Functional Layer Molding for DIMS Lenses With Microlenses
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Solution Overview
Problem
Existing lenses with microlenses or lenslets for treating myopia and inhibiting ametropia face challenges in efficiently incorporating functional layers such as photochromic or polarized layers without compromising the lens's performance or causing defects.
Innovation Solution
A method involving laminate technology and injection molding is used to add functional layers to lenses with microlenses, optimizing parameters like mold temperature, pack plastic pressure, and cooling time to ensure the same performance as clear DIMS lenses, while incorporating features like photochromic or polarized functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If injection molding is used to add functional layers to DIMS lenses, then photochromic or polarized functionality is achieved, but molding defects may occur and refractive performance may deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing front mold temperature (increased to 285-292°F), injection speed (decreased to 0.1 inches per second), pack plastic pressures (multiple iterations with specific PSI ranges and durations), and cooling time (240-260 seconds) to successfully integrate functional layers into DIMS lenses while maintaining microlens integrity and refractive performance
2Manufacturing precision
If multiple pack plastic pressures are applied sequentially, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The patent implements periodic action through multiple sequential pack plastic pressure iterations with specific durations (first iteration: 8-12 seconds at 1250-1750 PSI, second iteration: 13-17 seconds at 3250-3750 PSI, third iteration: 38-42 seconds at 8250-8750 PSI), allowing the molten polycarbonate to progressively conform to microlens features at different stages of filling and cooling
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method allows for the efficient addition of functional layers to lenses, maintaining the same performance characteristics as clear DIMS lenses, reducing defects, and enhancing the lenses with properties like photochromism or polarization.
Implementation Method 1
a photochromic functional layer may be desirable on certain lenses to allow the lenses to darken on exposure to light
Implementation Method 2
a polarized functional layer may be desirable on certain lenses to filter light, protect against ultraviolet rays, and minimize glare
Implementation Method 3
The first refraction area may have a first refraction force based on a prescription for correcting ametropia of the eyes. The second refraction area may have a refraction force different from the first refraction force so as to focus images on the positions except the retina of the eyes
Data Source
AI summary
Systems and methods for adding a functional layer to a lens having a plurality of microlenses for inhibition of ametropia. The lens may include defocus incorporated multiple segments (DIMS) having a plurality of microlenses or lenslets producing refraction areas with different refraction forces. Injection molding may be utilized to add a functional layer to such a DIMS lens having a plurality of microlenses or lenslets. The functional layer may add a functional utility to the lens, including but not limited to photochromic functionality, polarization functionality, and the like.