Method for optimizing a set of semi-finished optical lens designs

Abstract

Method for optimizing a set of semi-finished optical lens designs The disclosure relates to a method, for example implemented by computer means, for optimizing a set of semi-finished optical lens designs, the method comprising: - providing an initial set of semi-finished optical lens designs, each semi-finished optical lens design in the initial set of semi-finished optical lenses designs having a designated base curve and an initial geometry determined to allow manufacturing finished ophthalmic lenses for a full range of sphere and cylinder values, each semi-finished optical lens design being configured to allow manufacturing finished ophthalmic lenses for an initial sub-range of sphere and cylinder values included in the full range, - optimizing the initial set of semi-finished optical lens designs by determining an optimized set of semi-finished optical lens design allowing manufacturing finished ophthalmic lenses for the full range of sphere and cylinder values, comprising less semi-finished optical lenses designs than the initial set and in which for at least two initial sub-ranges of sphere and cylinder values, a common semi-finished optical lens design is selected from the initial set of semi-finished optical lenses designs.

Description

[0001] Method for optimizing a set of semi-finished optical lens designs

[0002] TECHNICAL FIELD

[0003] The disclosure relates to a method, for example implemented by computer means, for optimizing a set of semi-finished optical lens design. The disclosure further relates to a data processing device for optimizing a set of semi-finished optical lenses.

[0004] The disclosure also relates to a computer program product comprising one or more stored sequences of instructions that are accessible to a processor and which, when executed by the processor, causes the processor to carry out at the steps of a method according to the disclosure and to a computer-readable storage medium comprising instructions which, when executed by a computer, cause the computer to carry out the steps of a method of the disclosure.

[0005] BACKGROUND OF THE DISCLOSURE

[0006] The discussion of the background of the disclosure herein is included to explain the context of the disclosure.

[0007] An optical lens is generally manufactured in accordance with a wearer specification. In the case, for example, of an ophthalmic lens for the correction or improvement of eyesight, the ophthalmic lens is manufactured according to a wearer prescription corresponding to the visual requirements of that wearer. In addition, the shape and size of the spectacle frame supporting the ophthalmic lens is taken into account. At least one of the surfaces of the ophthalmic lens is processed to provide an ophthalmic lens according to the wearer prescription. The contour of the ophthalmic lens is edged according to the shape of the rim of the spectacle frame on which the ophthalmic lens is to be mounted.

[0008] An optical lens is generally manufactured from a semi-finished optical lens. A semi-finished optical lens generally has two opposite surfaces at least one of which is unfinished.

[0009] Generally, a lens manufacturer receives a lens order comprising prescription data for a wearer. Based on the prescription data the lens manufacturer selects from a set of semi-finished optical lenses a semi-finished optical lens for further grinding and polishing to produce a lens that fits the lens wearer's prescription.

[0010] The set of semi-finished optical lenses is made from a designated lens material with a designated refractive index, for example 1.56, and each of the semi-finished optical lenses has a determined geometry determined to allow manufacture of the finished optical lenses for substantially all ophthalmic lens prescriptions. The base curves, of the semi-finished optical lenses, provide surface power for the first side curve (e g. front) which, when combined with the second side curve (e.g. back, facing a wearer's eye), after it is ground and polished, produces in worn conditions the desired dioptric function to the wearer’ eyes.

[0011] For example, a lens manufacturer produces a set of twenty different semifinished optical lenses each of which have different base curves. Accordingly, each of the semi-finished optical lenses in the set, also referred to as blanks or pucks, satisfy a subset of wearer and / or frame data to produce suitable finished optical lenses.

[0012] As described, the geometries of each of the semi-finished optical lenses in the existing exemplary set of semi-finished optical lenses are determined to allow for an extensive range of ophthalmic prescriptions to be assigned to each base curve produced. In other words, each semi-finished optical lens in the set of semi-finished optical lenses is designed to have a geometry that is large enough in thickness and diameter to allow for manufacture over the full range of prescriptions that are assigned to said semi-finished optical lens. To do so, thick and large diameter semi-finished optical lenses are produced to suit all prescriptions and frame sizes which include some rare prescriptions that lie far outside the norm for common prescriptions.

[0013] Unfortunately, for common prescriptions that do not require such a thick and large semi-finished optical lens, there is significant waste in lens material during the griding, polishing and edging steps.

[0014] Therefore, existing method allow optimizing the geometry of some of the semifinished optical lens designs, in particular for the most common prescriptions.

[0015] These methods provide optimized semi-finished lens designs having optimized geometrical parameters. However, having such optimized semi-finished lenses actually increases the number of different semi-finished lenses required to be able to cover all prescription. The greater the number of different semi-finished optical lens designs the greater the cost in terms of logistic and having different molds to produce the different semi-finished optical lenses.

[0016] Therefore, there is a need for a method to determine differently the semifinished optical lens designs as to limit their number without changing their definition (diameter, thickness etc...) by avoiding the duplicates which means that we will have less different semi-finished optical lens designs and more usage of the remaining different semi-finished optical lens designs which means better management of stock, less change to have to throw away the semi-finished optical lenses because arrived at the limit usable date.

[0017] It is therefore an aim of the present disclosure to provide a method for optimizing a set of semi-finished optical lens designs.

[0018] SUMMARY OF THE DISCLOSURE

[0019] To this end, the disclosure proposes a method, for example implemented by computer means, for optimizing a set of semi-finished optical lens designs, the method comprising:

[0020] - providing an initial set of semi-finished optical lens designs, each semifinished optical lens design in the initial set of semi-finished optical lenses designs having a designated base curve and an initial geometry determined to allow manufacturing finished ophthalmic lenses for a full range of sphere and cylinder values, each semi-finished optical lens design being configured to allow manufacturing finished ophthalmic lenses for an initial sub-range of sphere and cylinder values included in the full range,

[0021] - optimizing the initial set of semi-finished optical lens designs by determining an optimized set of semi-finished optical lens design allowing manufacturing finished ophthalmic lenses for the full range of sphere and cylinder values, comprising less semi-finished optical lenses designs than the initial set and in which for at least two initial sub-ranges of sphere and cylinder values, a common semi-finished optical lens design is selected from the initial set of semi-finished optical lenses designs.

[0022] Advantageously, the method according to the disclosure allows providing an optimized set of semi-finished optical lens designs that allows manufacturing all of the optical lenses corresponding to each ophthalmic prescriptions comprised in the subset of ophthalmic prescription and is optimized in terms of number of different semifinished optical lenses designs and ultimately reducing waste by reducing the number of semi-finished optical lenses blanks that are to be throw away due to arriving at the limit usable date.

[0023] According to an embodiment, the optimization method does not involve any recalculation or modification of optical surface shapes. The semi-finished optical lens designs are predefined and fixed in terms of surface curvature and material. The optimization consists exclusively in selecting and mapping among these predetermined geometries, without ray tracing or optical power redistribution between front and back surfaces. This ensures that the optimization step is non-optical in nature and does not generate new lens designs but instead selects from an existing catalog of semi-finished optical lens geometries.

[0024] The optimization method comprises selecting, among a predefined set of semifinished optical lens designs having fixed surface curvature and material, without recalculating or generating new surface shapes, a subset of designs allowing prescription coverage over multiple sub-ranges.

[0025] According to an embodiment, the optimization method comprises a nonduplication strategy in which no base curve is duplicated between different geometrical variants of the same prescription area, for example between standard and optimized (slim fit) geometries. This approach allows reducing the number of required semi-finished optical lens designs by eliminating overlapping or redundant lens designs that previously coexisted for the same prescription values. This is distinct from optical optimization strategies, as it prioritizes SKU (Stock Keeping Unit) consolidation and logistic streamlining without modifying prescription coverage.

[0026] According to an embodiment, the optimization method is driven by prescription frequency data. The method identifies sub-ranges of prescriptions that are most commonly ordered and preferentially retains or assigns optimized semi-finished optical lens designs to these high-frequency zones. Conversely, rarely used prescriptions are assigned to standard designs with broader coverage. This demand- based allocation enables a reduction in overall SKU count while maintaining service levels. This approach differs from prior art methods which do not account for real- world prescription statistics.

[0027] In further embodiments, the optimization method does not require any optical compensation on the back surface to account for changes in base curve assignment. The semi-finished optical lenses retain their original surface parameters, and any reassignment of prescription ranges to a different base curve does not necessitate recalculation of optical function. As a result, the production flow remains stable and consistent with pre-qualified designs. This further emphasizes that the present method is oriented toward stock optimization rather than optical design transformation.

[0028] According to further embodiments which can be considered alone or in combination:

[0029] - the full range of sphere and cylinder values comprises all the discrete values comprised between two extreme values, for example comprises sphere values from -4 diopters to +4 diopters and cylinder values from 0 diopter to -5.5 diopters; and / or the set of discrete values of sphere and cylinder have an increment greater than or equal to 0.05 diopter, for example greater than or equal to 0.1 diopter, and smaller than or equal to 0.5 diopter, for example smaller than or equal to 0.25 diopter; and / or

[0030] - the initial set of semi-finished optical lens design comprise semi-finished optical lens design with standard geometrical parameters and at least two semi-finished lens optical designs having the same base curve, one having standard geometrical parameters and one having optimized geometrical parameters for range covering the most ordered prescription values in sphere and cylinder; and / or

[0031] - the optimized geometrical parameter is at least one of: o the diameter of the semi-finished optical lens, o the thickness at the center of the semi-finished optical lens, o the thickness at the periphery of the semi-finished optical lens, o the shape of the back surface of the semi-finished optical lens, for example the curvature of the back surface of the semi-finished optical lens; and / or during the optimization step, the common semi-finished optical lens design selected for at least two initial sub-ranges of sphere and cylinder values is one of the semi-finished lens designs having standard geometrical parameters; and / or during the optimization step, the initial set of semi-finished optical lens design is optimized by keeping at least one semi-finished optical lens designs having optimized geometrical parameters for a sub range of prescriptions that is the most ordered and the at least two initial semifinished optical lens designs corresponds to the most extreme sphere and cylinder values; and / or during the optimization step, the initial set of semi-finished optical lens design is optimized by keeping at least one of the semi-finished optical lens designs having optimized geometrical parameters and replacing the initial semi-finished optical lens designs having the same base curve as an initial semi-finished optical lens design having optimized geometrical parameters with a common semi-finished optical lens design corresponding to the initial semi-finished lens design having standard geometrical parameters and adapt for a 0D sphere and 0D cylinder prescription; and / or during the optimization step, the initial set of semi-finished optical lens design is further optimized by further replacing the initial semi-finished optical lens design having optimized geometrical parameters and adapted for a 0D sphere and 0D cylinder prescription by the initial semi-finished lens design having standard geometrical parameters and adapt for a 0D sphere and 0D cylinder prescription; and / or both semi-finished optical lens designs have the same base curve; and / or during the optimization step, the initial set of semi-finished optical lens design is further optimized by further replacing the initial semi-finished optical lens design having optimized geometrical parameters and adapted for a 0D sphere and 0D cylinder prescription by the initial semi-finished lens design having optimized geometrical parameters and adapt for a lower value of sphere, for example below -1 D, for example below -1.5D, over the part of the initial sub-range of sphere and cylinder of the initial semifinished optical lens design having optimized geometrical parameters and adapted for a 0D sphere and 0D cylinder prescription having the same cylinder values as the initial semi-finished optical lens design having optimized geometrical parameters and adapt for a lower value of sphere, for example below -1 D, for example below -1.5D; and / or during the optimization step, the initial set of semi-finished optical lens design is further optimized by further replacing a first initial semi-finished optical lens design having optimized geometrical parameters with a first designated base curve by a second initial set of semi-finished optical lens design having optimized geometrical parameters with a second designated base curve, the first and second base curve being different.

[0032] The disclosure also relates to a data processing device for optimizing a set of semi-finished optical lenses, wherein the data processing device comprises at least:

[0033] - an input for obtaining an initial set of semi-finished optical lenses designs, each semi-finished optical lens design in the initial set of semi-finished optical lenses designs having a designated base curve and an initial geometry determined to allow manufacturing finished ophthalmic lenses for a full range of sphere and cylinder values, each semi-finished optical lens design being configured to allow manufacturing finished ophthalmic lenses for an initial sub-range of sphere and cylinder values included in the full range,

[0034] - a processor for optimizing the initial set of semi-finished optical lenses designs by determining an optimized set of semi-finished optical lenses design allowing manufacturing finished ophthalmic lenses for the full range of sphere and cylinder values, comprising less optical lenses designs than the initial set and in which for at least two initial sub-ranges of sphere and cylinder values a common semifinished optical lens design is selected from the initial set of semi-finished optical lenses designs, and

[0035] - an output for outputting the optimized set of semi-fmished optical lenses designs. Furthermore, the disclosure also relates to a data processing device comprising a processor configured to perform the steps of at least one method of the disclosure.

[0036] According to a further aspect, the disclosure relates to a computer program product comprising one or more stored sequence of instruction that is accessible to a processor and which, when executed by the processor, causes the processor to carry out the steps of at least one method according to the disclosure.

[0037] According to another aspect the disclosure relates to a program which makes a computer execute at least one method of the disclosure.

[0038] The disclosure also relates to a computer readable medium carrying one or more sequences of instructions of the computer program according to the disclosure.

[0039] The disclosure further relates to a computer-readable storage medium having a program recorded thereon; where the program makes the computer execute at least one method of the disclosure.

[0040] The disclosure relates to a device comprising a processor adapted to store one or more sequence of instructions and to carry out at least one of the steps of at least one method according to the disclosure.

[0041] BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Non limiting embodiments of the disclosure will now be described with reference to the accompanying drawing wherein: o figure l is a flowchart of a method according to the disclosure, o figure 2 illustrates a semi-finished optical lens to be manufacture, o figure 3 represents an initial set of semi-finished optical lens designs adapted for a range of prescriptions, o figure 4 represents an optimized initial set of semi-finished optical lens designs adapted for a range of prescriptions, o figure 5 represents a first optimized set of semi-finished optical lens designs adapted for the same range of prescriptions as the initial set of figure 4, o figure 6 represents a second optimized set of semi-fmished optical lens designs adapted for the same range of prescriptions as the initial set of figure 4, o figure 7 represents a third optimized set of semi-finished optical lens designs adapted for the same range of prescriptions as the initial set of figure 4, o figure 8 represents a fourth optimized set of semi-finished optical lens designs adapted for the same range of prescriptions as the initial set of figure 4, and o figure 9 represents a data processing device according to the disclosure. Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help improve the understanding of the embodiments of the present disclosure.

[0043] DETAILED DESCRIPTION OF EMBODIMENTS OF THE DISCLOSURE

[0044] In the framework of the disclosure, the following terms have the meaning indicated herein below.

[0045] - The term “optical lens” is to be understood to mean any type of known lens intended to be positioned in front of the eye of a wearer. The term can refer to ophthalmic lenses such as non-corrective lenses, semi-finished lens blanks and corrective lenses, such as progressive addition lenses, unifocal or multifocal lenses. The term can also refer to said ophthalmic lenses which could present at least one added value such as, for example, tint, polarization filtering, electrochromism, antireflective properties, antiscratch properties or comprise a photochromic unit or a light guide unit,. . .

[0046] - The term “semi -finished optical lens” is to be understood to mean any type of known optical lens having two opposite surfaces at least one of which is unfinished.

[0047] - The term “semi -finished optical lens design” refers to the representation of a semi-finished optical lens in terms of geometry relative position of the surfaces and material of the semi-finished optical lens.

[0048] - The term “prescription” is to be understood to mean a set of optical characteristics comprising at least the optical power (sphere and cylinder) and eventually astigmatism, prismatic deviation, and, where relevant, of addition, determined by an ophthalmologist or optometrist in order to correct the vision defects of the wearer, for example by means of a lens positioned in front of his eye. For example, the prescription for a progressive addition lens comprises values of optical power and of astigmatism at the distance-vision point and, where appropriate, an addition value. The prescription data may include data for emmetrope eyes.

[0049] Unless specifically stated otherwise, as apparent from the following discussions, it is appreciated that throughout the specification discussions utilizing terms such as “determining”, “computing”, “calculating”, or the like, refer to the action and / or processes of a computer or computing system, or similar electronic computing device, that manipulate and / or transform data represented as physical, such as electronic, quantities within the computing system's registers and / or memories into other data similarly represented as physical quantities within the computing system's memories, registers or other such information storage, transmission or display devices.

[0050] Embodiments of the present disclosure may include apparatuses for performing the operations herein. This apparatus may be specially constructed for the desired purposes, or it may comprise a general purpose computer or Digital Signal Processor ("DSP") selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but is not limited to, any type of disk, read-only memories (ROMs), random access memories (RAMs) electrically programmable read-only memories (EPROMs), electrically erasable and programmable read only memories (EEPROMs), magnetic or optical cards, or any other type of media suitable for storing electronic instructions, and capable of being coupled to a computer system bus.

[0051] The processes and displays referred herein are not inherently related to any particular computer or other apparatus. Various general purpose systems may be used with programs in accordance with the teachings herein, or it may prove convenient to construct a more specialized apparatus to perform the desired method. The desired structure for a variety of these systems will appear from the description below. In addition, embodiments of the present disclosure are not described with reference to any particular programming language. It will be appreciated that a variety of programming languages may be used to implement the teachings of the disclosure. The disclosure relates to a method, for example implemented by computer means, for optimizing a set of semi-finished optical lens designs.

[0052] As illustrated on figure 1, the method of the disclosure comprises:

[0053] - an initial set of semi-finished optical lens design providing step SI, and

[0054] - an optimizing step S2.

[0055] During the initial set of semi-finished optical lens design providing step SI, a initial set of semi-finished optical lens designs is provided. For example, such initial set of semi-finished optical lens design is downloaded from a server or provided by any appropriate means.

[0056] Each semi-finished optical lens design in the initial set of semi-finished optical lenses designs has a designated base curve and an initial geometry determined to allow manufacturing finished ophthalmic lenses for a full range of sphere and cylinder values.

[0057] The initial set of semi-finished optical lens designs is configured so that each semi-finished optical lens design is configured to allow manufacturing finished ophthalmic lenses for an initial sub-range of sphere and cylinder values included in the full range,

[0058] Each semi-finished optical lens design of the initial set of semi-finished optical lenses designs comprises a surface having a given curvature and all the semi-finished optical lens designs comprised in the initial set of semi-finished optical lens designs have a finished surface with a geometrical center reference point and an unfinished surface.

[0059] Each of the semi-finished optical lens design in the initial set of semi-finished optical lenses designs has a determined geometry determined to allow for said set of semi-finished optical lens designs to manufacture finished optical lenses for substantially all ophthalmic lens prescriptions.

[0060] Typically, the full range of sphere and cylinder values comprises all the discrete values comprised between two extreme values

[0061] According to an embodiment, the sphere values are greater than or equal to - 12 diopters, for example greater than or equal to -8 diopters, for example greater than or equal to -4 diopters, and smaller than or equal to +8 diopters, for example smaller than or equal to +4 diopters. According to an embodiment, the cylinder values are smaller than or equal to 0 diopter and greater than or equal to -5.5 diopters.

[0062] The set of discrete values of sphere and cylinder have an increment greater than or equal to 0.05 diopter, for example greater than or equal to 0.1 diopter, and smaller than or equal to 0.5 diopter, for example smaller than or equal to 0.25 diopter.

[0063] It will be appreciated that extreme outlier ophthalmic prescriptions, such as clinical rarities, are manufactured as special cases using very large semi-finished optical lenses, and are not considered part of the "standard range population"; that is, substantially all ophthalmic lens prescriptions.

[0064] As illustrated on figure 2, a semi-finished optical lens 10 corresponding to a semi-finished optical lens design has a first optical surface 12, a second optical surface 14 and an external periphery surface 16 connecting the first 12 and second 14 optical surfaces.

[0065] It will be appreciated by those persons skilled in the art that the first and / or second surfaces can be spherical, aspherical and / or progressive surfaces. It will also be appreciated that the determined geometries of the lenses in the set may differ with different designated refractive indexes; for example, lenses with a refractive index of 1.57 are thinner than those with a refractive index of 1.53.

[0066] Each semi-finished optical lens design has a designated base curve and an geometry determined to allow manufacturing finished ophthalmic lenses for an initial set of ophthalmic prescriptions.

[0067] The base curves, on semi-finished optical lenses, provide surface power for the first surface, for example the front surface, which, when combined with the second surface, for example the back surface, facing a wearer's eye when mounted in a spectacle frame and worn by the wearer, after it is ground and polished, produces the desired dioptric function.

[0068] Figure 3 shows an example of a of representation of prescription data with sphere power on the y axis and cylinder power on the x axis.

[0069] It is shown in figure 3 that an initial set of semi-finished optical lens designs for a designated lens material with different base curves practically covers a whole range of ophthalmic prescriptions, in the example of figure 3 sphere from -12 D to +8 D and cylinder from 0 D to -6 D. In the example of figure 3, different semi-finished optical lens design corresponds to different ophthalmic prescriptions, however, one may have two or more different semi-finished optical lenses design for a given ophthalmic prescription. In other words, two different semi-finished optical lenses may correspond to a same ophthalmic prescription.

[0070] In the example of figure 3, all the prescriptions can be manufactured starting from 6 semi-finished optical lens designs with respecting base curves of 8.5, 6.75, 6, 3.75, 2.75 and 1.75.

[0071] A person skilled in the art understands that the different base curve delimitations represented on figure 3 are purely for explanatory purposes and do not necessarily represent actual base curve delimitations. Delimitations may, for example, be based on additional parameters such as addition power, prism power, decentration and diameter requirements. According to further embodiments, each semi-finished optical lens design of the initial set of semi-finished optical lens designs has an initially determined thickness at the periphery of the semi-finished optical lens and / or an initially determined thickness at the center of the semi-finished optical lens, and / or an initially determined diameter and / or an initially determined curvature, for example the curvature of the back surface of the semi-finished optical lens.

[0072] According to an embodiment, the initial set of semi-finished optical lens design comprise semi-finished optical lens design with standard geometrical parameters and at least two semi-finished lens optical designs having the same base curve, one having standard geometrical parameters and one having optimized geometrical parameters for range covering the most ordered prescription values in sphere and cylinder.

[0073] The optimized geometrical parameter may be at least one of:

[0074] - the diameter of the semi-finished optical lens,

[0075] - the thickness at the center of the semi-finished optical lens,

[0076] - the thickness at the periphery of the semi-finished optical lens,

[0077] - the shape of the back surface of the semi-finished optical lens, for example the curvature of the back surface of the semi-finished optical lens.

[0078] Figure 4 illustrates an optimized set of semi-finished optical lens designs covering the same range of prescription as figure 3.

[0079] Typically, part of the semi-finished optical lens designs is optimized to produced in thinner versions. On this example the semi-finished optical lens designs corresponding to base curves 2.75, 3.75 and 6 were optimized because they cover most of the ordered prescriptions.

[0080] Those optimized semi-finished optical lens designs cover partly the range of prescriptions which are covered by the standard semi-finished optical lens designs for those base curve in the example of figure 3.

[0081] As illustrated on figure 4, part of the range of prescription where optimized semi-finished optical lens designs are used is not covered and has to be manufactured starting from standard semi-finished optical lens designs and also half of the remaining prescription and different semi-finished optical lens designs are not addressed.

[0082] The set of semi-finished optical lens designs comprises six semi-finished optical lens designs with standard geometric having respective base curves 8.5, 6.75, 6, 3.75, 2.75 and 1.75. Some of the semi-finished optical lens designs have been optimized, in the example of figure 4, the semi-finished optical lens designs having the base curves 2.75, 3.75 and 6 have and optimized version, i.e. a thinner version.

[0083] Therefore, in the example displayed on figure 4, there is a total of nine semifinished optical lens designs to cover the full range of prescription, making the management of the stock of lens blank complex, costly and some of the lens blanks are wasted if not used over a too long period of time. Indeed, the prescriptions for very low sphere and cylinder values, such as for example SPH -12.25 & CYL -6 are managed with other type of lens and there are no semi-finished optical lens design for such prescription in the example displayed on figure 4.

[0084] The idea of the disclosure is to provide a method to improve the situation.

[0085] During the optimizing step S2, the initial set of semi-finished optical lens designs is optimized by determining an optimized set of semi-finished optical lens design allowing manufacturing finished ophthalmic lenses for the full range of sphere and cylinder values, comprising less semi-finished optical lenses designs than the initial set and in which for at least two initial sub-ranges of sphere and cylinder values, a common semi-finished optical lens design is selected from the initial set of semifinished optical lenses designs.

[0086] Advantageously, the method of the disclosure reduce the number of different semi-finished optical lens designs required to cover the range of prescription so as to to have less inventory to manage, since some of the semi-finished optical lens designs are removed and the ones left are used for more prescriptions which means that there are be less molds, gaskets to produce the different semi-finished optical lens corresponding to the semi-finished optical lens designs, and less chance that they will be low runners, i.e. less safety stock.

[0087] According to an embodiment of the invention, during the optimization step, the common semi-finished optical lens design selected for at least two initial sub-ranges of sphere and cylinder values is one of the semi-finished lens designs having standard geometrical parameters.

[0088] For example, during the optimization step, the initial set of semi-finished optical lens design is optimized by keeping at least one semi-finished optical lens designs having optimized geometrical parameters for a sub range of prescriptions that is the most ordered and the at least two initial semi-finished optical lens designs corresponds to the most extreme sphere and cylinder values.

[0089] Figure 5 illustrates an example of optimized set of semi-finished optical lens designs based on the initial set illustrated on figure 4.

[0090] In this example, the range of prescriptions associated with the standard semifinished optical lens design having a base curve of 6.75 has been increased to include the initial range of prescriptions associated with the initial standard semi-finished optical lens design having a base curve of 6.

[0091] Furthermore, the range of prescriptions associated with the standard semifinished optical lens design having a base curve of 1.75 has been increased to include the initial range of prescriptions associated with the initial standard semi-finished optical lens design having a base curve of 2.75 and 1.75.

[0092] In this example, only six semi-finished optical lens designs cover the full range of prescription of the initial set.

[0093] The advantage of this solution is to limit the number of standard semi-finished optical lens designs, i.e. the thicker ones, to the maximum.

[0094] According to an embodiment of the invention, during the optimization step, the initial set of semi-finished optical lens design is optimized by keeping at least one of the semi-finished optical lens designs having optimized geometrical parameters and replacing the initial semi-finished optical lens designs having the same base curve as an initial semi-finished optical lens design having optimized geometrical parameters with a common semi-finished optical lens design corresponding to the initial semi- finished lens design having standard geometrical parameters and adapt for a 0D sphere and OD cylinder prescription.

[0095] Figure 6 illustrates an example of optimized set of semi-finished optical lens designs based on the initial set illustrated on figure 4.

[0096] In this example, the range of prescriptions associated with the standard semifinished optical lens design having a base curve of 3.75 has been increased to include the initial range of prescriptions associated with the initial standard semi-finished optical lens designs having a base curve of 2.75 and part of the range of prescription associated with the initial standard semi-finished optical lens designs having a base curve of 6.

[0097] In this example, only seven semi-finished optical lens designs cover the full range of prescription of the initial set. In particular, the set of semi-finished optical lens designs has two version of the 3.75 base curve, a standard version for the most extreme values of cylinder and an optimized version (thinner) for the lower cylinder value and the most ordered prescription.

[0098] The advantage of this solution is to limit the number of standard semi-finished optical lens designs, i.e. the thicker ones, to the maximum.

[0099] The set of semi-finished optical lens designs based on the example of figure 5, replaces the standard semi-finished optical lens design having a base curve of 3.75 and 2.75 by a semi-finished optical lens designs having a base curve of 1.75. It means that lenses would be flatter than usual especially for lenses that were made from the standard semi-finished optical lens design having a base curve of 3.75 in the initial set illustrated on figure 4.

[0100] The optimized set of standard semi-finished optical lens designs illustrated on figure 6 solves this issue by having a standard semi-finished optical lens design with a base curve of 3.75 for sphere values close to 0 diopters.

[0101] An advantage of the embodiment illustrated on figure 6 is to provide a set of standard semi-finished optical lens designs with a reduce the number of standard semifinished optical lens designs while maintaining the geometry of the final lens as the one obtained from the known set of standard semi-finished optical lens designs illustrated on figure 4.

[0102] According to an embodiment, during the optimization step, the initial set of semi-finished optical lens design is further optimized by further replacing the initial semi-finished optical lens design having optimized geometrical parameters and adapted for a 0D sphere and 0D cylinder prescription by the initial semi-finished lens design having standard geometrical parameters and adapt for a 0D sphere and 0D cylinder prescription.

[0103] For example, both semi-finished optical lens designs have the same base curve.

[0104] Figure 7 illustrates such an embodiment.

[0105] Figure 7 illustrates an example of optimized set of semi-finished optical lens designs based on the initial set illustrated on figure 4.

[0106] In this example, the range of prescriptions associated with the standard semifinished optical lens design having a base curve of 3.75 has been increased to include the initial range of prescriptions associated with the initial standard semi-finished optical lens designs having a base curve of 6 and 2.75 and the optimized semi-finished optical lens designs having a base curve of 3.75.

[0107] In this example, only six semi-finished optical lens designs cover the full range of prescription of the initial set. In particular, the set of semi-finished optical lens designs has only one version of the 3.75 base curve, i.e. the standard version.

[0108] An advantage of this embodiment is to reduce the number of standard and optimized semi-finished optical lens designs to the maximum, in particular ensuring no duplication of base curve while maintaining the geometry of the final lenses.

[0109] According to an embodiment, during the optimization step, the initial set of semi-finished optical lens design is further optimized by further replacing the initial semi-finished optical lens design having optimized geometrical parameters and adapted for a 0D sphere and 0D cylinder prescription by the initial semi-finished lens design having optimized geometrical parameters and adapt for a lower value of sphere, for example below -1 D, for example below -1.5D, over the part of the initial sub-range of sphere and cylinder of the initial semi-finished optical lens design (having optimized geometrical parameters and adapted for a 0D sphere and 0D cylinder prescription) having the same cylinder values as the initial semi-finished optical lens design( having optimized geometrical parameters and adapt for a lower value of sphere, for example below -1 D, for example below -1.5D).

[0110] Figure 8 illustrates such an embodiment.

[0111] Figure 8 illustrates an example of optimized set of semi-finished optical lens designs based on the initial set illustrated on figure 4 In this example, the range of prescriptions associated with the standard semifinished optical lens design having a base curve of 3.75 has been increased to include the initial range of prescriptions associated with the initial standard semi-finished optical lens designs having a base curve of 2.75, part of the range of prescription associated with the initial standard semi-finished optical lens designs having a base curve of 6 and part of the range of prescription associated with the optimized standard semi-finished optical lens designs having a base curve of 3.75 in the initial set illustrated on figure 8.

[0112] The range of prescriptions associated with the optimized semi-finished optical lens design having a base curve of 2.75 has been increased to part of the range of prescription associated with the optimized standard semi-finished optical lens designs having a base curve of 3.75 in the initial set illustrated on figure 4.

[0113] The limit between the range of prescriptions associated with the optimized semi-finished optical lens designs having a base curve of 2.75 and the standard standard semi-finished optical lens designs having a base curve of 3.75 is a cylinder value of -2.5 diopters corresponding to the cylinder limit of the initial range of prescription covered by the optimized semi-finished optical lens designs having a base curve of 2.75.

[0114] In this example, only six semi-finished optical lens designs cover the full range of prescription of the initial set. In particular, the set of semi-finished optical lens designs has two optimized semi-finished optical lens designs, one having a base curve of 2.75 and the other having a base curve of 6.

[0115] An advantage of this embodiment is to reduce the number of standard and optimized semi-finished optical lens designs to the maximum while ensuring no duplication of base curve, maintaining the geometry of the final lens and using optimized semi-finished optical lens designs to the maximum to reduce waste during the manufacturing of the final lenses.

[0116] The disclosure further relates to a data processing device for optimizing a set of semi-finished optical lenses.

[0117] An example of such data processing device is represented on figure 9. For example the data processing device 20 comprising at least:

[0118] - one input 22,

[0119] - one processor 24, and - an output 26.

[0120] The data processing device is configured for optimizing a set of semi-finished optical lenses, typically to carry our methods according to the disclosure.

[0121] The input device 22 is configured at least to obtain, for example receive, an initial set of semi-finished optical lens designs, each semi-finished optical lens design in the initial set of semi-finished optical lenses designs having a designated base curve and an initial geometry determined to allow manufacturing finished ophthalmic lenses for a full range of sphere and cylinder values, each semi-finished optical lens design being configured to allow manufacturing finished ophthalmic lenses for an initial subrange of sphere and cylinder values included in the full range.

[0122] The processor 24 is configured at least for optimizing the initial set of semifinished optical lenses designs by determining an optimized set of semi-finished optical lenses design allowing manufacturing finished ophthalmic lenses for the full range of sphere and cylinder values, comprising less optical lenses designs than the initial set and in which for at least two initial sub-ranges of sphere and cylinder values a common semi-finished optical lens design is selected from the initial set of semifinished optical lenses designs.

[0123] The data processing device may further include a memory for storing at least instructions to which the processor 24 has access to implement the determining steps of the method of the disclosure.

[0124] The output 26 is configured at least for outputting the determined optimized et of semi-finished optical lenses designs.

[0125] The data processing device 20 may comprise the input, processor and output in a same location, such as in a same computing device.

[0126] In a further embodiment the processor 24 may reside on a distant server accessible over a network, such as the Internet, by a suitable data link. Accordingly, the server receives and transmits data over the network with any number of connected computing devices. The server may also include a memory, in addition to the processor, for storing instructions to implement the processor to perform the determination steps of at least one of the methods of the disclosure.

[0127] The description made for the method aspect of the disclosure also applies to the data processing device aspect of the disclosure in particular concerning the initial set of ophthalmic parameters, the subset of ophthalmic parameters, the geometrical parameters, the optimized semi-finished optical lens and the optimized set of semifinished optical lenses designs

[0128] The disclosure has been described above with the aid of embodiments without limitation of the general inventive concept. Many further modifications and variations will be apparent to those skilled in the art upon making reference to the foregoing illustrative embodiments, which are given by way of example only and which are not intended to limit the scope of the disclosure, that being determined solely by the appended claims.

[0129] In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that different features are recited in mutually different dependent claims does not indicate that a combination of these features cannot be advantageously used. Any reference signs in the claims should not be construed as limiting the scope of the disclosure.

Claims

CLAIMS1. A method, for example implemented by computer means, for optimizing a set of semi-finished optical lens designs, the method comprising:- providing an initial set of semi-finished optical lens designs, each semifinished optical lens design in the initial set of semi-finished optical lenses designs having a designated base curve and an initial geometry determined to allow manufacturing finished ophthalmic lenses for a full range of sphere and cylinder values, each semi-finished optical lens design being configured to allow manufacturing finished ophthalmic lenses for an initial sub-range of sphere and cylinder values included in the full range,- optimizing the initial set of semi-finished optical lens designs by determining an optimized set of semi-finished optical lens designs allowing manufacturing finished ophthalmic lenses for the full range of sphere and cylinder values, comprising less semi-finished optical lenses designs than the initial set and in which for at least two initial sub-ranges of sphere and cylinder values, a common set of semi-finished optical lens designs is selected from the initial set of semi-finished optical lenses designs having standard geometrical parameters, wherein the initial set of semi-finished optical lens designs comprise semi-finished optical lens designs with standard geometrical parameters and a set of at least two semi-finished optical lens optical designs having the same base curve, one having standard geometrical parameters and one having optimized geometrical parameters for a range covering the most ordered prescription values in sphere and cylinder, wherein the optimized semi-finished optical lens designs cover partly the range of prescriptions which are covered by the standard semi-finished optical lens designs for those base curves.

2. The method according to claim 1, wherein the full range of sphere and cylinder values comprises all the discrete values comprised between two extreme values, for example comprises sphere values from -4 diopters to +4 diopters and cylinder values from 0 diopter to -5.5 diopters.

3. The method according to claim 2, wherein the set of discrete values of sphere and cylinder have an increment greater than or equal to 0.05 diopter, for example greater than or equal to 0.1 diopter, and smaller than or equal to 0.5 diopter, for example smaller than or equal to 0.25 diopter.

4. The method according to any of the preceding claims, wherein the optimized geometrical parameter is at least one of:- the diameter of the semi-finished optical lens,- the thickness at the center of the semi-finished optical lens,- the thickness at the periphery of the semi-finished optical lens,- the shape of the back surface of the semi-finished optical lens, for example the curvature of the back surface of the semi-fmished optical lens.

5. The method according to claim 1 or 4, wherein during the optimization step, the common set of semi-fmished optical lens designs selected for at least two initial subranges of sphere and cylinder values is one of the semi-fmished lens designs having standard geometrical parameters.

6. The method according to any of claims 1, 4 or 5, wherein during the optimization step, the initial set of semi-fmished optical lens designs is optimized by keeping at least one semi-fmished optical lens design having optimized geometrical parameters for a sub range of prescriptions that is the most ordered and a set of at least two initial semi-fmished optical lens designs correspond to the most extreme sphere and cylinder values.

7. The method according to any of claims 1,4, or 5, wherein during the optimization step, the initial set of semi-finished optical lens designs is optimized by keeping at least one of the semi-fmished optical lens designs having optimized geometrical parameters and replacing the initial set of semi-fmished optical lens designs having the same base curve as an initial set of semi-fmished optical lens designs having optimized geometrical parameters with a common set of semi-fmished optical lens designscorresponding to the initial set of semi-finished lens designs having standard geometrical parameters and adapt for a 0D sphere and 0D cylinder prescription.

8. The method according to claim 7, wherein during the optimization step, the initial set of semi-finished optical lens designs is further optimized by further replacing the initial set of semi-finished optical lens designs having optimized geometrical parameters and adapted for a 0D sphere and 0D cylinder prescription by the initial set of semi-finished lens designs having standard geometrical parameters and adapt for a 0D sphere and 0D cylinder prescription.

9. The method according to the preceding claim, wherein both sets of semi-finished optical lens designs, namely the initial and the optimized sets, have the same base curve.

10. The method according to claim 7, wherein during the optimization step, the initial set of semi-finished optical lens designs is further optimized by further replacing the initial set of semi-finished optical lens designs having optimized geometrical parameters and adapted for a 0D sphere and 0D cylinder prescription by the initial set of semi-finished lens designs having optimized geometrical parameters and adapt for a lower value of sphere, for example below -1 D, for example below -1.5D, over the part of the initial sub-range of sphere and cylinder of the initial set of semi-finished optical lens designs having the same cylinder values as the initial set of semi-finished optical lens designs.

11. The method according to claim 7 or 10, wherein during the optimization step, the initial set of semi-finished optical lens designs is further optimized by further replacing a first initial set of semi-finished optical lens designs having optimized geometrical parameters with a first designated base curve by a second initial set of semi-finished optical lens designs having optimized geometrical parameters with a second designated base curve, the first and second base curve being different.

12. A data processing device for optimizing a set of semi -finished optical lenses, wherein the data processing device comprises at- an input for obtaining an initial set of semi-finished optical lenses designs, each semifinished optical lens design in the initial set of semi-finished optical lenses designs having a designated base curve and an initial geometry determined to allow manufacturing finished ophthalmic lenses for a full range of sphere and cylinder values, each semi-finished optical lens design being configured to allow manufacturing finished ophthalmic lenses for an initial sub-range of sphere and cylinder values included in the full range,- a processor for optimizing the initial set of semi-finished optical lenses designs by determining an optimized set of semi-finished optical lenses designs allowing manufacturing finished ophthalmic lenses for the full range of sphere and cylinder values, comprising less optical lenses designs than the initial set and in which for a set of at least two initial sub-ranges of sphere and cylinder values a common set of semifinished optical lens designs is selected from the initial set of semi-finished optical lenses designs, and- an output for outputting the optimized set of semi-finished optical lenses designs, wherein the initial set of semi-finished optical lens designs comprise semi-finished optical lens designs with standard geometrical parameters and a set of at least two semi-finished optical lens optical designs having the same base curve, one having standard geometrical parameters and one having optimized geometrical parameters for a range covering the most ordered prescription values in sphere and cylinder, wherein the optimized semi-finished optical lens designs cover partly the range of prescriptions which are covered by the standard semi-finished optical lens designs for those base curves.

13. A computer program product comprising one or more stored sequences of instructions that are accessible to a processor and which, when executed by the processor, causes the processor to carry out at the steps of the method according to any of claims 1 to 11.

14. A computer-readable storage medium comprising instructions which, when executed by a computer, cause the computer to carry out the steps of the method of claims 1 to 11.

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