Rotational alignment of cemented lenses

Abstract

The objective is to efficiently manufacture lenses that require their functional surfaces to be rotated and oriented in a specific direction. [Solution] An apparatus and method for use with a frame (21) of eyeglasses (18) is described. A cemented lens (20) is placed within the frame (21) that defines a horizontal axis configured to coincide with the horizontal meridian of the wearer's eye when the wearer wears the eyeglasses. The cemented lens includes a stock base lens (22) and a stock add-on lens (24). The add-on lens (24) is bonded to the base lens (22) in a state where the add-on lens (24) and the base lens (22) are rotated and aligned with respect to each other in a certain rotational orientation, so that the functional surfaces of the base lens (22) and the add-on lens (24) within the cemented lens (20) are rotated and oriented with respect to the horizontal axis (25) of the cemented lens (20) in a first rotational orientation and a second rotational orientation, respectively. Other application examples are also described.

Description

TECHNICAL FIELD

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 542,103 filed October 3, 2023, entitled "Rotational Alignment of Combined Lenses" by Engler et al., which is incorporated herein by reference in its entirety.

[0002] Some applications of the present invention relate generally to ophthalmic lenses. In particular, some applications relate to manufacturing a cemented lens that includes two lenses bonded to each other. BACKGROUND ART

[0003] Lenses are typically placed within the eyeglass frame to define a horizontal axis, which is configured to align with the horizontal meridian of the wearer's eye when the wearer is wearing the eyeglasses. There are several examples of ophthalmic lens functions that require the functional surface of the lens to be rotationally oriented in a specific direction relative to the horizontal axis of the lens. For example, a patient suffering from astigmatism (a condition in which the shape of the cornea and / or lens of the eye is distorted) can be treated with a cylindrical correction lens. This lens is designed so that the power of the cylindrical correction matches the strength of the astigmatism, and the axis of the cylindrical correction matches the direction of the astigmatism relative to the horizontal axis (which is configured to align with the horizontal meridian of the wearer's eye). Another example of a lens function that requires the functional surface of the lens to be rotationally oriented in a specific direction relative to the horizontal axis is polarization. Typically, polarized lenses are configured so that the direction of polarization approximately coincides with the horizon when the wearer is wearing the lenses with eyeglasses. Therefore, in practice, the direction of polarization usually coincides with the horizontal axis of the lens. Additional examples of lenses with functions that may require the functional surface of the lens to be rotated or oriented in a specific direction relative to the horizontal axis of the lens include, for example, lenses that perform a specific type of myopia suppression, lenses that include gradient tinting, lenses with protective coatings that require different levels of protection for distance and near vision (e.g., UV protection), and lenses that facilitate the overlaying of information onto the lens using electronic projection (for smart glasses).

[0004] Furthermore, there are eyeglasses manufactured using toric (cylindrical) lenses with a concave front for aesthetic purposes. Such lenses are usually non-prescription (used, for example, in sunglasses), but they can also be prescription. The rear surface of such lenses is usually shaped to correct for unwanted power and / or cylindrical power caused by the concave front. In such cases, the rear surface usually needs to be oriented in a specific direction relative to the front. [Overview of the project]

[0005] According to some applications of the present invention, a cemented lens (used with an eyeglass frame) comprises a base lens and an additional lens bonded to the base lens. As described in the background section above, the lens is typically placed within the eyeglass frame so as to define a horizontal axis that, when the wearer wears the eyeglasses, is configured to coincide with the horizontal meridian of the wearer's eye. In some applications, each lens performs a function within a functional plane that requires the lens to be rotationally oriented in a predetermined direction with respect to the horizontal axis of the cemented lens. (Typically, the cemented lens has a predetermined three-dimensional shape, and the functional plane refers to the x and y components of this shape.) Typically, the base lens and the additional lens perform corresponding functions within a functional plane that require the lenses to be rotationally oriented with different rotational orientations from each other. More typically, the functional plane of at least one of the lenses in the cemented lens (optionally, both the base lens and the additional lens in the cemented lens) requires that the functional plane of the lens be rotationally oriented with a non-zero rotational displacement from the horizontal axis of the cemented lens. In some embodiments, the functional planes of both the stock base lens and the stock additional lens are required to be rotationally oriented with a non-zero rotational displacement from the horizontal axis of the cemented lens.

[0006] Typically, before joining them together, the base lens and the add-on lens are rotated and aligned relative to each other so that, when joined, each lens is rotated orienting to the required orientation with respect to the horizontal axis of the cemented lens. The cemented lens is then placed within the spectacle frame so that, when the wearer puts on the glasses, the horizontal axis of the cemented lens coincides with the horizontal meridian of the wearer's eye.

[0007] There are several examples of ophthalmic lens functions that require the functional surface of the lens to be rotated or oriented in a specific direction relative to the horizontal axis of the lens. For example, a patient suffering from astigmatism (a condition in which the shape of the cornea and / or lens of the eye is distorted) can be treated with a cylindrical correction lens. This lens is designed so that the power of cylindrical correction matches the strength of the astigmatism, and the axis of cylindrical correction is perpendicular to the direction of astigmatism relative to the horizontal axis of the lens (which is configured to coincide with the horizontal meridian of the wearer's eye). Another example of a lens function that requires the functional surface of the lens to be rotated or oriented in a specific direction relative to the horizontal axis is polarization. Typically, polarized lenses are configured so that when the wearer wears the lenses with their glasses, the direction of polarization roughly coincides with the horizon. Therefore, in practice, the direction of polarization usually coincides with the horizontal axis of the lens. Additional examples of lenses with functions that may require the functional surface of the lens to be rotated or oriented in a specific direction relative to the horizontal axis of the lens include, for example, lenses that suppress myopia, lenses with gradient tinting, lenses with protective coatings that require different levels of protection for distance and near vision (e.g., UV protection), and lenses that facilitate the overlaying of information onto the lens using electronic projection (for smart glasses).

[0008] Furthermore, there are eyeglasses manufactured using toric (cylindrical) lenses with a concave front for aesthetic purposes. Such lenses are usually non-prescription (used, for example, in sunglasses), but they can also be prescription. The rear surface of such lenses is usually shaped to correct for unwanted power and / or cylindrical power caused by the concave front. In such cases, the rear surface usually needs to be oriented in a specific direction relative to the front.

[0009] It should be noted that some such examples may require the functional surface of the lens to be rotationally oriented so as to coincide with the horizontal axis of the lens, while others may require the functional surface of the lens to be rotationally oriented with a non-zero rotational displacement from the horizontal axis of the lens. According to some applications, any combination of the above lenses includes a base lens and an additional lens of a cemented lens.

[0010] Typically, by combining base lenses and add-on lenses as described above, lenses that provide two or more of the above functions can be manufactured, allowing lenses that conform to a wearer's prescription to be assembled from a relatively small minimum inventory unit. More typically, lenses can be assembled from combinations of mass-produced stock lenses without the need to machine custom lenses.

[0011] Therefore, according to some embodiments of the present invention, a device for use together with the frame of eyeglasses worn by the wearer, The eyeglasses include a cemented lens configured to be placed within the eyeglasses frame so as to define a horizontal axis that is configured to coincide with the horizontal meridian of the wearer's eye when the wearer is wearing the eyeglasses, and the cemented lens is, A stock base lens that provides a first function within a first functional surface, wherein the functional surface of the base lens is rotationally oriented with respect to the horizontal axis of the cemented lens in a first rotational orientation, A stock add-on lens comprising a stock add-on lens that provides a second function within a second functional surface, wherein the functional surface of the add-on lens is rotationally oriented with respect to the horizontal axis of the cemented lens in a second rotational orientation different from a first rotational orientation, An apparatus is provided in which an additional lens is bonded to the base lens in a state where the additional lens and the base lens are rotated and aligned with respect to each other in a certain rotational orientation, thereby causing the functional surfaces of the base lens and the additional lens within the cemented lens to be rotated and oriented with respect to the horizontal axis of the cemented lens in a first rotational orientation and a second rotational orientation, respectively.

[0012] In some embodiments, it is required that at least one of the functional surfaces of the stock base lens and the stock add-on lens be rotationally oriented with a non-zero rotational displacement from the horizontal axis of the cemented lens.

[0013] In some embodiments, one of the stock base lens and the stock add-on lens is a cylindrical lens configured to perform cylindrical correction, and the cylindrical lens is coupled to the other lens such that the functional surface of the cylindrical lens is rotationally oriented with respect to the horizontal axis of the cemented lens, so that the axis of cylindrical correction coincides with the direction of the wearer's astigmatism.

[0014] In some embodiments, one of the stock base lens and the stock add-on lens is a myopia suppression lens configured to suppress myopia in the wearer, and the myopia suppression lens is coupled to the other lens such that the functional surface of the myopia suppression lens is rotationally oriented with respect to the horizontal axis of the cemented lens in order to give the wearer a desired orientation of myopia suppression.

[0015] In some embodiments, one of the stock base lens and the stock add-on lens is a polarizing lens configured to polarize light along the polarization direction, and the polarizing lens is coupled to the other lens such that the functional surface of the polarizing lens is rotationally oriented with respect to the horizontal axis of the bonded lens in order to give the wearer the desired polarization of light.

[0016] In some embodiments, the base lens is a cylindrical photochromic lens, the additional lens is a polarizing lens, and the bonded lens is a polarizing photochromic bonded lens.

[0017] In some embodiments, one of the stock base lens and the stock add-on lens includes gradient coloring.

[0018] In some embodiments, one of the stock base lens and the stock add-on lens includes a lens with a protective coating that requires different levels of protection for distance and near vision.

[0019] In some embodiments, one of the stock base lens and the stock add-on lens includes a lens that facilitates superimposing information onto the lens using electron projection.

[0020] In some embodiments, one of the stock base lens and the stock add-on lens includes a lens configured to compensate for power or cylindrical power to account for a cemented lens having a concave front surface.

[0021] In some embodiments, the cemented lens is not configured to provide the wearer with add power for near vision correction.

[0022] In some embodiments, the cemented lens is configured to provide add power for near vision correction.

[0023] In some embodiments, the cemented lens is further configured to perform distance vision correction, and provide a progressive transition zone between the portion of the cemented lens that performs near vision correction and the portion that performs distance vision correction.

[0024] In some embodiments, the base lens is configured to perform all of the distance vision correction of the cemented lens.

[0025] In some embodiments, the combined optical properties of the base lens and the add-on lens provide the desired full optical correction of the cemented lens, while neither the base lens nor the add-on lens alone performs optical distance vision correction.

[0026] In some embodiments, the cemented lens is configured to provide near vision correction of up to 0.85 diopters.

[0027] In some embodiments, the cemented lens is configured to be used by pre-presbyopic wearers who read digital devices.

[0028] In some embodiments, the cemented lens comprises one or more functional coatings pre-applied to at least one of the front surface of the cemented lens and the rear surface of the cemented lens before the add-on lens is bonded to the base lens.

[0029] In some embodiments, one or more functional coatings include one or more functional coatings selected from a list consisting of hard coatings, anti-reflective coatings, hydrophobic coatings, superhydrophobic coatings, antistatic coatings, oleophobic coatings, clean coatings, blue light filters, reflective coatings, anti-UV coatings, photochromic coatings, colored coatings, and mirror coatings.

[0030] In some embodiments, the cemented lens comprises a first set of one or more functional coatings pre-applied to the front surface of the cemented lens and a second set of one or more functional coatings pre-applied to the rear surface of the cemented lens before the additional lens is bonded to the base lens.

[0031] In some embodiments, a first set of one or more functional coatings pre-applied to the front surface of the cemented lens is the same as a second set of one or more functional coatings pre-applied to the rear surface of the cemented lens.

[0032] In some embodiments, a first set of one or more functional coatings pre-applied to the front surface of the cemented lens differs from a second set of one or more functional coatings pre-applied to the rear surface of the cemented lens.

[0033] According to some embodiments of the present invention, a method for use together with the frame of eyeglasses worn by the wearer, This includes manufacturing a cemented lens configured to be placed within the frame of eyeglasses so as to define a horizontal axis that is configured to coincide with the horizontal meridian of the wearer's eye when the wearer is wearing the eyeglasses, and manufacturing A stock base lens that provides a first function within a first functional surface, wherein the functional surface of the base lens is rotationally oriented with respect to the horizontal axis of the cemented lens in a first rotational orientation, A stock add-on lens is provided, which requires that the functional surface of the add-on lens be rotated orienting with respect to the horizontal axis of the cemented lens in a second rotational orientation different from the first rotational orientation, by rotating and aligning a stock add-on lens with respect to each other, Once the cemented lens is formed, the functional surfaces of the base lens and the additional lens are rotated orienting with respect to the horizontal axis of the cemented lens in a first rotational orientation and a second rotational orientation, respectively. A method is further provided which is carried out by coupling the stock base lens and the stock add-on lens to each other while the stock base lens and the stock add-on lens are rotated and aligned with respect to each other.

[0034] In some embodiments, rotatably aligning the stock base lens and the stock add-on lens relative to each other includes rotatably aligning the stock base lens and the stock add-on lens relative to each other such that, when the cemented lens is formed, the functional surface of at least one of the stock base lens and the stock add-on lens is rotatably oriented with a non-zero rotational displacement from the horizontal axis of the cemented lens.

[0035] In some embodiments, one of the stock base lens and the stock add-on lens is a cylindrical lens configured to perform cylindrical correction, and the rotational alignment of the stock base lens and the stock add-on lens relative to each other includes aligning the stock base lens and the stock add-on lens relative to each other such that, when the cemented lens is formed, the axis of cylindrical correction coincides with the direction of the wearer's astigmatism, and the functional surface of the cylindrical lens is rotationally oriented with respect to the horizontal axis of the cemented lens.

[0036] In some embodiments, one of the stock base lens and the stock add-on lens is a myopia suppression lens configured to suppress myopia in the wearer, and the rotational alignment of the stock base lens and the stock add-on lens relative to each other includes aligning the stock base lens and the stock add-on lens relative to each other such that, when the cemented lens is formed, the functional surface of the myopia suppression lens is rotationally oriented with respect to the horizontal axis of the cemented lens so as to give the wearer the desired orientation of myopia suppression.

[0037] In some embodiments, one of the stock base lens and the stock add-on lens is a polarizing lens configured to polarize light along the polarization direction, and the rotational alignment of the stock base lens and the stock add-on lens relative to each other includes aligning the stock base lens and the stock add-on lens relative to each other such that, when the bonded lens is formed, the functional surface of the polarizing lens is rotationally oriented with respect to the horizontal axis of the bonded lens so as to give the wearer the desired polarization of light.

[0038] In some embodiments, the base lens is a cylindrical photochromic lens, the additional lens is a polarizing lens, and bonding the stock base lens and the stock additional lens together includes forming a polarizing photochromic bonded lens.

[0039] In some embodiments, one of the stock base lens and the stock add-on lens includes gradient coloring.

[0040] In some embodiments, one of the stock base lens and the stock add-on lens includes a lens with a protective coating that requires different levels of protection for distance and near vision.

[0041] In some embodiments, one of the stock base lens and the stock add-on lens includes a lens that facilitates superimposing information onto the lens using electron projection.

[0042] In some embodiments, one of the stock base lens and the stock add-on lens includes a lens configured to compensate for a power or cylindrical power to account for a cemented lens having a concave front surface.

[0043] In some embodiments, the bonded lens is not configured to provide the wearer with an add power for correcting near vision.

[0044] In some embodiments, the cemented lens is configured to provide an add power for correcting near vision.

[0045] In some embodiments, the cemented lens is further configured to correct distance vision and to provide a transitional progressive zone between the portion of the cemented lens that corrects near vision and the portion that corrects distance vision.

[0046] In some embodiments, the base lens is configured to perform all of the distance vision correction for the cemented lens.

[0047] In some embodiments, the combined optical properties of the base lens and the additional lens provide the desired complete optical correction of the cemented lens, while neither the base lens nor the additional lens performs optical distance vision correction on its own.

[0048] In some embodiments, the cemented lens is configured to correct near vision by up to 0.85 diopters.

[0049] In some embodiments, the cemented lens is configured for use by wearers who are nearing presbyopia and reading digital devices.

[0050] In some embodiments, bonding a stock base lens and a stock add-on lens to each other includes bonding the stock base lens and the stock add-on lens with one or more functional coatings pre-applied to at least one of the front surface and rear surface of the bonded lens before bonding the stock base lens and the stock add-on lens to each other.

[0051] In some embodiments, one or more functional coatings include one or more functional coatings selected from a list consisting of hard coatings, anti-reflective coatings, hydrophobic coatings, superhydrophobic coatings, antistatic coatings, oleophobic coatings, clean coatings, blue light filters, reflective coatings, anti-UV coatings, photochromic coatings, colored coatings, and mirror coatings.

[0052] In some embodiments, bonding a stock base lens and a stock add-on lens to each other includes bonding the stock base lens and the stock add-on lens with one or more functional coatings pre-applied to both the front and rear surfaces of the bonded lens before bonding the stock base lens and the stock add-on lens to each other.

[0053] In some embodiments, a first set of one or more functional coatings pre-applied to the front surface of the cemented lens is the same as a second set of one or more functional coatings pre-applied to the rear surface of the cemented lens.

[0054] In some embodiments, a first set of one or more functional coatings pre-applied to the front surface of the cemented lens differs from a second set of one or more functional coatings pre-applied to the rear surface of the cemented lens.

[0055] In some embodiments, the stock base lens and the stock add-on lens are coupled to each other. The stock base lens and the stock add-on lens are placed in corresponding first and second pressure chambers, with an adhesive layer between them, and the internal pressure of each chamber can be controlled independently. The convex surface of the stock lens is brought into contact with the adhesive layer, so that the central region of the convex surface of the stock lens initially contacts the adhesive layer, and then the contact between the convex surface of the stock lens and the adhesive layer radiates outward from the central region of the convex surface of the stock lens until the convex surface of the stock lens is covered by the adhesive layer, and This includes bringing the concave surface of the stock base lens into contact with the adhesive layer, such that the central region of the concave surface of the stock base lens is initially in contact with the adhesive layer, and then the contact between the concave surface of the stock base lens and the adhesive layer radiates outward from the central region of the concave surface of the stock base lens until the concave surface of the stock base lens is covered by the adhesive layer.

[0056] In some embodiments, rotatably aligning the stock base lens and the stock add-on lens relative to each other includes rotatably aligning the stock base lens and the stock add-on lens relative to each other within the corresponding first and second pressure chambers.

[0057] The present invention will be better understood from the following detailed description of embodiments in conjunction with the drawings. [Brief explanation of the drawing]

[0058] [Figure 1] This is a schematic diagram of eyeglasses including one or more lenses, each consisting of a base lens and an additional lens coupled to the base lens, according to a partial application example of the present invention. [Figure 2A] This is a schematic diagram of each step in the bonding process for bonding an additional lens to a base lens, according to some application examples of the present invention. [Figure 2B] This is a schematic diagram of each step in the bonding process for bonding an additional lens to a base lens, according to some application examples of the present invention. [Figure 2C] This is a schematic diagram of each step in the bonding process for bonding an additional lens to a base lens, according to some application examples of the present invention. [Figure 2D]This is a schematic diagram of each step in the bonding process for bonding an additional lens to a base lens, according to some application examples of the present invention. [Modes for carrying out the invention]

[0059] The following refers to Figure 1, a schematic diagram of eyeglasses 18 that include one or more cemented lenses 20 within an eyeglass frame 21. According to some applications of the present invention, each cemented lens consists of a base lens 22 and an additional lens 24 bonded to the base lens. As described in the background section above, lenses are typically placed within the eyeglass frame to define a horizontal axis that, when the wearer wears the eyeglasses, is configured to coincide with the horizontal meridian of the wearer's eye. In some applications, each of the lenses (i.e., the base lens 22 and the additional lens 24) performs a function within a functional plane that requires the lens to be rotationally oriented in a predetermined direction with respect to the horizontal axis 25 of the cemented lens. (Typically, the lens has a predetermined three-dimensional shape, and the functional plane refers to the x and y components of that shape.) Typically, the lenses perform corresponding functions within a functional plane that require the lenses to be rotationally oriented with different rotational orientations from each other. More typically, the functional plane of at least one lens within the cemented lens (optionally, both the base lens and the additional lens within the cemented lens) requires that the functional plane of the lens be rotationally oriented with a non-zero rotational displacement from the horizontal axis of the cemented lens.

[0060] Typically, the base lens and the additional lens are bonded to each other using the apparatus and method described below, for example, with reference to Figures 2A to 2D. Before bonding to each other, the lenses are rotationally aligned relative to each other, and once bonded, each lens is rotationally oriented to a desired orientation with respect to the horizontal axis of the cemented lens. The cemented lens is then placed in the spectacle frame so that when the wearer puts on the glasses, the horizontal axis 25 of the cemented lens coincides with the horizontal meridian of the wearer's eye. The additional lens is usually bonded to the rear side of the base lens, i.e., the concave side of the base lens that is closer to the patient's face when the patient puts on the glasses 18. In some applications, the additional lens is bonded to the front side of the base lens, i.e., the convex side of the base lens that is further from the patient's face when the patient puts on the glasses 18. Note that in the enlarged view of Figure 1, a gap is shown between the outer edge of the additional lens and the spectacle frame 21. Typically, such a gap does not actually exist and is shown in Figure 1 for illustrative purposes only to show the additional lens 24 and the base lens 22.

[0061] As explained in the background above, there are several examples of ophthalmic lens functions that require the functional surface of the lens to be rotated or oriented in a specific direction relative to the horizontal axis of the lens. For example, patients suffering from astigmatism (a condition in which the shape of the cornea and / or lens of the eye is distorted) can be treated with a cylindrical correction lens. This lens is designed so that the power of cylindrical correction matches the strength of the astigmatism, and the axis of cylindrical correction is perpendicular to the direction of astigmatism relative to the horizontal axis of the lens (which is configured to coincide with the horizontal meridian of the wearer's eye). Another example of a lens function that requires the functional surface of the lens to be rotated or oriented in a specific direction relative to the horizontal axis is polarization. Typically, polarized lenses are configured so that when the wearer wears the lenses with their glasses, the direction of polarization roughly coincides with the horizon. Therefore, in practice, the direction of polarization usually coincides with the horizontal axis of the lens. Examples of lenses with functions that may require the functional surface of the lens to be rotated or oriented in a specific direction relative to the horizontal axis of the lens include, for example, lenses that suppress myopia, lenses with gradient tinting, lenses with protective coatings that require different levels of protection for distance and near vision (e.g., UV protection), and lenses that facilitate the overlaying of information onto the lens using electronic projection (for smart glasses).

[0062] Furthermore, there are eyeglasses manufactured using toric (cylindrical) lenses with a concave front for aesthetic purposes. Such lenses are usually non-prescription (used, for example, in sunglasses), but they can also be prescription. The rear surface of such lenses is usually shaped to correct for unwanted power and / or cylindrical power caused by the concave front. In such cases, the rear surface usually needs to be oriented in a specific direction relative to the front.

[0063] It should be noted that some such examples may require the functional surface of the lens to be rotationally oriented so as to coincide with the horizontal axis of the lens, while other examples may require the functional surface of the lens to be rotationally oriented with a non-zero rotational displacement from the horizontal axis of the lens. According to some applications, any combination of the above lenses includes a base lens 22 and an additional lens 24 of a cemented lens 20.

[0064] In some applications, the cemented lens provides a single-focus optical correction function, such as distance vision correction. In some applications, the base lens provides all of the distance vision correction function provided by the cemented lens. Alternatively, the combined optical properties of the base and add-on lenses provide the desired complete optical correction of the cemented lens, while neither the base lens nor the add-on lens provides optical distance vision correction on its own (see, for example, Katzman's US11,378,821, incorporated herein by reference).

[0065] Typically, cemented lenses are not configured to provide add power for near vision correction. Alternatively, in some applications, add-on lenses are configured to provide add power for additional near vision correction. In some applications, add-on lenses are configured to provide only a small add power. For example, the correction may be up to 0.85 diopters to correct near vision for wearers (e.g., relatively young wearers) who are on the verge of presbyopia and reading digital devices. Typically, in such applications, the add-on lens provides add power for both near and far vision correction, as well as a progressive zone between near and far vision.

[0066] Typically, by combining base lenses and add-on lenses as described above, lenses that provide two or more of the above functions can be manufactured, allowing lenses that conform to a wearer's prescription to be assembled from a relatively small minimum inventory unit. More typically, lenses can be assembled from combinations of mass-produced stock lenses without the need to machine custom lenses.

[0067] For example, if a wearer requires a polarized lens with a cylindrical correction having a power of X diopters and an axis of Y degrees, the cemented lens is manufactured by bonding a cylindrical correction lens with a power of X diopters to the polarized lens, and rotating the cylindrical correction lens so that it is oriented at an angle of Y degrees with respect to the polarization direction of the polarized lens before bonding the lenses together. If another wearer requires a polarized lens with a cylindrical correction having a power of X diopters and an axis of Z degrees, the cemented lens is manufactured by bonding a cylindrical correction lens with the same power of X diopters to the polarized lens, but in this case, rotating the cylindrical correction lens so that it is oriented at an angle of Z degrees with respect to the polarization direction of the polarized lens before bonding the lenses together.

[0068] Alternatively, the base lens is a cylindrical photochromic lens, and the add-on lens is a polarized lens. By orienting the base lens and add-on lens in the appropriate orientation relative to each other, a polarized photochromic bonded lens that fits the patient's prescription is manufactured. According to the above paragraph, typically both the base lens and the add-on lens are stock lenses (i.e., lenses mass-produced to provide a specific type and / or value of optical correction that is generally required), as opposed to one or both lenses being custom lenses (i.e., lenses formed to provide a specific optical correction required by a particular patient).

[0069] Typically, after processing a custom lens, one or more functional coatings are applied to the front and / or rear surfaces of the lens, such as hard coatings, anti-reflective coatings, hydrophobic coatings, superhydrophobic coatings, oleophobic coatings, antistatic coatings, clean coatings, blue light filters, reflective coatings, anti-UV coatings, photochromic coatings, tinted coatings, mirror coatings, or any combination thereof. More typically, lens processing is time-consuming, and the application of functional coatings requires additional time and can only be done after lens processing, thus increasing the lens manufacturing time. Typically, according to the application of the present invention, both the base lens and the add-on lens are stock lenses. As described above, the add-on lens is usually bonded to the rear of the base lens. Typically, in such applications, one or more functional coatings are pre-applied to the front surface of the base lens. More typically, one or more functional coatings are pre-applied to the rear surface of the add-on lens. (Note that the coating applied to the rear surface of the add-on lens is not necessarily identical to the coating applied to the front surface of the custom base lens.) Therefore, as soon as the add-on lens is bonded to the base lens, the functional coating is already in place on the front and / or rear surfaces of the bonded lens. Typically, this significantly reduces the time from ordering to manufacturing of a custom lens compared to forming the custom lens first based on the order and then applying the functional coating only afterward. In some applications, the add-on lens is bonded to the front of the base lens, in which case the front surface of the add-on lens and the rear surface of the base lens are usually covered with a pre-applied coating. Often, lens coating cannot be applied cost-effectively on a per-lens basis and must be done in batches of several lenses. Custom lenses awaiting coating may waste considerable time waiting in the coating machine until a sufficient number of lenses have accumulated to fill the batch. Therefore, the above manufacturing method usually allows for a much greater reduction in production time compared to manufacturing and coating custom lenses, far exceeding the cycle time of a simple coating process.

[0070] The above techniques may be applied to lenses that include power or cylindrical power compensation to accommodate any other type of base lens or additional lens with a function that requires the functional surface of the lens to be rotated or oriented in a specific direction with respect to the horizontal axis of the lens, such as lenses that perform a specific type of myopia suppression, lenses that include gradient tinting, lenses with protective coatings that require different levels of protection for distance and near vision (e.g., UV protection), lenses that facilitate the superimposition of information onto the lens using electronic projection (for smart glasses), and / or cemented lenses with a concave front surface.

[0071] The following references to Figures 2A, 2B, 2C, and 2D, which are schematic diagrams of each step in the bonding process for bonding an additional lens to a base lens, according to some applications of the present invention. Note that the bonding process is largely the same as that described in Halahmi's US2023 / 0104521 (the U.S. national phase of Halahmi's WO2021-198822), which is incorporated herein by reference. In some applications, alternative apparatus and / or methods are used to bond the base lens and the additional lens to each other.

[0072] Typically, the steps shown in Figures 2A to 2D are performed with the lenses rotated and aligned relative to each other so that, once bonded together, each lens is rotationally oriented in the orientation required for its functional surface to perform its corresponding function with respect to the horizontal axis of the cemented lens, as described above. Typically, the additional lens defines at least one convex surface, the base lens defines at least one concave surface, and the convex surface of the additional lens is bonded to the concave surface of the base lens.

[0073] In some applications, as shown in Figure 2A, the additional lens 24 is held in a first chamber 71 and the base lens 22 is held in a second chamber 72. Typically, within each chamber, the lenses are rotated and aligned relative to each other so that, when bonded together, each lens is rotated and oriented to the required orientation relative to each other. As described above, typically, once the cemented lens is formed, it is placed within the spectacle frame so that when the wearer puts on the glasses, the horizontal axis of the cemented lens coincides with the horizontal meridian of the wearer's eye. More typically, when the wearer is in an upright position with the glasses on, the horizontal axis of the lens will coincide approximately with the horizon. In some applications, each of the chambers 71 and 72 functions as an oven, and the temperature of each chamber can be controlled. Alternatively, the chambers are not heated. Typically, chamber 71 is connected to a vacuum pressure source via a first tube 70, and chamber 72 is connected to the same or another vacuum pressure source via a second tube 75, so that the pressure in each chamber can be controlled independently of each other.

[0074] Typically, a thin, flexible adhesive layer 73 (usually a pressure-sensitive adhesive that is adhesive on both sides) is held between the two chambers. For example, as shown in the cross-sectional view of the chambers, the adhesive layer 73 may be held between the first and second chambers by a solid plate 79. Typically, the adhesive layer has a uniform thickness of more than 20 microns (e.g., more than 50 microns) and / or less than 300 microns (e.g., less than 200 microns), for example, 20 to 300 microns or 50 to 200 microns. In some applications, the pressure in the chambers is controlled according to the steps shown in Figures 2A to 2D, and the lens is moved toward the adhesive layer, thereby bonding the additional lens to the base lens by the adhesive layer 73, without leaving any large bubbles or other spaces in place between either lens and the adhesive layer. Typically, for much of this procedure, a vacuum pressure (e.g., a negative pressure of 1 millibar to 1 bar) is generated in each of the chambers so that the pressure is lower than the ambient pressure. At certain stages of the procedure, the pressure in one or both chambers may be increased or decreased, as described below. In some applications, at one or more stages of the bonding process, heating is performed on one or both of the lenses and / or the bonding layer and / or one or both of the pressure chambers.

[0075] The convex surface of the additional lens has a central region 76. As shown in Figure 2B, in some applications, a pressure difference is generated between chambers 71 and 72 that causes the adhesive layer to form a convex curved surface facing the convex surface of the additional lens, and as a result, the central region 74 of the adhesive layer is closer to the central region 76 of the convex surface of the additional lens than any other two points on the adhesive layer and the convex surface of the additional lens. As described above, typically the pressure in chambers 71 and 72 is controlled independently of each other. In some applications, the pressure in chamber 71 is made lower than the pressure in chamber 72 at this stage in order to curve the adhesive layer as described above.

[0076] While the adhesive layer is curved in the direction of the additional lens, the additional lens and the adhesive layer are attracted to each other, for example, using a mechanical pushing element 80. In some applications, the pushing element is a dome-shaped pushing element hydraulically controlled using a piston 81, as shown in the figure. Typically, the adhesive layer 73 and the additional lens 24 first come into contact at their respective central regions 74 and 76. As the additional lens continues to be attracted to the adhesive layer, the contact between the additional lens and the adhesive layer radiates outward from the central region 76 of the convex surface of the additional lens until the convex surface of the additional lens is completely covered by the adhesive layer. Note that in some applications, the adhesive layer is not curved in the direction of the additional lens. Nevertheless, the first point of contact between the additional lens and the adhesive layer is usually at the center of the additional lens thanks to the convex curvature of the convex surface of the additional lens. Typically, after the additional lens first comes into contact with the adhesive layer at its center, the contact between the additional lens and the adhesive layer radiates outward, effectively preventing air bubbles from being trapped between the additional lens and the adhesive layer, as air bubbles are pushed out from between the additional lens and the adhesive layer.

[0077] As described above, before the lenses are bonded to each other, within each chamber, the lenses are rotated and aligned relative to each other so that, once bonded, each lens is rotated and oriented relative to the others in the required orientation. Typically, the rotational alignment of the lenses is performed by rotating the pressing element 80, by rotating the element that holds the base lens 22, and / or by placing the lenses in the respective chambers in the desired rotational alignment.

[0078] In some applications, before the additional lens and the adhesive layer are drawn together, a vacuum pressure is established in at least the first chamber 71 (i.e., the pressure in the first chamber is lower than the ambient pressure) to remove air bubbles from between the adhesive layer and the additional lens. The establishment of a vacuum pressure in the first chamber is usually performed at this stage regardless of whether a differential pressure has been established between the first and second chambers (i.e., to bend the adhesive layer as described above). In some applications, after the adhesive layer has been bonded to the additional lens, the pressure in chambers 71 and / or chamber 72 is increased (to, for example, the ambient pressure) to remove any smaller air bubbles that may still be trapped between the additional lens and the adhesive layer and / or any voids that may be located between the additional lens and the adhesive layer. The pressure increase is usually done to cause any small air bubbles that may be trapped between the additional lens and the adhesive layer to seep out from between the additional lens and the adhesive layer, and to remove any voids that may be located between the additional lens and the adhesive layer by applying pressure to the adhesive layer.

[0079] Referring to Figures 2C and 2D, after the adhesive layer 73 is bonded to the additional lens 24, the additional lens and adhesive layer are pulled toward the base lens 22 (for example, using a mechanical pressing element 80). In some applications, before the additional lens and adhesive layer are pulled toward the base lens, a vacuum pressure is established in at least the second chamber 72 to remove air bubbles from between the adhesive layer and the base lens (i.e., the pressure in the second chamber is less than the ambient pressure). Typically, the convex curvature of the surface of the additional lens bonded to the adhesive layer is greater than the concave curvature of the surface of the base lens bonded to the adhesive layer. Thus, the shapes of the additional lens and the base lens are usually such that the initial contact point between the adhesive layer (which conforms to the shape of the additional lens at this stage) and the base lens is in the central region 77 of the concave surface of the base lens 22 (as shown in Figure 2C). As the additional lens continues to be pushed toward the base lens, the contact between the adhesive layer and the base lens radiates outward from the center of the concave surface of the base lens until the concave surface of the base lens is completely covered by the adhesive layer (as shown in Figure 2D). Typically, after initially bringing the base lens into contact with the adhesive layer at its center, the contact between the base lens and the adhesive layer is spread radially outward, effectively preventing air bubbles from becoming trapped between the base lens and the adhesive layer as they are pushed out from between the two layers.

[0080] In some applications, the pressure in chambers 71 and / or 72 is increased (e.g., to ambient pressure) to remove any smaller air bubbles that may still be trapped between the base lens and the adhesive layer and / or any voids that may be located between the additional lens and the adhesive layer. The pressure increase typically causes any smaller air bubbles that may be trapped between the base lens and the adhesive layer to seep out and any voids that may be located between the additional lens and the adhesive layer. Alternatively or additionally, mechanical pressure is applied to one or both sides of the bonded lens (e.g., using a mechanical press element 80 and / or an additional press element configured to press the outer surface of the base lens 22) to cause any smaller air bubbles that may be trapped between the additional lens and the adhesive layer and / or between the base lens and the adhesive layer to seep out and / or any voids that may be located between the additional lens and the adhesive layer and / or between the base lens and the adhesive layer. Further alternative or additionally, the bonded lens is moved to a separate chamber used to apply heat and pressure to one or both sides of the bonded lens.

[0081] Figures 2A to 2D show the adhesive layer being attached to the base lens first, after which the adhesive layer is attached to the additional lens; however, it should be noted that the scope of this application includes attaching the adhesive layer to the base lens first, after which the adhesive layer is attached to the additional lens. Similarly, the schematic arrangement shown in Figures 2A to 2D shows the additional lens positioned below the adhesive layer and the base lens; however, the scope of this application includes performing a substantially similar technique, except that the base lens is positioned below the adhesive layer and the additional lens, and / or the base lens, adhesive layer, and additional lens are positioned side by side, and / or a different arrangement.

[0082] Furthermore, it should be noted that the scope of this disclosure is not limited to the use of apparatus and methods for bonding a base lens and an additional lens to each other as described with reference to Figures 2A to 2D. Rather, the scope of this disclosure includes the use of any apparatus and methods for bonding a base lens and an additional lens to each other, as would be understood by those skilled in the art.

[0083] Those skilled in the art will understand that the present invention is not limited to what has been specifically shown and described above. Rather, the scope of the present invention includes both combinations and partial combinations thereof of the various features described in the above specification, as well as modifications and variations thereof that are not in the prior art and will be conceivable to those skilled in the art by reading the above description.

Claims

1. A device to be used together with the frame of eyeglasses worn by the wearer, The glasses include a cemented lens configured to be placed within the frame of the glasses so as to define a horizontal axis that is configured to coincide with the horizontal meridian of the wearer's eye when the wearer wears the glasses, and the cemented lens is A stock base lens, which provides a first function within a first functional surface, wherein the functional surface of the base lens is rotationally oriented with respect to the horizontal axis of the cemented lens in a first rotational orientation, A stock add-on lens comprising a stock add-on lens that provides a second function within a second functional surface, wherein the functional surface of the add-on lens is required to be rotationally oriented with respect to the horizontal axis of the cemented lens in a second rotational orientation different from the first rotational orientation, An apparatus in which the additional lens is coupled to the base lens in a state in which the additional lens and the base lens are rotated and aligned with respect to each other in a certain rotational orientation, so that the functional surfaces of the base lens and the additional lens within the cemented lens are rotated and oriented with respect to the horizontal axis of the cemented lens in the first rotational orientation and the second rotational orientation, respectively.

2. The apparatus according to claim 1, wherein the functional surface of at least one of the stock base lens and the stock attachment lens is required to be rotationally oriented with a non-zero rotational displacement from the horizontal axis of the cemented lens.

3. The apparatus according to claim 1, wherein one of the stock base lens and the stock add-on lens is a cylindrical lens configured to perform cylindrical correction, and the cylindrical lens is coupled to the other lens such that the functional surface of the cylindrical lens is rotationally oriented with respect to the horizontal axis of the cemented lens such that the axis of the cylindrical correction coincides with the direction of the wearer's astigmatism.

4. The apparatus according to claim 1, wherein one of the stock base lens and the stock add-on lens is a myopia suppression lens configured to suppress myopia in the wearer, and the myopia suppression lens is coupled to the other lens such that the functional surface of the myopia suppression lens is rotationally oriented with respect to the horizontal axis of the cemented lens so as to give the wearer a desired direction of myopia suppression.

5. The apparatus according to claim 1, wherein one of the stock base lens and the stock add-on lens is a polarizing lens configured to polarize light along the polarization direction, and the polarizing lens is coupled to the other lens such that the functional surface of the polarizing lens is rotationally oriented with respect to the horizontal axis of the bonded lens so that the polarizing lens provides the wearer with a desired polarization of light.

6. The apparatus according to claim 1, wherein the base lens is a cylindrical photochromic lens and the additional lens is a polarizing lens, so that the bonded lens is a polarizing photochromic bonded lens.

7. The apparatus according to claim 1, wherein one of the stock base lens and the stock add-on lens includes gradient coloring.

8. The apparatus according to claim 1, wherein one of the stock base lens and the stock add-on lens includes a lens having a protective coating that requires different levels of protection for distance and near vision.

9. The apparatus according to claim 1, wherein one of the stock base lens and the stock add-on lens includes a lens that facilitates superimposing information onto the lens using electron projection.

10. The apparatus according to claim 1, wherein one of the stock base lens and the stock add-on lens is configured to compensate for a power or cylindrical power to take into account the cemented lens having a concave front surface.

11. The apparatus according to claim 1, wherein the bonded lens is not configured to provide the wearer with an add power for correcting near vision.

12. The apparatus according to any one of claims 1 to 10, wherein the bonded lens is configured to provide an add power for correcting near vision.

13. The apparatus according to claim 12, wherein the bonded lens is further configured to correct distance vision and to provide a transitional progressive zone between the portion of the bonded lens that corrects near vision and the portion that corrects distance vision.

14. The apparatus according to claim 13, wherein the base lens is configured to perform all of the distance vision correction of the bonded lens.

15. The apparatus according to claim 13, wherein the combined optical properties of the base lens and the additional lens provide the desired complete optical correction of the cemented lens, while neither the base lens nor the additional lens performs optical distance vision correction on their own.

16. The apparatus according to claim 12, wherein the bonded lens is configured to correct near vision by a maximum of 0.85 diopters.

17. The apparatus according to claim 16, wherein the bonded lens is configured to be used by a wearer who is on the verge of presbyopia and reading a digital device.

18. The apparatus according to any one of claims 1 to 11, wherein the bonded lens comprises one or more functional coatings pre-applied to at least one of the front surface of the bonded lens and the rear surface of the bonded lens before the additional lens is bonded to the base lens.

19. The apparatus according to claim 18, wherein the one or more functional coatings include one or more functional coatings selected from the list consisting of hard coatings, anti-reflective coatings, hydrophobic coatings, superhydrophobic coatings, antistatic coatings, oil-repellent coatings, clean coatings, blue light filters, reflective coatings, anti-UV coatings, photochromic coatings, colored coatings, and mirror coatings.

20. The apparatus according to claim 18, wherein the bonded lens comprises a first set of one or more functional coatings pre-applied to the front surface of the bonded lens before the additional lens is bonded to the base lens, and a second set of one or more functional coatings pre-applied to the rear surface of the bonded lens.

21. The apparatus according to claim 20, wherein the first set of one or more functional coatings pre-applied to the front surface of the bonded lens is the same as the second set of one or more functional coatings pre-applied to the rear surface of the bonded lens.

22. The apparatus according to claim 20, wherein the first set of one or more functional coatings pre-applied to the front surface of the bonded lens is different from the second set of one or more functional coatings pre-applied to the rear surface of the bonded lens.

23. A method used in conjunction with the frames of eyeglasses worn by the wearer, The process includes manufacturing a cemented lens configured to be placed within the frame of the eyeglasses so as to define a horizontal axis that is configured to coincide with the horizontal meridian of the wearer's eye when the wearer wears the eyeglasses, The above manufacturing A stock base lens, which provides a first function within a first functional surface, wherein the functional surface of the base lens is rotationally oriented with respect to the horizontal axis of the cemented lens in a first rotational orientation, A stock add-on lens is provided, which requires that the functional surface of the add-on lens be rotated orienting with respect to the horizontal axis of the cemented lens in a second rotational orientation different from the first rotational orientation, and a stock add-on lens that provides a second function within the second functional surface is rotated orienting with respect to the horizontal axis of the cemented lens in a second rotational orientation different from the first rotational orientation, by rotating and aligning these two stock add-on lenses with respect to each other. When the bonded lens is formed, the functional surfaces of the base lens and the additional lens are rotated with respect to the horizontal axis of the bonded lens in the first rotational orientation and the second rotational orientation, respectively. A method comprising coupling the stock base lens and the stock add-on lens to each other while the stock base lens and the stock add-on lens are rotated and aligned with respect to each other.

24. The method according to claim 23, wherein the rotational alignment of the stock base lens and the stock add-on lens relative to each other is such that when the bonded lens is formed, the functional surface of at least one of the stock base lens and the stock add-on lens is rotationally oriented with a non-zero rotational displacement from the horizontal axis of the bonded lens.

25. The method according to claim 23, wherein one of the stock base lens and the stock add-on lens is a cylindrical lens configured to perform cylindrical correction, and the rotational alignment of the stock base lens and the stock add-on lens relative to each other is such that when the bonded lens is formed, the functional surface of the cylindrical lens is rotationally oriented with respect to the horizontal axis of the bonded lens so that the axis of cylindrical correction coincides with the direction of the wearer's astigmatism.

26. The method according to claim 23, wherein one of the stock base lens and the stock add-on lens is a myopia suppression lens configured to suppress myopia in the wearer, and the method of rotating and aligning the stock base lens and the stock add-on lens relative to each other such that when the bonded lens is formed, the functional surface of the myopia suppression lens is rotationally oriented with respect to the horizontal axis of the bonded lens so as to give the wearer a desired direction of myopia suppression.

27. The method according to claim 23, wherein one of the stock base lens and the stock add-on lens is a polarizing lens configured to polarize light along the polarization direction, and the method includes rotating and aligning the stock base lens and the stock add-on lens relative to each other such that when the bonded lens is formed, the functional surface of the polarizing lens is rotationally oriented with respect to the horizontal axis of the bonded lens so that the wearer is given the desired polarization of light.

28. The method according to claim 23, wherein the base lens is a cylindrical photochromic lens, the additional lens is a polarizing lens, and bonding the stock base lens and the stock additional lens to each other forms a polarizing photochromic bonded lens.

29. The method according to claim 23, wherein one of the stock base lens and the stock add-on lens includes gradient coloring.

30. The method according to claim 23, wherein one of the stock base lens and the stock add-on lens includes a lens having a protective coating that requires different levels of protection for distance and near vision.

31. The method according to claim 23, wherein one of the stock base lens and the stock add-on lens includes a lens that facilitates superimposing information onto the lens using electron projection.

32. The method according to claim 23, wherein one of the stock base lens and the stock add-on lens is configured to compensate for a power or cylindrical power to take into account the bonded lens having a concave front surface.

33. The method according to claim 23, wherein the bonded lens is not configured to provide the wearer with an add power for correcting near vision.

34. The method according to any one of claims 23 to 32, wherein the bonded lens is configured to provide an add power for correcting near vision.

35. The method according to claim 34, wherein the bonded lens is further configured to correct distance vision and to provide a transitional progressive zone between the portion of the bonded lens that corrects near vision and the portion that corrects distance vision.

36. The method according to claim 35, wherein the base lens is configured to perform all of the distance vision correction of the bonded lens.

37. The method according to claim 35, wherein the combined optical properties of the base lens and the additional lens provide the desired complete optical correction of the bonded lens, while neither the base lens nor the additional lens performs optical distance vision correction on their own.

38. The method according to claim 34, wherein the bonded lens is configured to correct near vision by a maximum of 0.85 diopters.

39. The method according to claim 38, wherein the bonded lens is configured to be used by a wearer who is on the verge of presbyopia and reading a digital device.

40. The method according to any one of claims 23 to 33, wherein bonding the stock base lens and the stock add-on lens to each other includes bonding the stock base lens and the stock add-on lens with one or more functional coatings pre-applied to at least one of the front surface and the rear surface of the bonding lens before bonding the stock base lens and the stock add-on lens to each other.

41. The method according to claim 40, wherein the one or more functional coatings include one or more functional coatings selected from the list consisting of hard coatings, anti-reflective coatings, hydrophobic coatings, superhydrophobic coatings, antistatic coatings, oil-repellent coatings, clean coatings, blue light filters, reflective coatings, anti-UV coatings, photochromic coatings, colored coatings, and mirror coatings.

42. The method according to claim 40, wherein bonding the stock base lens and the stock add-on lens to each other includes bonding the stock base lens and the stock add-on lens with one or more functional coatings pre-applied to both the front surface and the rear surface of the bonded lens before bonding the stock base lens and the stock add-on lens to each other.

43. The method according to claim 42, wherein the first set of one or more functional coatings pre-applied to the front surface of the bonded lens is the same as the second set of one or more functional coatings pre-applied to the rear surface of the bonded lens.

44. The method according to claim 42, wherein the first set of one or more functional coatings pre-applied to the front surface of the bonded lens is different from the second set of one or more functional coatings pre-applied to the rear surface of the bonded lens.

45. The stock base lens and the stock attachment lens are connected to each other. The stock base lens and the stock attachment lens are placed in corresponding first and second pressure chambers, with an adhesive layer between them, and the internal pressure of each chamber can be controlled independently. The convex surface of the stock-adding lens is brought into contact with the adhesive layer, so that the central region of the convex surface of the stock-adding lens initially contacts the adhesive layer, and then the contact between the convex surface of the stock-adding lens and the adhesive layer extends radially outward from the central region of the convex surface of the stock-adding lens until the convex surface of the stock-adding lens is covered by the adhesive layer, and The method according to any one of claims 23 to 33, comprising bringing the concave surface of the stock base lens into contact with the adhesive layer, such that the central region of the concave surface of the stock base lens is initially in contact with the adhesive layer, and then the contact between the concave surface of the stock base lens and the adhesive layer extends radially outward from the central region of the concave surface of the stock base lens until the concave surface of the stock base lens is covered by the adhesive layer.

46. The method according to claim 45, wherein rotatably aligning the stock base lens and the stock add-on lens relative to each other includes rotatably aligning the stock base lens and the stock add-on lens relative to each other within the corresponding first and second pressure chambers.

Images