Method and apparatus for manufacturing an optical element, optical element and optical system

Description

1 / 38 METHOD AND APPARATUS FOR MANUFACTURING OPTICAL ELEMENTS, OPTICAL ELEMENTS AND OPTICAL SYSTEMS Description

[001] The invention relates to a method for optically modifying an optical component with an optical element, as well as to an optical system comprising an optical element.

[002] Optical elements can be used in optical devices and systems to influence a beam of light, for example, by deflection, refraction, or focus. In particular, this makes it possible to correct image formation aberrations.

[003] Typically, optical elements are produced through complex manufacturing processes, in which desired optical properties are defined according to the individual application of the optical element. However, these manufacturing processes are time-consuming and expensive. Furthermore, it is disadvantageous that optical devices, which comprise optical elements, have optical properties that can only be changed by disassembling the device and replacing the optical element.

[004] It is an object of the invention to provide a method and means by which an optical element can be manufactured economically and with a high degree of flexibility with respect to the adjustability of the optical properties of the optical element, wherein the optical element must be connected in a Petition 870250110086, dated 01 / 12 / 2025, p. 10 / 53 2 / 38 optical component, which must be adjusted in terms of its optical properties.

[005] The objective is solved by means of a method as defined in claim 1, and an optical system as defined in claim 15. Additional advantageous embodiments are the subject of dependent claims.

[006] According to a first aspect of the invention, a method for optically modifying an optical component, such as a lens, conventional eyeglasses and / or protective glasses, with an optical element, comprises at least the following steps: A) arranging a transparent, solidifiable, particularly curable liquid material, such as a polymer, in a cavity, wherein the cavity comprises a first surface portion, particularly a first soft surface portion, and a second surface portion, particularly a second soft surface portion, wherein the first surface portion of the cavity is formed by a first deformable membrane; B) Adjust the shape of the first membrane, so as to adjust the shape of the first surface portion of the cavity, in order to adjust the optical power of the optical element to be manufactured; C) to solidify, particularly cure, the material Petition 870250110086, dated 01 / 12 / 2025, p. 11 / 53 3 / 38 liquid to obtain the optical element, wherein the optical element comprises a first surface that conforms to the first surface portion of the cavity and a second surface that conforms to the second surface portion of the cavity, wherein the optical element comprises an optical power adjusted by the shape of the first and second surfaces; D) Connecting the optical element to an optical surface, particularly a soft optical surface of the optical component, wherein the first or second surface of the optical element faces, or in particular makes contact with, the optical surface of the optical component, such that the optical component is optically modified by the optical power of the optical element.

[007] The invention is based on the realization that liquids or solidifiable liquid materials, particularly curable ones, can be used for the manufacture of optical elements with individually adjustable optical properties. The liquid material can, in particular, be a curable transparent liquid polymer. A polymer such as this is typically easy to manipulate and has good forming properties, which makes it particularly suitable for the manufacture of optical elements.

[008] The cavity may have one or more openings, Petition 870250110086, dated 01 / 12 / 2025, p. 12 / 53 4 / 38 particularly where the cavity may be formed by a recess or a circumferentially open volume bounded by the first and second surface portions.

[009] According to the invention, the solidifiable liquid material is provided for a cavity at least partially formed by at least one first deformable membrane. The invention is not limited to a specific embodiment of the membrane. It is only required that said membrane be deformable, for example, by an external force, and at the same time that the membrane exhibits sufficiently high tensile strength, for example, to maintain a desired shape. In a simple embodiment, the first membrane can be made of a thin film, in particular a thin polymer film.

[0010] By providing the solidifiable liquid material to the first membrane and then adjusting the shape of said membrane, the liquid material adapts to the shape of the membrane surface portion due to its liquid aggregate state. By solidifying the liquid material, the optical element is obtained and the shape, particularly the shape of the first surface of the optical element, is defined according to the shape of the membrane surface portion.

[0011] In other words, the membrane partially forms a selectively controllable deformable mold through which the optical element can be produced with a Petition 870250110086, dated 01 / 12 / 2025, page 13 / 53 5 / 38 individually adjustable format. Investigations have shown that, using the method according to the invention, it is possible to manufacture the optical element at least partially with any type of geometry, preferably, however, with a cylindrical or spherical geometry. Since the optical properties of the optical element depend on its shape, the deformation of the first membrane allows directly defining the optical properties of the optical element. In particular, the optical element is at least transparent to visible light and is configured for use in optical devices.

[0012] The invention is not limited to a specific sequence according to which process steps A) and B) must be carried out. For example, the liquid material may first be dispensed onto the first membrane and subsequently the first membrane may be deformed, or vice versa.

[0013] According to another embodiment of the invention, the second surface portion can be formed by the optical surface of the optical component. This allows for an integrated process that, in essence, combines steps C) and D).

[0014] According to another embodiment of the invention, a circumferential shape and size of the optical element are identical to a circumferential shape and size of Petition 870250110086, dated 01 / 12 / 2025, p. 14 / 53 6 / 38 optical surface of the optical component, so that the optical element and the optical surface can be arranged aligned with respect to each other.

[0015] This option allows for a design that is both appealing and discreet.

[0016] According to another embodiment of the invention, the second surface portion is formed by a second deformable membrane, and in which a shape of the second membrane is adjusted in step B), so as to adjust a shape of the second surface portion of the cavity.

[0017] In particular, the characteristics and definitions provided in the context of the first membrane are applicable to the second membrane in an analogous manner.

[0018] The specific sequence according to which the first and second adjusted membrane shapes can be selected. The membrane shapes can be adjusted simultaneously or sequentially.

[0019] The second membrane may be positioned in such a way that the liquid material is arranged, particularly confined, between the first and second membranes and is then solidified. Alternatively, it is within the scope of the invention that neither membrane is deformed, i.e., adjusted in relation to its shape, until the liquid material is confined between the membranes.

[0020] For the above-described modality, the material Petition 870250110086, dated 01 / 12 / 2025, page 15 / 53 7 / 38 A liquid, in particular a liquid polymer, can be placed between the first and second membranes so that the membranes form a pressure-tight space in which the polymer is located. If one of the membranes is deformed, the deformation leads to an increase in pressure in the liquid polymer and to a deformation of the other membrane. The membranes are thus deformed essentially simultaneously.

[0021] The invention is not limited to the manner in which a pressure-tight space is formed. In a simple embodiment, however, the membranes may be in circumferential contact with each other in their respective edge regions and thus form a chamber in which the polymer is located. Alternatively, the membranes may be connected indirectly by means of a ring as a spacer element that confines the liquid material in the lateral direction and by the membranes in the axial direction. It is also within the scope of the invention that the membranes are each retained by molds, which are movable in such a way as to allow easy application of the polymer between the membranes in an open state and are movable in a closed state, in which the polymer is confined by the membranes and the molds.

[0022] According to another embodiment of the invention, between steps C) and D), the optical element is removed, particularly separated, from the second and / or first surface portions of the cavity. Petition 870250110086, dated 01 / 12 / 2025, p. 16 / 53 8 / 38

[0023] This allows the reuse of the first and / or second membranes.

[0024] According to another embodiment of the invention, the first and / or second membranes remain attached to the optical element when the optical element is attached to the optical component.

[0025] This embodiment allows a particularly simple method, which can use the properties of the membrane(s) for the optical component or the bonding to it. For example, the membrane(s) can provide an additional layer of protection against scratches or anti-reflective properties. The latter can be achieved by selecting appropriate membrane materials or by coating the membrane(s) with a corresponding material.

[0026] According to another embodiment of the invention, the first membrane and / or the second membrane are at least partially transparent to ultraviolet radiation, and wherein the liquid material is an ultraviolet curing liquid polymer, and wherein the step of method C) comprises exposing the liquid polymer to ultraviolet radiation through the first and / or the second membranes.

[0027] This method allows the use of optical curing while maintaining transparency in the visible spectral region, that is, at wavelengths longer than 380 nm. Petition 870250110086, dated 01 / 12 / 2025, p. 17 / 53 9 / 38

[0028] Specifically, the term ultraviolet refers to a wavelength range from 200 nm to 380 nm.

[0029] The use of transparent membranes and, for example, an ultraviolet (UV) curable polymer is advantageous because the required ultraviolet radiation can be provided from outside the membranes, in particular, so that no additional means are required to cause the polymer to cure. Preferably, one or more ultraviolet radiation sources are arranged on one side of the first and / or second membranes that face away from the liquid polymer.

[0030] According to one embodiment of the invention, the first membrane and / or the second membrane are at least partially transparent to infrared radiation, and wherein the liquid material is an infrared-curing liquid polymer, and wherein the step of the method C) comprises exposing the liquid polymer to infrared radiation through the first and / or the second membranes.

[0031] This modality allows the use of optical curing, while maintaining transparency in the visible spectral region, that is, at wavelengths shorter than 750 nm.

[0032] The use of transparent membranes and, for example, an infrared (IR) curable polymer is advantageous because the required infrared radiation can be Petition 870250110086, dated 01 / 12 / 2025, p. 18 / 53 10 / 38 provided from outside the membranes, in particular, so that no additional means are required to cause the polymer to cure. Preferably, one or more infrared radiation sources are arranged on one side of the first and / or second membranes that face away from the liquid polymer.

[0033] Specifically, the term infrared refers to a wavelength range of 750 nm to 1,500 nm.

[0034] According to another embodiment of the invention, the liquid material is liquid at a first temperature and a first pressure, wherein the liquid is filled into the cavity at said first temperature and pressure, wherein, in the step of method C) for solidification, the liquid is cooled to a second temperature, particularly wherein the first pressure is essentially maintained, particularly wherein the second temperature is lower than the first temperature, wherein the liquid polymer solidifies due to the lower second temperature.

[0035] This modality allows the use of thermal curing, so that no additional optical light source is required to form the optical element.

[0036] Specifically, the second temperature is below 60°C, more specifically below 45°C. Specifically, the second temperature is above 15°C. A Petition 870250110086, dated 01 / 12 / 2025, p. 19 / 53 11 / 38 first temperature may exceed 60°C.

[0037] According to another embodiment of the invention, the liquid material comprises a first component and a second component that are configured to begin a curing process at the moment they come into contact with each other or are mixed with each other, so that the liquid material cures by means of the two-component curing components.

[0038] The two components can be mixed shortly before the liquid material is supplied to the cavity, or they can be supplied subsequently or simultaneously to the cavity.

[0039] This modality allows healing processes without the need for an external light source.

[0040] According to another embodiment of the invention, the second surface of the optical element is connected to the surface of the optical surface of the component by means of Van der Waals forces, particularly only by means of Van der Waals forces.

[0041] This method allows the optical element to be connected to the optical component without any additional adhesive, which makes applying the optical element to the optical component particularly easy.

[0042] The second surface of the optical element, as well as the optical surface of the optical component, can be Petition 870250110086, dated 01 / 12 / 2025, p. 20 / 53 12 / 38 configured to exhibit the properties necessary to allow Van der Waals forces to be high enough to achieve this effect. Those skilled in the art are aware of ways to achieve this, or of which materials might be suitable, particularly with regard to material selection for the optical element.

[0043] According to another embodiment of the invention, the optical element, particularly the first and / or second surface of the optical element, is shaped so that, alone or in combination with the optical component, one or more optical parameters selected from the group consisting of cylinder, astigmatism, coma, prism or a higher-order Zernike polynomial aberration are adjusted, particularly to adjust a person's vision deficit.

[0044] This modality allows a method that is capable of readapting or enhancing an optical component for specific vision deficits of a person wearing the optical component.

[0045] According to another embodiment of the invention, the shape of the first membrane and / or the shape of the second membrane are adjusted by a mechanical element, wherein the mechanical element is configured to adjust the shape of the first and / or second membranes so as to produce the optical element exhibiting one or more optical parameters, Petition 870250110086, dated 01 / 12 / 2025, page 21 / 53 13 / 38 particularly where the mechanical element is a lens shaping device.

[0046] The mechanical element can be a structural component through which it is possible to exert a force on one of the membranes in a linear or planar point region. Preferably, multiple mechanical elements can be provided to exert a force on the first and / or second membranes. In particular, by using the mechanical elements, it is possible to apply a compressive force or a tensile force to one of the membranes. To exert the tensile force, the mechanical element can be bonded to the first or second membranes by means of an adhesive. Preferably, the adhesive is soluble, so that the mechanical element can be detached from the membrane(s). However, it is also within the scope of the invention that the first and / or second membranes can be detached from the optical element after curing and discarded.

[0047] Preferably, the deformation of the membrane(s) is controlled by a control unit, designed to operate a closed control loop, in particular so that the deformation of the second membrane is carried out as a function of the hydraulic pressure of the liquid material and / or the deformation of the first membrane and / or the movement and / or the force of the mechanical elements.

[0048] According to another embodiment of the invention, Petition 870250110086, dated 01 / 12 / 2025, page 22 / 53 14 / 38 the shape of the first membrane is formed by the mechanical element, and the shape of the second membrane is formed as a function of hydraulic pressure from the liquid material or vice versa.

[0049] This modality allows a directly controlled method for producing the optical element to increase the accuracy of the first membrane's positioning.

[0050] According to another embodiment of the invention, the shape of the first membrane and / or the shape of the second membrane are adjusted by a fluid pressure that is applied to a surface of the first and / or second membranes that is facing away from the liquid material.

[0051] In this embodiment, the pressure of a fluid, preferably air pressure or fluid pressure, can be used to cause a desired deformation of the first and / or second membranes. In particular, different pressures can be defined on the two membranes, particularly on the sides of the membrane(s) facing away from the liquid material.

[0052] In an alternative embodiment, step B) of method B) comprises a successive deformation of the first membrane and the second membrane.

[0053] The invention is not limited to a simultaneous deformation of the membranes. Instead, the deformation of the membranes can also occur one after the other. In a Petition 870250110086, dated 01 / 12 / 2025, page 23 / 53 15 / 38 preferred embodiment, in step A) the liquid material is first applied to the first membrane so that the first membrane deforms as a result of a force exerted by the application of the liquid material, in particular as a result of a weight force of the liquid material. The second membrane is placed in contact with the liquid material and deforms as a result of an adhesive force of the liquid material, preferably the curable liquid polymer.

[0054] It is an advantage of the above-described embodiment that, in principle, no additional means of deformation is required to cause the deformation of the first and / or second membranes. Instead, the membranes can be designed to be flexible to a degree such that a small amount of curable liquid material leads to a deformation of the first membrane due to its weight. If the second membrane is then brought into contact with the material, the second membrane is dragged in the direction of the first membrane as a result of adhesion to the liquid material and is thus deformed. This effect is particularly achievable if the liquid material is an ultraviolet curable polymer.

[0055] According to another embodiment of the invention, the shapes of the first and second membranes are formed by successive deformations of the first membrane and the second membrane.

[0056] According to another embodiment of the invention, Petition 870250110086, dated 01 / 12 / 2025, page 24 / 53 16 / 38 the liquid material is applied to the first membrane or to the second membrane in such a way that the shape of the respective membrane is formed as a result of a force exerted by the application of the liquid material, in particular as a result of a weight force of the liquid material on the respective membrane, and wherein the respective other membrane (of the first and second membrane) is placed in contact with the liquid material, wherein the shape of the respective other membrane is formed as a result of an adhesive force of the liquid material.

[0057] According to another embodiment of the invention, a solidification, particularly a curing process of the liquid material is controlled so that the particularly cured solidified optical element becomes flexible, particularly wherein the solidification is terminated before the liquid material is solidified into a solid state.

[0058] According to another embodiment of the invention, the liquid material comprises a duroplast, an elastomer and / or a thermoplast.

[0059] The above-described additional embodiment is based on the understanding that it is not necessary to allow the liquid material, particularly UV-curable polymer, to fully cure in order to obtain an optical element with the desired optical properties. Instead, the curing process can be terminated when the liquid material has Petition 870250110086, dated 01 / 12 / 2025, p. 25 / 53 17 / 38 partially solidified as a result of curing, but not yet fully cured, and thus has good elastic deformability. This makes it possible to subsequently apply the optical element to curved optical surfaces. This can be done in a simple way by controlling the radiation duration and / or radiation intensity, on which the degree of curing depends.

[0060] According to another embodiment of the invention, the optical component is selected from the group consisting of a rigid lens, ski goggles, diving goggles, safety glasses, prescription glasses, sunglasses, virtual reality, augmented reality glasses, a waveguide structure, a waveguide diffraction structure, a waveguide refraction structure.

[0061] This modality provides a particularly useful application of the method, as it allows adjusting optical components that are typical at a consumer level.

[0062] In a preferred embodiment, the optical element is processed after its extraction between the membranes by means of a cutting step, in particular in an edge region. In this context, the edge region should be understood as a circumferential area that surrounds the edge of the optical element in relation to an optical geometric axis.

[0063] In a further embodiment, the optical element is provided with a mark during or after the execution of a Petition 870250110086, dated 01 / 12 / 2025, p. 26 / 53 18 / 38 of the process steps A), B), C), D). A mark like this can be used to identify the optical element to easily distinguish its optical surfaces from one another or, for example, to simplify the positioning of the optical element in another optical component by orienting the optical element depending on the position of the mark.

[0064] In particular, the optical element can be connected to the optical component, like an adhesive with an adhesive surface.

[0065] According to a second aspect of the invention, an optical system is disclosed comprising a transparent optical element having an optical power, wherein the optical element comprises a material, particularly a polymer, with a first surface, particularly a soft first surface, and a second surface, particularly a soft second surface facing the opposite direction from the first surface, wherein the optical element is flexible and foldable so that the first surface can be bent to conform to a curved surface, particularly a curved soft surface, wherein the first surface is configured so that, when the first surface is placed in extensive contact with a complementary surface, particularly wherein the complementary surface comprises or consists of a polymer, a synthetic polymer or a glass, Van der Waals forces, Petition 870250110086, dated 01 / 12 / 2025, page 27 / 53 19 / 38 particularly only Van der Waals forces between the first surface and the complementary surface cause the optical element to be bonded, particularly permanently bonded to the complementary surface, where the optical element is shaped so that, alone or in combination with the optical component, one or more optical parameters selected from the group consisting of cylinder, astigmatism, coma, prism or a higher-order Zernike polynomial aberration are adjusted, particularly to adjust a person's vision deficit.

[0066] The system according to the second aspect of the invention allows for refitted optical components comprising an optical element that adjusts an optical power or an optical parameter, for example, for a visually impaired person. This makes it possible to manufacture optical components, such as sunglasses, goggles or VR / AR goggles without specific optical properties with respect to optical power or aberrations, which are refitted with the optical element that provides or adjusts a pre-existing optical power of the optical component.

[0067] The term “flexible and bendable” signals a restart particularly to a Shore hardness that is considered to describe a flexible and bendable material, particularly directly after manufacturing. In particular, the Shore hardness may be less than 80 D, Petition 870250110086, dated 01 / 12 / 2025, p. 28 / 53 20 / 38 particularly smaller than 60 D, more particularly smaller than 50 A.

[0068] The optical element may consist at least partially of a curable component, in particular a curable transparent liquid polymer, and comprise a first surface, which is designed to bond the optical element to an optical surface of an optical component.

[0069] An advantage associated with the optical element according to the invention is that the optical element can be used in a simple way to form the optical system whose optical properties can be individually adjusted by application in an optical component. This is a particular advantage for any type of rigid lens, as well as ski goggles, diving goggles, safety glasses, prescription glasses, sunglasses, conventional virtual reality glasses.

[0070] According to another embodiment of the invention, a circumferential shape and the size of the optical element are identical to a circumferential shape and the size of the optical surface of the optical component. This embodiment allows for an aligned design of the optical system, which reduces reflections at the edges of the optical element and the optical component and provides a visually appealing and discreet system.

[0071] According to another embodiment of the invention, the second surface is concave or convex, particularly Petition 870250110086, dated 01 / 12 / 2025, p. 29 / 53 21 / 38 where the second surface is coated with an anti-reflective coating.

[0072] This allows adjusting the optical properties of the optical system to a greater extent. Additionally, the anti-reflective coating can be advantageous for suppressing unwanted reflections within, or on, the optical system.

[0073] Preferably, the optical element is coated with an anti-reflective coating and / or has an anti-reflective treated surface on a side facing away from the optical surface of the optical component. This improves the optical properties of the optical element for use in a wearable optical component.

[0074] According to another embodiment of the invention, the optical system comprises an optical component with an optical surface comprising the complementary surface, wherein the optical element is connected through its first surface to the optical surface of the optical component by means of Van der Waals forces.

[0075] This modality stipulates the advantageous combination of the optical element with an optical component that can be readapted or adjusted by means of the optical element.

[0076] The optical component may or may not comprise an optical power or an aberration that can be corrected by the optical element.

[0077] According to another embodiment of the invention, Petition 870250110086, dated 01 / 12 / 2025, p. 30 / 53 22 / 38 an adhesive is arranged on the first surface of the optical element, so that when the optical element is attached to the optical surface of the optical component, the optical element is glued to the optical component.

[0078] This method complements the adhesive forces exerted by Van der Waals forces between the first surface and the optical surface of the optical component. The resulting system is more robust, and the optical element can be permanently fixed in a fixed location on the optical component.

[0079] According to another embodiment of the invention, the optical component is selected from the group consisting of: protective eyewear, conventional eyewear, VR protective eyewear, wherein the optical surface is oriented towards the eyes of a person when the person is wearing the optical component.

[0080] An adjustment of the optical power and aberrations of a selected optical component from this group allows for the adjustment of optical components that are manufactured independently of a person's vision deficits.

[0081] According to another embodiment of the invention, the optical component comprises two optical surface portions composed of optical surfaces, wherein the surface portions are arranged so that a person wearing the optical component has one of the surface portions arranged in front of the person's eye, wherein, in each portion Petition 870250110086, dated 01 / 12 / 2025, p. 31 / 53 23 / 38 of optical surface, an optical element is connected.

[0082] This modality, in essence, describes protective eyewear that can be equipped with two optical elements that adjust the optical properties of the optical component individually for each eye.

[0083] This modality allows, for each eye, the adjustment of the optics according to a person's vision deficits in each eye. For this purpose, the two optical elements can exhibit different optical parameters and / or optical powers.

[0084] Optical surface portions can be conventional glasses or safety glasses.

[0085] According to another embodiment of the invention, the circumferential shape and size of each optical element are identical to the circumferential shape and size of the optical surface portion of the optical component.

[0086] This approach allows for an aligned design of the optical system, which reduces reflections at the edges of the optical element and the optical component and provides a system with visual appeal and discreetness.

[0087] According to another embodiment of the invention, the optical power of each optical element is selected so that the optical power of the optical component is adjusted, particularly where the optical power of each optical element is different, particularly where the Petition 870250110086, dated 01 / 12 / 2025, p. 32 / 53 The 24 / 38 optical component does not display an optical power.

[0088] This modality specifies advantageous properties of the optical system, in which each optical element can exhibit different optical properties.

[0089] According to another embodiment of the invention, each optical element is molded as a thin lens, which is adapted to conform to the first surface of the optical element on the optical surface of the optical component.

[0090] This modality allows for a discreet modification of the optical component. The thin lens can essentially be a self-adhesive type optical element, which is attached to the optical component and alters the optical properties with respect to optical power and aberrations in a defined manner.

[0091] In particular, the optical power adjustment can be greater than 0.5 diopters or less than -0.5 diopters.

[0092] According to another embodiment of the invention, the width of each optical element is at least 5 to 20 times greater, particularly 10 to 20 times greater, than the thickness of the optical element.

[0093] A thin lens can be summarized under these geometric properties of the topic element.

[0094] Such a thin optical element with optical power and aberration correction is difficult to manufacture. The method according to the invention allows the manufacture of such thin optical elements with defined properties. Petition 870250110086, dated 01 / 12 / 2025, p. 33 / 53 25 / 38

[0095] In particular, each optical element comprises a principal extension plane and an optical geometric axis oriented orthogonally to the principal extension plane, wherein the ratio of an axial extension of the optical element along the optical geometric axis and a lateral extension of the optical element in the principal extension plane is less than 1 / 5, preferably less than 1 / 10.

[0096] With the aforementioned dimensions of the optical element, it is possible to easily apply them to existing optical surfaces in a space-saving manner. In particular, the optical element can be applied to the optical component in an optically subtle way. This is particularly advantageous for aesthetic reasons when the optical element is applied to conventional wearable eyewear.

[0097] According to another embodiment of the invention, each optical element is manufactured by performing the steps of method A) to D) of the method according to the invention and / or any other embodiment of said method.

[0098] Preferably, the apparatus membranes are retained by movable molds. These molds are preferably mounted in such a way that they can be moved linearly by means of a guide means and can be adjusted along a geometric guide axis by means of an adjustment means. Preferably, the membranes are retained by Petition 870250110086, dated 01 / 12 / 2025, p. 34 / 53 26 / 38 replaceable form with molds.

[0099] Preferably, the apparatus comprises a spacer element, which, at least in the second relative position of the membranes, is arranged between the membranes or molds. The spacer element allows the thickness of the optical element to be adjusted in one direction of the axial and radial extension. Preferably, the spacer is retained in a replaceable manner in the apparatus so that the axial and / or radial extension of the optical element can be adjusted by replacing the spacer.

[00100] Preferably, the apparatus has at least one mechanical means for deforming the first and / or second membranes. Preferably, the apparatus has an applicator means by which the liquid polymer can be applied to the first or second membranes in an adjustable quantity.

[00101] Preferably, the first and / or second membranes are arranged so that, when the curable liquid polymer material is located between the membranes, one side of the membrane facing away from the polymer can be applied with mechanical force or fluid pressure in order to deform the membranes. Brief Description of the Drawings

[00102] The advantages attainable with the invention are explained below in relation to examples of embodiments and figures. Petition 870250110086, dated 01 / 12 / 2025, p. 35 / 53 27 / 38

[00103] Figure 1 shows the steps of a method for manufacturing an optical element according to a first embodiment in views a), b1), b2), c), d), e); Figure 2 shows the steps of a method for manufacturing an optical element according to a second embodiment in views a), b); Figure 3 shows an optical system according to the invention; Figure 4 shows one embodiment of the manufacturing steps of an optical system according to the invention; and Figure 5 shows one embodiment of the manufacturing steps of an optical element according to the invention. Detailed Description

[00104] For a better understanding of the figures, reference is made to the following list of reference numbers.

[00105] Figure 1 shows a schematic cross-sectional drawing of a device 1 for manufacturing an optical element 12 in views a), b1), b2), c) and d). The apparatus comprises a first membrane 2 and a second membrane 3 that form a cavity 100 with a first and a second surface portion 101, 102 of the cavity 100. The first and second membranes 2, 3 are transparent and consist of an elastic polymer. The following features and functionalities of the apparatus can be referred to in the method according to the invention in the same manner. Petition 870250110086, dated 01 / 12 / 2025, p. 36 / 53 28 / 38 so that figure 1 also serves to illustrate the method and its steps for optically modifying an optical component 20.

[00106] As shown in view a) of figure 1, both the first membrane 2 and the second membrane 3 in an initial state of apparatus 1 extend along a principal extension plane xe and are essentially planar. In a manner not shown here, each of the membranes 2, 3 has a substantially circular cross-section, which extends into the interior of the image plane of figure 1.

[00107] Membranes 2, 3 are spaced by a ring-type spacer 4 and together form cavity 100 filled with a transparent liquid polymer 5. The polymer is a so-called UV-curing polymer 5 that crosslinks when exposed to UV radiation, changing from a liquid state to an increasingly solid state. This effect is used to obtain the optical element 12 from the transparent liquid polymer 5.

[00108] Optical element 12 serves as an applicable element for optical component 20, to adjust the optical properties of optical component 20 as required. Optical component 20 can be the lens of a pair of conventional eyeglasses, in particular sunglasses, ski goggles or conventional virtual reality glasses (see, for example, figure 3).

[00109] In order to adjust the optical properties of Petition 870250110086, dated 01 / 12 / 2025, p. 37 / 53 29 / 38 said optical component 20 as required, the liquid polymer 5 is adjusting a shape of the first membrane 2 and the second membrane 3 according to the shape of the desired optical element 12 and its optical properties.

[00110] This is shown in views b1) and b2) of figure 1, each of which illustrates different ways in which membranes 2, 3 can be deformed to obtain the shape of the first and second surface portions 101, 102 of cavity 100 and thus a first and second surface 12-1, 12-2 of optical element 12.

[00111] According to view b1) of figure 1, a mechanical deformation element 6 is used, which exerts a compressive force 7 on the first membrane 2, thereby deforming it and adjusting its shape.

[00112] As a result of the deformation of the first membrane 2, the hydraulic pressure in the polymer 5 increases, causing the second membrane 3 to also deform. In this way, the first 2 and the second membrane 3 can be deformed simultaneously and according to the desired shape.

[00113] During or after deformation, polymer 5 is exposed to ultraviolet radiation 8 from a radiation source 9 through the second membrane 3.

[00114] As an alternative to the process shown in view b1) in figure 1, according to view b2), the Petition 870250110086, dated 01 / 12 / 2025, p. 38 / 53 The 30 / 38 deformation device 6 can also be used to exert a tensile force 10 that is applied to the first membrane 2. Due to the low pressure thus generated, the second membrane 3 is also deformed, according to which the desired shape of the optical element 12 to be produced can also be adjusted. Here, the deformation device 6 is bonded to the first membrane 2 by means of an adhesive.

[00115] The curing process shown in views b1) and b2) is controlled depending on the curing state of the polymer and can be terminated before the polymer is completely cured. This can be done in a simple way by controlling the duration of irradiation or the intensity of irradiation, on which the degree of curing depends.

[00116] As shown in view c) of figure 1, following the curing process, membranes 2 and 3 are removed and the cured polymer is trimmed along the cut edges 12.

[00117] Subsequently, in view d), the optical element 12 with the first 12-1 and second surfaces 12-2 is obtained according to the format shown in view d) of figure 1.

[00118] The optical element 12 can be connected to the optical component 20, as shown in figure 1e). This can be facilitated by means of Van der Waals forces, particularly only by means of Van der Waals forces. Petition 870250110086, dated 01 / 12 / 2025, page 39 / 53 31 / 38 For this purpose, the optical element can be bonded or pressed with its first surface 12-1 onto an optical surface 20-1 of the optical component 20, so that the optical element 12 and the optical component 20 come into immediate contact to enable Van der Waals forces to permanently fix the optical element 12 to the optical component 20.

[00119] Figure 2 shows another embodiment of device 1, which has partially the same components already explained in relation to Figure 1. For better comprehensibility, the same reference signs are used for the same components, and reference is made to the explanations for Figure 1.

[00120] According to figure 2, each of the membranes 2 and 3 is retained at the edge by means of a mold 13 and 14, respectively.

[00121] Molds 13 and 14 are movable between a first and a second relative position. In the first relative position, which is shown in view a) of figure 2, a liquid ultraviolet curable polymer 5 is applied to the second membrane 3.

[00122] The second membrane 3 is elastic so that it deforms as a result of the application of the liquid polymer. In particular, the deformation of the second membrane 3 is caused by the weight force of the polymer 5. Petition 870250110086, dated 01 / 12 / 2025, pages 40 / 53 32 / 38

[00123] Subsequently, the first mold 13 is moved in such a way that the first membrane 3 arranged in it comes into contact with the polymer 5 and deforms substantially in accordance with the second membrane 3 as a result of an adhesion force. This can be seen in view b) of figure 2.

[00124] In the state shown in view b) of figure 2, polymer 5 can be cured, in the manner described in figure 1.

[00125] The optical element 12, which is manufactured according to the processes illustrated in figures 1 and 2, can have one of its surfaces applied to another optical component (not shown in figure 2), in particular, by means of a soluble adhesive and / or Van der Waals forces.

[00126] Figure 3 shows an optical component 20 in the form of sunglasses having an optical element 12 attached to it on the eye side of a sunglasses wearer (the optical element 12 is particularly visible in its circumference as a dark circular line on the surface portion 20-a). The optical component 20 and the optical element 12 form an optical system 200, wherein the optical element 12 is manufactured to adjust an optical aberration, such as cylinder, astigmatism, or another higher-order Zernike polynomial aberration that describes an optical aberration. In this way, sunglasses 20 that may not exhibit any optical power or aberrational adjustment can be Petition 870250110086, dated 01 / 12 / 2025, pp. 41 / 53 33 / 38 adjusted in terms of optical power and optical aberrations by optical element 12 to correct user vision deficits in an economical way.

[00127] Figures 4 a) through c) schematically represent an embodiment of the method employing the optical surface 20-1 of the optical component 20 as the second surface portion 102 of the cavity 100. According to this embodiment, the liquid material 5 is directly applied onto the optical surface 20-1 of the optical component 200. In this case, the optical surface is part of a lens of the protective eyewear. In a subsequent step, shown in Figure 4b), the first surface portion 101 of the cavity 10 is provided for the liquid material 5 arranged on the optical surface 201. As always, the first surface portion corresponds to the first membrane 2.

[00128] The first membrane 2 is part of a molding device 1, wherein the molding device 1 is configured to adjust a pressure 6 on the side of the first membrane 2 that faces away from the liquid material 5. For this purpose, the molding device 1 comprises a pressure chamber 300 in which a pressure can be adjusted. In this example, the pressure in the pressure chamber 300 can be adjusted by pumping a fluid into or out of the pressure chamber 300 through an opening 301. The pressure chamber may comprise, in the portion of Petition 870250110086, dated 01 / 12 / 2025, pp. 42 / 53 34 / 38 wall, 4 spacers that allow a pressure chamber volume of 300. The molding device 1 can be movable along the geometric z-axis, that is, along an optical geometric axis of the optical surface 20-1 and, furthermore, it can be movable along x, y, as well as tiltable around one, two or three geometric axes.

[00129] By moving (as indicated by arrows 400) the molding device 1, direct contact is established between the liquid material 5 and the first membrane 2. Before or after this, the pressure in the pressure chamber 300 can be adjusted so that the membrane 2 deforms the liquid 5, adjusts a volume of the liquid material and forms a surface of the liquid material 5 on the side facing the first membrane 2.

[00130] Once the correct shape of liquid material 5 is achieved, liquid material 5 can be solidified.

[00131] The molding device 1 can then be retracted (as indicated by arrows 400), so that an optical system 200 is provided (as shown in figure 4c)), having an optical component optically fitted to its optical surface by means of an optical element.

[00132] It can be seen that the molding device 1 may comprise additional molding elements (not shown) that allow adjusting the shape of the first membrane 2 of Petition 870250110086, dated 01 / 12 / 2025, pp. 43 / 53 35 / 38 in order to provide and manufacture a shape of the optical element 12 that adjusts the optical component 20 for higher-order Zernike polynomial optical aberrations, as described in the preceding paragraphs.

[00133] In figure 5, another embodiment of the invention is shown schematically. In this example, the liquid material 5 is placed between the first and second membranes 2, 3 within the cavity 5 that is formed between them. For this purpose, the device 1 has an injection opening indicated by the black arrow 50.

[00134] Additionally, the membranes are connected to device 1, wherein, between a particularly transparent top part 1-1 of device 1 and the first membrane 2, a first pressure chamber 300-1 is formed which is configured to maintain a pressure p1 of a fluid, such as air. The fluid can be pumped into the first pressure chamber 300-1 through an opening 51 indicated by a black double arrow. Device 1 may further comprise a second pressure chamber 300-2 formed between a particularly transparent bottom part 1-2 of device 1 and the second membrane 3, wherein, also, the second pressure chamber 300-2 is configured to maintain a pressure p2 of a fluid, such as air. The fluid can be pumped into the second pressure chamber 300-2 through an opening 52, Petition 870250110086, dated 01 / 12 / 2025, pages 44 / 53 36 / 38 as indicated by a black double arrow.

[00135] Once the liquid material 5 is injected into the cavity 100 between the first and second membranes 2, 3, the pressures p1, p2 of the first and second membranes are adjusted, such as to form the first and second membranes 2, 3. Once the first and second membranes 2, 3 have adopted the correct and desired shape, the liquid material 5 can be cured in order to fix the shape and thus the optical properties of the optical element 12. For this purpose, it may be advantageous if at least the top or bottom portion is transparent to the curing wavelength.

[00136] In order to precisely adjust the shape of the first and second membranes 2, 3, the first and second pressures p1, p2 can be adjusted separately by their respective openings 51, 52. Reference Numbers device first membrane second membrane spacer transparent liquid polymer deformation medium compression force radiation medium Petition 870250110086, dated 01 / 12 / 2025, pages 45 / 53 37 / 38 ultraviolet radiation tensile force cutting line optical element 12-1 first surface 12-2 second surface first mold second mold Z optical geometric axis x principal extension plane of the optical component 20-1 optical surface 100 cavity 101 first surface portion 102 second surface portion 200 optical system 300 pressure chamber 300-1 first pressure chamber 300-2 second pressure chamber 301 opening 400 directions of movement p1, p2, pressure 1-1 serving of top 1-2 portion of bottom opening Petition 870250110086, dated 01 / 12 / 2025, pages 46 / 53 38 / 38 opening opening Petition 870250110086, dated 01 / 12 / 2025, pages 47 / 53

Claims

1 / 9 CLAIMS 1. Method for optically modifying an optical component with an optical element (12), the method characterized in that it comprises the following steps: A) Arranging a transparent solidifiable liquid material (5) in a cavity (100), wherein the cavity (100) comprises a first surface portion (101) and a second surface portion (102), wherein the first surface portion (101) of the cavity (100) is formed by a first deformable membrane (2); B) Adjusting a shape of the first membrane (2) so that an optical power of the optical element (12) to be manufactured is adjusted;C) Solidify the liquid material (5) to obtain the optical element (12), wherein the optical element (12) comprises a first surface (12-1) that conforms to the first surface portion (101) of the cavity (100) and a second surface (12-2) that conforms to the second surface portion (102) of the cavity (100), wherein the optical element (12) comprises an optical power adjusted by the shape of the first and second surfaces (12-1, 12-2); D) Connect the optical element (12) to an optical surface (20-1) of the optical component (20), wherein the first surface (12-1) or the second surface (12-2) of the element Petition 870250090289, dated 03 / 10 / 2025, p. 27 / 45 2 / 9 optical (12) is facing the optical surface (20-1) of the optical component (20), so that the optical component (20) is optically modified by the optical power of the optical element (12).; 2. Method according to claim 1, characterized in that the second surface portion (102) is formed by a second deformable membrane (3) and in which a shape of the second membrane (3) is adjusted in step B), so as to adjust a shape of the second surface portion (102) of the cavity (100).

3. Method according to claim 1 or 2, characterized in that between steps C) and D) the optical element (12) is removed from the second and / or first surface portions (101, 102) of the cavity (100).

4. Method according to claim 1 or 2, characterized in that the first and / or second membrane (2, 3) remain attached to the optical element (12) when the optical element is attached to the optical component (20).

5. Method, according to one of the preceding claims, characterized in that the first membrane (2) and / or the second membrane (3) is at least partially transparent to ultraviolet radiation (9) and in which the liquid material (5) is an ultraviolet curing liquid polymer and in which the method step C) comprises Petition 870250090289, dated 03 / 10 / 2025, page 28 / 45 3 / 9 an exposure of the liquid polymer to ultraviolet radiation (9) through the first and / or second membrane (2, 3).

6. Method, according to one of the preceding claims, characterized in that the second surface (12-2) of the optical element (12) is connected to the surface of the optical surface (20-1) of the component (20) by means of Van der Waals forces, particularly only by means of Van der Waals forces.

7. Method, according to any of the preceding claims, characterized in that the optical element (12), particularly the first and / or second surface (12-1, 12-2) of the optical element (12) is shaped so that, alone or in combination with the optical component (20), one or more optical parameters selected from the group consisting of cylinder, astigmatism, coma, prism or a higher-order Zernike polynomial aberration are adjusted, particularly to adjust a person's vision deficit.

8. Method according to claim 7, characterized in that the shape of the first membrane (2) and / or the shape of the second membrane (3) is adjusted by a mechanical element (6), wherein the mechanical element (6) is configured to adjust the shape of the first and / or second membrane (2,3) so as to produce the optical element exhibiting one or more optical parameters, particularly in Petition 870250090289, dated 03 / 10 / 2025, page 29 / 45 4 / 9 that the mechanical element (6) is a lens molding device.

9. Method according to claim 8, characterized in that the shape of the first membrane (2) is formed by the mechanical element (6) and in that the shape of the second membrane (3) is formed as a function of hydraulic pressure of the liquid material in the cavity (100) or vice versa.

10. Method, according to at least one of claims 1 to 9, characterized in that the shape of the first membrane (2) and / or the shape of the second membrane (3) is adjusted by a fluid pressure that is applied to a surface of the first and / or second membrane (2,3) that is facing away from the liquid material (5).

11. Method, according to any one of claims 2 to 10, characterized in that the shapes of the first and second membranes (2, 3) are successive deformations of the first membrane (2) and the second membrane (3).

12. Method, according to any of the preceding claims, characterized in that the liquid material (5) is applied to the first membrane (2) or to the second membrane (3) such that the shape of the respective membrane (2, 3) is formed as a result of a force exerted by the application of the liquid material (5), in particular as a result of a weight force of the liquid material (5) on the respective membrane (2, 3), and in which the respective other membrane (3, 2) is placed in contact with the liquid material (5), in which the shape of the respective other membrane is formed as a result of an adhesive force of the liquid material (5).

13. Method, according to any of the preceding claims, characterized in that a solidification, particularly a curing stage of the liquid material (5), is controlled so that the particularly cured solidified optical element (12) is flexible, particularly in that the solidification is terminated before the liquid material (5) is cured to a solid state, particularly in that the material comprises a duroplast, an elastomer and / or a thermoplast.

14. Method, according to any of the preceding claims, characterized in that the optical component (20) is selected from the group consisting of a rigid lens, ski goggles, diving goggles, safety glasses, prescription glasses, sunglasses, virtual reality, augmented reality glasses, a waveguide structure, a waveguide diffraction structure, a waveguide refraction structure.

15. Method according to any of the preceding claims, characterized in that the second surface portion is formed by the optical surface of the optical component, allowing an integrated process combining steps C) and D).

16. Optical system (200), characterized in that it comprises a transparent optical element (12) having an optical power, wherein the optical element (12) comprises a material, particularly a polymer, a first surface (12-1) and a second surface (12-2) facing in the opposite direction from the first surface (12-2), wherein the optical element (12) is flexible and foldable so that the first surface (12-1) can be bent to conform to a curved surface, wherein the first surface (12-1) is configured so that when the first surface (12-1) is placed in extensive contact with a complementary surface, particularly wherein the surface comprises or consists of a polymer, a synthetic polymer or a glass, Van der Waals forces, particularly only Van der Waals forces between the first surface (12-1) and the complementary surface cause the optical element (12) to bond to the complementary surface,wherein the optical element (12) is shaped so that, alone or in combination with the optical component (20), one or more optical parameters selected from the group consisting of cylinder, astigmatism, coma, prism or a higher-order Zernike polynomial aberration are adjusted, particularly Petition 870250090289, dated 03 / 10 / 2025, p. 32 / 45 7 / 9 to adjust a person's vision deficit.

17. Optical system (200), according to claim 16, characterized in that the second surface (12-2) is concave or convex, particularly in that the second surface is coated with an anti-reflective coating.

18. Optical system (200), according to claim 16 or 17, characterized in that it comprises an optical component (20) with an optical surface (20-1) comprising the complementary surface, wherein the optical element (12) is connected through its first surface (12-1) to the optical surface (20-1) of the optical component (20) by means of Van der Waals forces, particularly only Van der Waals forces.

19. Optical system (200), according to any one of claims 16 to 18, characterized in that an adhesive is arranged on the first surface (12-1), such that when the optical element (12) is connected to the optical surface of the optical component (20-1), the optical element (12) is bonded to the optical component (20).

20. Optical system (200), according to one of claims 16 to 19, characterized in that the optical component (20) is selected from the group consisting of: protective eyewear, conventional eyewear, virtual reality eyewear, wherein the optical surface (20-1) is Petition 870250090289, dated 03 / 10 / 2025, page 33 / 45 8 / 9 facing the eyes of a person when the person is wearing the optical component (20).

21. Optical system (200), according to one of claims 16 to 20, characterized in that the optical component (20) comprises two optical surface portions (20-a, 20-b) enclosed by the optical surface (20-1), wherein the surface portions (20-a, 20-b) are arranged so that a person wearing the optical component (20) has one of the surface portions (20-a, 20-b) arranged in front of the person's eye, wherein in each optical surface portion an optical element (12) is attached.

22. Optical system (200), according to one of claims 16 to 21, characterized in that the optical power of each optical element (12) is selected so that an optical power of the optical component (20) is adjusted, particularly in that the optical power of each optical element (12) is different, particularly in that the optical component (20) does not exhibit an optical power.

23. Optical system (200), according to any one of claims 16 to 22, characterized in that each optical element (12) is shaped as a thin lens, which is adapted to conform with the first surface (12-1) of the optical element (12) to the optical surface (20-1) of the optical component (20).

24. Optical system (200), according to any one of claims 16 to 23, characterized in that the width of each optical element is at least 5 to 20 times greater, particularly 10 to 20 times greater, than the thickness of the optical element.

25. Optical system, according to any one of claims 16 to 24, characterized in that each optical element is manufactured by performing the steps of method A) to D) as defined in claim 1 and / or in any one of claims 2 to 9. Petition 870250090289, dated 03 / 10 / 2025, p. 35 / 45

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