Lens, assembly, and mounting same

Abstract

A lens includes a technology layer and an ophthalmic lens where the technology layer is an active or passive optical device. An eyeglass frame can include the lens.

Description

LENS, ASSEMBLY, AND MOUNTING SAMECROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of United States Provisional Patent Application No. 63 / 650,198, filed May 21, 2024, the entire contents of which is incorporated by reference for all purposes as if fully set forth herein.BACKGROUND

[0002] The present disclosure relates to eyewear. More specifically, the present disclosure relates to an eyeglass lens including a technology layer, assembly of the lens, and mounting the lens in an eyeglass frame.SUMMARY OF THE DISCLOSURE

[0003] Embodiments of the present disclosure include an ophthalmic lens including technology layer, a method of assembling a lens that includes a technology layer, and a method of mounting a lens that includes a technology layer in an eyeglass frame. The present application incorporates by reference, in its entirety, United States Patent Application No. 18 / 290,619.

[0004] According to an exemplary embodiment, a lens includes a technology layer that provides an optical effect; and a first ophthalmic lens optically bonded to a first side of the technology layer.

[0005] The lens can further include a second ophthalmic lens optically bonded to a second side of the technology layer that is opposite to the first side of the technology layer such that the technology layer is between the first ophthalmic lens and the second ophthalmic lens.

[0006] In an aspect, the technology layer includes an electro-optical device defined as a cell including an electrochromic material sealed between two substrates.

[0007] In an aspect, a perimeter of the first ophthalmic lens is substantially aligned with an edge of the electrochromic material.

[0008] In an aspect, a perimeter of the first ophthalmic lens and a perimeter of the second ophthalmic lens are substantially aligned with an edge of an active area of the technology layer, wherein the active area is a space where there is optical activity in the technology layer.

[0009] In an aspect, a portion of the technology layer extending outside a perimeter of at least one of the first and the second ophthalmic lenses includes an electrode.

[0010] In an aspect, one of the first ophthalmic lens and the second ophthalmic lens includes a flange that extends outside of a perimeter of the technology layer.

[0011] In an aspect, the technology layer is curved.

[0012] In another exemplary embodiment, spectacles include eyeglass frames; and the lens.

[0013] In an another exemplary embodiment, eyeglasses include a lens including a technology layer that provides an optical effect; and a first frame piece and a second frame piece configured to mount the lens therebetween, wherein at least one of the first frame piece and the second frame piece defines a recess that is sized and configured to accommodate a protrusion of the technology layer that extends outwardly from a perimeter of the lens.

[0014] In an aspect, an inside of the first piece and an inside of the second piece are flush against each other when the lens is mounted with the eyeglass frame.

[0015] The eyeglass frame can further include technology circuitry connected to the technology layer.

[0016] In an aspect, the lens is concave or convex.

[0017] In an aspect, a perimeter edge of the technology layer protrudes outside a perimeter profile of a front or rear lens surface of the lens.

[0018] In an aspect, the technology layer is an electro-optical material.

[0019] In an aspect, the technology layer is an electrochromic device.

[0020] In an aspect, the electrochromic device is a cell including an electrochromic material sealed between two substrates.

[0021] In an aspect, the lens includes a flange around a perimeter of the lens.

[0022] In an aspect, the eyeglass frame includes a gap between the first piece and the second piece and a perimeter of the lens.

[0023] In another exemplary embodiment, a method of assembling a lens includes aligning a first ophthalmic lens to a first side of the technology layer that provides an optical effect using machine vision; and bonding the first ophthalmic lens to the technology layer.

[0024] The method can further include aligning and bonding a second ophthalmic lens to a second side of the technology layer.

[0025] In an aspect, the technology layer is an electro-optical material.

[0026] In an aspect, the aligning the technology layer is provided in a jig.

[0027] In an aspect, an outer edge of the technology layer extends outside of an outer edge of the first ophthalmic lens.

[0028] In an aspect, a perimeter of the technology layer extends outside of a perimeter of the first ophthalmic lens.

[0029] In an aspect, a perimeter of the technology layer extends outside of a perimeter of the first ophthalmic lens and the second ophthalmic lens.

[0030] In an aspect, a perimeter of the technology layer extends outside of a perimeter of only one of the first ophthalmic lens and the second ophthalmic lens.

[0031] In another exemplary embodiment, a method of fabricating a lens includes comolding a technology layer with an ophthalmic lens.

[0032] In an aspect, the lens includes a first ophthalmic lens molded on one side of the technology layer and a second ophthalmic lens molded on a second side of the technology layer.

[0033] In an aspect, a portion of the technology layer extends outside of a perimeter of the ophthalmic lens and the portion includes an electrode.

[0034] The method can further include physically treating a molding of the technology layer and the ophthalmic lens to reduce a size of the molding.

[0035] In an aspect, treating the molding includes machining a border around a perimeter of the technology layer.

[0036] In another exemplary embodiment, a method of fabricating a lens includes 3D printing an ophthalmic lens to a technology layer.

[0037] In an aspect, the lens includes a first ophthalmic lens 3D printed on one side of the technology layer and a second ophthalmic lens 3D printed on a second side of the technology layer.

[0038] In an aspect, a perimeter of the technology layer is flush with a perimeter of the ophthalmic lens.

[0039] The above and other features, elements, characteristics, steps, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0040] FIG. 1 and FIG. 2 show a lens constructed to include an electro-optical device in accordance with some embodiments.

[0041] FIG. 3 shows a lens constructed to include an electro-optical device in accordance with some embodiments.

[0042] FIG. 4, FIG. 5 A, and FIG. 5B show examples of a curved lens including an electro-optical device in accordance with some embodiments.

[0043] FIG. 6 shows an example of a lens in an eyeglass frame in accordance with some embodiments.

[0044] FIG. 7 and FIG. 8 show an example of a lens mounted in an eyeglass frame in accordance with some embodiments.

[0045] FIG. 9 to FIG. 12 show an example of a lens assembly technique in accordance with some embodiments.

[0046] FIG. 13 and FIG. 14 show another example of a lens assembly technique in accordance with some embodiments.

[0047] FIG. 15 shows an assembled lens in accordance with some embodiments.

[0048] FIG. 16A to FIG. 16F show a lens molded in accordance with some embodiments.

[0049] FIGS. 17 is a side view of one example of a lens that has been molded into a final shape in accordance with some embodiments.

[0050] FIG. 18 is a side view of another example of a lens that has been molded into a final shape in accordance with some embodiments.

[0051] FIG. 19 to FIG. 23 show results of steps to define a lens according to another example of a molding method in accordance with some embodiments.

[0052] FIG. 24 to FIG. 27 show lenses that have been define according to another example of a molding method in accordance with some embodiments.

[0053] FIG. 28 is a block diagram of a circuit to control an electro-optical device in accordance with some embodiments.DETAILED DESCRIPTION

[0054] In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustrating specific exemplary embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the concepts disclosed herein, and it is to be understood that modifications to the various disclosed embodiments may be made, and other embodiments may be utilized, without departing from the scope of the present disclosure. The following detailed description is, therefore, not to be taken in a limiting sense.

[0055] Disclosed are lenses and eyeglasses in which the lenses can include an embedded technology layer that can include an electro-optical material, an active electro-optical device, and / or a passive optical device. In some embodiments, an electro-optical material or devicechanges optical properties of an optically active material in response to a stimulus such as irradiation or an electric field or current. Electro-optical materials / devices can include liquid crystals, microLEDs, organic light-emitting diodes (OLED) other emissive, absorbing, or sensing materials, light valves, and electrochromic devices, to list only a few non-limiting examples. Such optically active materials can include liquid crystals and electrochromic materials, for example. Electrically modulating an optically active material with an electric field can change the birefringence, polarization, index of refraction, transmission / opacity, color / tint, and clarity / haze of an electro-optical device having the optically active material. A passive optical device can include a waveguide, for example, that does not rely on an electric field or current to affect optical properties or redirect light. While part of a lens, a waveguide can guide light from a projector or light source to the wearer’s eye. In some embodiments, a lens can include more than one technology layer to enhance an optical effect or provide more than one optical function. Including a technology layer can be used to an optical effect to change properties of a lens like color, tint, reflection, transmission, and optical power or redirect light.

[0056] The eyeglasses can include a frame and prescription lenses including the technology layer. In some embodiments, the included technology layer can permit the wearer to switch electronically between a clear state and a dark state using an electrochromic effect. This situation may be similar to that of a traditional pair of eyeglasses (in the clear state) and a typical pair of sunglasses (in the dark state). The disclosed lenses and frames including the technology layer can be capable of all-day wear and are different from existing eyeglasses with transitional lenses by providing sufficient transmission in the clear state to be worn in low-light (dark) environments. The combination of a technology layer, prescription lenses, and electronic-equipped frame has driven the creation of new lens manufacturing and insertion techniques.

[0057] FIGS. 1 and 2 show one example of a lens 100 constructed to include a technology layer 130 in accordance with some embodiments. For example, the lens 100 can be a prescription ophthalmic lens. The lens 100 can include a front lens 110 and a rear lens 120 optically bonded or laminated to the technology layer 130, as shown in FIG. 2. The technology layer 130 can be constructed as an electro-optical cell that includes an electrochromic material 132 sealed between a first substrate 131 and a second substrate 132.

[0058] FIG. 2 shows that two (e.g., a front and a rear) lens halves (or portions) 110, 120, respectively, can be optically bonded or laminated to outer surfaces of corresponding substrates 131, 133 with one lens half (or one portion) 110, 120 on each substrate 131, 133.In some embodiments, only one of the substrates 131 or 133 can be bonded to one of the ophthalmic lenses 110 or 120. As shown, circumferences of the front and rear ophthalmic lens portions 110, 120 can be smaller than the technology layer 130 to which they are attached. The perimeter of the front and rear ophthalmic lens portions 110, 120 can be substantially aligned with an edge of the electro-optical material 132. This arrangement produces a lens 100 that does not require edging (edge treatment) after final assembly of the lens and also creates a new opportunity for assembly / mounting. Lamination, such as by using optical-grade adhesives, for example a UV curable adhesive provided by Norland Products, can be used to combine the front lens 110 and the rear lens 120 to the substrates 131 and 133.

[0059] With the configuration shown in FIGS. 1 and 2, the lens prescription and pupillary distance can be customized for a specific prescription. The front lens 110 and / or the rear lens 120 can be made through traditional manufacturing processes or via 3D printing, for example. Such a laminated lens 110 on the front surface allows for easier plus prescriptions or for reducing aberrations created by the back surface (especially for strong minus prescriptions). Also, a direct lamination allows for a thinner total lens stack and reduces reflections and visual artifacts by not including an air gap. Using (refractive) indexed matched materials, direct lamination eliminates the need for an anti -refl ection (AR) coating between lens surfaces. In some embodiments, an intentional air gap can be maintained for a waveguide, another light coupling device, or desired optical effect. It should be understood that, in some embodiments, instead of laminating an ophthalmic lens to a technology layer, an ophthalmic lens can be co-molded, 3D printed or produced in another way directly onto the technology layer. These methods can permit creation of an overall thinner lens.

[0060] The technology layer 130 can be defined with a shape suitable for an eyeglass lens. The technology layer 130 can include an optically active (electrochromic) material 132 sandwiched between two substrates 131, 133 and surrounded by spacers 135 and a sealing material 134. For example, the optically active (electrochromic) material 132 can be an electrochromic gel. The substrates 131, 133 can be glass as the outermost layers of the optically active (electrochromic) device 130 to provide an encapsulation envelope and environmental barrier for the optically active (electrochromic) material 132. In some embodiments, the substrates 131, 133 can be glass, plastic, laminate, or any other suitable material. The substrates 131, 133 also provide a structural base in which to attach other lens components and for mechanically mounting lenses to an eyeglass frame. The interior surfaces of respective substrates 131, 133 can be coated with a transparent electrode material. For example, the electrode material can be indium tin oxide (ITO) or another suitable material.The circumferential edge of the technology layer 130 can be sealed with a sealing material 134 to join the substrates 131, 133 together and protect the optically active (electrochromic) material 132. The distance between the two substrates 131, 133 or cell gap can be determined and uniformly maintained by a suitable spacer 135 such as a bead, rod, or polymer plug.

[0061] As shown in FIG. 2, the perimeter profile of the front lens 110 and the rear lens 120 can be smaller than the technology layer 130 such that a perimeter edge 136 of the technology layer 130 protrudes from the lens 100 and is exposed. A portion of this protruding edge 136 can be an electrode 1302 used to electrically connect to the technology layer 130 to a power source, wiring, or other electrical components such as driving and control circuity and sensors or be structured to include an input to a waveguide. The electrode 1302 can be on any suitable portion of the protruding edge 136 including the tops, side edge, bottom, or any combination of the above. The electrode can be made of any suitable contact material such as ITO, gold, copper, or any other suitable material. This protruding edge 136 can also be used to mount the lens 100 in a frame.

[0062] As shown in FIG. 28, technology circuitry 2810, such as a battery, other power source, driving circuitry, control circuity, and a sensor, for example, can be connected to electrodes 1302 of the technology layer 130 via wiring 2820. The technology circuitry 2810 can be used to provide a voltage potential across the two electrodes 1302 and send and / or receive other types of electronic signals depending on the technology circuitry’s purpose and function. The technology circuitry 2810 can electrically, physically, and / or optically interact with the technology layer 130. For example, technology circuitry 2810 can include an AC or DC power source, microcontroller, processor, sensor such as a light, temperature, or pressure sensor, and / or the like. For example, the wiring 2820 can be any suited for the geometry and desired interface including discrete wire, printed circuit board, flexible cable, fiber optic, optical path, and the like, with associated connection. An optical property of electro-optical material 132 between the two electrodes can be changed or controlled by varying the voltage potential and / or electrical current or providing a control signal from the technology circuitry 2810 across the electrodes 1302.

[0063] In some embodiments, only the region of the technology layer 130 including the electro-optical material 132, for example, can be controlled to change the optical property. For example, the outer perimeter of the lens 100 can have a portion that is not controllable. That portion is around the perimeter of the technology layer 130 where there is no electro- optical material but instead includes the sealing material 134.

[0064] In an alternate arrangement of a lens 300, shown in FIG. 3, the edge of a technology layer 330 can be configured such that it does not protrude outside the perimeter profile of the front lens 310 and the rear lens 320. Instead, one or both of the front lens 310 and the rear lens 320, for example, can be configured to include a flange or bevel 3202 around a portion or the entire perimeter that can be used for mounting the lens 300 in a frame. Using one or both of the front lens 310 and the rear lens 320 for mounting reduces the mechanical stress to the edge of the technology layer 330. In some embodiments, an interim tray, sheet, frame, substrate, or another suitable component can be laminated within the lens 300 such that it can be used for mounting.

[0065] Although FIGS. 1-3 illustrates the technology layers 100, 300 as being flat, it should be understood that a technology layer can be curved, as shown in FIGS. 4 and 5. FIGS. 4 and 5 show that the technology layer 430, 530 may be curved (i.e., a curved embedded technology layer) to match or mate with an ophthalmic lens 400, 500, 550 that also is curved (concave or convex). FIG. 4 shows a curved lens 400 that includes the curved technology layer 430 disposed between a curved front ophthalmic lens 410 and a curved rear ophthalmic lens 420. FIG. 5 shows two configurations of curved lenses 500 and 550 with only a front or rear lens. As shown, ophthalmic lens 500 may include a rear lens 520 bonded or adhered to the technology layer 530 and ophthalmic lens 550 may include a front lens 510 bonded or adhered to the technology layer 530. Although the components of the technology layers 430, 530 are not expressly shown in FIGS. 4 and 5, it should be understood that each of the technology layers 430, 530 may include some or all of the components of the technology layers 130, 330 described above with respect to FIGS. 1-3, e.g., an optically active (electrochromic) material sandwiched between two substrates and surrounded by spacers and a sealing material.

[0066] FIGS. 5A and 5B show that an oversized (e.g., larger) technology layer 530 can be laminated to one surface of a meniscus lens 510, 520. However, the technology layer 530 need not mimic the shape of the ophthalmic lens 510, 520.

[0067] FIG. 6 shows one example of how an ophthalmic lens 600 including a technology layer can be mounted in an eyeglass frame in accordance with some embodiments. For example, the eyeglass frame can include at least two pieces, e.g., a first piece 640 and a second piece 650. FIG. 6 shows that the frame pieces 640, 650 can each include a respective groove, recess, or cavity 642, 652 sized and configured to accommodate a protrusion 602 of the technology layer 630 that is around the perimeter of the lens 600. The protrusion can include the perimeter edge of the technology layer 630 and / or include a flange of materialused for the ophthalmic lens structures, as described herein. Although the components of the technology layer 630 are not expressly shown in FIG. 6, it should be understood that the technology layer 630 may include some or all of the components of the technology layers 130, 330 described above with respect to FIGS. 1-3, e.g., an optically active (electrochromic) material sandwiched between two substrates and surrounded by spacers and a sealing material.

[0068] As shown in FIG. 6, the frame portions 640, 650 can each include a respective cavity, groove, or recess 642, 652 that surrounds the edge of the lens 600 and therefore allows the two frame pieces 640, 650 to be arranged as flush against each other. The benefit of this approach is that there is no need for edging the lens 600 to ensure the lens 600 fits in the frame. Additionally, there is no risk of damaging internal components or interconnections of the technology layer caused by force fitting or snapping a lens into a frame. Additionally, portions of the frame 640, 650 can be used to route wiring to the electrodes located on a protruding edge of the technology layer.

[0069] FIG. 7 is one example of a close-up rear view of a lens 700 including a technology layer mounted within an eyeglass frame 740 in accordance with some embodiments.Mounting the lens 700 into the frame 740 can be provided via an adhesive. As shown, connection area 7302 of a technology layer 730 may not be in contact with frame 740 to avoid interference with the frame 740 that could induce mechanical stress to the technology layer and / or the electrical interconnection 7304. As shown, in some embodiments, gaps 742 and 744 are provided between the frame 740 and the connection area 7302 of the technology layer 730. Instead, a stronger front or rear ophthalmic lens bears weight of lateral shifting and load with only a portion of the load transferred to the technology layer through the robust adhesive, as illustrated in the close-up front perspective view shown in FIG. 8. FIG. 8 shows that an ophthalmic lens on the front of lens 700 may contact the frame 740, which may absorb stress from relative movement of the lens 700 within the frame 740 caused by environmental conditions and / or flexing of the frame 740. Here again, although the components of the technology layer 730 are not expressly shown in FIGS. 7 and 8, it should be understood that the technology layer 730 may include some or all of the components of the technology layers 130, 330 described above with respect to FIGS. 1-3, e.g., an optically active (electrochromic) material sandwiched between two substrates and surrounded by spacers and a sealing material

[0070] FIGS. 9 to 14 are used to describe techniques for assembling a lens including a technology layer in accordance with some embodiments. FIGS. 9 to 12 show a first assemblytechnique with a tool-aided alignment system that can be custom made for the size and shape of the ophthalmic lenses and accompanying technology layer. FIGS. 13 and 14 show another example of an assembly technique using optical or machine-vision-aided alignment in accordance with some embodiments.

[0071] FIG. 9 shows that a technology layer 930, which may include some or all of the components of the technology layers 130, 330 described above with respect to FIGS. 1-3, e.g., an optically active (electrochromic) material sandwiched between two substrates and surrounded by spacers and a sealing material, or other active or passive optical device can be aligned and supported along its outer edge by a first jig 960. The jig may include one or more protrusions 964 that inwardly extend into the central opening 962 defined by the jig 960 and support or engage an outer periphery of the technology layer 930. The protrusions can include steps and / or other alignment features for orienting the technology layer 930 and ophthalmic lenses on one or both major surfaces of the technology layer 930. The jig 960 may also include one or more peripheral openings 966, which may be disposed adjacent to the protrusions 964. FIG. 10 shows that a second jig 970, which may have a similar structure to jig 960, i.e., a central opening 972 and one or more protrusions 974 and peripheral openings 976, can be aligned and placed on top of the technology layer 930 to lock the technology layer 930 in place between the jigs 960, 970. Thus, the technology layer 930 can be clamped from the top and bottom sides with jigs 960, 970 and one or more clamps 980 can be used to hold the jigs 960 and 970 together with the technology layer 930 disposed between them.

[0072] As shown in FIGS. 11 and 12, a front lens 910 and a rear lens 920 can be aligned into the central openings 962, 972 of the respective jigs 960, 970 on both sides of the technology layer 930 to provide proper alignment. Optical centers for both front and rear lenses 910 and 920 may be designed to be aligned within the jigs 960, 970. Once orientation and alignment of lenses 910 and 920 are verified, outer faces of the lenses 910, 920 can be gripped and separated from the jig (in the Z direction) while maintaining the same X-Y orientation. Optical adhesive can be applied to the top surface of the technology layer 930 and the rear lens 920 prior to final placement of the lenses 910 and 920. Optical bonding can be completed of the 910 / 930 / 920 lens stack using any combination of UV curing, pressure, temperature, and any other suitable process.

[0073] FIGS. 13 and 14 illustrate one example of a technique using vision-aided alignment for assembling a lens that includes a technology layer 1330 in accordance with some embodiments. The vision-aided system can be a machine vision system including acamera and programmable alignment tools such as robotic handling devices that can grip the lens components by outer surface of their edges, use a suction or vacuum, or any other suitable mechanism. For example, conforming vacuum pads can be used for handling while assembling complex lens surfaces.

[0074] FIG. 13 shows alignment of a first ophthalmic lens 1310 to a technology layer 1330, which may include some or all of the components of the technology layers 130, 330 described above with respect to FIGS. 1-3, e.g., an optically active (electrochromic) material sandwiched between two substrates and surrounded by spacers and a sealing material. The vision-aided system optimizes orientation of the two components so that the footprint of the first ophthalmic lens 1310 on the technology layer 1330, for example, shown as the target area 1340 defined by the dotted line 1332, maintains a designed or consistent offset to the edge of the technology layer 1330. The first ophthalmic lens 1310 can be aligned so that the distance between the outer edge of the technology layer 1330 and lens 1310 is as uniform as possible or otherwise conforms to the geometric specification of the lens assembly.

[0075] FIG. 14 shows that a second ophthalmic lens 1320 can be similarly aligned using vision-aided alignment. The second ophthalmic lens 1320 can be aligned by minimizing a mismatch with the edge of the first ophthalmic lens 1310 on the opposite side of the technology layer 1330. If the edge 1315 of the first ophthalmic lens 1310 is not visible through the technology layer 1330, the second lens ophthalmic lens 1320 can be aligned using the same methods as aligning the first ophthalmic lens, via reference to an outer edge of the technology layer 1330.

[0076] Optical adhesive can be applied to the any appropriate surface of the technology layer 1330, the first ophthalmic lens 1310, and the second lens ophthalmic lens 1320 prior to final placement of the lenses 1310 and 1320. Optical bonding can be completed of the 1310 / 1330 / 1320 lens stack using any combination of UV curing, pressure, temperature, and any other suitable process.

[0077] FIG. 15 shows an assembled lens 1500 with a uniform and consistent protruding edge 1502 of a technology layer 1530 for mounting the lens 1500 into a frame. Alternatively, as previously described, the diameter of one or more of the first 1510 and second 1520 ophthalmic lenses can be larger than the diameter of the technology layer 1530 such that less delicate edges of ophthalmic lenses 1510, 1520 can be used for mounting the lens 1500 into a frame.

[0078] FIGS. 16-18 are different views of lenses made using a method according to another embodiment of the disclosure. In this method, ophthalmic lenses are co-molded witha technology layer. For example, FIGS. 16A-16F show a lens 1600 molded into a final shape that includes a first lens surface 1610 and a second lens surface 1620 and a centrally located technology layer 1630 between the first and second lens surfaces 1610, 1620, viewed best in FIG. 16E. FIGS. 16A-16C are different perspective views of lens 1600. FIG. 16D is a plan view of lens 1600. FIG. 16E is a cross-section view of lens 1600 taken along line A-A of FIG. 16D. As shown, the technology layer 1630 can include a protruding portion 1635 for interfacing with the technology layer 1630. For example, the protruding portion 1635 can include an electrode or opening for a waveguide. FIG. 16F is a close-up view of the protruding portion 1635.

[0079] FIGS. 17 and 18 show examples of two different configurations of lenses 1700 and 1800 that have been molded into the final shape in accordance with some embodiments. For example, lens 1700 can be a -2 diopter lens and lens 1800 can be a +2 diopter lens. The lens 1700 can include a front ophthalmic lens 1710 that is concave and thicker in the middle and a rear ophthalmic lens 1720 that is convex and thinner in the middle. The lens 1800 can include a front ophthalmic lens 1810 that is concave and thicker in the middle that the front lens 1710 and a rear ophthalmic lens 1820 that is convex and thinner in the middle than the rear lens 1720. The direct molding method can result in a minimum thickness of lens material around the technology layer 1730, around the edges, and at an optical center of the rear surface, for example at 1725 of lens 1700.

[0080] FIGS. 19-23 show stages of another example of a molding method of the disclosure. In this method, rather than molding to the final shape, the lens material is molded to a larger shape as a “puck” and then machined, ground, polished, or otherwise treated to remove material to arrive at the final shape. FIG. 19 shows an initial stage in which the puck 1900 may be molded using a mask to protect and not cover a protruding edge 1935 of a technology layer 1930. FIG. 20 shows a stage in which a front surface 1910 of the puck 1900 has been machined to create a border 1912 around the technology layer 1930. FIG. 21 shows a stage in which the back surface 1920 of the puck 1900 has been machined to create a border 1922 around the technology layer 1930. FIG. 22 shows a lens 2200 after the edge of the puck 1900 has been treated to the final shape.

[0081] FIG. 23 is a cross section of the lens 2200 taken at line B-B in FIG. 22. As shown, the lens 200 can include a front ophthalmic lens 2210 and a rear ophthalmic lens 2220 sandwiching the technology layer 1930. Thickness of lens material around the protruding edge 2240 can be slightly thicker than the edge shown in FIGS. 17 and 18 because the edge 2240 must withstand forces caused by machining.

[0082] In another example of a method of fabricating a lens with a technology layer according to an embodiment of the disclosure, FIGS. 24-27 show lenses that have been 3D printed. In a first option of 3D printing, FIGS. 24 and 25 show that the portions of the lens 2400 can be 3D printed only within an active area of a technology layer 2430, the active area being a space where there is optical activity in the technology layer. As shown, the technology layer 2430 includes a protrusion 2435 for interfacing to the technology layer 2430. FIG. 25 is a cross-sectional view of the lens 2400 taken along C-C of FIG. 24 showing a front lens 2410, a rear lens 2420, and the technology layer 2430 exposed around the periphery of the lens 2400.

[0083] In a second option of 3D printing, FIGS. 26 and 27 show that the material of a lens 2600 can be printed into the inactive area of the technology layer 2630 for additional rigidity and protection of the technology layer 2630. FIG. 27 is a cross-section view of lens 2600 along D-D of FIG. 26 and includes a close-up detail of an edge 2640 showing that the lens material can extend just before and end, at a same distance to be flush with, or over the technology layer 2630 such that the edge of the technology layer 2630 can be exposed.

[0084] In some embodiments, a method of fabricating a lens including a technology layer can include any combination of optical bonding, over molding, 3D printing, machining, grinding, polishing, edge treatment, and / or any other suitable process to achieve the desired shape and performance.

[0085] It should be understood that the foregoing description is only illustrative of the present invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variances that fall within the scope of the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A lens, comprising: a technology layer that provides an optical effect; and a first ophthalmic lens optically bonded to a first side of the technology layer.

2. The lens of claim 1, further comprising a second ophthalmic lens optically bonded to a second side of the technology layer that is opposite to the first side of the technology layer such that the technology layer is between the first ophthalmic lens and the second ophthalmic lens.

3. The lens of claim 2, wherein a perimeter of the first ophthalmic lens and a perimeter of the second ophthalmic lens are substantially aligned with an edge of an active area of the technology layer, wherein the active area is a space where there is optical activity in the technology layer.

4. The lens of claim 3, wherein a portion of the technology layer extending outside a perimeter of at least one of the first and the second ophthalmic lenses includes an electrode.

5. The lens of claim 2, wherein one of the first ophthalmic lens and the second ophthalmic lens includes a flange that extends outside of a perimeter of the technology layer.

6. Spectacles, comprising: eyeglass frames; and the lens of claim 1.

7. Eyeglasses, comprising: a lens including a technology layer that provides an optical effect; and a first frame piece and a second frame piece configured to mount the lens therebetween, wherein at least one of the first frame piece and the second frame piece defines a recess that is sized and configured to accommodate a protrusion of the technology layer that extends outwardly from a perimeter of the lens.

8. The eyeglass frame of claim 7, wherein an inside of the first piece and an inside of the second piece are flush against each other when the lens is mounted with the eyeglass frame.

9. The eyeglass frame of claim 7, further comprising technology circuitry connected to the technology layer.

10. The eyeglass frame of claim 7, wherein a perimeter edge of the technology layer protrudes outside a perimeter profile of a front or rear lens surface of the lens.

11. The eyeglass frame of claim 7, wherein the technology layer includes an electro- optical material.

12. The eyeglass frame of claim 11, wherein the technology layer is an electrochromic device.

13. The eyeglass frame of claim 7, wherein the lens includes a flange around a perimeter of the lens.

14. The eyeglass frame of claim 7, including a gap between the first piece and the second piece and a perimeter of the lens.

15. A method of assembling a lens, comprising: aligning a first ophthalmic lens to a first side of a technology layer that provides an optical effect using machine vision; and bonding the first ophthalmic lens to the technology layer.

16. The method of claim 15, further comprising aligning and bonding a second ophthalmic lens to a second side of the technology layer.

17. The method of claim 15, wherein the technology layer is an electro-optical device.

18. A method of fabricating a lens, comprising co-molding a technology layer with an ophthalmic lens.

19. The method of claim 18, wherein the lens includes a first ophthalmic lens molded on one side of the technology layer and a second ophthalmic lens molded on a second side of the technology layer.

20. The method of claim 18, wherein the technology layer is an electro-optical device.

21. The method of claim 18, further comprising physically treating a molding of the technology layer and the ophthalmic lens to reduce a size of the molding, wherein treating the molding includes machining a border around a perimeter of the technology layer.

22. A method of fabricating a lens, comprising 3D printing an ophthalmic lens to a technology layer.

23. The method of claim 22, wherein the lens includes a first ophthalmic lens 3D printed on one side of the technology layer and a second ophthalmic lens 3D printed on a second side of the technology layer.

24. The method of claim 22, wherein the technology layer is an electro-optical device.

Images