Ophthalmic lenses having printed enhancement

Abstract

A printing system for optically enhancing a deposition substrate to produce an ophthalmic lens comprises a receptacle for receiving the deposition substrate, an inkjet printing head for depositing drops of a curable ink onto a surface of the substrate, and a computerized control system. The control system is operative to define a printing volume bounded by a target surface shape and a non-planar shape of the first major surface, to divide the printing volume into a set of vertically ordered printing layers, and to cause the inkjet printing head to deposit the printing layers onto the first major surface of the deposition, the deposited printing layers comprising drops of the curable ink. The printed optical enhancement is encapsulated by respective non-ophthalmic layers comprising the same curable ink.

Description

[0001] OPHTHALMIC LENSES HAVING PRINTED ENHANCEMENT

[0002] CROSS-REFERENCE TO OTHER PUBLICATIONS

[0003] This application claims priority from UK patent application no. GB2416828.8 filed on November 15, 2024, from UK patent application no. GB2416822.1 filed on November 15, 2024, the teachings of both of which are incorporated herein by reference in their entirety.

[0004] FIELD OF THE INVENTION

[0005] The present invention relates to methods, apparatus and systems for fabricating optical articles, and particularly to optical articles formed, inter alia, by drop deposition of radiation-polymerizable compositions on a substrate.

[0006] BACKGROUND

[0007] Eyeglass lenses are currently produced in a variety of different processes. A common method for producing an eyeglass lens in an optical laboratory involves first selecting a clear lens blank, which is obtainable commercially in a variety of diopters. The lens blanks are outsourced from large producers who produce them using molding and / or machining. Even a small laboratory must track and maintain inventories of a very large number of differently powered lens blanks. When tints and other coatings are involved, the number of different blanks increases even further. The work of the laboratory may involve measuring or scanning a selected eyeglass frame and trimming or edging the lens blank to fit the frame. Some methods include selecting and then machining a semi-finished or finished lens blank with a given base power, i.e., the curvature of a first surface, to produce a lens with the final diopter.

[0008] At present, there is no known practical approach that gives the optical laboratory more control over the production of the lenses, e.g., setting the optical power, customizing bi-focal, multi-focal and progressive lenses, addressing cylinder and prism, and so on. A practical approach is needed that would reduce the need to manage large, expensive inventories of prescription-specific lens blanks and that would allow the optical laboratory to control all or a large part of lens production while producing precise lenses in an expedited and less expensive manner.

[0009] Past attempts to print optical enhancements on substrates have been unable to achieve desired optical quality and ophthalmic characteristics. In some cases, the attempts were limited to flat substrates, and in other cases to horizontal, planar printing layers even on curved substrates. New approaches will be necessary in order to meet optical and ophthalmic standards.

[0010] SUMMARY

[0011] According to embodiments disclosed herein, a printing system for optically enhancing a deposition substrate to produce an ophthalmic lens comprises: (a) a deposition-substrate receptacle; (b) an inkjet printing head operable, in a first operating mode in which a deposition substrate has been received in or upon the depositionsubstrate receptacle, to deposit drops of a curable ink onto a first major surface of the deposition substrate; and (c) a computerized control system configured to regulate operation of the inkjet printing head. The control system is programmed or programmable to carry out the following steps: (i) defining a printing volume bounded by a target surface shape and a non-planar shape of a first major surface of the deposition substrate, (ii) dividing the printing volume into a set of vertically ordered printing layers, a majority of the printing layers having respective non-planar three-dimensional target shapes, and (iii) when in the first operating mode, causing the inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape. The deposited printing layers comprise drops of the curable ink.

[0012] A method is disclosed, according to embodiments, for optically enhancing a deposition substrate to produce an ophthalmic lens. The method comprises: (a) receiving the deposition substrate in or upon a deposition-substrate receptacle comprising a first major surface having a non-planar shape; (b) defining a printing volume bounded by a target surface shape and the non-planar shape of the first major surface; (c) dividing the printing volume into a set of vertically ordered printing layers, a majority of the printing layers having respective non-planar three-dimensional target shapes; and (d) causing an inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape. The deposited printing layers comprise drops of a curable ink. The defining and dividing and causing are carried out by a control system.

[0013] A method is disclosed, according to embodiments, for optically enhancing a deposition substrate to produce an ophthalmic lens. Ihe method comprises: (a) receiving the deposition substrate, the deposition substrate comprising a first major surface having a non-planar shape; (b) defining a printing volume bounded by a target surface shape and the non-planar shape of the first major surface; (c) dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates; and (d) causing an inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape. The deposited printing layers comprising drops of the curable ink. The method additionally comprises: (i) depositing, before the deposition of the printing layers, at least one bottom layer comprising drops of the curable ink, and (ii) optionally depositing, before the deposition of the at least one bottom layer, at least one primer layer having a different composition than the curable ink. At least the defining, dividing and causing are carried out by a control system.

[0014] According to embodiments disclosed herein, a printing system for optically enhancing a deposition substrate to produce an ophthalmic lens comprises: (a) a deposition-substrate receptacle; (b) an inkjet printing head operable, in a first operating mode in which a deposition substrate has been received in or upon the depositionsubstrate receptacle, to deposit drops of a curable ink onto a first major surface of the deposition substrate; and (c) a computerized control system configured to regulate operation of the inkjet printing head. The control system is programmed or programmable to carry out the following steps: (i) defining a printing volume bounded by a target surface shape and a non-planar shape of the first major surface, (ii) dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates, and (iii) when in the first operating mode, causing the inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape. The deposited printing layers comprise drops of the curable ink. The control system is further programmed or programmable to cause the inkjet printing head to deposit, before the sequential depositing of the printing layers and when in the first operating mode, at least one bottom layer comprising drops of the curable ink. The control system is optionally programmed or programmable to cause, before the depositing of the one or more bottom layers and when in the first operating mode, application of a primer layer to the first major surface of the deposition substrate. A method is disclosed, according to embodiments, for optically enhancing a deposition substrate to produce an ophthalmic lens. The method comprises: (a) receiving the deposition substrate, the deposition substrate comprising a first major surface having a non-planar shape; (b) defining a printing volume bounded by a target surface shape and the non-planar shape of the first major surface; (c) dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates; (d) depositing at least one bottom layer comprising drops of the curable ink, and (e) after depositing the at least one bottom layer, sequentially depositing the printing layers, by an inkjet printing head, onto the first major surface in a sequence that is ordered differently than the set of vertically ordered printing layers. The deposited printing layers comprising drops of the curable ink.

[0015] According to embodiments disclosed herein, an ophthalmic lens comprises, and in the following sequence: (a) a first layer, having a minimum thickness of at least 500 microns and a convex major surface; (b) a second layer, having a maximum thickness between 20 and 100 microns; and (c) a plurality of at least partly overlapping layers each having a maximum thickness between 1 and 10 microns. A portion of each partly overlapping layer is in contact with the second layer.

[0016] BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The invention will now be described further, by way of example, with reference to the accompanying drawings, in which the dimensions of components and features shown in the figures are chosen for convenience and clarity of presentation and not necessarily to scale. In the drawings:

[0018] Fig. 1 is a hybrid-view schematic illustration of selected elements of a printing system for optically enhancing a deposition substrate to produce an ophthalmic lens, showing the optically-enhanced deposition substrate in cross section, where the optically-enhancing deposition is on a convex surface according to embodiments of the present invention.

[0019] Fig. 2 is a schematic cross-sectional illustration of an optically-enhanced deposition substrate, where the optically-enhancing deposition is on a convex surface, according to embodiments of the present invention.

[0020] Fig. 3 is a schematic cross-sectional illustration of the optically-enhancing deposition of Fig. 1, according to embodiments of the present invention. Fig. 4 is a schematic cross-sectional illustration of a plurality of deposited printing layers making up the optically-enhancing deposition of Fig. 1, according to embodiments of the present invention.

[0021] Fig. 5 is a schematic illustration showing deposition of ink droplets onto a non-planar three-dimensional surface, according to embodiments of the present invention.

[0022] Fig. 6A is a schematic illustration showing the optically-enhanced deposition substrate of Fig. 1 with one or more additional bottom layer(s), according to embodiments of the present invention.

[0023] Figs. 6B and 6C show a schematic detail showing the interface between printed layers and the substrate surface , respectively without and with one or more additional bottom layer(s), according to embodiments of the present invention.

[0024] Fig. 6D shows the detail of Fig. 6C with the addition of a primer layer between the substrate surface and the additional bottom layer(s), according to embodiments of the present invention.

[0025] Fig. 7A is a schematic illustration showing the optically-enhanced deposition substrate, having the one or more additional bottom layer(s) as in Fig. 6A, and one or more additional top layer(s), according to embodiments of the present invention.

[0026] Fig. 7B schematically illustrates the bottom and top layer(s) of Fig. 7A as encapsulating the deposited printing layers, according to embodiments of the present invention.

[0027] Fig. 7C shows the elements of Fig. 7C with the addition of a primer layer deposited between the substrate surface and the additional bottom layer(s), according to embodiments of the present invention.

[0028] Fig. 7D shows the elements of Fig. 7C with a schematic representation of the dimensions of the eyeglass lens to be finished by edging, according to embodiments of the present invention.

[0029] Fig. 8 is a block diagram of a printing system for optically enhancing a deposition substrate to produce an ophthalmic lens, according to embodiments of the present invention.

[0030] Fig. 9 is a block diagram of a control system for the printing system of Fig. 9, according to embodiments of the present invention. Figs. 10, 11 A, 11B, 12A and 12B show flowcharts of methods for optically enhancing a deposition substrate to produce an ophthalmic lens, according to embodiments of the present invention.

[0031] DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0032] The invention is herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. Throughout the drawings, like-referenced characters are generally used to designate like elements.

[0033] Embodiments of the invention relate to ophthalmic lenses for eyeglasses, produced by optically enhancing a deposition substrate. In embodiments, the substrate comprises a polymer. The optical enhancement is carried out by printing layers of a curable ink, e.g., by inkjet printing or micro-jetting (single-nozzle jetting), on an optical-grade substrate. The printed layers thus make up the ‘optical enhancement’ as the term is used herein. In some examples, the deposition substrate (or, simply, ‘substrate’) comprises a single-vision lens blank having a non-zero optical power. The single-vision lens blank can be a meniscus lens, i.e., concave-convex, in which case the printed layers are deposited at least on the concave surface. In some such examples, the substrate, the printing of the layers can produce an enhanced ophthalmic lens comprising, and not exhaustively: a bifocal lens, a multifocal lens or a progressive lens.

[0034] In some examples, the substrate comprises a curved printing surface but has substantially zero optical power, or alternatively, a lower optical power than is required in a final prescription.

[0035] In some examples, the substrate comprises a lens blank with some but not all of the ophthalmic features required by an eyeglass prescription. In some such examples, the substrate, the printing of the optically enhancing layers can produce, and not exhaustively, a bifocal lens, a multifocal lens, a progressive lens, a lens having a higher or lower optical power (diopter), or a lens having a prism correction or a cylinder correction.

[0036] In some examples, an optically enhancing deposition is applied to each of two major surfaces, where at least one of the printing surfaces is curved, and the printing of the optical enhancement includes printing, successively, respective layers of a curable ink on both of the two printing surfaces.

[0037] A ‘curved surface’, generally speaking, is one that is not flat, and can be concave or convex. The embodiments disclosed herein are also applicable to substrates characterized by complex shapes having both concave and convex shapes, and / or discontinuities (gradual or non-gradual changes in slope). Further, the embodiments disclosed herein are also applicable to the printing of layers to optically enhance a deposition substrate to produce an ophthalmic lens characterized in part by discontinuities or by non-horizontal planar surface shapes. The foregoing examples are not excluded from the scope of the embodiments by not being specifically described.

[0038] As used herein, the term ‘curved surface’ means a surface that is not flat and not nearly flat, where ‘nearly flat’ would describe a surface that is not strictly flat but that does not diverge from a flat, planar surface by more than a small amount, such as, by way of example, by less than 10 microns, or by less than 50 microns, or by less than 100 microns, or by less than 200 microns, or by less than 500 microns, or, additionally or alternatively, by less than the thickness of one printed layer, or two printed layers, or five printed layers. Additionally or alternatively, a curved surface is one that if it were placed opposite a planar surface to form a plano-convex or plano-concave lens, the resultant optical power would be (plus or minus, respectively) no more than 0.1 diopter, or no more than 0.2 diopter, or no more 0.3 diopter, or no more than 0.4 diopter, or no more than 0.5 diopter.

[0039] A printing system provided for carrying out any of the embodiments disclosed herein comprises a control system programmed and / or programmable to take a prescription or other written or digital description of an ophthalmic lens, whether explicit or implied, e.g., by codes and / or model numbers, and translate that information to a target surface shape to be printed. The term ‘target’ as used herein relates to a digital representation, e.g., of a surface shape that is to be produced according to the embodiments. In some examples, the control system (or another computer system, whether local or remote) translates the prescription information to an ‘optical design’ as is known in the ophthalmic industry, which comprises, inter alia, a two-dimensional diopter map. In such examples, the control system translates the optical design to a three-dimensional topographic map representing the target shape of the enhanced ophthalmic lens.

[0040] Using the three-dimensional map representing the target surface shape, and information available to the control system about the shape of the printing surface of the substrate, it is possible to define a printing volume, which is the volume to be printed in order to transform the substrate into an enhanced ophthalmic lens.

[0041] The control system is further programmed or programmable to ‘slice’ the printing volume into printable layers, and this includes mapping individual pixels or voxels to individual printing layers. In some embodiments, the mapping defines a set of drop locations having ink quantity values at respective x-y coordinates. In some implementations, ink quantity values can be zero or one. In some implementations, ink quantity values can be a positive number, e.g., an integer, within a range reflecting the capabilities of an inkjet print head of the printing system to deposit any number multiple drops at a single x-y drop location. The positive number (of individual drops) can be, in illustrative, non-limiting examples, between 1 and 5, or between 1 and 7, or between 1 and 10, or between 2 and 5, or between 2 and 7, or between 2 and 10. In some implementations, the ink quantity value can be zero or a positive integer within any of the foregoing ranges.

[0042] In some implementations, the layers can be three-dimensional and non-planar such that different drop locations on a single layer have different respective z-axis coordinates. The references to x-, y- and z- axis values refer to the commonly used coordinate system where x- and y-axis vectors define the horizontal plane, while the z-axis represents the vertical direction orthogonal to the horizontal plane. The skilled artisan will understand that depositing the ink in parallel, horizontal layers as is known in the art results is can be particularly disadvantageous in applications involving printing on a curved optical substrate. Printing on a curved optical substrate typically means that both the bottom and the top of the printed optical enhancement are curved, and thus both surfaces can suffer from production artefacts when depositing only horizontal layers. In some implementations, the printed optical enhancement can be further improved by one or more additional layers of, e.g., the same curable ink used for printing the layers created by the dividing of the printing volume. It is now disclosed that the use of the additional layers, i.e., at least one layer beneath and optionally at least one layer above, is effective to improve optical quality of enhanced ophthalmic lens, and / or to improve one or more optical properties of the ophthalmic lens. When the further improvement includes both bottom and top layers, the layers can, in some implementations, fully or substantially encapsulate the printed optical enhancement. The term ‘optical quality’ is used herein to mean an attribute, e.g., of an ophthalmic lens, that contributes to, or detracts from, the production quality of the lens. Examples of such attributes can include, but not exhaustively: transparency, e.g., in terms of transmissivity in the visible spectrum; clarity, e.g., in terms of constancy of refraction index; refraction and scattering, e.g., due to the presence of opaque material of embedded particles or surface roughness; material-related defects including rheologic parameters and polymerization kinetics; and visible artefacts of a discrete printing process including steps between layer edges and evidence of inter-drop spacing. The somewhat similar term ‘optical properties’ as used herein refers to ophthalmic characteristics such as diopter, cylinder, prism, and the like. ‘Improving’ an optical property means improving the accuracy with which an ophthalmic characteristic is reproduced in the drop-deposition process described herein.

[0043] The printing layers are deposited as patterns of a radiation-curable ink. In some embodiments, the ink is radiation-curable but not necessarily polymerizable; nonetheless the terms are used interchangeably in the present disclosure and in the appended claims, and both can be understood to mean radiation-polymerized or otherwise radiation-cured. In an illustrative example, a polymeric dispersion such as an aqueous polyurethane dispersion can be radiation cured but does not undergo further polymerization.

[0044] Various methods and processes are known for polymerizing curable inks and similar compositions, e.g., by irradiating the compositions, e.g., with actinic radiation such as, and not exhaustively, UV, IR, microwave and / or visible light. In an example, a suitable polymerizable composition can be cured to 80% of a final hardness (e.g., Rockwell hardness value) within no more than 2 minutes. In some embodiments, the printing system includes a source of curing and / or polymerizing radiation. An example of a polymerizing or curing radiation includes electromagnetic radiation in the ultraviolet spectrum, and especially in the upper end of the UV-A range, e.g., 390-400nm, or 395-405nm, or 395-400nm. In some implementations, a polymerizing wavelength or range of wavelengths depends on the formulation of the specific radiation-polymerizable composition. In some implementations, the wavelength is user- or software-selectable based on the specific composition used, and in some implementations different UV -radiation emitters, e.g., different lamps, are used in conjunction with different compositions requiring different wavelengths.

[0045] In an example, with respect to a suitable polymerizable composition, a radiation-cured polymer can comprise a photoinitiator or a reaction product thereof.

[0046] Examples of suitable photoinitiators include, and not exhaustively: aromatic ketones and synergistic amines, alkyl benzoin ethers, thioxathones and derivatives, benzil ketals, acylphosphine oxide, ketoxime or acyl oxime esters, cationic curing quaternary ammonium salts, and acetophenone derivatives.

[0047] Examples of suitable resins acting as oligomers can include, and not exhaustively, acrylate oligomers, including epoxy acrylates, urethane acrylates and polyester acrylates.

[0048] More specific families include unsaturated poly ester / aery lated polyester, acrylated epoxy resin, acrylated aliphatic urethanes, acrylated aromatic urethanes, acrylated silicone resins, acrylated polyethers, acrylated melamines, acrylated oils, N-vinyl urethanes, and thiol-ene systems.

[0049] Examples of suitable monomers for use in UV-curing include, and not exhaustively, acrylate monomers such as linear monoacrylate, cyclic monofunctional, aromatic monofunctional, difunctional acrylate, trifunctional acrylate, tetrafunctional acrylate monomers, as well as higher functional acrylate monomers.

[0050] Additional examples of suitable monomers for use in UV-curing include, and not exhaustively: neopentyl glycol diacrylate, hexanediol diacrylate 1,6, polyethylene glycol diacrylate, trimethylolpropane triacrylate, pentaerythritol triacrylate, dianol 2,2 diacrylate, and UV E70 polyester acrylate.

[0051] Various commercially available UV-curable, jettable varnishes may be used, including:

[0052]

[0053]

[0054] Referring now to the illustrations, and in particular to Fig. 1, selected elements of a printing system for optically enhancing a deposition substrate to produce an ophthalmic lens 100 are shown. As shown the printing system 200 comprises a multiple-nozzle inkjet print head 210 for depositing drops of a curable ink 7, and an optional source 250 of curing radiation. A deposition substrate 38 is shown in cross-section as having deposited thereupon an optically enhancing deposition 75 comprising a plurality of deposited printing layers (shown in Fig. 4). The optically enhancing deposition 75 is bounded from above by an upper surface 83 based on the target shape used to define the printing volume as described above. The optically enhancing deposition 75 is shown as deposited on a first major surface 81 of the deposition substrate 38, which, in the non-limiting example of Fig. 1, has a concave surface. In another non-limiting example illustrated in Fig. 2, the first major surface 81 of the deposition substrate 38 - the one to printed upon -is convex, and the second major surface 82 is concave. In some embodiments, both major surfaces 81, 82 can have optically enhancing depositions printed thereupon.

[0055] Both Figs. 1 and 2 schematically illustrate, again in cross section, the outline of an eyeglass lens that is the object of the printing. The eyeglass lens has a dimension 800. e.g., length, width or diagonal, which is less than a corresponding dimension of the deposition substrate 38 such that not all of the substrate is part of the final eyeglass lens. As can be seen, it is not necessary to print the layers on the entire surface 81 of the deposition substrate 38, since the rest of the deposition substrate 38 is later removed to finish the lens, and some material cost and printing time can be saved. On the other hand, there may be commercial, operational or logistical considerations indicating the printing of layers that are larger than the outline of the eyeglass lens.

[0056] Fig. 3 schematically illustrates, in isolation, the optically enhancing deposition 75 of Fig. 1. The upper surface 83 of the optically enhancing deposition 75 matches or emulates the target surface shape of the optical design (emulates, i.e., to the extent that the printing process succeeded in matching the optical design). The lower surface of the optically enhancing deposition 75 has a shape given it by the first major surface 81 of the deposition substrate 38.

[0057] We now refer to Fig. 4, which shows the optically enhanced ophthalmic lens 100 of Fig. 1 according to embodiments, with the optically enhancing deposition 75 shown as a plurality of n printed layers 35 deposited in accordance with the layers created by division of the printing volume by the control system. The number of layers 35 shown in Fig. 4 is merely for purposes of illustration, and in practice the number of layers 35 can be higher, e.g., more than 20, more than 30, more than 40, or more than 50, depending, inter alia on the thickness of the printing volume and the size of the deposited drops of curable ink. In embodiments, after each layer is deposited by the inkjet printing head 210, it can be at least partially cured by the source 250 of curing radiation, which can include any suitable radiation emitter in accordance with material-specific and process-specific requirements for curing the a given curable ink 7. An individual layer can be in the thickness range of 1.5-25 microns, and more typically, 1.5-15 microns or 1.5-10 microns.

[0058] In embodiments, after each layer is deposited by the inkjet printing head 210, it can be at least partially cured by the source 250 of curing radiation, which can include any suitable radiation emitter in accordance with material-specific and process-specific requirements for curing the a given curable ink 7. In some embodiments, the at least partial curing takes place after a given number of layers 35, e.g., every 5-10 layers, depending in part on drop volume, viscosity and substrate shape, and / or a given accumulated thickness since the previous partial curing, e.g., every 20-50 microns, or as little as every 10 microns for a less viscous curable ink 7. In examples, the partial curing can take 1-5 seconds, or 1-3 seconds.

[0059] Fig. 5 is a schematic illustration that shows the dynamics of printing / depositing a non-planar three-dimensional layer of curable ink drops on a curved substrate or on a previously deposited and at least partially cured non-planar three-dimensional layer according to an exemplary embodiment. Part ‘A’ of Fig. 5 shows a ‘snapshot’ at time A, when the drops of the curable ink 7 are released or ejected by the nozzles of the inkjet print head 210. This, the drops of the curable ink 7, at time A, are substantially co-planar. Part ‘B’ of Fig. 5 shows a snapshot at time B, after all of the drops have reached the substrate or, as shown in Fig. 5, a previously deposited layer 35. The different drops travel different distances for different lengths of time and reach different speeds before landing. In embodiments, the nozzles (not shown) are co-planar, as shown by horizontal line 850. and neither the print head 210 nor any individual nozzles are configured to move vertically during the printing operation with respect to the receptacle of the substrate, the substrate 38 itself, or previously printed layers 35. Similarly, the control system is not programmed to move the inkjet printing head 210 (or its individual nozzles) vertically. Therefore, in such embodiments, the control system of the printing system 200 translates the three-dimensional target shapes of the layers to respective two-dimensional projections, and the release or ejection of the drops of curable ink 7, which as already mentioned occurs on a horizontal plane as illustrated in Fig. 5, is in accordance with the two-dimensional projections.

[0060] In embodiments, it can be desirable to increase optical quality of the ophthalmic lens 100, and / or to improve one or more optical properties of the ophthalmic lens 100, by printing additional layers of the curable ink below and, optionally, above the printed layers 35 of the deposited enhancement 75. These layers are not necessarily intended to increase or decrease the optical power of the ophthalmic lens 100, and in some embodiments, design and printing of the additional layers is done while specifically avoiding any change to the optical power of the lens, which is provided by the printed layers 35 of the deposited enhancement 75 together with the substrate 38.

[0061] We now refer to Fig. 6A. According to embodiments, one or more bottom layers 31 are printed before the printing layers of the divided printing volume are printed. The bottom layer(s) 31 is / are printed by deposition of the same curable ink as the printed layers 35, between the upper surface 81 of the substrate 38 and the printed layers 35 of the deposited enhancement 75. The total thickness of the one or more bottom layers 31 can be between 20 and 100 microns, and in some embodiments between 30 and 60 microns. There can be as few as a single bottom layer 31 deposited, and as many as 20, or even more.

[0062] While according to embodiments the bottom layer(s) 31 is / are deposited using the same curable ink 7 as the printed layers 35 of the optical enhancement 75, the small-drop resolution afforded by the inkjet printing head 210 may not necessarily be required, and therefore the printing of the bottom layers 31 can be accomplished by different means, including, without limitation, a single-nozzle printing device such as a micro-jetting device.

[0063] In embodiments, a bottom layer 31 of the curable ink can improve the interface of the printed layers 35 with the upper surface 81 of the substrate 35, which generally involves two different materials, including providing a smoothed surface of the curable ink of the printed layers 35 as an interface with the substrate 38. Fig. 6B schematically shows a detail of Fig. 4 according to some embodiments in which successive printed layers 35, i.e., when moving away from the substrate 35, can have successively larger footprints. Fig. 6B illustrates the meeting of multiple printed layers 35 with the upper surface 81, without the presence of an intervening bottom layer 31 therebetween. The combined printed layers 35 do not present a smooth interface of the curable ink with the material of the substrate 38, and this can increase the presence of detectable and unwanted optical artifacts. Fig. 6C adds one or more bottom layers 31 to Fig. 6B, showing that the less smooth interface presented by the printed layers 35 faces the bottom layer(s) 31, which as already mentioned, is of the same composition as that of the printed layers 35. While still detectable in some cases, the optical artifacts will have been greatly reduced relative to the no-bottom-layers case.

[0064] As shown in Fig. 6A, the bottom layer 31 is preferably deposited to be present and underneath the entire footprint of the optical enhancement 75. In embodiments, the bottom layer(s) 31 can be deposited to cover all of the upper surface 81 of the substrate 38, or most of it, e.g., covering all but the 1-5 mm closest to the perimeter of the substrate 38.

[0065] Fig. 6D shows a non-limiting example of a surface energy treatment involving application of at least one primer layer 45. The primer layer performs a different function than does the bottom layer 31, which does not perform a surface energy treatment function. The primer is deposited (or coated) using a composition that is different than the curable ink 7 of the printed layers 35 and the bottom layers 31.

[0066] In some embodiments, it can be desirable to provide a ‘smoothing’ effect as a top layer as well, involving the deposition of one or more top layers of the same curable ink composition, atop the ‘stack’ of printed layers 31.

[0067] Fig. 7A shows one or more top layers 39 of the same curable ink as the that of the printed layers 35, printed after the printed layers 35 of the optical enhancement 75. Shown in a slightly exploded view, it can be seen that the one or more of the top layers 39 is / are sized to have a larger footprint than that of the printed optical enhancement 75.

[0068] In some embodiments, as illustrated in Fig. 7B, the depositing of the top layer(s) 39 has a large enough footprint to coat the sides 37 of the optical enhancement 75, and thus is positioned to ‘meet’ one or more of the bottom layers 31 around a respective edge so as to substantially (or mostly) encapsulate the optical enhancement 75.

[0069] Fig. 7C shows the prior application of the primer layer 45 as disclosed above with reference to Fig. 6D. Fig. 7D shows the ‘eyeglass lens dimensions’ 800 of Figs. 1 and 2. In embodiments, the final eyeglass lens is cut (edged) to a final shape such that some of the ‘encapsulation’ ink composition on the sides 37 of the optical enhancement 75 is retained in the final product. In some embodiments, the edging is such that the bottom and optional top layers 31, 39 remain but that the side encapsulation 37 is partially or completely removed.

[0070] As mentioned above in connection with the bottom layers, the small-drop resolution afforded by the inkjet printing head is also not necessary for depositing the top layer(s), and so depositing the curable ink of the top layer(s) 39 can be accomplished by different means, including, without limitation, a single-nozzle printing device such as a micro-jetting device.

[0071] In embodiments, a finished ophthalmic lens 100, optionally after edging and produced using any of the methods disclosed herein, includes the substrate 38, which has a minimum thickness of at least 500 microns and a convex major surface, the one or more bottom layer(s) 31, having a combined maximum thickness between 10 and 100 microns, or 20 and 100 microns, and at least two least partly overlapping printed layers 35 each having a maximum thickness between 1 and 10 microns and, as shown in Fig. 6C, partially in contact with the second layer. In some embodiments, the finished ophthalmic lens 100 includes the one or more top layers 39, which has a combined maximum thickness between 10 and 100 microns, or 20 and 100 microns. Other features of the finished ophthalmic lens 100 include those disclosed in any the embodiments.

[0072] In some embodiments, it can be desirable to treat the upper surface 81 of the substrate 38 with a surface energy treatment before the depositing, including before the depositing of the extra bottom layers of Fig. 6A. Examples of suitable energy treatments include, and not exhaustively: a corona treatment, a plasma treatment, an electron beam treatment, an electromagnetic (e.g., actinic) radiation treatment, and an electrical discharge treatment.

[0073] In some embodiments, the surface energy treatment may include one or more energy treatments coupled with the application of at least one primer layer 45.

[0074] In some embodiments, the primer is a polymeric primer. In some embodiments, the polymeric primer is in the form of a waterborne emulsion (e.g., an acrylic emulsion). In some embodiments, the polymeric primer is in the form of an aqueous dispersion (e.g., a polyurethane dispersion). In some embodiments, the polymeric primer is, or includes, a UV-curable material such as UV curable oligomers, epoxy acrylates, polyester acrylates, and urethane acrylates. In some embodiments, the polymeric primer is in the form of a solution (e.g., a polyurethane resin solution).

[0075] In some of these embodiments, the thickness and / or average thickness of the wet primer layer is at least 0.5pm, at least 0.8pm, at least 1pm, at least 1.5pm, at least 2pm, at least 3pm, at least 5pm, or at least 7pm. In some of these embodiments, the thickness and / or average thickness of the wet primer layer is at most 80pm, at most 60pm, at most 40pm, and more typically, at most 25pm, at most 20 pm, at most 15pm, at most 12pm, at most 105 pm, or at most 8 pm, and typically at most 5 pm or at most 4pm.

[0076] Exemplary Primers

[0077] • Acrylic polymer emulsions:

[0078] o Joncryl®1532 - waterborne acrylic emulsion offering excellent adhesion to a wide variety of substrates including plastics (BASF)

[0079] o Joncryl®1534 - waterborne acrylic emulsion offering excellent adhesion to a wide variety of substrates including plastics (BASF)

[0080] o Joncryl®2110 - waterborne acrylic emulsion, styrene acrylate copolymer (BASF)

[0081] o Joncryl®9530-A — waterborne acrylic emulsion self-crosslinking polymer • PU polymer emulsions and dispersions:

[0082] o CrystalCoat® PR 670 — water-based emulsion (SDC)

[0083] • Resin Solvent Based Solutions:

[0084] o Versamid®PUR 1010

[0085] o Laroflex®HS-9000 Fig. 8 is a block diagram of a printing system 200 for optically enhancing a deposition substrate to produce an ophthalmic lens according to embodiments. The elements shown in solid-line boxes, substrate receptable 225, inkjet printing head 210 and control system 50, are always part of a system 200. The substrate receptable 225 for receiving a deposition substrate 38 is configured to support the substrate 38 and optionally secure it. The inkjet printing head 210, as shown in Fig. 1, comprises multiple ink-ejection nozzles, preferably arranged co-planarly. Details of an exemplary control system 50 are shown in the block diagram of Fig. 9. As shown in the block diagram of Fig. 10, an exemplary control system 50 comprises computing equipment and ancillary equipment configured for monitoring, controlling, regulating and / or actuating one or more components or sub-systems of the printing system 200. Depending on location and customization, the control system can include any or all of (and not exhaustively): one or more computer processors 55, computer-readable storage media 58, 59, and a communications module 57. The computer-readable program storage media 58, 59 can include transient and / or transient storage, and can include one or more storage units, all in accordance with desired functionality and design choices. Some or all of the computer-readable program storage media 58, 59 can be cloud-based. In embodiments, the program storage 58 can be used for storing program instructions in firmware and / or software, for execution by the one or more processors 55; operating data and / or maintenance data relating to components of the printing system 200 and / or produced ophthalmic lenses 100 can be stored in the data storage module 59. The communications module 57 can be configured to establish communications links with external computers, e.g., for software and firmware updates, database access, etc., and to interact with users through a user interface (not shown). In some embodiments, not all of the illustrated components of the control system 50 are provided.

[0086] Referring again to Fig. 9, elements shown in dashed-line boxes, which are not required to be part of the printing system 200 in every implementation and configuration. These include:

[0087] A source 250 of curing radiation, e.g., an emitter of actinic radiation. A single-nozzle ink source 280, e.g., a micro-jetting device for aspects of lens production, including without limitation coatings or bottom and top layers 31, 39 that do not require drops as small as those available from an inkjet printing head 210.

[0088] An energy treatment apparatus 285, e.g., for applying an energy treatment to change the surface energy of the first major surface 81 of the deposition substrate 38. Examples of suitable energy treatments can include, and not exhaustively: a corona treatment, a plasma treatment, an electron beam treatment, an electromagnetic (e.g., actinic) radiation treatment, and an electrical discharge treatment.

[0089] A coater such as, for example, a spin coater or dip coater, for applying a coating to either or both of the two major surfaces 81, 82 of the deposition substrate 38 at any time before and / or after the deposition of the printing layers 35. Examples of suitable coatings can include, and not exhaustively: a protective coating such as a hard coat, a tintable hard coat, and a tinted hard coat, and a functional coating such as a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating. In some embodiments, one or more of the coatings is applied by the inkjet printing head 210. A coater can also be used, in embodiments, for applying at least one primer layer 45.

[0090] The skilled artisan will understand that the printing system 200 may additionally include any number of additional elements necessary for carrying out the embodiments but not shown in Fig. 9, including, and not exhaustively, housings, electrical systems and equipment, internal and external material supply and transport systems and equipment, cleaning stations and equipment, and quality control stations and equipment.

[0091] Referring now to Fig. 10, a method is disclosed for optically enhancing a deposition substrate 38 to produce an ophthalmic lens 100. As illustrated by the flow chart in Fig. 10, the method comprises at least the four steps SOI, S02, S03 and S04.

[0092] Step SOI includes: receiving the deposition substrate 38, the deposition substrate 38 comprising a first major surface 81 having a non-planar shape.

[0093] Step S02 includes: defining a printing volume bounded by a target surface shape and the non-planar shape of the first major surface 81. In some embodiments, the defining of the printing volume includes calculating a respective vertical distance Az for each (x,y) point in a two-dimensional projection of the printing volume, and the dividing of the printing volume into the set of printing layers includes dividing the respective vertical distance Az for each (x,y) point into a corresponding height at the (x,y) point for each printing layer.

[0094] Step S03 includes: dividing the printing volume 75 into a set of printing layers 35, a majority of the printing layers 35 having respective non-planar three-dimensional target shapes.

[0095] Step S04 includes: sequentially depositing the printing layers 35, by an inkjet printing head 210, onto the first major surface 81 so as to form the target surface shape 83, the deposited printing layers 35 comprising drops of a curable ink 7. In some embodiments, the sequential depositing of the printing layers 35 includes translating the three-dimensional target shapes to respective two-dimensional projections thereof and releasing drops of the curable ink 7 in accordance with the two-dimensional projections.

[0096] In some embodiments, active nozzles of the inkjet printing head 210 are arranged in a horizontal plane.

[0097] In some embodiments, the inkjet printing head 210 is not configured to move vertically during the sequential depositing.

[0098] In some embodiments, the sequential depositing of the printing layers 35 does not include moving the inkjet printhead 210 vertically during operation.

[0099] In some embodiments, not all of the steps of the method are carried out.

[0100] Referring now to Fig. 11 A, a method is disclosed for optically enhancing a deposition substrate 38 to produce an ophthalmic lens 100. As illustrated by the flow chart in Fig. 11, the method comprises at least the five steps Sil, S12, S13, S14 and S16, and optionally comprises Step S15., i.e., comprises Step S15 in some implementations.

[0101] Step Sil includes: receiving the deposition substrate 38, the deposition substrate 38 comprising a first major surface 81 having a non-planar shape.

[0102] Step S12 includes: defining a printing volume bounded by a target surface shape and the non-planar shape of the first major surface 81.

[0103] Step S13 includes: dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates.

[0104] Step S14 includes: sequentially depositing the printing layers, by an inkjet printing head 210, onto the first major surface 81 of the deposition substrate 38 to form the target surface shape, the deposited printing layers 35 comprising drops of the curable ink 7.

[0105] Step S15 includes: depositing, before the deposition of the printing layers 35, at least one primer layer 45 having a different composition than the curable ink 7. In some embodiments, Step S15 is optional. In some embodiments, Step S15 is not carried out., Step S16 includes: depositing, before the deposition of the printing layers 35, at least one bottom layer 31 comprising drops of the curable ink 7.

[0106] In some embodiments, as illustrated in the flowchart of Fig 1 IB, the method additionally comprises Step S17. Step S17 includes: depositing, after the deposition of the printing layers 35, at least one top layer 39 comprising drops of the curable ink 7. In some embodiments, the at least one bottom layer 31 and at least one top layer 39 combining to encapsulate the deposited printing layers 35.

[0107] In some embodiments, the top and bottom layers 31, 39 neither increase nor decrease an optical power of the ophthalmic lens 100. In some embodiments, the top and bottom layers 31, 39 increase or decrease an optical power of the ophthalmic lens by no more than 0.1 diopter, or by no more than 0.2 diopter, or by no more than 0.3 diopter.

[0108] According to embodiments, an improvement of one or more optical properties can be achieved by controlling the deposition order of layers 35, by modifying a distribution of drop locations within a layer, and / or by manipulating drop-layer assignments - all of which are elements of a slicing / printing policy. In some embodiments, an improvement in optical quality or in an optical property can be based on an optimization of one or more slicing / printing policy elements.

[0109] Referring now to Fig. 12A, a method is disclosed for optically enhancing a deposition substrate 38 to produce an ophthalmic lens 100. As illustrated by the flow chart in Fig. 11, the method comprises at least the five steps S21, S22, S23, S24 and S25.

[0110] Step S21 includes: receiving the deposition substrate 38, the deposition substrate 38 comprising a first major surface 81 having a non-planar shape.

[0111] Step S22 includes: defining a printing volume bounded by a target surface shape and the non-planar shape of the first major surface 81.

[0112] Step S23 includes: dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates. Step S24 includes: depositing at least one bottom layer 31 comprising drops of the curable ink 7.

[0113] Step S25 includes sequentially depositing the printing layers, by an inkjet printing head 210, onto the first major surface 81 of the deposition substrate 38, in a sequence that is ordered differently than the set of vertically ordered printing layers, the deposited printing layers comprising drops of the curable ink. In some embodiments, the depositing sequence is ordered in a reverse order relative to the set of vertically ordered printing layers. In some embodiments, the depositing sequence is a substantially randomized sequence. An example of an ophthalmic lens 100 produced by the foregoing steps is that illustrated schematically in Figs. 6A and 6C.

[0114] In some embodiments, the top and bottom layers 31, 39 neither increase nor decrease an optical power of the ophthalmic lens 100. In some embodiments, the top and bottom layers 31, 39 increase or decrease an optical power of the ophthalmic lens by no more than 0.1 diopter, or by no more than 0.2 diopter, or by no more than 0.3 diopter.

[0115] In some embodiments, as illustrated in the flowchart of Fig 12B, the method additionally comprises Step S26. Step S26 includes: depositing, after the deposition of the printing layers 35, at least one top layer 39 comprising drops of the curable ink 7. An example of an ophthalmic lens 100 produced by the instant method including Step S26 is that illustrated schematically in Fig. 7A.

[0116] In some embodiments, the at least one bottom layer 31 and at least one top layer 39 combining to encapsulate the deposited printing layers 35, as illustrated schematically, for example, in Fig. 7B.

[0117] In some embodiments, not all of the steps of the method are carried out. The steps of any of the methods disclosed herein may be combined in any way, according to the scope of the embodiments.

[0118] The scope of the present disclosure includes, without limitation, the following exemplary inventive concepts:

[0119] Inventive concept 1. A printing system for optically enhancing a deposition substrate to produce an ophthalmic lens, the system comprising: (a) a deposition-substrate receptacle; (b) an inkjet printing head operable, in a first operating mode in which a deposition substrate has been received in or upon the deposition-substrate receptacle, to deposit drops of a curable ink onto a first major surface of the deposition substrate; and (c) a computerized control system configured to regulate operation of the inkjet printing head, wherein the control system is programmed or programmable to carry out the following steps: (i) defining a printing volume bounded by a target surface shape and a non-planar shape of a first major surface of the deposition substrate, (ii) dividing the printing volume into a set of vertically ordered printing layers, a majority of the printing layers having respective non-planar three-dimensional target shapes, and (iii) when in the first operating mode, causing the inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape, the deposited printing layers comprising drops of the curable ink.

[0120] Inventive concept 2. The printing system of Inventive Concept 1, wherein the causing includes translating the three-dimensional target shapes to respective two-dimensional projections thereof and releasing drops of the curable ink in accordance with the two-dimensional projections.

[0121] Inventive concept 3. The printing system of either one of Inventive Concepts 1 or 2, wherein active nozzles of the inkjet printing head are arranged in a horizontal plane.

[0122] Inventive concept 4. The printing system of any one of Inventive Concepts 1 to 3, wherein the inkjet printing head is not configured to move vertically with respect to the receptacle during the sequential depositing.

[0123] Inventive concept 5. The printing system of any one of Inventive Concepts 1 to 3, wherein the control system is not programmed to move the inkjet printing head vertically with respect to the receptacle during the sequential depositing.

[0124] Inventive concept 6. The printing system of any one of Inventive Concepts 1 to 5, wherein the defining of the printing volume includes calculating a respective vertical distance Az for each (x,y) point in a two-dimensional projection of the printing volume, and the dividing of the printing volume into the set of printing layers includes dividing the respective vertical distance Az for each (x,y) point into a corresponding height at the (x,y) point for each printing layer.

[0125] Inventive concept 7. A method of optically enhancing a deposition substrate to produce an ophthalmic lens using the printing system of any one of Inventive Concepts 1 to 6, the method comprising: (a) receiving the deposition substrate; (b) defining the printing volume; (c) dividing the printing volume into the set of vertically ordered printing layers such that a majority of the printing layers have respective non-planar three-dimensional target shapes; and d. using drops of the curable ink, sequentially depositing the printing layers onto the first major surface of the deposition substrate so as to form the target surface shape.

[0126] Inventive concept 8. A method of optically enhancing a deposition substrate to produce an ophthalmic lens, the method comprising: (a) receiving the deposition substrate in or upon a deposition-substrate receptacle, the deposition surface comprising a first major surface having a non-planar shape; (b) defining a printing volume bounded by a target surface shape and the non-planar shape of the first major surface; (c) dividing the printing volume into a set of vertically ordered printing layers, a majority of the printing layers having respective non-planar three-dimensional target shapes; and (d) causing an inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape, the deposited printing layers comprising drops of a curable ink, the defining and dividing and causing being carried out by a control system.

[0127] Inventive concept 9. The method of Inventive Concept 8, wherein the sequential depositing of the printing layers includes translating the three-dimensional target shapes to respective two-dimensional projections thereof and releasing drops of the curable ink in accordance with the two-dimensional projections.

[0128] Inventive concept 10. The method of either one of Inventive Concepts 8 or 9, wherein the drops of the curable ink are active nozzles of the inkjet printing head are arranged in a horizontal plane.

[0129] Inventive concept 11. The method of any one of Inventive Concepts 8 to 10, wherein the inkjet printing head is not configured to move vertically during the sequentially depositing.

[0130] Inventive concept 12. The method of any one of Inventive Concepts 8 to 11, wherein the sequentially depositing of the printing layers does not include moving the inkjet printhead vertically during operation.

[0131] Inventive concept 13. The method of any one of Inventive Concepts 8 to 12, wherein the defining of the printing volume includes calculating a respective vertical distance Az for each (x,y) point in a two-dimensional projection of the printing volume, and the dividing of the printing volume into the set of printing layers includes dividing the respective vertical distance Az for each (x,y) point into a corresponding height at the (x,y) point for each printing layer.

[0132] Inventive concept 14. A method of optically enhancing a deposition substrate to produce an ophthalmic lens, the method comprising: (a) receiving the deposition substrate, the deposition substrate comprising a first major surface having a non-planar shape; (b) defining a printing volume bounded by a target surface shape and the non-planar shape of the first major surface; (c) dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates; and (d) causing an inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape, the deposited printing layers comprising drops of the curable ink, the method additionally comprising: (i) depositing, before the deposition of the printing layers, at least one bottom layer comprising drops of the curable ink, and (ii) optionally depositing, before the deposition of the at least one bottom layer, at least one primer layer having a different composition than the curable ink, wherein at least the defining, dividing and causing are carried out by a control system.

[0133] Inventive concept 15. The method of Inventive Concept 14, additionally comprising: applying a surface energy treatment to the deposition substrate, the surface energy treatment comprising at least one of a corona treatment, a plasma treatment, an electron beam treatment, an electromagnetic (e.g., actinic) radiation treatment, and an electrical discharge treatment.

[0134] Inventive concept 16. The method of any one of Inventive Concepts 13 to 15, additionally comprising: depositing, after the deposition of the printing layers, at least one top layer comprising drops of the curable ink.

[0135] Inventive concept 17. The method of Inventive Concept 16, wherein the at least one top layer has a footprint larger than a two-dimensional projection of the printing volume.

[0136] Inventive concept 18. The method of either one of Inventive Concepts 16 or 17, wherein the at least one bottom layer and at least one top layer combine to encapsulate the deposited printing layers. Inventive concept 19. The method of any one of Inventive Concepts 16 to 18, wherein the top and bottom layers neither increase nor decrease an optical power of the ophthalmic lens.

[0137] Inventive concept 20. The method of any one of Inventive Concepts 16 to 18, wherein the top and bottom layers increase or decrease an optical power of the ophthalmic lens by no more than 0.1 diopter.

[0138] Inventive concept 21. The method of any one of Inventive Concepts 16 to 18, wherein the top and bottom layers increase or decrease an optical power of the ophthalmic lens by no more than 0.2 diopter.

[0139] Inventive concept 22. The method of any one of Inventive Concepts 16 to 18, wherein the top and bottom layers increase or decrease an optical power of the ophthalmic lens by no more than 0.3 diopter.

[0140] Inventive concept 23. The method of any one of Inventive Concepts 14 to 22, wherein the at least one bottom layer has a maximum dimension at least 2 mm greater than a corresponding dimension of a two-dimensional projection of the printing volume.

[0141] Inventive concept 24. The method of any one of Inventive Concepts 14 to 22, wherein the at least one bottom layer has a maximum dimension at least 5 mm greater than a corresponding dimension of a two-dimensional projection of the printing volume.

[0142] Inventive concept 25. The method of any one of Inventive Concepts 14 to 22, wherein the at least one bottom layer has a maximum dimension at least 10 mm greater than a corresponding dimension of a two-dimensional projection of the printing volume.

[0143] Inventive concept 26. The method of any one of Inventive Concepts 14 to 25, wherein the at least one bottom layer has a maximum combined thickness between 10 and 60 microns.

[0144] Inventive concept 27. The method of any one of Inventive Concepts 14 to 25, wherein the at least one bottom layer has a maximum combined thickness between 20 and 50 microns.

[0145] Inventive concept 28. A printing system for optically enhancing a deposition substrate to produce an ophthalmic lens, the system comprising: (a) a deposition-substrate receptacle; (b) an inkjet printing head operable, in a first operating mode in which a deposition substrate has been received in or upon the deposition-substrate receptacle, to deposit drops of a curable ink onto a first major surface of the deposition substrate; and (c) a computerized control system configured to regulate operation of the inkjet printing head, wherein the control system is programmed or programmable to carry out the following steps: (i) defining a printing volume bounded by a target surface shape and a non-planar shape of the first major surface, (ii) dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates, and (iii) when in the first operating mode, causing the inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape, the deposited printing layers comprising drops of the curable ink, wherein the control system is further programmed or programmable to cause the inkjet printing head to deposit, before the sequential depositing of the printing layers and when in the first operating mode, at least one bottom layer comprising drops of the curable ink, and wherein the control system is optionally programmed or programmable to cause, before the depositing of the one or more bottom layers and when in the first operating mode, application of a primer layer to the first major surface of the deposition substrate.

[0146] Inventive concept 29. The printing system of Inventive Concept 28, wherein the control system is programmed or programmable to cause the inkjet printing head to deposit, when in a second operating mode in which the optically enhanced deposition substrate remains in or upon the deposition-substrate receptacle and after the sequential depositing of the printing layers, at least one top layer comprising drops of the curable ink, the depositing of the at least one top layer being such that the at least one top layer has a footprint larger than a two-dimensional projection of the printing volume.

[0147] Inventive concept 30. The printing system of Inventive Concept 29, wherein the top and bottom layers neither increase nor decrease an optical power of the ophthalmic lens.

[0148] Inventive concept 31. The printing system of Inventive Concept 29, wherein the top and bottom layers increase or decrease an optical power of the ophthalmic lens by no more than 0.1 diopter.

[0149] Inventive concept 32. The printing system of Inventive Concept 29, wherein the top and bottom layers increase or decrease an optical power of the ophthalmic lens by no more than 0.2 diopter. Inventive concept 33. The printing system of Inventive Concept 29, wherein the top and bottom layers increase or decrease an optical power of the ophthalmic lens by no more than 0.3 diopter.

[0150] Inventive concept 34. A method of optically enhancing a deposition substrate to produce an ophthalmic lens using the printing system of any one of Inventive Concepts 28 to 33, the method comprising: (a) receiving the deposition substrate; (b) defining the printing volume; (c) dividing the printing volume into the set of vertically ordered printing layers; (d) depositing the at least one bottom layer; and (e). after the depositing of the at least one bottom layer, sequentially depositing the printing layers onto the first major surface of the deposition substrate so as to form the target surface shape.

[0151] Inventive concept 35. The method of Inventive Concept 34, additionally comprising, after the sequential depositing of the printing layers, depositing at least one top layer comprising drops of the curable ink, the depositing of the at least one top layer being such that the at least one top layer has a footprint larger than a two-dimensional projection of the printing volume, ands the at least one bottom layer and at least one top layer combine to encapsulate the deposited printing layers.

[0152] Inventive concept 36. A method of optically enhancing a deposition substrate to produce an ophthalmic lens, the method comprising: (a) receiving the deposition substrate, the deposition substrate comprising a first major surface having a non-planar shape; (b) defining a printing volume bounded by a target surface shape and the non-planar shape of the first major surface; (c) dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates; (d) depositing at least one bottom layer comprising drops of the curable ink, and (e) after depositing the at least one bottom layer, sequentially depositing the printing layers, by an inkjet printing head, onto the first major surface in a sequence that is ordered differently than the set of vertically ordered printing layers, the deposited printing layers comprising drops of the curable ink.

[0153] Inventive concept 37. The method of Inventive Concept 36, wherein the depositing sequence is ordered in a reverse order relative to the set of vertically ordered printing layers.

[0154] Inventive concept 38. The method of Inventive Concept 36, wherein the depositing sequence is a substantially randomized sequence. Inventive concept 39. The method of any one of Inventive Concepts 36 to 38, wherein the at least one bottom layer has a maximum combined thickness between 10 and 60 microns.

[0155] Inventive concept 40. The method of any one of Inventive Concepts 36 to 39, wherein the at least one bottom layer has a maximum combined thickness between 20 and 50 microns

[0156] Inventive concept 41. The method of any one of Inventive Concepts 36 to 40, additionally comprising: depositing, after the deposition of the printing layers, at least one top layer comprising drops of the curable ink, the at least one bottom layer and at least one top layer combining to encapsulate the deposited printing layers, the at least one top layer having a footprint larger than a two-dimensional projection of the printing volume.

[0157] Inventive concept 42. The method of any one of Inventive Concepts 36 to 41, wherein the top and bottom layers neither increase nor decrease an optical power of the ophthalmic lens.

[0158] Inventive concept 43. An ophthalmic lens, comprising, in the following physical sequence: (a) a first layer, having a minimum thickness of at least 500 microns and a convex major surface; (b) a second layer, having a maximum thickness between 20 and 100 microns; and (c) a plurality of at least partly overlapping layers each having a maximum thickness between 1 and 10 microns, a portion of each partly overlapping layer being in contact with the second layer.

[0159] Inventive concept 44. The ophthalmic lens of Inventive Concept 43, in which the ray of light passes through the plurality of at least partly overlapping layers such that a distal layer of the plurality of at least partly overlapping layers has a larger footprint than a proximal layer of the plurality of at least partly overlapping layers.

[0160] Inventive concept 45. The ophthalmic lens of either one of Inventive Concepts 43 or 44, wherein the first layer neither increases nor decreases an optical power of the ophthalmic lens.

[0161] Inventive concept 46. The ophthalmic lens of any one of Inventive Concepts 43 to 45, wherein the second layer neither increases nor decreases an optical power of the ophthalmic lens. Inventive concept 47. The ophthalmic lens of any one of Inventive Concepts 43 to 46, wherein the first layer has a base curvature of at least 2 diopter.

[0162] Inventive concept 48. The ophthalmic lens of any one of Inventive Concepts 43 to 47, wherein the first layer has a base curvature of no more than 12 diopter.

[0163] Inventive concept 49. The ophthalmic lens of any one of Inventive Concepts 43 to 48, wherein none of the at least partly overlapping layers are in contact with the first layer.

[0164] Inventive concept 50. The ophthalmic lens of any one of Inventive Concepts 43 to 49, wherein the second layer and the plurality of at least partly overlapping layers comprise a first composition, and the first layer comprises a second composition which is not the first composition.

[0165] Inventive concept 51. The ophthalmic lens of any one of Inventive Concepts 43 to 49, additionally comprising a distal layer in contact with one or more of the plurality of at least partly overlapping layers and having a footprint larger than a cumulative footprint of the plurality of at least partly overlapping layers.

[0166] Inventive concept 52. The ophthalmic lens of any one of Inventive Concept 51, wherein the distal layer is in contact with the second layer.

[0167] Inventive concept 53. The ophthalmic lens of either one of Inventive Concepts 51 or 52, wherein the distal layer and the second layer combine to encapsulate the plurality of at least partly overlapping layers.

[0168] Inventive concept 54. The printing system of any one of Inventive Concepts 1 to 6 or 28 to 33, wherein the deposition-substrate receptacle is dimensioned and adapted to receive an eyeglass lens or lens blank.

[0169] Inventive concept 55. The printing system of any one of Inventive Concepts 1 to 6, 28 to 33, or 54, the system further including the deposition substrate.

[0170] Inventive concept 56. The printing system of Inventive Concepts 1 to 6, 28 to 33, or 54 to 55, wherein the deposition substrate is an or the eyeglass lens or lens blank.

[0171] Inventive concept 57. The printing system of any one of Inventive Concepts 1 to 6, 28 to 33, or 54 to 56, wherein the first major surface is a curved surface.

[0172] The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons skilled in the art to which the invention pertains.

Claims

WHAT IS CLAIMED IS:

1. A printing system for optically enhancing a deposition substrate to produce an ophthalmic lens, the system comprising:a. a deposition-substrate receptacle;b. an inkjet printing head operable, in a first operating mode in which a deposition substrate has been received in or upon the deposition-substrate receptacle, to deposit drops of a curable ink onto a first major surface of the deposition substrate; andc. a computerized control system configured to regulate operation of the inkjet printing head,wherein the control system is programmed or programmable to carry out the following steps:i. defining a printing volume bounded by a target surface shape and a non-planar shape of the first major surface, ii. dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates, andiii. when in the first operating mode, causing the inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape, the deposited printing layers comprising drops of the curable ink, wherein the control system is further programmed or programmable to cause the inkjet printing head to deposit, before the sequential depositing of the printing layers and when in the first operating mode, at least one bottom layer comprising drops of the curable ink, andwherein the control system is optionally programmed or programmable to cause, before the depositing of the one or more bottom layers and when in the first operating mode, application of a primer layer to the first major surface of the deposition substrate.

2. The printing system of claim 1, wherein the control system is programmed or programmable to cause the inkjet printing head to deposit, when in a second operating mode in which the optically enhanced deposition substrate remains in orupon the deposition-substrate receptacle and after the sequential depositing of the printing layers, at least one top layer comprising drops of the curable ink, the depositing of the at least one top layer being such that the at least one top layer has a footprint larger than a two-dimensional projection of the printing volume.

3. The printing system of claim 2, wherein the top and bottom layers neither increase nor decrease an optical power of the ophthalmic lens.

4. A method of optically enhancing a deposition substrate to produce an ophthalmic lens using the printing system of any one of claims 1 to 3, the method comprising:a. receiving the deposition substrate;b. defining the printing volume;c. dividing the printing volume into the set of vertically ordered printing layers;d. depositing the at least one bottom layer; ande. after the depositing of the at least one bottom layer, sequentially depositing the printing layers onto the first major surface of the deposition substrate so as to form the target surface shape.

5. A method of optically enhancing a deposition substrate to produce an ophthalmic lens, the method comprising:a. receiving the deposition substrate, the deposition substrate comprising a first major surface having a non-planar shape;b. defining a printing volume bounded by a target surface shape and the non- planar shape of the first major surface;c. dividing the printing volume into a set of vertically ordered printing layers, each printing layer defining a set of drop locations having respective x-y coordinates; andd. causing an inkjet printing head to sequentially deposit the printing layers onto the first major surface of the deposition substrate to form the target surface shape, the deposited printing layers comprising drops of the curable ink,the method additionally comprising:i. depositing, before the deposition of the printing layers, at least one bottom layer comprising drops of the curable ink, andii. optionally depositing, before the deposition of the at least one bottom layer, at least one primer layer having a different composition than the curable inkwherein at least the defining, dividing and causing are carried out by a control system.

6. The method of claim 5, additionally comprising: applying a surface energy treatment to the deposition substrate, the surface energy treatment comprising at least one of a corona treatment, a plasma treatment, an electron beam treatment, an electromagnetic (e.g., actinic) radiation treatment, and an electrical discharge treatment.

7. The method of either one of claims 5 or 6, additionally comprising: depositing, after the deposition of the printing layers, at least one top layer comprising drops of the curable ink.

8. The method of claim 7, wherein the at least one top layer has a footprint larger than a two-dimensional projection of the printing volume.

9. The method of either one of claims 7 or 8, wherein the at least one bottom layer and at least one top layer combine to encapsulate the deposited printing layers.

10. An ophthalmic lens, comprising, and physically ordered in the following sequence from proximal to distal:a. a first layer, having a minimum thickness of least 500 microns and a convex major surface;b. a second layer, having a maximum thickness between 20 and 100 microns;andc. a plurality of at least partly overlapping layers each having a maximum thickness between 1 and 10 microns, a portion of each partly overlapping layer being in contact with the second layer.

11. The ophthalmic lens of claim 10, wherein a more distal layer of the plurality of at least partly overlapping layers has a larger footprint than a more proximal layer of the plurality of at least partly overlapping layers.

12. The ophthalmic lens of either one of claims 10 or 11, wherein none of the at least partly overlapping layers are in contact with the first layer.

13. The ophthalmic lens of any one of claims 10 to 12, wherein the second layer and the plurality of at least partly overlapping layers comprise a first composition, and the first layer comprises a second composition which is not the first composition.

14. The ophthalmic lens of any one of claims 10 to 13, additionally comprising a distal-most layer having a maximum thickness between 10 and 100 microns and having a footprint larger than a cumulative footprint of the plurality of at least partly overlapping layers.

15. The ophthalmic lens of any one of claim 14, wherein the distal-most layer is in contact with the second layer.

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