Method and apparatus for manufacturing optical elements, optical elements, and optical systems

Abstract

The present invention relates to a method for optically modifying an optical component, the method comprising: A) placing a liquid material (5) in a cavity (100) having a first surface portion (101) and a second surface portion (102), wherein the first surface portion (101) of the cavity (100) is formed by a first deformable film (2); B) shaping the first film (2) so that the optical power of the optical element (12) to be manufactured is adjusted; C) forming a first surface (12-1) that fits the first surface portion (101) of the cavity (100); The process includes: D) Solidifying a liquid material (5) to obtain an optical element (12) having a second surface (12-2) that fits into a second surface portion (102) of a cavity (100), wherein the optical element (12) has optical power that is adjusted by the shape of the first surface and the second surface (12-1, 12-2); D) Mounting the optical element (12) to the optical surface (20-1) of an optical component (20), wherein the first surface (12-1) of the optical element (12) faces the optical surface (20-1) of the optical component (20).

Description

Technical Field

[0001] The present invention relates to a method for optically modifying an optical component using an optical element, and an optical system comprising an optical element.

Background Art

[0002] Optical elements can be used in optical devices and systems to affect light beams, for example, by deflection, refraction, or focusing. In particular, this enables the correction of imaging aberrations.

[0003] Typically, optical elements are manufactured by complex manufacturing processes, and the desired optical properties are set according to the individual uses of the optical elements. However, such manufacturing processes are time-consuming and costly. Furthermore, an optical device comprising an optical element has the drawback that its optical properties can only be changed by disassembling the device and replacing the optical element.

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide a method and means that can manufacture an optical element at a low cost and have high flexibility with respect to the adjustability of the optical properties of the optical element, where the optical element is attached to an optical component that is the object to be adjusted in terms of optical properties.

Means for Solving the Problems

[0005] This object is solved by the method according to claim 1 and the optical system according to claim 15. Advantageous further embodiments are the subject matter of the dependent claims.

[0006] According to a first aspect of the present invention, a method for optically modifying an optical component, such as a lens, glasses and / or goggles, using an optical element includes at least the following steps: A) A step of placing a transparent, solidifiable, and especially curable liquid material such as a polymer into a cavity, wherein the cavity comprises a first surface portion, particularly a first smooth surface portion, and a second surface portion, particularly a second smooth surface portion, wherein the first surface portion of the cavity is formed by a first deformable film; B) A step of adjusting the shape of the first film, for example, by adjusting the shape of the first surface portion of the cavity, so that the optical power of the manufactured optical element is adjusted; C) A step of solidifying, particularly hardening, a liquid material in order to obtain an optical element, wherein the optical element comprises a first surface conforming to a first surface portion of the cavity and a second surface conforming to a second surface portion of the cavity, and the optical element has an optical power adjusted by the shape of the first surface and the second surface; D) A step of attaching an optical element to the optical surface of an optical component, particularly a smooth optical surface, wherein a first surface or a second surface of the optical element faces, particularly contacts, the optical surface of the optical component, such that the optical component is optically modified by the optical power of the optical element.

[0007] This invention is based on the recognition that optical elements with individually tuned optical properties can be manufactured using solidifiable, particularly curable, liquids or liquid materials. The liquid material may be a transparent, curable liquid polymer in particular. Such polymers are generally easy to handle and have good moldability, making them particularly suitable for the manufacture of optical elements.

[0008] The cavity may have one or more openings, and in particular, the cavity may be formed by a recess or a circumferentially open volume confined by a first surface portion and a second surface portion.

[0009] According to the present invention, a solidifiable liquid material is supplied to a cavity at least partially formed by at least a first deformable membrane. The present invention is not limited to any particular embodiment of the membrane. It is only required that the membrane be deformable, for example by external force, and at the same time exhibit sufficiently high tensile strength to maintain a desired shape, for example. In a simple embodiment, the first membrane is made from a thin film, in particular a polymer thin film.

[0010] A liquid material that can be solidified is supplied to a first membrane, and then the shape of the membrane is adjusted so that the liquid material adapts to the shape of the surface portion of the membrane due to its liquid aggregation state. By solidifying the liquid material, an optical element is obtained, and its shape, in particular the shape of the first surface of the optical element, is set according to the shape of the surface portion of the membrane.

[0011] In other words, the film forms a deformable template that can be partially and selectively controlled, thereby allowing optical elements to be manufactured in individually adjustable shapes. Investigations have shown that the method according to the present invention makes it possible to manufacture optical elements having at least partially any shape, preferably cylindrical or spherical. Since the optical properties of the optical element depend on its shape, the optical properties of the optical element can be directly set by deforming the first film. In particular, the optical element is transparent to at least visible light and is configured for use in optical devices.

[0012] The present invention is not limited to any particular order in which steps A) and B) of the process are carried out. For example, the liquid material may first be dispensed into the first membrane, and then the first membrane may be deformed, or vice versa.

[0013] According to another embodiment of the present invention, the second surface portion may be formed by the optical surface of an optical component. This enables an integrated process that essentially combines steps C) and D).

[0014] According to another embodiment of the present invention, the circumferential shape and size of the optical element are the same as the circumferential shape and size of the optical surface of the optical component, so that the optical element and the optical surface can be arranged on the same plane with respect to each other.

[0015] This embodiment enables an attractive and unobtrusive design.

[0016] According to another embodiment of the present invention, the second surface portion is formed by a second deformable film, and in step B), the shape of the second film is adjusted to adjust the shape of the second surface portion of the cavity, for example.

[0017] In particular, the features and definitions provided in the context of the first membrane can be applied to the second membrane in a similar manner.

[0018] The specific order in which the shapes of the first and second membranes are adjusted may be selectable. The membrane shapes may be adjusted simultaneously or sequentially.

[0019] The second membrane can be positioned such that the liquid material is placed between the first and second membranes, particularly surrounding it, and then solidified. Alternatively, neither membrane can be deformed; that is, they cannot be adjusted in terms of their shape, until the liquid material is surrounded between them; this is also within the scope of the present invention.

[0020] In the embodiments described above, a liquid material, particularly a liquid polymer, can be introduced between the first and second membranes, thereby creating a pressure-sealed space in which the membranes contain the polymer. When one membrane deforms, the deformation increases the pressure of the liquid polymer, causing the other membrane to deform. Thus, the membranes deform substantially simultaneously.

[0021] The present invention is not limited to the manner of forming a pressure-sealed space. However, in a simple embodiment, these membranes can be in circumferential contact with each other in their respective end regions, thereby forming a chamber in which the polymer is disposed. Alternatively, these membranes can be indirectly connected via a ring-shaped spacer element that laterally surrounds the liquid material and can be axially surrounded by the membranes. These membranes are each held by a die that is movable in a manner that allows easy application of the polymer between these membranes in the open state and can move to a closed state in which the polymer is surrounded by these membranes and the die, which is also within the scope of the present invention.

[0022] According to another embodiment of the present invention, between steps C) and D), the optical element is removed from, in particular separated from, the second surface portion and / or the first surface portion of the cavity.

[0023] Thereby, the first membrane and / or the second membrane can be reused.

[0024] According to another embodiment of the present invention, when the optical element is attached to an optical component, the first membrane and / or the second membrane remains attached to the optical element.

[0025] This embodiment enables a particularly simple method that can utilize the properties of the membrane for the optical component or its attachment. For example, the membrane can further provide an anti-scratch layer or an anti-reflection layer. The latter can be achieved by selecting an appropriate membrane material or coating the membrane with a corresponding material.

[0026] According to another embodiment of the present invention, the first membrane and / or the second membrane is at least partially transparent to ultraviolet light, the liquid material is an ultraviolet-curable liquid polymer, and step C) of the method includes exposing the liquid polymer to ultraviolet light through the first membrane and / or the second membrane.

[0027] In this embodiment, photocuring can be used while maintaining transparency in the visible spectral region, i.e., wavelengths longer than 380 nm.

[0028] In particular, the term "ultraviolet light" refers to the wavelength range of 200 nm to 380 nm.

[0029] The use of a transparent film and, for example, an ultraviolet (UV) curable polymer is advantageous because the required ultraviolet light can be supplied from the outside of the film, thereby not requiring any additional means for curing the polymer in particular. Preferably, one or more ultraviolet light sources are arranged on the side of the first and / or second film facing away from the liquid polymer.

[0030] According to one embodiment of the present invention, the first film and / or the second film is at least partially transparent to infrared light, the liquid material is an infrared curable liquid polymer, and step C) of the method comprises exposing the liquid polymer to infrared light through the first film and / or the second film.

[0031] In this embodiment, photocuring can be used while maintaining transparency in the visible spectral region, i.e., wavelengths shorter than 750 nm.

[0032] The use of a transparent film and, for example, an infrared (IR) curable polymer is advantageous because the required infrared light can be supplied from the outside of the film, thereby not requiring any additional means for causing the curing of the polymer in particular. Preferably, one or more infrared light sources are arranged on the side of the first and / or second film facing away from the liquid polymer.

[0033] In particular, the term "infrared" refers to the wavelength range of 750 nm to 1,500 nm.

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

[0035] In this embodiment, thermosetting can be used, thereby eliminating the need for an additional light source to form the optical element.

[0036] In particular, the second temperature is lower than 60°C, and more specifically, lower than 45°C. In particular, the second temperature is higher than 15°C. The first temperature may be higher than 60°C.

[0037] According to another embodiment of the present invention, the liquid material comprises a first component and a second component configured to initiate a curing process at the moment they come into contact with each other or are mixed with each other, thereby curing the liquid material by these two curing components.

[0038] These two components may be mixed immediately before supplying the liquid material to the cavity, or they may be supplied to the cavity afterward or simultaneously.

[0039] This embodiment enables a curing process that does not require an external light source.

[0040] According to another embodiment of the present invention, the second surface of the optical element is attached to the surface of the optical surface of the component by van der Waals forces, and in particular by van der Waals forces alone.

[0041] In this embodiment, the optical elements can be attached to the optical components without any additional adhesive, making the application of optical elements to optical components particularly easy.

[0042] Similar to the optical surface of an optical component, the second surface of an optical element can also be configured to exhibit the properties necessary to enable van der Waals forces of sufficient magnitude to achieve this effect. Those skilled in the art will know how to achieve this, or in particular, which materials are suitable for the optical element.

[0043] According to another embodiment of the present invention, an optical element, particularly a first surface and / or second surface of the optical element, is shaped, either alone or in combination with an optical component, to adjust one or more optical parameters selected from the group consisting of cylindrical aberration, astigmatism, coma aberration, prism aberration, or higher-order Zernike polynomial aberration, particularly to adjust for human visual acuity defects.

[0044] This embodiment enables a method for improving or upgrading optical components to address specific vision defects in individuals wearing them.

[0045] According to another embodiment of the present invention, the shape of a first film and / or a second film is adjusted by a mechanical element, which is configured to adjust the shape of the first film and / or the second film to produce an optical element exhibiting one or more optical parameters, and in particular the mechanical element is a lens molding apparatus.

[0046] Mechanical elements can be structural components capable of applying force to one of the films in a point-like, linear, or planar region. Preferably, multiple mechanical elements can be provided to apply force to the first and / or second films. In particular, mechanical elements can be used to apply a pushing or pulling force to one of the films. To apply a pulling force, mechanical elements can be attached to the first or second film by adhesive. Preferably, the adhesive is soluble and the mechanical elements can be removed from the films. However, it is also within the scope of the present invention to remove and arrange the first and / or second films from the optical elements after curing.

[0047] Preferably, the deformation of the membrane is controlled by a control unit designed to operate a closed control loop such that the deformation of the second membrane, in particular, is performed in response to the hydraulic pressure of the liquid material, and / or the deformation of the first membrane, and / or the movement and / or force of the mechanical elements.

[0048] According to another embodiment of the present invention, the shape of the first membrane is formed by mechanical elements, and the shape of the second membrane is formed according to the hydraulic pressure of the liquid material, or vice versa.

[0049] In this embodiment, the optical elements can be manufactured in a directly controlled manner to improve the positioning accuracy of the first film.

[0050] According to another embodiment of the present invention, the shape of the first membrane and / or the shape of the second membrane are adjusted by the fluid pressure applied to the surface of the first membrane and / or the second membrane facing the direction opposite to the liquid material.

[0051] In this embodiment, fluid pressure, preferably pneumatic or fluid pressure, can be used to induce a desired deformation of the first and / or second membrane. In particular, different pressures can be set on the two membranes, especially on the side of the membrane facing away from the liquid material.

[0052] In another embodiment, step B) of the method includes sequentially deforming the first and second films.

[0053] The present invention is not limited to the simultaneous deformation of the films. Rather, the deformation of the films may occur sequentially. In a preferred embodiment, in step A) of the method, the liquid material is first applied to the first film so that the first film deforms as a result of the force exerted by the application of the liquid material, particularly as a result of the force of the weight of the liquid material. The second film comes into contact with the liquid material and deforms as a result of the adhesive force of the liquid material, preferably a curable liquid polymer.

[0054] An advantage of the embodiments described above is that, in principle, no additional deformation means are required to cause deformation of the first and / or second films. Rather, the films can be designed to be flexible enough that a small amount of curable liquid material causes deformation of the first film due to its weight. When the second film is then brought into contact with the material, the second film is attracted toward the first film as a result of adhering to the liquid material, and thus deforms. This effect is particularly achievable when the liquid material is an ultraviolet-curable polymer.

[0055] According to another embodiment of the present invention, the shapes of the first and second films are formed by continuous deformation of the first and second films.

[0056] According to another embodiment of the present invention, a liquid material is applied to a first or second film such that the shape of each film is formed as a result of the force exerted by the application of the liquid material, in particular as a result of the force of the weight of the liquid material on each film, and each other film (of the first and second films) is in contact with the liquid material, and the shape of each other film is formed as a result of the adhesive force of the liquid material.

[0057] According to another embodiment of the present invention, the solidification, in particular the curing process of a liquid material is controlled such that the solidified, in particular the cured optical element is flexible, in particular here the solidification is completed before the liquid material solidifies into a solid state.

[0058] According to another embodiment of the present invention, the liquid material includes duloplast, elastomer and / or thermoplast.

[0059] The further embodiments described above are based on the understanding that it is not necessary to completely cure the liquid material, particularly a UV-curable polymer, in order to obtain an optical element having the desired optical properties. Rather, the curing process can be terminated when the liquid material has partially solidified as a result of curing, but is not yet completely cured and therefore has good elastic deformability. This makes it possible to subsequently apply the optical element to a curved optical surface. This can be done in a simple manner by controlling the radiation exposure time and / or radiation intensity, and the degree of curing depends on these.

[0060] According to another embodiment of the present invention, the optical component is selected from the group consisting of hard lenses, ski goggles, scuba diver goggles, safety goggles, eyeglasses, sunglasses, virtual reality augmented glasses, waveguide structures, waveguide diffraction structures, and waveguide refraction structures.

[0061] This embodiment provides a particularly useful application of this method to enable the adjustment of typical optical components at the consumer level.

[0062] In a preferred embodiment, the optical element is processed by a cutting process, particularly in the end region, after being drawn out from between the films. In this context, the end region is understood as the circumferential region surrounding the end of the optical element with respect to the optical axis.

[0063] In further embodiments, the optical element is marked during or after one of the processes A), B), C), D). Such marks can be used to identify the optical element and easily distinguish its optical surface from one another, or to facilitate positioning the optical element relative to another optical component, for example, by orienting the optical element according to the position of the marks.

[0064] In particular, optical elements can be attached to optical components like stickers with an adhesive surface.

[0065] According to a second aspect of the present invention, an optical system is disclosed comprising a transparent optical element having optical power, the optical element comprising a material, particularly a polymer, having a first surface, in particular a first smooth surface, and a second surface, in particular a second smooth surface facing in the opposite direction to the first surface, wherein the optical element is flexible and bendable such that the first surface can be bent to conform to a curved surface, in particular a smooth curved surface, and when the first surface is brought into broad contact with the complementary surface (in particular here the complementary surface comprises a polymer, synthetic polymer or glass, or The first surface is configured such that van der Waals forces between the first surface and the complementary surface, in particular van der Waals forces alone, result in the attachment of the optical element to the complementary surface, in particular permanent attachment, and the optical element is shaped, either alone or in combination with optical components, to adjust one or more optical parameters selected from the group consisting of cylindrical aberration, astigmatism, coma aberration, prism aberration, or higher-order Zernike polynomial aberration, in particular to adjust for human visual impairment.

[0066] A system according to a second aspect of the present invention makes it possible to improve optical components that include an optical element that adjusts optical power or optical parameters in relation to, for example, a person's visual impairment. This makes it possible to manufacture optical components such as sunglasses, goggles, and VR / AR goggles that do not have specific optical properties with respect to optical power or aberrations, which are improved by an optical element that provides or adjusts the existing optical power of the optical component.

[0067] In particular, the term “flexible and bendable” refers to the Shore durometer, which is considered to represent the flexible and bendable material, especially immediately after manufacture. Specifically, the Shore durometer may be less than 80D, especially less than 60D, and more particularly less than 50A.

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

[0069] An advantage related to the optical elements according to the present invention is that the optical elements can be used in a simple manner to form an optical system in which the optical properties can be individually adjusted by applying them to optical components. This is particularly advantageous for all kinds of hard lenses, such as ski goggles, scuba diving goggles, safety goggles, eyeglasses, sunglasses, and virtual reality glasses.

[0070] According to another embodiment of the present invention, the circumferential shape and size of the optical element are identical to the circumferential shape and size of the optical surface of the optical component. This embodiment enables a flush design of the optical system, thereby reducing reflections at the edges of the optical element and optical component, and providing a visually attractive and inconspicuous system.

[0071] According to another embodiment of the present invention, the second surface is concave or convex, and in particular the second surface is coated with an anti-reflective coating.

[0072] This allows for a wider range of adjustment of the optical properties of the optical system. Furthermore, anti-reflective coatings can be advantageous in suppressing unwanted reflections within or in the optical system.

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

[0074] According to another embodiment of the present invention, the optical system comprises an optical component having an optical surface with complementary surfaces, wherein the optical element is attached to the optical surface of the optical component via its first surface by van der Waals forces.

[0075] This embodiment teaches advantageous combinations of optical elements and optical components that can be improved or adjusted by the optical elements.

[0076] Optical components may or may not have optical power or aberrations that can be corrected by optical elements.

[0077] According to another embodiment of the present invention, an adhesive is placed on the first surface of the optical element so that the optical element adheres to the optical component when the optical element is attached to the optical surface of the optical component.

[0078] In this embodiment, the adhesive force exerted by van der Waals forces between the first surface and the optical surface of the optical component is complemented. The resulting system is more robust, and the optical element can be permanently fixed in the fixed position of the optical component.

[0079] According to another embodiment of the present invention, the optical component is selected from the group consisting of goggles, eyeglasses, and VR goggles, and the optical surface faces the direction of the person's eyes when the person wears the optical component.

[0080] By adjusting the optical power and aberrations of optical components selected from this group, it is possible to adjust manufactured optical components regardless of human visual impairment.

[0081] According to another embodiment of the present invention, the optical component comprises two optical surface portions provided by an optical surface, the surface portions being arranged such that a person wearing the optical component positions one of the surface portions in front of one of their eyes, and an optical element is attached to each optical surface portion.

[0082] This embodiment essentially describes goggles that may have two optical elements that individually adjust the optical properties of the optical components for each eye.

[0083] This embodiment allows for the adjustment of the optical system for each eye according to the visual impairment of each eye. For this purpose, the two optical elements may exhibit different optical parameters and / or optical power.

[0084] The optical surface portion can be the glass part (eyeglass part) of the goggles.

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

[0086] This embodiment enables the design of a flash optical system, thereby reducing reflections at the edges of optical elements and components, and providing a visually appealing and inconspicuous system.

[0087] According to another embodiment of the present invention, the optical power of each optical element is selected such that the optical power of the optical component is adjusted, in particular here the optical power of each optical element is different, and in particular here the optical component does not exhibit optical power.

[0088] In this embodiment, the advantageous characteristics of an optical system in which each optical element may exhibit different optical properties are defined.

[0089] According to another embodiment of the present invention, each optical element is formed as a thin lens whose first surface is adapted to fit the optical surface of an optical component.

[0090] This embodiment allows for individual modification of optical components. A thin lens can essentially be a sticker-like optical element that is attached to an optical component and alters its optical properties in terms of optical power and aberration in a defined manner.

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

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

[0093] Thin lenses can be summarized based on the geometric properties of these local elements.

[0094] Manufacturing thin optical elements with such optical power and aberration correction capabilities is difficult. The method according to the present invention makes it possible to manufacture such thin optical elements with defined characteristics.

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

[0096] Given the dimensions of the aforementioned optical elements, they can be easily and compactly applied to existing optical surfaces. In particular, the optical elements can be applied to optical components in an optically minute manner. This is especially advantageous for aesthetic reasons when applying the optical elements to wearable eyeglasses.

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

[0098] Preferably, the film in the apparatus is held by a movable die. These dies are preferably mounted to move linearly by guide means and can be adjusted along the guide axis by adjustment means. Preferably, the film is held by the die in a replaceable manner.

[0099] Preferably, the apparatus includes a spacer element, which is positioned between the film or die at least at a second relative position of the film. This spacer element allows the thickness of the optical element to be adjusted in the axial and radial elongation directions. Preferably, the spacer is kept in a replaceable manner within the apparatus so that the axial and / or radial elongation of the optical element can be adjusted by replacing the spacer.

[0100] Preferably, the apparatus has at least one mechanical means for deforming the first and / or second film. Preferably, the apparatus has an applicator means that can apply a liquid polymer to the first or second film in an adjustable amount.

[0101] Preferably, when a curable liquid polymer material is placed between the films, the first and / or second films are arranged such that a mechanical force or fluid pressure can be applied to the side of the film facing away from the polymer to deform the film.

[0102] Description of Examples and Figures The advantages that can be achieved by the present invention will be described below with reference to examples of embodiments and figures. [Brief explanation of the drawing]

[0103] [Figure 1-1] Figure 1 shows the steps of the manufacturing method for optical elements according to the first embodiment, as shown in figures a), b1), b2), c), d), and e). [Figure 1-2] Figure 1 shows the steps of the manufacturing method for optical elements according to the first embodiment, as shown in figures a), b1), b2), c), d), and e). [Figure 2] Figure 2 shows the steps of the manufacturing method for an optical element according to the second embodiment, as shown in figures a) and b). [Figure 3] Figure 3 shows the optical system according to the present invention. [Figure 4] Figure 4 shows one embodiment of the manufacturing process for the optical system according to the present invention. [Figure 5] Figure 5 shows one embodiment of the manufacturing process for an optical element according to the present invention. [Modes for carrying out the invention]

[0104] To better understand the diagram, please refer to the following list of reference figures.

[0105] Figure 1 is a schematic cross-sectional view of apparatus 1 for manufacturing an optical element 12, as shown in Figures a), b1), b2), c), and d). The apparatus comprises a first film 2 and a second film 3 that form a cavity 100, and has first and second surface portions 101 and 102 of the cavity 100. The first film and the second films 2 and 3 are transparent and made of an elastic polymer. The features and functions of the apparatus may relate in the same manner to the method according to the present invention, and Figure 1 is also useful for illustrating a method and process for optically modifying an optical component 20.

[0106] As shown in Figure 1a), in the first state of apparatus 1, the first film 2 and the second film 3 both extend along the main extension plane x and are substantially flat. Although not shown here, these films 2 and 3 each have substantially circular cross-sections, and these cross-sections extend within the image plane of Figure 1.

[0107] These films 2 and 3 are spaced apart by ring-shaped spacers 4, and together they form a cavity 100 filled with a transparent liquid polymer 5. This polymer is a so-called UV-curable polymer 5, which crosslinks when exposed to ultraviolet light and gradually changes from a liquid state to a solid state. This effect is used to obtain an optical element 12 from the transparent liquid polymer 5.

[0108] The optical element 12 functions as an applicable element of the optical component 20, adjusting the optical properties of the optical component 20 as needed. The optical component 20 may be the lenses of a pair of eyeglasses, particularly sunglasses, ski goggles, or virtual reality glasses (see, for example, Figure 3).

[0109] In order to adjust the optical properties of the optical component 20 as needed, the liquid polymer 5 adjusts the shapes of the first film 2 and the second film 3 according to the desired shape and optical properties of the optical element 12.

[0110] This is shown in Figures b1) and b2) of Figure 1, each showing different ways in which films 2, 3 can be deformed to obtain the shapes of the first and second surface portions 101, 102 of the cavity 100, and consequently the shapes of the first and second surfaces 12-1, 12-2 of the optical element 12.

[0111] According to Figure 1, Figure b1), a mechanical deformation element 6 is used, which applies a compressive force 7 to the first membrane 2, thereby deforming the membrane and adjusting its shape.

[0112] As a result of the deformation of the first membrane 2, the hydraulic pressure within the polymer 5 increases, which in turn causes the second membrane 3 to deform as well. In this way, both the first membrane 2 and the second membrane 3 can be simultaneously deformed into a desired shape.

[0113] During or after deformation, the polymer 5 is exposed to ultraviolet light 8 from a radiation source 9 through the second film 3.

[0114] As an alternative to the process shown in Figure 1, b1), according to Figure b2), the deformation device 6 can also be used to apply a tensile force 10 to the first film 2. As a result of the low pressure thus generated, the second film 3 is also deformed, and the desired shape of the optical element 12 produced thereby is also adjusted. Here, the deformation device 6 is attached to the first film 2 by adhesive.

[0115] The curing process shown in Figures b1) and b2) is controlled according to the curing state of the polymer and can be terminated before the polymer is completely cured. This can be done in a simple way by controlling the irradiation time or irradiation intensity, which depends on the degree of curing.

[0116] As shown in Figure 1(c), after the curing process, films 2 and 3 are removed, and the cured polymer is trimmed along the cut end 12.

[0117] Next, in Figure d), an optical element 12 having a first surface 12-1 and a second surface 12-2 is obtained according to the shape shown in Figure d) of Figure 1.

[0118] The optical element 12 can be attached to the optical component 20 as shown in Figure 1e). This can be facilitated by van der Waals forces, and moreover, by van der Waals forces alone. For this purpose, the optical element can be attached to or pressed against the optical surface 20-1 of the optical component 20 such that the optical element 12 and the optical component 20 can be brought into close contact so that the optical element 12 can be permanently fixed to the optical component 20 by van der Waals forces.

[0119] Figure 2 shows another embodiment of apparatus 1, which partially has the same parts as those already described with respect to Figure 1. For easier understanding, the same reference numerals are used for the same parts, and refer to the description in Figure 1.

[0120] As shown in Figure 2, films 2 and 3 are held at their ends by dies 13 and 14, respectively.

[0121] Dies 13 and 14 are movable between a first relative position and a second relative position. At the first relative position shown in Figure 2a), the UV-curable liquid polymer 5 is applied to the second film 3.

[0122] The second film 3 has elasticity such that it deforms as a result of the application of the liquid polymer. In particular, the deformation of the second film 3 is caused by the force of the weight of the polymer 5.

[0123] Subsequently, the first die 13 moves such that the first film 3 placed on it comes into contact with the polymer 5 and deforms substantially according to the second film 3 as a result of the adhesive force. This can be seen in Figure 2(b).

[0124] In the state shown in Figure 2(b), polymer 5 can be cured as described in Figure 1.

[0125] The optical element 12, manufactured according to the process shown in Figures 1 and 2, can have one of its surfaces applied to another optical component (not shown in Figure 2), particularly by a soluble adhesive and / or van der Waals forces.

[0126] Figure 3 shows an optical component 20 in the form of sunglasses with an optical element 12 attached to the side of the user's eyes (the optical element 12 is visible, in particular, as a dark circular line on the surface portion 20-a). The optical component 20 and the optical element 12 form an optical system 200, and the optical element 12 is manufactured to adjust for optical aberrations such as cylindrical aberration, astigmatism, or another higher-order Zernike polynomial describing optical aberrations. In this way, sunglasses 20 that may not show any adjustment of optical power or aberrations can be adjusted in terms of optical power and optical aberrations by the optical element 12, and the user's vision loss can be corrected in a cost-effective manner.

[0127] Figures 4a) to 4c schematically illustrate one embodiment of a method for using the optical surface 20-1 of the optical component 20 as the second surface portion 102 of the cavity 100. In this embodiment, the liquid material 5 is applied directly to the optical surface 20-1 of the optical component 200. In this case, the optical surface is part of the goggles' lenses. In the next step shown in Figure 4b), the first surface portion 101 of the cavity 10 is brought to the liquid material 5 placed on the optical surface 20-1. As before, the first surface portion corresponds to the first film 2.

[0128] The first membrane 2 is part of the molding apparatus 1, which is configured to adjust the pressure 6 on the side of the first membrane 2 facing away from the liquid material 5. For this purpose, the molding apparatus 1 includes a pressure chamber 300 on which the pressure can be adjusted. In this example, the pressure in the pressure chamber 300 can be adjusted by pumping fluid into or out of the pressure chamber 300 through an opening 301. The pressure chamber may include all the partial spacers 4 that make up the volume of the pressure chamber 300. The molding apparatus 1 may be movable along the z axis, i.e., along the optical axis of the optical surface 20-1, and may also be movable along the x and y axes, and may be tiltable around one axis, two axes or three axes.

[0129] By moving the molding apparatus 1 (see arrow 400), direct contact is established between the liquid material 5 and the first film 2. Before or after this, the pressure in the pressure chamber 300 can be adjusted so that the film 2 deforms the liquid 5, adjusts the volume of the liquid material, and shapes the surface of the liquid material 5 on the side facing the first film 2.

[0130] After the correct shape of the liquid material 5 is achieved, the liquid material 5 can be solidified.

[0131] Subsequently, the molding apparatus 1 can be retracted (see arrow 400) so that an optical system 200 is provided in which an optical component is optically adjusted on its optical surface by an optical element (see Figure 4c).

[0132] It should be noted that the molding apparatus 1 may include additional molding elements (not shown) that enable the shape of the first film 2 to be adjusted so as to provide and manufacture the shape of the optical element 12 that adjusts the optical component 20 to the optical aberrations of higher-order Zernike polynomials, as described in the previous paragraph.

[0133] Figure 5 schematically illustrates another embodiment of the present invention. In this example, a liquid material 5 is injected between a first membrane 2 and a second membrane 3, into a cavity 5 formed between them. For this purpose, the apparatus 1 has an injection opening indicated by a black arrow 50.

[0134] Furthermore, these membranes are attached to the apparatus 1, and a first pressure chamber 300-1 is formed between the particularly transparent upper part 1-1 of the apparatus 1 and the first membrane 2, configured to maintain a fluid pressure p1 such as air. The fluid is pumped into the first pressure chamber 300-1 through an opening 51 as indicated by the black double-headed arrow. The apparatus 1 may further comprise a second pressure chamber 300-2 formed between the particularly transparent lower part 1-2 of the apparatus 1 and the second membrane 3, the second pressure chamber 300-2 also configured to maintain a fluid pressure p2 such as air. The fluid can be pumped into the second pressure chamber 300-2 through an opening 52 as indicated by the black double-headed arrow.

[0135] After the liquid material 5 is injected into the cavity 100 between the first film 2 and the second film 3, the first and second pressures p1 and p2 are adjusted to shape the first and second films 2 and 3. After the first and second films 2 and 3 have correctly conformed to the desired shape, the liquid material 5 can be cured to fix the shape of the optical element 12 and, consequently, its optical properties. For this purpose, it is advantageous that at least the upper or lower part is transparent to the curing wavelength.

[0136] To precisely adjust the shapes of the first and second membranes 2 and 3, the first and second pressures p1 and p2 can be adjusted separately by their respective openings 51 and 52.

[0137] reference numbers 1 device 2. First membrane 3. The second membrane 4 Spacers 5 Transparent liquid polymer 6. Means of transformation 7. Pushing force 8 Irradiation means 9. Ultraviolet rays 10. Pulling force 11 Cutting line 12 Optical elements 12-1 First surface 12-2 Second Surface 13 The first die 14 The second die z optical axis x Main extension plane 20 Optical Components 20-1 Optical surface 100 Cavity 101 First surface portion 102 Second surface portion 200 Optical Systems 300 Pressure Chamber 300-1 First pressure chamber 300-2 Second pressure chamber 301 Opening 400 Direction of movement p1, p2 pressure 1-1 Top 1-2 Lower 50 openings 51 Opening 52 Opening

Claims

1. A method for optically modifying an optical component using an optical element (12), the method comprising the following steps: A) The step of placing a transparent, solidifiable liquid material (5) into a cavity (100), wherein the cavity (100) comprises a first surface portion (101) and a second surface portion (102), and the first surface portion (101) of the cavity (100) is formed by a first deformable film (2); B) A step of adjusting the shape of the first film (2) so that the optical power of the optical element (12) to be manufactured is adjusted; C) A step of solidifying a liquid material (5) to obtain an optical element (12), wherein the optical element (12) comprises a first surface (12-1) that fits into a first surface portion (101) of the cavity (100) and a second surface (12-2) that fits into a second surface portion (102) of the cavity (100), and the optical element (12) comprises optical power adjusted by the shapes of the first surface and the second surface (12-1, 12-2); D) A step of attaching the optical element (12) to the optical surface (20-1) of the optical component (20), wherein the first surface (12-1) or the second surface (12-2) of the optical element (12) faces the optical surface (20-1) of the optical component (20) so that the optical component (20) is optically modified by the optical power of the optical element (12), The method, including the method described above.

2. The method according to claim 1, wherein a second surface portion (102) is formed by a second deformable film (3), and in step B), the shape of the second film (3) is adjusted to adjust the shape of the second surface portion (102) of the cavity (100).

3. The method according to claim 1 or 2, wherein between step C) and step D), the optical element (12) is removed from the second surface portion and / or the first surface portion (101, 102) of the cavity (100).

4. The method according to claim 1 or 2, wherein when the optical element is attached to the optical component (20), the first film and / or the second film (2, 3) remain attached to the optical element (12).

5. The method according to any one of claims 1 to 4, wherein the first film (2) and / or the second film (3) are at least partially transparent to ultraviolet light (9), and the liquid material (5) is an ultraviolet-curable liquid polymer, and step C) of the method comprises exposing the liquid polymer to ultraviolet light (9) through the first film and / or the second film (2, 3).

6. The method according to any one of claims 1 to 5, wherein the second surface (12-2) of the optical element (12) is attached to the surface of the optical surface (20-1) of the component (20) by van der Waals forces, particularly by van der Waals forces alone.

7. The method according to any one of claims 1 to 6, wherein the optical element (12), in particular the first surface and / or second surface (12-1, 12-2) of the optical element (12), is shaped, either alone or in combination with the optical component (20), to adjust one or more optical parameters selected from the group consisting of cylindrical aberration, astigmatism, coma aberration, prism aberration or higher-order Zernike polynomial aberration, in particular to adjust for human visual impairment.

8. The method according to claim 7, wherein the shape of the first film (2) and / or the shape of the second film (3) is adjusted by a mechanical element (6), the mechanical element (6) is configured to adjust the shape of the first film and / or the second film (2, 3) to produce an optical element exhibiting one or more optical parameters, and in particular the mechanical element (6) is a lens molding apparatus.

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

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

11. The method according to any one of claims 2 to 10, wherein the shapes of the first membrane and the second membrane (2, 3) are continuous deformations of the first membrane (2) and the second membrane (3).

12. The liquid material (5) is applied to the first film (2) or the second film (3) such that the shape of each film (2, 3) is formed as a result of the force exerted by the application of the liquid material (5), particularly as a result of the force of the weight of the liquid material (5) on each film (2, 3), and The method according to any one of claims 1 to 11, wherein each of the other films (3, 2) is brought into contact with a liquid material (5), and the shape of each of the other films is formed as a result of the adhesive force of the liquid material (5).

13. The method according to any one of claims 1 to 12, wherein the solidification, particularly the curing, of the liquid material (5) is controlled such that the solidified, particularly cured, optical element (12) is flexible, and the solidification, particularly, is terminated before the liquid material (5) hardens into a solid state, the material particularly includes duroplast, elastomer and / or thermoplast.

14. The method according to any one of claims 1 to 13, wherein the optical component (20) is selected from the group consisting of hard lenses, ski goggles, scuba diver goggles, safety goggles, eyeglasses, sunglasses, virtual reality augmented glasses, waveguide structures, waveguide diffraction structures, and waveguide refraction structures.

15. An optical system (200) comprising a transparent optical element (12) having optical power, wherein the optical element (12) comprises a material, particularly a polymer, having a first surface (12-1) and a second surface (12-2) facing in the opposite direction to the first surface (12-1), wherein the optical element (12) is flexible and bendable such that the first surface (12-1) can be bent to conform to a curved surface, wherein the first surface (12-1) is in broad contact with a complementary surface (in particular, wherein the surface includes or is made of a polymer, synthetic polymer or glass). The optical system (200) is configured such that van der Waals forces between the first surface (12-1) and a complementary surface, particularly van der Waals forces alone, result in the attachment of the optical element (12) to the complementary surface, where the optical element (12) is shaped either alone or in combination with the optical component (20) to adjust one or more optical parameters selected from the group consisting of cylindrical aberration, astigmatism, coma aberration, prism aberration, or higher-order Zernike polynomial aberration, particularly to adjust for human visual impairment.

16. The optical system (200) according to claim 15, wherein the second surface (12-2) is concave or convex, and in particular the second surface is coated with an anti-reflective coating.

17. The optical system (200) comprises an optical component (20) having an optical surface (20-1) having complementary surfaces, and an optical element (12) is attached to the optical surface (20-1) of the optical component (20) via its first surface (12-1) by van der Waals forces, particularly by van der Waals forces alone, according to claim 15 or 16.

18. The optical system (200) according to any one of claims 15 to 17, wherein an adhesive is placed on the first surface (12-1) so that the optical element (12) is bonded to the optical component (20) when the optical element (12) is attached to the optical surface (20-1) of the optical component.

19. The optical system (200) according to any one of claims 15 to 18, wherein the optical component (20) is selected from the group consisting of goggles, eyeglasses, and VR goggles, and when a person wears the optical component (20), the optical surface (20-1) faces the direction of the person's eyes.

20. The optical system (200) according to any one of claims 15 to 19, wherein the optical component (20) comprises two optical surface portions (20-a, 20-b) provided by an optical surface (20-1), the optical surface portions (20-a, 20-b) are arranged such that a person wearing the optical component (20) positions one surface portion (20-a, 20-b) in front of one of their eyes, and an optical element (12) is attached to each optical surface portion.

21. The optical power of each optical element (12) is selected so as to adjust the optical power of the optical component (20), and in particular the optical power of each optical element (12) is different, and in particular the optical component (20) does not exhibit optical power, as described in any one of claims 15 to 20.

22. The optical system (200) according to any one of claims 15 to 21, wherein each optical element (12) is formed as a thin lens adapted so that the first surface (12-1) of the optical element (12) is fitted to the optical surface (20-1) of the optical component (20).

23. The optical system (200) according to any one of claims 15 to 22, wherein the width of each optical element is at least 5 to 20 times greater than the thickness of the optical element, and particularly 10 to 20 times greater.

24. The optical system according to any one of claims 15 to 23, wherein each optical element is manufactured by performing steps A) to D) of the method of claim 1 and / or any one of claims 2 to 9.

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