Method for manufacturing ophthalmic devices by machining

Abstract

The present disclosure relates to a method of manufacturing an ophthalmic device, the method comprising: providing a plastic part (1) having a predetermined shape consistent with its deployment in an ophthalmic application, the plastic part (1) having a first face (3) and a second face (4); providing a mineral component (2) having a first face (5) and a second face (6); assembling an ophthalmic blank from the plastic part (1) and the mineral part (2) wherein the second face (4) of the plastic part (1) coincides with part or all of the first face (5) of the mineral part (2); positioning and fixing the ophthalmic blank on a mounting of a machining device; the first face (3) of the plastic component is machined on the mounting using a tool.

Description

Technical Field

[0001] The present disclosure relates to the manufacture of lightweight and structurally rigid ophthalmic devices, such as those suitable for use in augmented reality systems, mixed reality systems, and virtual reality systems.

[0002] The present disclosure relates to a method for manufacturing an ophthalmic device from a blank, the method including machining; and to a method for machining a predetermined surface on a component that is an ophthalmic device.

[0003] The present disclosure also relates to a component of a manufacturing system configured to determine the position of a hybrid blank during a machining process.

[0004] The present disclosure also relates to a command and control unit that includes system elements configured to run a computer program to at least implement the machining of the method; and to a manufacturing system that includes such a command and control unit and is configured to perform such a method.

[0005] The present disclosure also relates to a computer program that includes instructions configured to implement the machining of the method when the computer program is run by a computer.

[0006] The present disclosure also relates to a blank for manufacturing a lightweight and structurally rigid ophthalmic device. Background Art

[0007] Many ophthalmic applications require an ophthalmic device (such as a lens of a certain size) to achieve desired optical properties (such as a field of view) and to avoid contact with eyelashes when presented in front of a person's eye. Further, the optical properties often have to be adapted depending on a person's eyesight. Traditionally, lenses have had the problem of being too thick and thus too heavy in a specific application. This situation is exacerbated in cases where greater optical correction is required.

[0008] One known method of reducing weight is to reduce the thickness of the lens. In particular, it is desirable to reduce the critical thickness (CR) as much as possible (the edge thickness for a lens that produces a negative or diverging effect or the center thickness for a lens that produces a positive or converging effect).

[0009] Reducing the CR presents additional challenges. Polymer lenses, if thin enough, will not be able to maintain mechanical and optical properties due to insufficient rigidity.

[0010] Another challenge is to maintain mechanical integrity and accurate positioning during machining for various ophthalmic requirements. This is particularly evident when the lens is edged (cut to the expected size for the application) before ophthalmic machining.

[0011] U.S. Patent Application Publication No. US2003 / 0022610 discloses a method for manufacturing an ophthalmic lens in which the critical thickness is minimized. An ophthalmic lens (semi-finished blank) finished on one side is manufactured to have a predetermined (e.g., circular) outer contour. Then, a portion is cut out from the blank, for example using a laser. The outer contour of the cut-out portion generally corresponds to the contour of the finished ophthalmic lens, and the remaining material forms an edge portion. The cut-out portion is connected to the edge portion in such a way that the edge portion serves as a handle for subsequent machining operations. Thus, the edge portion serves as a ring for holding and positioning the cut-out portion during subsequent machining. SUMMARY OF THE INVENTION

[0012] The present disclosure relates to a method for manufacturing an ophthalmic device with reduced thickness and increased stiffness.

[0013] According to the present disclosure, an ophthalmic device is prepared by machining a hybrid ophthalmic blank. As described, the hybrid blank is formed by providing a plastic component having a predetermined shape consistent with its deployment in an ophthalmic application, the plastic component having a first face and a second face; providing a mineral component having a first face and a second face; and assembling the plastic component and the mineral component such that the second face of the plastic component coincides with part or all of the first face of the mineral component. In some arrangements, the surface area of the first face of the mineral component is described as being greater than the second face of the plastic component.

[0014] As subsequently disclosed, the ophthalmic blank is positioned and fixed on a fixture of a machining device, where the first face of the plastic component is machined using a tool. As described, such machining includes surface treatment of the first face of the plastic component, the surface treatment including rough machining and / or finish machining and / or polishing, and the machining may further include at least coating the surface-treated first face.

[0015] In another aspect of the present disclosure, the method for preparing an ophthalmic device includes adding a ring around the ophthalmic blank and fixing the ring within the machining device. This ring can be anchored to the plastic component.

[0016] In yet another aspect of the present disclosure, the machining is controlled at least in part based on a measurement of the position of the ophthalmic blank within the machining device. As described, this measurement is performed using a measurement probe that interacts with the first face or the second face of the mineral component. A positioning error can be determined at least in part based on the measurement, and the positioning error can be numerically compensated. The positioning error can be determined based on a comparison between the critical thickness of the ophthalmic blank measured inside and outside the machining device.

[0017] In still another aspect of the present disclosure, the ophthalmic device obtained by machining the hybrid blank is used as a component of an eye-wear device such as an augmented reality, mixed reality, or virtual reality system.

[0018] In another related aspect, a command and control unit is described, the command and control unit including a system element configured to run a computer program, the computer program including instructions configured to at least partially implement a method for manufacturing an ophthalmic device when the computer program is run by a computer. A manufacturing system is also described, the manufacturing system including machining means and a command and control unit.

[0019] A client-server communication interface is also disclosed, the client-server communication interface for transmitting at least manufacturing data to a remote computer, the manufacturing data determined by a computer program implementing at least a part of a method for machining an ophthalmic device, the remote computer implementing other parts of the manufacturing method when the computer program runs in the command and control unit.

[0020] An ophthalmic device is also disclosed herein, the ophthalmic device formed from an ophthalmic blank including: a plastic component having a first face and a second face, the plastic component formed into a predetermined shape consistent with its deployment in an ophthalmic application; a mineral component having a first face and a second face. The mineral component is disclosed as being assembled with the plastic component such that the second face of the plastic component coincides with part or all of the first face of the mineral component. In addition, the first face of the plastic component is a machined ophthalmic surface. An eye wear device is also disclosed, the eye wear device including the ophthalmic device thus formed.

[0021] The increased stiffness and reduced weight achieved by such an ophthalmic device manufactured according to this method are particularly useful in eye wear devices such as augmented reality (AR), mixed reality (MR), and virtual reality (VR) systems, such eye wear devices being complex and requiring very good ophthalmic accuracy, particularly in the case of binocular systems. This allows for a reduction in the weight of such systems on the wearer's head and avoids contact with the eyelashes.

[0022] By using the above method, an installation tolerance on the order of about 0.1 mm can be achieved to meet the need for a critical thickness (CT). Further ensure that the diamond turning tool is not damaged by touching anything other than the plastic lens component. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The description of the present disclosure now continues with a detailed description of the advantageous embodiments given below by way of non-limiting examples and with reference to the drawings.

[0024] Figure 1 A side view of a hybrid blank according to the present disclosure is schematically depicted.

[0025] Figure 2 is Figure 1Front view of the hybrid blank depicted in

[0026] Figure 3 shows a Figure 1 schematic cross-sectional view of the hybrid blank with the ring attached.

[0027] Figure 4 is a Figure 3 front view of the configuration depicted in

[0028] Figure 5 schematic diagram of the Figure 1 hybrid blank mounted on a machining device.

[0029] Figure 6 is a block diagram showing the operating steps of a method for manufacturing an ophthalmic device according to the present disclosure.

[0030] Figure 7 Schematically depicts a manufacturing system (such as a digital surface treatment machine) according to the present disclosure, which is configured to perform the steps of a method for manufacturing an ophthalmic device.

[0031] Figure 8 Illustrates a client-server communication interface, which includes system components configured to transfer at least one configuration parameter determined by a method according to the present disclosure to a remote data processing system. Detailed Description

[0032] The present disclosure relates to a method for manufacturing an ophthalmic device, which includes a machining step. In particular, it relates to the use of a so-called hybrid blank during the manufacture of an ophthalmic device.

[0033] A hybrid blank is an ophthalmic blank composed of two components, typically a plastic component that can be easily machined and a mineral component with high stiffness.

[0034] Figure 1 Shows a schematic diagram of a hybrid blank 100 formed by bonding a plastic component 1, specifically a plastic lens component 1, to a mineral component 2.

[0035] The plastic component 1 includes a first surface 3 and a second surface 4 opposite to the first surface 3.

[0036] In some applications, the first surface 3 will be the surface closest to the user's eye, and the second surface 4 will face away from the user.

[0037] The mineral component 2 is typically a layer of mineral material, such as Gorilla Glass or similar tempered glass.

[0038] The mineral component 2 includes a first surface 5 and a second surface 6 opposite to the first surface 5.

[0039] The hybrid blank is formed by stacking and assembling a plastic part 1 and a mineral part 2.

[0040] This is achieved by placing the second face 4 of the plastic part against the first face 5 of the mineral part in the desired position.

[0041] The plastic part and the mineral part are preferably permanently fixed, for example by chemical bonding or welding. Alternatively, the plastic part 1 and the mineral part 2 can be temporarily fixed and then separated after machining.

[0042] As Figure 2 shown in the example, the entire second face 4 of the plastic part 1 coincides with the first face 5 of the mineral part 2.

[0043] In the depicted arrangement, the mineral part 2 projects beyond the edge of the plastic part 1 in the plane of the interface between the plastic part 1 and the mineral part 2.

[0044] In other arrangements, the first face 5 of the mineral part 2 and the second face 4 of the plastic part 1 have the same surface area, so the mineral part does not project.

[0045] As Figure 2 shown, the plastic part 1 has a predetermined size and shape compatible with its final application.

[0046] The plastic part can be formed into the predetermined size and shape, for example, by edging.

[0047] Similarly, as Figure 2 shown, the mineral part 2 is not sized and edged. That is, the mineral part 2 does not exhibit the same predetermined size and shape as the plastic part 1. The mineral part 2 can be edged in a separate step.

[0048] Now, a method for manufacturing such a hybrid blank and an ophthalmic device made from the hybrid blank will be described with reference to Figure 6 ...

[0049] Provide 201 the plastic part 1 as described above, and provide 202 the mineral part 2 as described above.

[0050] The plastic part has a predetermined shape consistent with its deployment in the ophthalmic device.

[0051] The predetermined shape is formed, for example, by edging.

[0052] In Figure 6 step 204, the plastic part 1 and the mineral part 2 are assembled together to form a hybrid blank.

[0053] The assembly is carried out by placing the second face 4 of the plastic part in coincidence with the first face 5 of the mineral part, in a position corresponding to their deployment in the ophthalmic device.

[0054] In some arrangements, the assembly is a permanent assembly, for example by using an adhesive or welding.

[0055] Figure 1 and Figure 2 The hybrid blank thus formed is illustratively depicted in

[0056] As Figure 5 depicted, the hybrid blank is positioned and fixed 205 on the mount 8 of the machining device 21 to machine the first face 3 of the plastic part. The positioning in the machining device 21 also takes into account wearer parameters, which include the pupil distance and the mounting height.

[0057] The positioning and fixing 205 of the hybrid blank 100 in the machining device can be carried out by, for example, directly fixing the hybrid blank on the mount 8 by means of a chuck or a suction cup.

[0058] Alternatively, the hybrid blank can first be anchored to the ring 7 and then the ring 7 can be fixed to the mount 8 by means of a chuck, for example.

[0059] The use of the ring 7 helps to position and fix the hybrid blank on a machining device that has been designed to carry traditional round blanks. The use of the ring reduces the need to re-design the machining device. This advantage is further carried over to the subsequent coating steps in the mechanical design for traditional round blanks. The ring also provides protection for the mineral part against accidental tool collisions.

[0060] Figure 3 and Figure 4 depict the application of the ring 7 to the hybrid blank. As Figure 3 depicted, the ring is anchored to the plastic part 1.

[0061] However, the ring can be anchored to the mineral part 1 or both.

[0062] Figure 3 and Figure 4 The depicted ring has a diameter larger than that of the mineral part 1.

[0063] Furthermore, as depicted, the ring is anchored to the plastic part 1 and contacts a part of the first face 5 of the mineral part 2.

[0064] In other arrangements, a gap is provided between the ring 7 and the first face 5 of the mineral part.

[0065] To achieve the desired ophthalmic profile of the first side 3 of the plastic part, a positioning mechanism such as a servo system is used to control the relative position between the tool and the first side 3.

[0066] Precise position control is required to achieve the desired optical properties.

[0067] Additionally, it is highly undesirable for the tool to touch or collide with the mineral part, as this can cause significant and costly damage to both the machining device and the hybrid blank 100.

[0068] To obtain the desired level of position control, the position of the hybrid blank within the machining device needs to be accurately determined.

[0069] As Figure 5 depicted, the probe 9 is brought into contact with or in close proximity to the hybrid blank in order to determine the position of the hybrid blank within the mount 8.

[0070] As Figure 5 depicted in the example of

[0071] the probe 9 is used to measure the position of the first side 5 of the mineral part 6.

[0072] The measurement data obtained from the probe is used to calculate the positioning error.

[0073] The positioning error is used as part of the control of the positioning mechanism of the machining device.

[0074] More specifically, the critical thickness of the plastic part can be measured either before assembly with the mineral part to form the hybrid blank or as soon as the plastic part 1 and the mineral part 2 are assembled.

[0075] Alternatively or additionally, the critical thickness can be measured as soon as the hybrid blank is positioned and fixed within the machining device. Thus, the comparison between the critical thickness of the hybrid blank measured outside the machining device and the critical thickness of the hybrid blank measured inside the machining device can be used to determine the positioning error.

[0076] In step 206, the first side 3 of the plastic part 1 is machined with a machining tool in order to achieve the ophthalmic profile desired for its intended application. For example, the geometries include flat, spherical, aspherical, toric, complex, concave, and convex.

[0077] Machining should be understood as surface treatment of the first side 3 of the plastic part 1, including rough machining and / or finish machining and / or polishing.

[0078] In another step, a coating can be applied at least to the surface-treated first side 3 of the plastic part.

[0079] Figure 7 shows a manufacturing system configured to perform at least step 206: machining a first face 3 (ophthalmic surface) of a plastic part 1, the plastic part being temporarily and fixedly maintained on a mounting 8 during machining.

[0080] The system includes a machining device 21 and system components generally formed by at least one command and control unit 22, the at least one command and control unit being configured to communicate with a data processing system (or control unit) of the machining device 21 and being configured to run a computer program having instructions configured to at least implement the machining steps of the method when the computer program is run by a computer.

[0081] The machining device 21 is here, for example, a numerically controlled "free-form" turning machine, the numerically controlled indicating a set of equipment and software whose function is to give movement instructions to all elements of the machine.

[0082] The machining device 21 includes a machining tool 27 (for example, a movable machining arm on which a cutting tool provided with a cutting edge is mounted) and a data processing system or control unit (not shown) configured to control the tool 27.

[0083] The command and control unit 22 includes a microprocessor 23 having a memory 24, in particular a non-volatile memory, thereby allowing it to load and store a computer program (also called software), which, when executed in the microprocessor 23, allows implementation of the method according to the present disclosure. The non-volatile memory 24 is, for example, of the ROM ("read-only memory") type.

[0084] The command and control unit 22 further includes a memory 25, in particular a volatile memory, thereby allowing data to be stored during the execution of the software and the implementation of the method. The volatile memory 25 is, for example, of the RAM or EEPROM type (respectively "random access memory" and "electrically erasable programmable read-only memory").

[0085] The command and control unit may be integrated into the machining device only at least partially. In other words, the control unit may be arranged partially or entirely outside the machine.

[0086] The command and control unit may at least partially form part of the machine and may include one or more command and control modules located inside and / or outside the machine.

[0087] The command and control unit 22 is configured to command and control at least some of the steps of the manufacturing method described below.

[0088] Figure 8 The client-server communication interface 26 is shown, including, for example, a so-called provider side 29a and another so-called client side 29b, and the two sides communicate via the Internet interface 28.

[0089] The provider side includes a server 29a that is linked to a data processing system or to a command and control unit 22a of the same type as Figure 7 that in, and the server 29a is configured to communicate with the Internet interface 28.

[0090] The client side 29b is configured to communicate with the Internet 25 interface 28 and is linked to a data processing system or to a command and control unit 22b of the same type as the provider side.

[0091] Furthermore, the command and control unit 22b on the client side is linked to a machining device 21b of the same type as Figure 7 that in for manufacturing at least the first face 8b of the ophthalmic substrate.

[0092] The command and control unit 22a on the provider side executes the computer program it contains in order to implement, for example, the step of determining the parameters for machining the first surface 3 of the plastic part 1.

[0093] Using the server 29a and the Internet interface 28, the command and control unit 22a on the provider side sends the parameters to the command and control unit 22b on the client side.

[0094] The command and control unit 22b on the client side is herein configured to execute software to implement other steps of the method of manufacturing an ophthalmic device by machining using the parameters representing the surface to be machined.

[0095] It should be noted that the ophthalmic device obtained by the method disclosed above can be a component part of an eye-wear device such as an augmented reality, mixed reality or virtual reality system, etc.

Claims

1. A method of manufacturing an ophthalmic device, the method comprising: - providing (201) a plastic component (1) having a predetermined shape consistent with its deployment in an ophthalmic application, the plastic component (1) having a first face (3) and a second face (4); - providing (202) a mineral component (2) having a first face (5) and a second face (6); - assembling (204) an ophthalmic blank from the plastic component (1) and the mineral component (2), wherein the second face (4) of the plastic component (1) coincides with part or all of the first face (5) of the mineral component (2); - positioning and fixing (205) the ophthalmic blank on a mount (8) of a machining device (21); - machining (206) the first face (3) of the plastic component (1) on the mount (8) using a tool.

2. The method according to claim 1, wherein, The machining (206) comprises surface treatment of the first face (3) of the plastic component (1), the surface treatment comprising rough machining and / or finish machining and / or polishing, and then the method comprises at least coating the surface-treated first face (3).

3. The method according to claim 1 or claim 2, wherein The positioning and fixing (205) further comprises adding a ring (7) around the ophthalmic blank and fixing the ring within the machining device (21).

4. The method according to claim 3, wherein, The ring (7) is anchored to the plastic lens (1).

5. The method according to any one of claims 1 to 4, wherein, The surface area of the first face (5) of the mineral component (2) is larger than the second face (4) of the plastic component (1) such that the mineral component (2) extends beyond the plastic component (1).

6. The method according to any one of claims 1 to 5, wherein The machining (206) is controlled at least in part based on a measurement of the position of the ophthalmic blank within the machining device (21).

7. The method according to claim 6, wherein, The measurement is performed using a measurement probe (9) that interacts with the first face (5) or the second face (6) of the mineral component (2).

8. The method according to any one of claims 6 and 7, further comprising: - determining a positioning error at least in part based on the measurement; and - numerically compensating for the positioning error.

9. The method according to claim 8, wherein, The measurement is performed by: - measuring a critical thickness of the ophthalmic blank outside the machining device (21); - measuring a critical thickness of the ophthalmic blank within the machining device (21); - determining the positioning error at least by comparing the critical thickness measured outside the machining device (21) with the critical thickness measured within the machining device (21).

10. The method according to any one of claims 1 to 9, further comprising: The ophthalmic device obtained after machining is assembled as a component part of an eye-wear device such as an augmented reality, mixed reality or virtual reality system.

11. A command and control unit, the command and control unit comprising system elements configured to run a computer program, the computer program comprising instructions configured to at least partially implement the method for manufacturing an ophthalmic device according to any one of claims 1 to 9 when the computer program is run by a computer.

12. A manufacturing system, the manufacturing system comprising a machining device and a command and control unit according to claim 11, the system being configured to perform the manufacturing method according to claims 1 to 10.

13. A client-server communication interface, the client-server communication interface for transmitting at least manufacturing data to a remote computer, the manufacturing data being determined by a computer program implementing at least a part of the method for manufacturing an ophthalmic device according to any one of claims 1 to 10, the remote computer implementing the other parts of the manufacturing method when the computer program runs in the command and control unit.

14. An ophthalmic device, the ophthalmic device being formed from an ophthalmic blank, the ophthalmic blank comprising: - a plastic part (1), the plastic part having a first face (3) and a second face (4); - the plastic part (1) being formed in a predetermined shape consistent with its deployment in an ophthalmic application; - a mineral part (2), the mineral part having a first face (5) and a second face (6); - the mineral part (2) being assembled with the plastic part (1) such that the second face (4) of the plastic part (1) coincides with part or all of the first face (5) of the mineral part (2); and wherein the first face (3) of the plastic part (1) is a machined ophthalmic surface.

15. An eye wear device, the eye wear device comprising the ophthalmic device according to claim 14.

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