Electroactive ophthalmic devices for prescriptions that meet diopter correction, manufacturing methods, and applications of semi-finished hybrid lenses.

Abstract

This invention relates to an electroactive ophthalmic device (1) that satisfies a prescription for at least one power of correction for a wearer, a method of manufacturing the device, and the use of a semi-finished hybrid ophthalmic lens. The device includes at least one electroactive unit (3) comprising a rear housing (4) and a front housing (5) defining a dorsal surface and an opposite front surface of the device, the housings (4 and 5) being provided with transparent electrodes and defining a sealed cavity. According to the invention, the rear housing (4) is derived from a semi-finished hybrid ophthalmic lens comprising: - a front mineral portion having a first mineral surface adjacent to the front housing (5) and a second mineral surface opposite to the first mineral surface; and - a rear plastic portion attached to the front mineral portion, the rear plastic portion having a front plastic surface bonded to the second mineral surface and an untreated rear plastic surface, the untreated rear plastic surface defining the dorsal surface and configured to impart the prescription to the ophthalmic device after surface treatment of the semi-finished hybrid ophthalmic lens.

Description

Technical Field

[0001] This invention relates to an ophthalmic device intended for use with a wearer and to satisfy a prescription for at least one power of correction in that wearer, the ophthalmic device comprising at least one electroactive unit, a method for manufacturing the ophthalmic device, and the use of a semi-finished hybrid ophthalmic lens comprising an anterior mineral portion and a rear plastic portion attached to the anterior mineral portion in a rear housing of the electroactive ophthalmic device. The invention is applicable to electroactive units, such as electrochromic or variable-power units, for example, but not limited to, for augmented reality glasses, virtual reality glasses, and electrofocusing tunable lenses, including devices that provide a wearer with monofocal or multifocal correction (e.g., progressive lenses) and optional astigmatism correction. Background Technology

[0002] Electrochromic (EC) cells typically have a structure comprising two transparent housings, both made of mineral or organic materials, with a transparent conductive coating deposited on their inner surfaces to form electrodes. An EC liquid or gel composition, comprising at least one oxidizing compound and at least one reducing compound, is typically filled in the cavity formed between the facing conductive coatings. When an electric field is applied between the electrodes of the cell, the at least one oxidizing compound and the at least one reducing compound are reduced and oxidized, respectively. Alternatively, only one conductive coating may be provided on the inner surface of the same housing, in which case this conductive coating is divided into two electrodes by structuring on the same housing (e.g., having a comb-like or interdigitated structure). At least one of these oxidizing and reducing compounds is an EC compound. Therefore, the light transmittance of the cell can be changed by applying this electric field. Support for the two transparent housings and sealing of the cavity are typically achieved by means of peripheral seals.

[0003] EC compounds possess the EC property, meaning they change color between their reduced and oxidized states. It can be a mixture of different EC compounds. When an EC compound is reduced or oxidized, another redox-active compound is needed to donate or accept electrons that the EC compound correspondingly accepts or donates. This other redox-active compound can itself be an EC compound. With such an EC unit, the redox state can be controlled by applying an electric field between the electrodes, and thus the color of the EC compound in the unit can be controlled. Combining several EC compounds in the EC unit can be used to adjust the unit's color when no electric field is applied between the electrodes (passivated state) and when an electric field is applied (active state).

[0004] It is known to glue finished (i.e., surface-treated) prescription lenses to the rear surface of an assembled EC unit (both housings of which have been surface-treated, ground, filled, and sealed), or alternatively, to provide clip-on prescription lenses to the EC unit. Since the thickness of an EC unit is typically between 1.8 mm and 2.3 mm, the added prescription lens must be as thin as possible.

[0005] To date, only polycarbonate is known to allow the manufacture of thin portions of such bonded prescription lenses, and the front of the finished prescription lens to be bonded to the rear surface of the EC cell must exhibit a stable surface over time (i.e., not experience warping after a few days). Plastic materials other than polycarbonate, once bonded, obviously do not allow the achievement of the determined final power of the EC cell added to the prescription.

[0006] Another drawback of gluing pre-prescription lenses to the assembled EC unit is its complex implementation, particularly due to the critical relative positioning steps between the EC unit and the two contours of the added prescription, which must be precisely aligned with each other. Furthermore, some adhesive may overflow the edges of the EC unit assembly with the added prescription, thus leaving air bubbles and / or dust residue in / on the adhesive. For these reasons, if such defects arising from the gluing process occur in a later stage, the entire EC assembly consisting of the EC unit and the added prescription lens must be discarded, proving to be very costly.

[0007] Regarding an alternative to providing clip-on prescription lenses to assembled EC units, although very thin prescription lenses can be manufactured in this way, the main drawback of this alternative solution lies in other technical and specification issues of the resulting components.

[0008] EP 3 413 121 A1 relates to a semi-finished lens comprising: a blank formed of a first material having a first hardness, the blank having an outline, a first surface, and a second surface, the second surface being configured to be surface-treated to form a first optical surface of an ophthalmic lens; and a top layer formed of a second material having a second hardness greater than the first hardness, the top layer having an outline, a first surface, and a second surface, the second surface of the top layer being disposed on the first surface of the blank. The outline of the top layer is equal to or contained within the outline of the blank and satisfies a predetermined size selection criterion related to the final outline of the ophthalmic lens.

[0009] More specifically, the lens of EP 3 413 121 A1 may have a finished pre-electrochromic layer based on glass and forming the top layer, a post-finished plastic layer forming the blank is bonded to the finished pre-electrochromic layer, and a functional film is inserted and adhered to the top layer and the blank, the blank being surface-treated to provide a prescription for the lens.

[0010] The main drawback of the EP 3 413 121 A1 lens is the complex bonding process, which is due to the functional coating being bonded to both the mineral top layer and the plastic blank. Summary of the Invention

[0011] The object of the present invention is to provide a novel ophthalmic device intended for use with a wearer and to satisfy the wearer's prescription for at least one power of correction and optional astigmatism. The ophthalmic device includes at least one electroactive unit comprising a rear housing and a front housing, the rear housing and the front housing defining a dorsal surface of the ophthalmic device adjacent to at least one eye of the wearer and an opposite anterior surface, respectively. The rear housing and the front housing are provided with at least one pair of transparent electrodes and define a sealed cavity, which allows at least the aforementioned disadvantages to be overcome.

[0012] For this purpose, the ophthalmic device according to the invention comprises a rear housing derived from a semi-finished hybrid ophthalmic lens, the semi-finished hybrid ophthalmic lens comprising:

[0013] - The front mineral portion, having a first mineral face adjacent to the front shell and a second mineral face opposite to the first mineral face, and

[0014] - A rear plastic portion, which is attached to the front mineral portion, having a front plastic surface bonded to the second mineral surface and an untreated rear plastic surface, the untreated rear plastic surface defining the back surface and configured to impart the prescription to the ophthalmic device after surface treatment of the semi-finished hybrid ophthalmic lens.

[0015] In this specification, an electroactive unit refers to a unit configured to exhibit a passivated state when no electric field is applied between the electrodes and to exhibit at least one active state when an electric field is applied between the electrodes. As described below, at least one electroactive unit of the present invention may, for example, be selected from EC units, variable focus units, and other tunable units.

[0016] It should be noted that the ophthalmic device according to the invention allows for the addition of a prescription to the electroactive unit with a very low thickness (significantly reduced compared to most commercially available prescription-added electroactive lenses), regardless of the polymer used for the transparent substrate of the prescription lens, which is in contrast to the aforementioned prior art involving prescription lenses bonded to the rear housing of the EC unit (where such polymer is limited to polycarbonate).

[0017] In practice, the rear plastic portion of the device of the present invention can be based on virtually any organic polymer suitable for optical purposes, as detailed below, primarily because the rear plastic portion is attached to the front mineral portion in an untreated state and is therefore advantageously stable over time (e.g., does not experience any warping after bonding). In other words, the device of the present invention allows for the avoidance of deformation of the first mineral surface of the front mineral portion during the manufacturing processes of the rear housing and the resulting lens.

[0018] Therefore, the device of the present invention benefits from having the correct prescription value of optical power after surface treatment of the semi-finished hybrid lens, because the curvature of the front plastic surface remains constant due to the front mineral portion to which it is attached.

[0019] Since the curvature of the front plastic surface remains constant, it should also be noted that the final addition of the front housing to the rear housing keeps the thickness of the sealed cavity constant as well (i.e., the rear surface of the front housing and the first mineral surface of the rear housing both have the same curvature), and thus the color tone of the ophthalmic device will be advantageously uniform.

[0020] It should be further noted that the ophthalmic device according to the invention is significantly different from the lens disclosed in EP 3 413 121A1 above, because the device of the invention does not include any functional membrane that is adhesively inserted between the rear plastic portion and the remainder of the device, as defined above.

[0021] According to another feature of the invention, the front mineral portion may include a mineral glass substrate, and the rear plastic portion may form an ophthalmic lens blank, the ophthalmic lens blank including a transparent plastic substrate defining the front plastic surface and may be based on at least one organic polymer selected from thermoplastic, thermosetting and photocurable polymers.

[0022] Advantageously, the rear plastic portion may include the transparent plastic substrate, which may be a single layer or multiple layers depending on the weight fraction, and the weight fraction may be greater than 50%, preferably greater than 70%.

[0023] According to the first embodiment, the transparent plastic substrate may be based on at least one transparent thermoplastic polymer selected from, for example, the following:

[0024] 2-(meth)acrylic acid (co)polymers, especially polymethyl methacrylate (PMMA),

[0025] - Triacetyl cellulose (TAC),

[0026] - Polyesters, such as polyethylene furanate (PEF), polyethylene terephthalate (PET), or polyethylene naphthalate (PEN),

[0027] -Copolyester,

[0028] - Polycarbonate (PC),

[0029] - Cyclic olefin copolymers (COC),

[0030] - Cyclic olefin polymers (COP), and

[0031] - A multilayer film of at least one of these polymers and / or at least one of ethylene and vinyl alcohol copolymer (EVOH), poly(vinyl alcohol) (PVA), polytrifluoroethylene chloride (PCTFE), polyvinylidene chloride (PVDC) or polyamide (PA).

[0032] According to the second embodiment, the transparent plastic substrate can be based on at least one transparent thermosetting or photocurable polymer, such as polyurethane, polyurethane / polyurea, polythiourethane, polyol (allyl carbonate) (co)polymer, polycyclic sulfide, polyepoxide, and, as a thermosetting polymer, can be, for example, the following:

[0033] - Homopolymers or copolymers of allyl carbonate from linear or branched aliphatic or aromatic polyols, even more preferably homopolymers of diethylene glycol bis(allyl carbonate), such as or

[0034] - Polyurethane copolymers, such as the so-called "MR8", "MR"7 and "1.74" lenses.

[0035] According to a general embodiment of the invention (which may include any of the foregoing features), the rear plastic portion may have the untreated front plastic surface.

[0036] As discussed above, this untreated front plastic surface of the rear plastic portion is significantly different from the conventional bonding process of finished (i.e., treated) prescription lenses made of polycarbonate and added to the EC unit.

[0037] Alternatively, it can be noted that the rear plastic portion attached to the front mineral portion may have the front plastic surface that has been surface-treated.

[0038] According to other general embodiments of the invention (which may include any of the foregoing features), in the rear housing (which has a mixed mineral-organic structure), the rear plastic portion may

[0039] 1) Chemically bonded to the preceding portion of the mineral without any adhesive device between them, preferably:

[0040] (i) Direct injection molding onto the pre-mineral portion, wherein the transparent plastic substrate is a thermoplastic polymer, such as a multilayer film selected from (meth)acrylic acid (co)polymer, cellulose triacetate (TAC), polyester, copolyester, polycarbonate (PC), cyclic olefin copolymer (COC), cyclic olefin polymer (COP), and at least one of these polymers and / or ethylene and vinyl alcohol copolymer (EVOH), poly(vinyl alcohol) (PVA), polychlorotrifluoroethylene (PCTFE), polyvinylidene chloride (PVDC), and polyamide (PA), or

[0041] (ii) Directly cast onto the pre-mineral portion, wherein the transparent plastic substrate is a thermosetting or photocurable polymer, such as selected from polyurethane, polyurethane / polyurea, polysulfuric acid ester, polyol (allyl carbonate) (co)polymer, polycyclic sulfide and polyepoxide;

[0042] or

[0043] 2) Attached to the pre-mineral portion by an adhesive device under gravity or pressure, wherein preferably the transparent plastic substrate is based on a thermoplastic polymer and the adhesive device is selected from liquid adhesives, pressure-sensitive adhesives, and photocurable adhesives, for example, in the case where the thermoplastic polymer is polycarbonate, the adhesive device comprises:

[0044] a) at least one urethane acrylate oligomer, in an amount ranging from about 50 wt.% to about 75 wt.%;

[0045] b) At least one alkyl acrylate or diacrylate monomer, in an amount ranging from about 10 wt.% to about 25 wt.%;

[0046] c) at least one hydroxyl-functionalized acrylic monomer, in an amount ranging from about 8 wt.% to about 25 wt.%; and

[0047] d) At least one free radical generation initiator, in an amount ranging from about 5 wt% to about 9.5 wt%.

[0048] According to other general embodiments of the invention (which may include any of the foregoing features), the mixed housing may:

[0049] (i) A conductive layer is coated on the first mineral surface, the conductive layer forming the electrodes of the at least one pair of transparent electrodes and being made of at least one of the following:

[0050] - Transparent conductive oxides (TCOs) deposited by sputtering, such as those selected from ATO (AlSnO), ATZO (AlSnZnO), AZO (AlZnO), FTO (FSnO), GZO (GaZnO), ITO (InSnO), ITZO (InSnZnO), IZO (InZnO), and mixtures thereof.

[0051] - Deformable conductive nanostructures, including metals and selected, for example, from nanonets, nanowires, nanotubes, and nanogrids, and

[0052] A stack of -insulator layer (I1) -metal layer (M) -insulator layer (I2), wherein M is, for example, silver, gold or copper and wherein I1 is equal to or different from I2.

[0053] The insulating layer (I2) in contact with the electrochromic composition includes, for example, a TCO such as ITO, while the other insulating layer (I1) includes, for example, a TCO such as ITO, or a non-conductive layer that can increase light transmission through the stack or form a barrier layer.

[0054] The conductive layer preferably comprises high-temperature ITO; and / or

[0055] (ii) A hard coating is applied to the back surface, which is preferably coated with an anti-reflective coating itself.

[0056] It can be noted that the rear housing and the front housing may each have curved inner surfaces opposite to the back surface of the rear housing and the front surface of the front housing, and these curved inner surfaces may be provided with the at least one pair of transparent electrodes, which are respectively facing each other on the rear housing and the front housing.

[0057] It is also worth noting that the deposition of high-temperature ITO for the conductive layer before assembling the rear housing into the front housing allows for an increase in visual transmittance (Tv) in the visible area.

[0058] Accordingly, the conductive layer may include, for example, a combination of the transparent conductive oxide (TCO) and the deformable conductive nanostructure and / or a stack of the insulating layer (I1)-metal layer (M)-insulator layer (I2).

[0059] According to an exemplary embodiment of the present invention, the curved inner surfaces of the front housing (which is, for example, a mineral structure) and the hybrid rear housing may be provided with the pair of transparent electrodes, which face each other on the rear housing and the front housing respectively and are defined by the following combination:

[0060] - The inner surface of the front housing, serving as the front electrode, comprises at least one TCO (e.g., at least one of ATO, ATZO, AZO, FTO, GZO, ITO, ITZO, and IZO) deposited by sputtering, and

[0061] - The inner surface of the rear housing serves as the relative rear electrode and, optionally in addition to the barrier layer, includes one of the conductive metal nanostructures selected from one or more nanonets, nanowires, and nanogrids (when necessary, treated with a conductive coating as at least one passivation layer (including multiple layers made of several stacked conductive layers and alternating passivation layers), as explained below, to avoid undesirable reactions between the metal and the oxidizing compounds of the EC formulation in the EC unit. It should be noted that the passivation layer can be a conductive coating, such as an inert metal layer (e.g., a gold layer)).

[0062] These nanomesh and nanowires can be obtained by methods known in the art, including depositing a nanostructure suspension layer in a solvent and subsequently removing the solvent, for example, by drying. Nanomesh can be obtained by photolithography applied to a metal layer, as known in the art. Compared to existing brittle TCO materials (such as thick ITO coatings conventionally deposited by sputtering), these metal nanomesh, nanowires, or nanomesh layers are also advantageously able to maintain a high level of deformation without losing their conductivity.

[0063] Advantageously, the passivation layer, which can be a single layer or multiple layers (in the above cases where conductive nanostructures and passivation layers alternate), can:

[0064] - Deposited on deformable conductive nanostructures, the passivation layer is preferably a conductive layer, such as PEDOT, a gold, rhodium, platinum, or palladium-based coating, or a transparent conductive oxide (TCO) coating, or may also be...

[0065] - Directly incorporated into the at least one conductive layer, preferably a mixture of deformable conductive nanostructure and one or more conductive layers (including bilayer or multilayer with more than two layers), or a mixture of deformable conductive nanostructure and one or more transparent conductive oxides (TCOs).

[0066] The TCO that can be used in the passivation layer of the present invention is typically a doped metal oxide whose chemical formula includes oxygen atoms and at least two other elements in different proportions, such as ATO (AlSnO), ATZO (AlSnZnO), AZO (AlZnO), FTO (FSnO), GZO (GaZnO), ITO (InSnO), ITZO (InSnZnO), IZO (InZnO), or mixtures thereof.

[0067] It should be noted that the TCO structured electrodes that can be used in the conductive layer are advantageously much less brittle than the entire TCO layer.

[0068] According to an exemplary embodiment of the invention (which may include any of the foregoing features), the rear housing may further optionally include a single layer or multiple layers of deformable barrier coating on the back surface. The deformable barrier coating may form a barrier layer against at least one of oxygen, water vapor, and solvents, and preferably is:

[0069] - Based on at least one polymer derived from an alcohol unit, such as ethylene and vinyl alcohol copolymer (EVOH) or poly(vinyl alcohol) (PVA), or

[0070] - An adhesive layer based on at least one polymer not derived from alcohol units, such as polyisobutylene (PIB), or

[0071] - Inorganic or mixed organic / inorganic gas barrier coatings, such as those selected from Al2O3, Si3N4, SN, TiN, SiO x N y SiO x C y Indium tin oxide (ITO), SiO2, ZnO2, and TiO2, wherein x and y are greater than 0 and less than or equal to 4.

[0072] This barrier layer can be applied by physical vapor deposition (such as vacuum evaporation or sputtering), plasma-enhanced chemical vapor deposition (PECVD), atomic layer deposition (ALD), or by neutral beam assisted sputtering (NBAS).

[0073] According to a preferred embodiment of the present invention (which may include any of the foregoing features):

[0074] - The front housing comprises a mineral glass substrate and has a mineral rear surface opposite to the front surface of the front housing.

[0075] - The rear mineral surface of the front housing is concave, and the first mineral surface of the rear housing is convex, both being curved with the same curvature, including at least one of cylindrical, toric, and spherical curvature.

[0076] The rear housing and the front housing are spaced 10 μm to 400 μm apart, for example 20 μm to 250 μm apart, thereby forming a gap that defines the sealing cavity, which is defined at its periphery by an adhesive seal.

[0077] According to another aspect of the invention (which may include any of the foregoing features), the ophthalmic device forms at least one electroactive lens, such as those selected from variable-power lenses and electrochromic lenses, and the ophthalmic device includes augmented reality glasses, virtual reality glasses and electrofocusing adjustable lenses, sports goggles (e.g. for skiing, cycling, motorcycling or other sports using goggles), preferably glasses that provide monofocal or multifocal correction (e.g., progressive glasses).

[0078] The glasses according to the invention can have their color and transmittance modified as needed. In most cases, it is preferred that the electroactive units (such as EC units) have higher transmittance in the passivated state and become darker in the active state.

[0079] As for the eyeglass frame to which the ophthalmic device of the present invention is adapted, the eyeglass frame may advantageously include an electronic system configured to control the electroactive unit.

[0080] It should be noted that the ophthalmic device according to the invention as defined in the appended claims may be without a frame and / or electronic system, battery and sensors to control the lens, i.e., like a semi-finished device.

[0081] According to other features of the invention (which may include any of the foregoing features), the front housing and / or the rear housing may each further include at least one of a polarizing film, a photochromic layer, a photochromic polarizing layer, a hard coating, an anti-reflective coating, an anti-fog coating, a blue light blocking coating, and an antistatic coating, for example, on the front surface and / or the back surface.

[0082] As explained above, the rear housing may be coated with a hard coating on the back side surface, which is preferably coated with an anti-reflective coating itself.

[0083] According to another general feature of the invention (which may include any of the foregoing features), when the electroactive ophthalmic device is an EC device, the sealed cavity between the front housing and the rear housing is, for example, filled with an electrochromic (EC) composition.

[0084] The EC composition can be a liquid solution or a gel, including:

[0085] - At least one EC oxidizing agent, such as selected from monovioletin or divioletin, anthraquinone, benzoazole, imidazo[1,2-α]pyridine, 2,1,3-benzothiadiazole, imidazolium, benzoselenazolium, benzoselenic acid azole and its derivatives, and

[0086] - At least one EC reducing compound, such as derivatives selected from ferrocene, phenoxazine, phenazine, phenothiazine, thioanthraene, tetrathiofulvalene, and mixtures thereof.

[0087] - Solvents, such as propylene carbonate

[0088] - Thickeners, such as multifunctional polymers containing at least two carboxyl groups, for example selected from carboxylic acid-functionalized polyesters, carboxylic acid-functionalized polyethers, carboxylic acid-functionalized polyurethanes, carboxylic acid-functionalized polyacrylates, carboxylic acid-functionalized polymethyl methacrylates, carboxylic acid-functionalized polyethylene acetate copolymers, combinations thereof, or their reaction products or copolymers (polymethyl methacrylate, polyvinyl acetate, or polyvinyl acetate derivatives are particularly suitable), and

[0089] - Optional electrolytes, such as tetrabutylammonium tetrafluoroborate (TBA).

[0090] It is worth noting that at least one of the EC oxidants can act as an electrolyte, making it possible that the optional electrolytes mentioned above do not need to be added.

[0091] Preferably, the sealed cavity is defined at its periphery by an adhesive seal, which is a flexible adhesive preferably selected from acrylates, methacrylates, cyanoacrylates, epoxy resins, polyurethanes, polyisobutylene, silicones, and pressure-sensitive adhesives.

[0092] It should be noted that all types of EC units, including EC compositions, can be used in this invention, preferably so-called “integrated” ECs, which are defined, for example, as EC units in Alesanco et al. (Material 2018, 11, 414), wherein the EC formulation comprises at least one oxidizing compound and at least one reducing compound, which are reduced and oxidized respectively when an electric field is applied between the electrodes (at least one of these oxidizing and reducing compounds is an EC compound).

[0093] According to an exemplary embodiment of the EC composition of the hybrid lens:

[0094] - The at least one EC oxidant is selected from monovioletin or bisvioletin (i.e., 4,4'-bipyridinium salt or bis[4,4'-bipyridinium] salt), such as alkylvioletin, arylvioletin, alkylarylvioletin, anthraquinone, benzo[2,2-α]pyridine, 2,1,3-benzothiadiazole, imidazole, benzo[2,3-]selenazazole, benzo[2,3-]seleno[2,3-]pyridine, and their derivatives.

[0095] - The at least one EC reducing compound is selected from ferrocene derivatives, phenoxazine derivatives, phenazine derivatives, phenothiazine derivatives, thioanthraene derivatives, tetrathiofulvalene derivatives and mixtures thereof (e.g., 10-methylphenothiazine (MePhtz)).

[0096] Non-limiting examples of such viologen compounds or viologen derivatives, more particularly substituted dialkyl, diaryl 4,4'-bipyridinium salts, substituted dialkyl, diaryl bis[4,4'-bipyridinium] salts, and mixtures thereof are described in documents EP 2848667 A1, EP 2848668 A1, EP 2848669 A1, EP 2848670 A1, EP 3115433 A1 and EP3345981A1, the teachings of which are incorporated herein by reference. Preferred examples, such as 1,1'-bis(3-(tert-butyl)phenyl)[4,4'-bipyridinium]-1,1'-dionium bis(tetrafluoroborate), are mentioned herein.

[0097] In a preferred embodiment, the redox chemical mixture comprises one of the reducing compounds (e.g., 10-methylphenothiazine) and at least one EC oxidizing compound, preferably at least two EC oxidizing compounds, such as two or three EC oxidizing compounds, preferably each EC oxidizing compound is independently selected from substituted dialkyl 4,4'-bipyridinium salts, substituted diaryl 4,4'-bipyridinium salts, substituted dialkyl bis[4,4'-bipyridinium] salts or substituted diaryl bis[4,4'-bipyridinium] salts, more preferably at least one substituted diaryl 4,4'-bipyridinium and at least one substituted diaryl bis[4,4'-bipyridinium].

[0098] As an EC composition, the following solutions may be mentioned: the solution includes a solvent (such as propylene carbonate), a thickener as defined above (i.e., such as the multifunctional polymer containing at least two carboxyl moieties), at least one oxidizing agent and a reducing agent as defined above, and an electrolyte (such as tetrabutylammonium tetrafluoroborate (TBA)).

[0099] In a known manner, at least a portion of the EC compound in the EC unit is contained in a liquid or gel that forms the EC composition and fills the space between the electrodes to ensure ion conduction between the electrodes through an electrolyte (which may comprise the EC material itself and / or other redox-active species and / or charged species of other ions that do not possess EC properties and redox activity). Thus, the EC composition provides the EC unit with at least a portion of its EC properties.

[0100] EC compounds can be selected to be colorless or weakly colored in the passivated state. Combinations of EC compounds in an EC unit can also provide the EC unit with a neutral color, such as gray or brown, especially in the active state of the EC unit.

[0101] The method according to the invention for manufacturing an ophthalmic device defined in any of the foregoing features essentially comprises the following steps:

[0102] a) The semi-finished hybrid ophthalmic lens is manufactured by attaching the back plastic portion having the untreated back plastic surface to the front mineral portion;

[0103] b) Surface-treating the semi-finished hybrid ophthalmic lens to impart the formulation to the untreated back plastic surface, thereby obtaining the back surface; and

[0104] c) Once surface treated, the at least one electroactive unit is assembled by connecting the front housing and the rear housing, which includes the semi-finished hybrid ophthalmic lens, together.

[0105] As explained above, it should be noted that performing this surface treatment step b) after attaching the untreated rear plastic portion to the front mineral portion allows the rear housing of the ophthalmic device to be obtained without compromising the stability of the first plastic surface of the rear plastic portion over time, even if the plastic portion is subsequently glued to the front mineral portion without being based on polycarbonate, as is the case with conventional gluing of finished prescription lenses based on polycarbonate after assembly into other parts of the device.

[0106] According to another preferred feature of this method of the invention, in step a), attaching the rear plastic portion to the front mineral portion is achieved by one of the following methods:

[0107] (i) The thermoplastic transparent substrate of the rear plastic portion (which may be for thermoplastic polymers as defined above and may not include polycarbonate) is directly injection molded onto the front mineral portion.

[0108] (ii) Directly casting the transparent thermosetting or photocurable substrate of the post-plastic portion (which may be for thermosetting or photocurable polymers as defined above that can be used in the post-plastic portion) onto the pre-mineral portion, and

[0109] (iii) Attaching the thermoplastic transparent substrate of the rear plastic portion (which may be for the thermoplastic polymer as defined above and may not contain polycarbonate) to the front mineral portion using an adhesive device selected from liquid adhesives, pressure-sensitive adhesives, and photocurable adhesives, for example by gluing under gravity or pressure using a photocurable adhesive:

[0110] a0) Apply the photocurable adhesive to the respective surfaces of the thermoplastic transparent substrate and the pre-mineral portion;

[0111] a1) The thermoplastic transparent substrate and the corresponding surfaces of the pre-mineral portion are bonded together by gravity or under pressure, wherein the pre-mineral portion is horizontally covered by the thermoplastic transparent substrate; and

[0112] a2) Apply at least one type of radiation through the thermoplastic transparent substrate for a period of time to allow the light-curing adhesive to solidify.

[0113] It should be noted that, according to options (i) and (ii) of the above attachment method, the rear plastic portion can therefore be chemically bonded to the front mineral portion without an adhesive device between them, or according to option (iii) of this attachment method, the rear plastic portion is bonded to the front mineral portion with an adhesive device.

[0114] According to other preferred features of the method of the present invention (including any of the foregoing features), the method further includes the following successive steps between step b) and c):

[0115] b1) Depositing a hard coating, for example by spin-jet or inkjet coating, and an optional anti-reflective coating on the back surface to obtain a surface-treated and coated hybrid ophthalmic lens forming the rear housing; and

[0116] b2) The surface-treated and coated hybrid ophthalmic lens is edge-ground according to the defined shape of the frame configured to receive the ophthalmic device, for example by the following method:

[0117] - The position of the optical center and horizontal axis of the surface-treated and coated hybrid ophthalmic lens is detected by a sealing and centering device, such that the optical center and the axis are well positioned according to the shape of the frame, or

[0118] - The reference mark located outside the shape of the frame, which provides the optical center and the horizontal axis, is directly engraved onto the reference element of the surface-treated and coated hybrid ophthalmic lens.

[0119] According to other preferred features of the method of the present invention (including any of the foregoing features), the sealed cavity may be filled with an EC composition, and the at least one electroactive unit is an EC unit, and

[0120] The method further includes filling the cavity between the front housing and the rear housing with the EC composition, while protecting the rear housing from the effects of the EC composition by:

[0121] - A liquid solution of the electrochromic composition, wherein the filling is achieved by means of:

[0122] *Micro-injection of this liquid solution,

[0123] *Prior to assembly step c), a drop-filling technique for the liquid solution on the front housing and a dispensing technique for sealing the rear housing, or

[0124] *If step a) is achieved through alternative (iii), the component obtained in step c) is immersed in the liquid solution while using the sacrificial coating that isolates the post-plastic portion from the photocurable adhesive in step a), and the sacrificial coating is removed after immersion; or

[0125] - The gel of the electrochromic composition is achieved by applying the gel to the rear shell prior to assembly step c).

[0126] According to other preferred features of the method of the invention (including any of the foregoing features), the method further includes depositing a conductive layer on the first mineral surface to form electrodes of the at least one pair of transparent electrodes, wherein the conductive layer is applied:

[0127] - Prior to assembly step c), for any deposition temperature including the high temperature of the conductive layer, such as high-temperature ITO deposited during step a); or

[0128] - After assembly step c), only for the low deposition temperature of the conductive layer, which is, for example, low-temperature ITO.

[0129] It is worth noting again that the deposition of high-temperature ITO for the conductive layer prior to assembly step c) allows for an increase in visual transmittance Tv in the visible region.

[0130] It is also worth noting that after assembly step c), preferably after surface treatment of the semi-finished hybrid ophthalmic lens, low-temperature ITO can be deposited only on the conductive layer, since the post-plastic portion cannot withstand the high temperature required for high-temperature ITO.

[0131] Another preferred feature of the method according to the invention (including any of the foregoing features) is that in the surface treatment step b):

[0132] - For example, by means of a metal alloy with a low melting point (or by means of any other known sealing technique) sealing the semi-finished hybrid ophthalmic lens,

[0133] -If the front mineral portion of the rear housing is coated with a conductive layer on the first mineral surface in step a), a protective film is used to protect the conductive layer during the surface treatment process and optionally in the subsequent deposition of a hard coating step b1) and the edging step b2) of the surface-treated and coated hybrid ophthalmic lens.

[0134] - Calculate the dorsal surface of the ophthalmic device to be obtained, such that the total power of the front shell, the front mineral portion, and the rear plastic portion is equal to the prescription of the wearer to be obtained, and

[0135] - The subsequent plastic portion is surface-treated accordingly using a surface treatment tool, without contact between the surface treatment tool and the preceding mineral portion.

[0136] Advantageously, the assembly step c) may include connecting the front housing and the rear housing together by means of a clamping system and by compressed air and other possible easily implemented techniques.

[0137] According to another aspect of this disclosure, the present invention also relates to the use of a semi-finished hybrid ophthalmic lens comprising an anterior mineral portion and a rear plastic portion attached to the anterior mineral portion in a rear housing of an electroactive ophthalmic device selected from variable-power lenses and EC lenses, such as augmented reality devices, virtual reality glasses, or electrofocusing tunable lenses:

[0138] The prescription is applied to the ophthalmic device by surface treatment of the back surface of the semi-finished hybrid ophthalmic lens, the semi-finished hybrid ophthalmic lens is assembled onto the front housing, and a sealed cavity is obtained, for example, between the semi-finished hybrid ophthalmic lens and the front housing, which is filled with the EC composition in the case that the electroactive ophthalmic device is an EC device.

[0139] This use of the semi-finished hybrid ophthalmic lens according to the invention may further include any of the aforementioned features related to ophthalmic devices and their manufacturing methods. Attached Figure Description

[0140] The invention will be described in more detail with reference to the accompanying drawings, in which:

[0141] - Figure 1 This is a perspective view of an ophthalmic device according to an example of the present invention, the ophthalmic device comprising eyeglasses including EC units in two ophthalmic lenses;

[0142] - Figure 2A yes Figure 1 A front view of an EC ophthalmic lens for eyeglasses;

[0143] - Figure 2B This EC ophthalmic lens is in Figure 2A A schematic cross-sectional view on plane IIB-IIB shows the EC unit that forms this lens;

[0144] - Figure 3 This is a front view of an EC ophthalmic lens according to another example of the present invention, which is connected to a control circuit via a conductive intermediate element;

[0145] - Figure 4 It is by Figure 2BAn enlarged schematic cross-sectional view of the EC ophthalmic lens according to the present invention, which is composed of EC units visible in the image, wherein the control circuit is located directly between two connecting elements;

[0146] - Figure 5 It is similar to the EC lens according to the present invention. Figure 2B A schematic cross-sectional view showing the EC unit that forms the ophthalmic lens or each ophthalmic lens;

[0147] - Figure 6 yes Figure 5 A schematic (not to scale) cross-sectional view of the semi-finished rear housing of the EC unit according to the present invention, as visible in the figure;

[0148] - Figure 7 It is a schematic cross-sectional view of an injection mold in which the thermoplastic substrate of the rear plastic portion is injected onto the front mineral portion to provide the semi-finished hybrid ophthalmic lens of the ophthalmic device;

[0149] - Figure 8 It is a schematic perspective view of a casting apparatus configured to cast a thermosetting or photocurable substrate of the rear plastic portion onto the front mineral portion to provide the semi-finished hybrid ophthalmic lens of the ophthalmic device.

[0150] - Figure 9A This is a partial schematic cross-sectional view of an apparatus configured to bond a thermoplastic substrate of the rear plastic portion to the front mineral portion under negative pressure to provide a semi-finished hybrid ophthalmic lens; and

[0151] - Figure 9B This is a schematic cross-sectional view of an alternative device configured to bond the thermoplastic substrate of the rear plastic portion to the front mineral portion under positive pressure. Detailed Implementation

[0152] The terms “comprises” (and any of its grammatical variations, such as “comprises” and “comprising”), “has” (and any of its grammatical variations, such as “has” and “having”), “contains” (and any of its grammatical variations, such as “contains” and “containing”), and “includes” (and any of its grammatical variations, such as “includes” and “including”) are all open-ended linking verbs. They are used to indicate the presence of a feature, integer, step, or component or group thereof, but do not exclude the presence or inclusion of one or more other features, integers, steps, or components or groups thereof. Therefore, a method or a step in a method that “comprises,” “has,” “contains,” or “includes” one or more steps or elements has, but is not limited to, only those steps or elements.

[0153] Unless otherwise specified, all figures or expressions relating to quantities of ingredients, ranges, reaction conditions, etc., used herein should be understood to be modified in all cases by the term “about”. Similarly, unless otherwise specified, indications of a range of values ​​“from X to Y” or “between X and Y” according to the present invention mean that the values ​​of X and Y are included.

[0154] Exemplary ophthalmic device according to the present invention:

[0155] Figures 1 to 6 The following description relates to non-limiting examples of electroactive units (such as EC units) and related ophthalmic devices disclosed in WO 2017 / 009563 A1, except that, apart from the combination of materials selected for the front and rear housings respectively, examples according to the invention are described in detail below.

[0156] according to Figure 1 In the embodiment shown, the ophthalmic device 1 includes a frame 2 in which two EC units 3a and 3b are installed.

[0157] like Figure 2B As shown, each EC unit 3 includes two transparent shells 4 and 5 that form an advantageously non-conductive outer layer, and a cavity 6 is defined between the two transparent shells, which is intended to be filled with an electrochromic composition 7.

[0158] Therefore, each transparent shell 4, 5 includes inner surfaces 4a, 5a and outer surfaces 4b, 5b. Thus, the term "inner" more specifically refers to the surfaces 4a, 5a that define the cavity 6 of the unit 3, and the term "outer" more specifically refers to the surfaces 4b, 5b outside the cavity 6. Therefore, the cavity 6 has a thickness e between the two inner surfaces 4a, 5a.

[0159] Specifically, the transparent housing 4 is designed such that the resulting EC ophthalmic lens, formed through its outer surface 4b, is close to the dorsal surface of one of the wearer's eyes once worn by the wearer. The transparent housing defines the hybrid housing 4 of the present invention as defined above, which therefore comprises, in weight primarily, the organic polymer substrate of the thermoplastic, thermosetting, or photocurable type.

[0160] Conversely, another transparent housing 5 is designed to form the opposite front surface of the resulting EC ophthalmic lens once worn by the wearer through its outer surface 5b. This other transparent housing is, for example, a mineral front housing 5, which therefore comprises primarily the mineral glass substrate in terms of weight.

[0161] The transparent housings 4 and 5 can also be selected to filter ultraviolet radiation, particularly absorbing wavelengths below 420 nm. Typically, the material of the housings 4 and 5, or the treatment of their inner surfaces 4a and 5a and / or outer surfaces 4b and 5b, can give the housings 4 and 5 advantageous features, such as the ability to achieve color reflection, specular effect, protection against blue light, or protection against infrared radiation, and this list is not limiting. These outer surfaces 4b and 5b can also be coated with scratch-resistant coatings, anti-reflective (AR) coatings, stain-resistant coatings, anti-fog coatings, primer coatings, etc. According to one embodiment, the housings 4 and 5 can be colored, photochromic, and / or polarized. According to one embodiment, the front housing 5 can be made of tempered material to increase its mechanical strength.

[0162] For example, each housing 4, 5 may have a hard coating, an AR coating, an anti-fouling coating, or an antistatic coating on its outer surface 4b, 5b. Some hard coatings or AR coatings may also be used beneath the conductive coatings 9, 10 described below. Furthermore, the rear housing 4 and / or the front housing 5 may also include a polarizing film, or a photochromic layer, or even a photochromic polarizing layer.

[0163] Preferably, the thickness of the shells 4 and 5 is between 50 μm and 2000 μm, or even between 300 μm and 1000 μm. The shells 4 and 5 may be, for example, spherical shells, and particularly have a spherical or oval shape defined by the peripheral edge 8.

[0164] According to the invention, at least one inner surface 4a, 5a, and particularly both inner surfaces 4a, 5a of the housings 4, 5 are curved, i.e., they have non-zero curvature. For example, the inner surfaces 4a, 5a of the housings 4, 5 can each be concave or convex. Moreover, the outer surfaces 4b, 5b of the housings 4, 5 can also be curved, and particularly concave or convex.

[0165] The inner surfaces 4a, 5a of each transparent housing 4, 5 are at least partially, preferably completely, covered by the conductive coatings 9, 10 as defined above, i.e., each conductive coating includes, for example:

[0166] - A transparent conductive coating of at least one TCO (e.g., at least one of ATO, ATZO, AZO, FTO, GZO, ITO, ITZO, and IZO) deposited by sputtering, or

[0167] - Conductive nanostructures based on metals (e.g., silver), selected from nanomesh, nanowire, and nanogrid, and treated with at least one passivation layer when necessary to prevent the metal from reacting with the EC formulation of the EC units.

[0168] A stack of -insulator layer (I1) -metal layer (M) -insulator layer (I2), wherein M is, for example, silver, gold or copper and wherein I1 is equal to or different from I2.

[0169] The insulating layer (I2) in contact with the electrochromic composition (7) comprises a transparent conductive oxide (TCO), such as indium tin oxide (ITO), and

[0170] The other insulating layer (I1) includes a transparent conductive oxide (TCO), such as indium tin oxide (ITO), or a non-conductive layer, such as one that can increase light transmission through the stack or form a barrier layer, and / or

[0171] - Polymer conductive coating.

[0172] It should be noted that if the conductive nanostructure (e.g., nanowire) used has already been passivated, it may not be necessary to treat the conductive nanostructure with at least one passivation layer (including multilayers made of multiple stacked conductive layers and alternating passivation layers).

[0173] The rear housing 4 may include at least one barrier layer (which may be a single or multiple barrier coatings) on its inner surface 4a (i.e., designed to form the first mineral surface) and / or outer surface 4b (designed to form the back side surface). The barrier layer of the rear housing 4 may be, for example, a barrier layer against gases (e.g., oxygen) and / or water vapor, and allows for further protection of the EC ophthalmic device 1 and extends its lifespan.

[0174] As disclosed above, in a particularly preferred embodiment of the invention, an advantageous combination of conductive coatings 9 and 10 for both the rear housing 4 and the front housing 5 can be:

[0175] - The hybrid housing 4 is provided with a combination of the barrier layer and conductive coating disclosed above, the conductive coating being made of a conductive polymer layer combined with metal nanowires, nanomesh, or nanogrid as a passivation layer, and

[0176] - Provide a TCO (e.g., ITO) coating that exhibits satisfactory electrical conductivity to the mineral front shell 5.

[0177] Specifically, nanowires or nanomesh can be applied, for example, by spraying, rod coating, inkjet coating, spin coating, or also by screen printing on a flat substrate or by spraying, spin coating, or inkjet coating on a curved substrate. Metal nanomesh can be fabricated by photolithography, and the passivation layer can be applied by various techniques (e.g., from PEDOT or other conductive polymer layers applied by spin coating, spraying, inkjet coating, rod coating, or screen printing processes; from gold or rhodium coatings applied by electrochemical or electroless plating processes; or from TCO (e.g., ITO) thin layers deposited by PVD, PECVD, or sputtering). Silver nanowires or nanomesh can also be directly included in a polymer conductive coating, such as in a commercially available mixture of PEDOT and silver nanowires (e.g., from Heraeus).

[0178] The radii of curvature of shells 4 and 5 are adapted to maintain a constant gap between the two shells after assembly. To assemble shells 4 and 5, a process similar to one apparently used for mineral glass shells can be used, provided it minimizes the constraints applied to the mixed shell 4 to avoid any deformation, especially if shell 4 is subsequently thin. Nevertheless, other known methods may also be used.

[0179] Unit 3, particularly the two transparent housings 4 and 5, is held together by a peripheral seal 11. Therefore, the seal 11 completely surrounds the cavity 6. The seal 11 ensures sufficient thickness e for unit 3 and prevents direct contact between the conductive coatings 9 and 10 of each housing 4 and 5.

[0180] The height h of the seal 11 (especially after assembly unit 3) is between tens and hundreds of micrometers, preferably between 20 μm and 400 μm, or even more specifically between 80 μm and 300 μm, or even more specifically between 90 μm and 250 μm. As an example, the height h of the seal 11 can be approximately 200 μm. This height h corresponds to the thickness e of the cavity 6 near the peripheral edges 8 of the transparent housings 4 and 5, particularly near the peripheral edges of the inner surfaces 4a and 5a.

[0181] More specifically, such as Figure 2B The height h of the seal 11 shown corresponds to the seal 11 not deposited on the connecting elements 14, 15 as described below. However, in an embodiment where the seal 11 is partially deposited on the connecting elements 14, 15, the height h corresponds to the height of the seal 11 and the height of the connecting elements 14, 15 that are joined together.

[0182] Furthermore, the width L of the seal 11 is preferably less than 5000 μm for goggles, or less than 1000 μm for ophthalmic lenses, or even less than 3000 μm for goggles and less than 800 μm for ophthalmic lenses. Therefore, when the ophthalmic device 1 is installed in the frame 2, the seal 11 will be invisible and will not restrict the wearer's field of vision or the usable area of ​​the ophthalmic device 1.

[0183] The term "width" refers to the size of an element extending in a plane substantially parallel to the inner surfaces 4a and 5a of the transparent housings 4 and 5. The term "height" or "thickness" refers to the size of an element extending in a direction substantially transverse to the inner surfaces 4a and 5a of the housings 4 and 5.

[0184] The seal 11 is made of an adhesive material that maintains the cohesion between the two transparent housings 4 and 5. The adhesive material can be any flexible adhesive that can retain its shape during the selected assembly process.

[0185] According to embodiments, the adhesive material may be a flexible adhesive selected from acrylates, methacrylates, cyanoacrylates, epoxides, polyurethanes, polyisobutylene, or silicone sealants, preferably polyisobutylene, cationic epoxy resins, epoxy amines, epoxy anhydrides, or oxime silicone sealants. Alternatively, the adhesive material may be a pressure-sensitive adhesive, which can be applied as if based on or not based on a hot melt adhesive solvent.

[0186] The adhesive material is preferably a photopolymerizable and / or thermopolymerizable resin, and in particular, it may be a polyisobutylene pressure-sensitive adhesive or a cationic initiating epoxy resin. In addition to polyisobutylene adhesives, such resins (e.g., cationic epoxy resins) can be crosslinked by exposure to light and / or by heating, as described below. Once the filled epoxy resin is crosslinked, a seal 11 with good mechanical strength can be obtained. Moreover, the seal 11 thus obtained is both watertight and airtight.

[0187] According to one embodiment, the adhesive material is compatible with or inert to the EC composition 7, i.e., it does not cause chemical interactions or degradation of the EC composition 7.

[0188] According to one embodiment, the adhesive material includes spacer elements 12, such as glass beads or polymer beads. The spacer elements 12 are electrically isolated. Specifically, the spacer elements 12 of the adhesive material contact each of the inner surfaces 4a, 5a of the housings 4, 5. Therefore, the spacer elements 12 can define and control the height h of the seal 11, and thus achieve a sufficient thickness e of the cavity 6. When using a drop-fill process, the spacer elements 12 may not be necessary (in which case the thickness is controlled by the volume of liquid distributed on a surface and the height through the seal 11).

[0189] According to one embodiment, the adhesive material further includes a thixotropic agent. This thixotropic agent can optimize the shape of the seal 11 by controlling the amount of adhesive material deposited on one of the housings 4 and 5.

[0190] Thixotropic agents can particularly achieve a satisfactory ratio between the height h and width L of the seal 11. Therefore, a cavity 6 with sufficient thickness e can be obtained while minimizing the width L of the seal 11. This avoids edge effects, i.e., localized diffusion of the adhesive material during its deposition on the housings 4, 5, which would lead to a significant increase in the width L of the seal 11. For example... Figure 2B As shown, the seal extends perpendicularly to the inner surfaces 4a and 5a of the transparent housings 4 and 5.

[0191] Furthermore, thixotropic agents allow for the deposition of seals onto curved surfaces while controlling the ratio between the seal's height h and width L. Therefore, the seal's cross-section (height h and width L) remains essentially constant, even when deposited along complex lines on curved surfaces, because the rheological control of the seal prevents diffusion or slippage and avoids defects in sealing or aesthetics. Other additives, such as fillers, can be used in the adhesive material, for example, carbon black that can color the seal.

[0192] The conductive coatings 9 and 10 of each housing 4 and 5 form electrodes. These electrodes are not in direct contact with each other and are designed to be electrically connected to an external power source 13, such as... Figure 1 The battery shown.

[0193] For this purpose, connecting elements 14, 15 (also referred to as “buses”), particularly metallic, may be deposited at the periphery of each housing 4, 5, in direct contact with each conductive coating 9, 10. Each connecting element 14, 15 partially, and particularly completely, surrounds each housing at its peripheral edge 8, particularly at the edge face of unit 3. Each connecting element 14, 15 is positioned particularly at the peripheral edge 8 of each housing 4, 5, thereby forming an equipotential, particularly around each housing 4, 5. Connecting elements 14, 15 are made, for example, of copper, gold, silver, or nickel. Preferably, connecting elements 14, 15 are passivated to prevent interaction with the EC composition 7, thereby preventing its corrosion.

[0194] Each connecting element 14, 15 is positioned outside the cavity 6 formed by unit 3 and therefore does not contact the EC composition 7 filling the cavity 6. As a variant, seal 11 may at least partially cover connecting elements 14 and 15.

[0195] The seal 11 is positioned between the cavity 6 and each connecting element 14, 15. In other words, the perimeter of the seal 11 is smaller than the perimeter of each connecting element 14, 15. Therefore, each connecting element 14, 15 is isolated from the EC composition 7, particularly electrically isolated, to prevent any local failure of the unit 3.

[0196] For the goggles, the width of each connecting element 14, 15 is preferably between 500 μm and 1500 μm. Furthermore, the height of each connecting element 14, 15 is preferably between 0.5 μm and 50 μm, preferably between 1 μm and 30 μm, and more preferably between 1 μm and 25 μm. The total thickness of the two connecting elements 14, 15 is necessarily less than the thickness e of unit 3, ensuring that the two connecting elements 14 and 15 do not contact each other.

[0197] To ensure the electrical operation of unit 3, each connecting element 14, 15 is electrically connected to control circuit 16. Control circuit 16 is, for example, a small electronic control board equipped with a microcontroller that can control the on / off and / or transmission level of unit 3.

[0198] According to, for example Figure 4 In one embodiment, the control circuit 16 is positioned directly between the two connecting elements 14 and 15. The seal 11 does not contact or interfere with the control circuit 16. The control circuit 16 also includes two surfaces 16a and 16b, each of which is electrically connected to the connecting elements 14 and 15, particularly in direct contact or with the aid of conductive adhesive or conductive glue. According to this embodiment, the height of the control circuit 16 between its two surfaces 16a and 16b is equal to the thickness e of the cavity of unit 3 minus the thickness of the connecting elements 14 and 15.

[0199] according to Figure 3 In another embodiment shown, the control circuit 16 is not directly positioned between the two connecting elements 14 and 15. The ophthalmic device 1 includes a conductive intermediate element 17 (also referred to as a "cord"). The conductive intermediate element 17 is preferably positioned on the nasal or temporal side of the frame 2 of the ophthalmic device 1, such as... Figure 1 As shown.

[0200] According to this embodiment, the conductive intermediate element 17 is independently electrically connected to each connecting element 14, 15 at a first end 17a. The conductive intermediate element 17 can have a relatively large surface contact area with each connecting element 9, 10. According to this embodiment, the conductive intermediate element 17 can, for example, partially adopt the shape of the peripheral edge 8 of the housing 4, 5 to facilitate its assembly with the unit 3.

[0201] Therefore, the conductive intermediate element 17 may partially or completely surround the peripheral edge 8 of each housing 4, 5. In this embodiment where the conductive intermediate element 17 completely surrounds the peripheral edge 8 of the housing 4, 5, the unit 3 does not need to include connecting elements 14, 15, and the conductive intermediate element 17 serves as the connecting elements 14, 15.

[0202] Therefore, as a variant, unit 3 may not include connecting elements 14 and 15, especially when the aforementioned coatings 9 and 10 are made of a sufficiently conductive material.

[0203] The conductive intermediate element 17 is also electrically connected to the control circuit 16 at the second end 17b, so as to enable the operation of the control unit 3.

[0204] Conductive tracks may be required around each side of the lens to maintain a constant potential around the lens. These conductive tracks can be applied, for example, by dispensing metallic ink (such as silver ink) directly onto the conductive layer before or after the assembly process (this ink should be compatible with the assembly process).

[0205] Method for manufacturing the ophthalmic device according to the present invention:

[0206] In the exemplary case where each electroactive unit is an EC unit 3, the invention is described in more detail but not in a limiting manner in the following exemplary method.

[0207] As in Figure 5 As seen, the rear housing 4 and the front housing 5 are assembled together with the adhesive seal 11 to form the EC unit 3 and the resulting EC ophthalmic lens, the unit 3 being filled with the EC liquid or gel composition 7.

[0208] As explained above and referenced Figure 6 EC ophthalmic lenses 1 are basically manufactured in the following ways:

[0209] a) Attach a rear plastic part 4A having an untreated rear plastic face 4b' to a front mineral part 4B to obtain a semi-finished hybrid ophthalmic lens 4';

[0210] b) Subject the semi-finished hybrid lens 4' obtained in a) to a surface treatment to obtain a hybrid rear housing 4, and assign a determined prescription to the rear plastic face to form Figure 2B the dorsal surface 4b; and

[0211] c) Assemble the Figure 5 EC unit 3 by connecting a front housing 5 and the surface-treated rear housing 4 obtained in b).

[0212] Step a) of obtaining the semi-finished hybrid ophthalmic lens 4':

[0213] As seen in Figure 7 In the first embodiment, in step a), the rear plastic part 4A is attached to the front mineral part 4B by directly injection molding a thermoplastic transparent substrate 4A' onto the front mineral part 4B, and the thermoplastic transparent substrate is designed to form the rear plastic part 4A (as Figure 7 shown when injected into the injection mold M by the injection device I).

[0214] As seen in Figure 8 In an alternative embodiment, in step a), the rear plastic part 4A is attached to the front mineral part 4B by directly casting a transparent thermosetting or photocurable substrate onto the front mineral part 4B, and the transparent thermosetting or photocurable substrate is designed to form the rear plastic part 4A. For this purpose, a dorsal mold M' and a casting gasket G are schematically shown above the front mineral part 4B.

[0215] As seen in Figure 9A and Figure 9B both, in other alternative embodiments, in step a), the rear plastic part 4A is attached to the front mineral part 4B by gluing under pressure with an adhesive 4C. The part 4B, the adhesive 4C, and then the part 4A are successively stacked on an annular support S, and a flexible film 30 is placed on top, while being sealed and fixed via an annular seal 50 by a closure ring 40. In Figure 9A and Figure 9B the pressure value P0 on the outer side of the flexible film 30 and the pressure value P1 on the other inner side of the film 30 (facing the two parts 4A and 4B) can be seen.

[0216] In the Figure 9A embodiment, the suction generated by P1 < P0 generates an adhesive bond at 4C by gluing between the parts 4A and 4B through a depression effect.

[0217] In Figure 9B In one embodiment, the overpressure generated due to P1>P0 is bonded together at 4C by adhesive bonding between portions 4A and 4B through high pressure.

[0218] Preferably, the front mineral portion 4B is coated with a conductive layer (such as high-temperature ITO), as explained above. Nevertheless, if the conductive layer is deposited after the rear housing 4 is assembled to the front housing 5, it is preferable to deposit this conductive layer after surface treatment of the semi-finished hybrid lens 4' to avoid the conductive layer being used to prevent damage to the protective film of the conductive layer during the surface treatment step (because adhesive may diffuse into the conductive layer).

[0219] In summary, the above three technologies (i.e. injection molding, casting, and bonding under pressure) can be achieved by using a bare pre-mineral portion 4B (without a conductive layer) or a pre-mineral portion 4B with a conductive layer pre-coated on its convex side.

[0220] Step b) of obtaining a surface-treated, mixed shell with a defined formulation:

[0221] At the beginning of step b), for example, by using a metal alloy with a low melting point to seal the semi-finished hybrid ophthalmic lens 4' obtained in a).

[0222] If a conductive layer has already been provided on the pre-mineral portion 4B, a surface treatment protective film (often referred to as a "blue film") can be used to protect this layer during the sealing / surface treatment step.

[0223] The same "blue" protective film can also be used to protect the conductive layer during the subsequent edge grinding process.

[0224] The semi-finished lens 4' is then surface-treated to provide the wearer with the required prescription.

[0225] For this purpose, the back surface 4b of the semi-finished lens 4' is calculated so that the power of the anterior shell 5 + anterior mineral portion 4B + posterior plastic portion 4A + is equal to the wearer's prescription related to the design to be obtained for the ophthalmic device. This means that the base curve or refractive power of the anterior shell 5 and the posterior shell 4 are known.

[0226] Therefore, the rear plastic portion 4A is surface-treated using a surface-treatment tool (such as a diamond tool), while ensuring that there is no contact between the surface-treatment tool and the front mineral portion 4B, since the thickness of the front mineral portion is known (the thickness of the front mineral portion 4B is typically greater than 200 μm). Backside geometry modifications can be made to ensure no contact, for example, by increasing the center thickness if it is too small (in the case of negative power lenses), or by increasing the edge thickness if the edges of the frame shape are too thin (in the case of positive power lenses).

[0227] Step c) involves providing a hard coating and an optional anti-reflective coating to the rear housing 4:

[0228] For example, a hard coating is deposited onto the back surface 4b of the rear housing 4, which has been surface-treated in step b), by spin coating, spray coating, or inkjet coating. Optionally, an anti-reflective coating is further deposited onto the deposited hard coating to obtain a surface-treated and coated hybrid ophthalmic lens forming the rear housing 4.

[0229] Spin coating is preferred because the hard coating will not be deposited on the "blue" film protecting the first mineral portion 4B (it is best to avoid covering the hard coating on the "blue" film if it is also used in the subsequent edge grinding step), but other deposition techniques (such as dipping) may also be used if the first mineral surface 4a is protected.

[0230] Therefore, the "blue" protective film can be used to protect the conductive layer of the front mineral portion 4B before providing a hard coating to the back surface 4b, after this conductive layer has been protected during the sealing / surface treatment process.

[0231] Alternatively, the conductive layer can be protected by a temporary coating that can be removed after using a suitable solvent.

[0232] Then, after the hard coating is deposited onto the back surface 4b of the rear housing 4, an anti-reflective (AR) coating can be further deposited onto this hard coating using standard vacuum deposition techniques.

[0233] Step d) of grinding the edges of surface-treated and coated hybrid ophthalmic lenses:

[0234] Based on the defined shape of the frame configured to receive an ophthalmic device (by standard edging), the surface-treated and coated hybrid ophthalmic lens obtained in step c) is edged, for example by:

[0235] - The position of the optical center and horizontal axis of the surface-treated and coated hybrid ophthalmic lens is detected by a sealing and centering device, such that the optical center (OC) and axis are well positioned according to the shape of the frame (i.e., the OC must be aligned with the position of the pupil in the frame shape, and the axis of the lens must be horizontal), or

[0236] - Reference marks located outside the shape of the frame, which provides the optical center and horizontal axis, are directly engraved onto the reference element of the surface-treated and coated hybrid ophthalmic lens.

[0237] This edging of hybrid lenses is performed on a standard edging machine (e.g., known as "Mr. Blue"), using a low-pressure cycle and grinding wheels designed for mineral lenses. Alternatively, a standard sealing solution (e.g., Essilor's "Mr. Blue" centering device) is used, which automatically detects the OC position and axis of the lens and then attaches a sealing cup to it.

[0238] As mentioned above, instead of using this OC / axis detection on the lens, two reference marks located outside the frame shape can be engraved directly on the reference element of the lens (e.g., using the surface treatment tool), where the optical axis is given in the middle of the reference marks and the line connecting the reference marks indicates the horizontal axis.

[0239] As mentioned above, the "blue" protective film used for surface treatment can also be used for edge grinding. In this case, the edge grinding pad is attached to the lens protected by this protective film, which avoids contamination of the conductive coating by the edge grinding pad adhesive.

[0240] Step e) of assembling each electroactive unit:

[0241] Each electroactive unit (which is configured as an EC unit, for example) is assembled by connecting the front mineral housing 5 and the rear housing 4, which are based on mineral glass, together by means of a standard robotic gripping system and by using a compression membrane to force the two housings 4 and 5 against each other.

[0242] Step f): Fill the cavity between the front housing 5 and the rear housing 4 with the EC composition and then seal it.

[0243] The EC composition can be filled between the front housing 5 and the rear housing 4, while protecting the rear housing 4 from the effects of the EC composition by means of:

[0244] - A liquid solution of the electrochromic composition, wherein the filling is achieved by means of:

[0245] *Microinjection of liquid solutions

[0246] *Before assembly step e), a drop-filling technique for the liquid solution on the front housing 5 and a dispensing technique for sealing the rear housing 4, or

[0247] *In step a), it is through Figure 9A or Figure 9B In the case of bonding under pressure, the component obtained in step e) is immersed in a liquid solution while using the sacrificial coating that isolates the rear plastic portion 4A from the adhesive 4C in step a), and the sacrificial coating is removed after immersion; or

[0248] - The gel of the EC composition is achieved by applying the gel to the rear shell 4 prior to assembly step e).

[0249] As in Figure 2B and Figure 4 As seen in the diagram, each EC cell, once filled, is then sealed by a peripheral seal 11, as is known in the art.

Claims

1. An ophthalmic device (1) intended for a wearer and fulfilling a prescription of at least one power correction of said wearer, said ophthalmic device comprising at least one electroactive cell, said at least one electroactive cell comprising a back housing (4) and a front housing (5), said back and front housings respectively defining a back surface (4b) of said ophthalmic device (1) facing at least one eye of said wearer and an opposite front surface, said back housing (4) and said front housing (5) being provided with at least one pair of transparent electrodes and delimiting a sealed cavity, wherein said back housing (4) being derived from a semi-finished hybrid ophthalmic lens (4') comprising: - a front mineral portion (4B) having a first mineral face (4a) facing said front housing (5) and a second mineral face opposite to said first mineral face (4a), and - a back plastic portion (4A) attached to said front mineral portion (4B), said back plastic portion (4A) having a front plastic face bonded to said second mineral face and an un-surfaced back plastic face (4b') defining said back surface (4b) and configured to impart said prescription to said ophthalmic device (1) after surfacing said semi-finished hybrid ophthalmic lens (4'), and wherein said back plastic portion (4A) comprises a thermoplastic transparent substrate defining said front plastic face, said back plastic portion (4A) being attached to said front mineral portion (4B) by chemical bonding without adhesive means between both, said back plastic portion (4A) being directly injection molded onto said front mineral portion (4B).

2. The ophthalmic device (1) according to claim 1, wherein, said front mineral portion (4B) comprises a mineral glass substrate, and wherein said back plastic portion (4A) forms an ophthalmic lens blank comprising said thermoplastic transparent substrate based on at least one organic polymer selected from thermoplastic polymers.

3. The ophthalmic device (1) according to claim 2, wherein said back plastic portion (4A) has said front plastic face which is not surfaced.

4. The ophthalmic device (1) according to claim 2, wherein, said thermoplastic transparent substrate is based on a thermoplastic polymer selected from the group consisting of: (meth)acrylic (co)polymers, cellulose triacetate (TAC), polyesters, copolyesters, polycarbonates (PC), cyclic olefin copolymers (COC), cyclic olefin polymers (COP), and a multilayer film of at least one of these polymers and / or at least one of ethylene and ethylene vinyl alcohol copolymer (EVOH), poly(vinyl alcohol) (PVA), polychlorotrifluoroethylene (PCTFE), polyvinylidene chloride (PVDC) and polyamide (PA).

5. The ophthalmic device (1) according to any one of claims 1 to 4, wherein, said back housing (4) is coated on said first mineral face with an electrically conductive layer forming an electrode of said at least one pair of transparent electrodes and made of at least one of: - a transparent conductive oxide (TCO) deposited by sputtering, - a deformable electrically conductive nanostructure comprising a metal, and - a multilayer film of at least one of these polymers and / or at least one of ethylene and ethylene vinyl alcohol copolymer (EVOH), poly(vinyl alcohol) (PVA), polychlorotrifluoroethylene (PCTFE), polyvinylidene chloride (PVDC) and polyamide (PA). - a stack of a first insulator layer - a metal layer (M) - a second insulator layer, wherein the first insulator layer is equal to or different from the second insulator layer, the second insulator layer in contact with an electrochromic composition comprises a transparent conductive oxide (TCO) and the first insulator layer comprises a transparent conductive oxide (TCO) or a non-conductive layer.

6. The ophthalmic device (1) according to claim 5, wherein The transparent conductive oxide (ITO) is selected from ATO (AlSnO), ATZO (AlSnZnO), AZO (AlZnO), FTO (FSnO), GZO (GaZnO), ITO (InSnO), ITZO (InSnZnO), IZO (InZnO) and mixtures thereof; The deformable conductive nanostructure is selected from nanonets, nanowires, nanotubes and nanomeshes; The metal layer (M) is silver, gold or copper; and / or The non-conductive layer can increase the light transmission through the stack or can form a barrier layer.

7. The ophthalmic device (1) according to claim 5, wherein The conductive layer comprises high temperature ITO.

8. The ophthalmic device (1) according to any one of claims 1 to 4, wherein, The rear housing (4) is coated on the back side surface (4b) with a hard coating.

9. The ophthalmic device (1) according to claim 8, wherein The hard coating is itself coated with an anti-reflective coating.

10. The ophthalmic device (1) according to any one of claims 1 to 4, wherein, The front housing (5) comprises a mineral glass substrate and has a mineral back surface opposite the front surface of the front housing (5), wherein the mineral back surface of the front housing (5) is concave and the first mineral surface (4a) of the rear housing (4) is convex is curved, has the same curvature, comprises at least one of a cylindrical, toric and spherical curvature, wherein the rear housing (4) and the front housing (5) are at a distance of 10 µm to 400 µm from each other, thereby forming a gap defining the sealed cavity, the sealed cavity being delimited at its periphery by an adhesive seal (11), and wherein the ophthalmic device (1) forms at least one electroactive unit selected from a variable power lens and an electrochromic lens, and the ophthalmic device comprises an augmented reality eyewear, a virtual reality eyewear and an electrically focus-tunable lens.

11. The ophthalmic device (1) according to claim 10, wherein, The rear housing (4) and the front housing (5) are at a distance of 20 µm to 250 µm from each other.

12. An ophthalmic device (1) according to any one of claims 1 to 4, wherein, The prescription comprises astigmatism.

13. A method for manufacturing an ophthalmic device (1) according to any of the preceding claims, wherein, The method essentially comprises the following steps: a) manufacturing the semi-finished hybrid ophthalmic lens (4') by attaching the rear plastic portion (4A) having the non-surfaced rear plastic surface (4b') to the front mineral portion (4B), wherein the attachment of the rear plastic portion (4A) to the front mineral portion (4B) is achieved by direct injection molding of the thermoplastic transparent substrate of the rear plastic portion (4A) onto the front mineral portion (4B); b) surfacing the semi-finished hybrid ophthalmic lens (4') to impart the prescription to the non-surfaced rear plastic surface (4b'), thereby obtaining the back side surface (4b); and b) surfacing the semi-finished hybrid ophthalmic lens (4') to impart the prescription to the non-surfaced rear plastic surface (4b'), thereby obtaining the back side surface (4b); and c) assembling the at least one electroactive cell once the surface treatment is done by joining the front housing (5) and the rear housing (4) comprising the semi-finished hybrid ophthalmic lens.

14. The method of claim 13, wherein, The thermoplastic transparent substrate of the rear plastic part (4A) is not polycarbonate.

15. The method of claim 13, wherein, The method further comprises the following successive steps between steps b) and c): b1) depositing a hard coating on the back side surface (4b) to obtain a surface-treated and coated hybrid ophthalmic lens forming the rear housing (4); and b2) edging the surface-treated and coated hybrid ophthalmic lens according to the determined shape of the frame (2) configured to receive the ophthalmic device (1) by: - detecting the position of the optical center and of the horizontal axis of the surface-treated and coated hybrid ophthalmic lens by blocking with centering means, so that the optical center and the axis are well positioned according to the shape of the frame (2), or - engraving directly onto a reference element of the surface-treated and coated hybrid ophthalmic lens a reference mark located outside the shape of the frame (2) providing the optical center and the horizontal axis.

16. The method of claim 15, wherein, The hard coating is deposited by rotary spraying or inkjet coating.

17. The method of claim 15, wherein, In step b1), a reflection-reducing coating is further deposited on the hard coating.

18. The method of any one of claims 13 to 17, wherein, The sealed cavity is filled with an electrochromic composition (7), the at least one electroactive cell is an electrochromic cell, and wherein the method further comprises filling the sealed cavity between the front housing (5) and the rear housing (4) with the electrochromic composition (7), while protecting the rear housing (4) from the electrochromic composition (7) by using: - a liquid solution of the electrochromic composition (7), the filling being achieved by: * micro-injection of the liquid solution, or * drop filling technique of the liquid solution on the front housing (5) and spot gluing for sealing the rear housing (4) before assembly step c), or - a gel of the electrochromic composition (7), the filling being achieved by applying the gel on the rear housing (4) before assembly step c).

19. The method of any one of claims 13 to 17, wherein, The method further comprises depositing an electrically conductive layer on the first mineral face (4a) to form an electrode of the at least one pair of transparent electrodes, the electrically conductive layer being applied: - for a high deposition temperature including the electrically conductive layer before assembly step c), or - for a low deposition temperature of the electrically conductive layer only after assembly step c).

20. The method according to claim 19, wherein, the high deposition temperature is for a high temperature ITO deposited during step a), or the low deposition temperature is for a low temperature ITO.

21. The method of any one of claims 13 to 17, wherein, In the surface treatment step b): - the semi-finished hybrid ophthalmic lens (4') is blocked, - the back side surface (4b) of the ophthalmic device (1) to be obtained is calculated so that the total power of the front housing (5), front mineral part (4B) and rear plastic part (4A) is equal to the prescription of the wearer to be obtained, and - said rear plastic part (4A) is respectively surface treated with a surface treatment tool, without contact between said surface treatment tool and said front mineral part (4B).

22. The method of claim 21, wherein, - said semi-finished hybrid ophthalmic lens (4') is blocked by means of a metal alloy having a low melting point.

23. The method of claim 19, wherein, In the surface treatment step b), a protective film is used to protect the conductive layer during the surface treatment.

24. The method of claim 15, wherein, The method further comprises depositing a conductive layer on the first mineral face (4a) to form an electrode of the at least one pair of transparent electrodes, and In the surface treatment step b), a protective film is used to protect the conductive layer during the subsequent step bl) of depositing a hard coating and the edging step b2) of the surface treated and coated hybrid ophthalmic lens.

25. The method of any one of claims 13 to 17, wherein, The assembly step c) comprises connecting the front housing (5) and the rear housing (4) together by means of a clamping system and by compressed air.

26. Use of a semi-finished hybrid ophthalmic lens (4') comprising a front mineral part (4B) and an injection molded rear thermoplastic part (4A) chemically joined to the front mineral part without adhesive means between the two, in a rear housing (4) of an electroactive ophthalmic device (1) selected from a variable power lens and an electrochromic lens: - prescribing the ophthalmic device (1) by surface treating a back side surface (4b) of the semi-finished hybrid ophthalmic lens (4'), assembling the semi-finished hybrid ophthalmic lens to a front housing (5), and obtaining a sealed cavity between the semi-finished hybrid ophthalmic lens and the front housing, the sealed cavity being filled with an electrochromic composition (7) in the case where the electroactive ophthalmic device (1) is an electrochromic device.

27. Use of a semi-finished hybrid ophthalmic lens (4') according to claim 26, wherein, The electroactive ophthalmic device (1) comprises an augmented reality device, a virtual reality eyewear or an electrically focus-tunable lens. The electroactive ophthalmic device (1) comprises an augmented reality device, a virtual reality eyewear or an electrically focus-tunable lens.

Images