижн Кэа, Инк. Линзы свободной формы с варьируемым показателем преломления

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114885605A (zh) * 2019-12-09 2022-08-09 元平台技术有限公司 制造透镜组件
WO2021126552A1 (fr) 2019-12-20 2021-06-24 Brentwood Industries, Inc. Feuilles de remplissage et ensembles de supports de remplissage associés

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