Electro-active lens seal with index-matched encapsulation

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Solution Overview

Problem

Conventional methods for encapsulating liquid optical materials in ophthalmic lenses result in visible seal rings, compromising structural integrity and the ability to alter the refractive index electronically, making electro-active lenses commercially unviable.

Innovation Solution

An electro-active lens design that uses a solid transparent optical material to encapsulate liquid crystal, with a seal feature that minimizes visibility and maintains structural robustness, allowing for electronic refractive index alteration without disrupting containment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional methods are used to encapsulate liquid optical material, then the lens can be manufactured, but visible seal rings appear compromising cosmetic appearance

Engineering Contradiction:

Improveencapsulation capabilityVSAvoidvisible seal ring

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent applies index matching by selecting a seal material whose refractive index closely matches that of the liquid crystal material (within ±0.05). This causes the seal ring to become optically invisible by eliminating refraction at the interface, resolving the cosmetic appearance problem while maintaining effective sealing.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The patent changes the refractive index parameter of the seal material to match the liquid crystal material. This parameter optimization makes the seal ring invisible while preserving the sealing function, thus resolving the contradiction between manufacturability and cosmetic appearance.

Inventive Principle:

Principle #35Parameter changes

2Strength

If the lens is processed to improve structural integrity, then strength increases, but containment of liquid optical material is disturbed

Engineering Contradiction:

Improvestructural integrityVSAvoidcontainment integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent uses a composite structure where a solid transparent optical material encapsulates the liquid crystal material. The solid material provides structural integrity for processing and handling, while the liquid crystal maintains its containment within the encapsulated volume, allowing both strength and containment integrity to coexist.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs a thin film encapsulation approach where the solid transparent material forms a barrier that maintains liquid crystal containment while allowing the overall lens structure to be processed. The encapsulation layer provides both mechanical strength and containment reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If conventional encapsulation structures are used, then manufacturing is simplified, but the ability to alter refractive index electronically is disrupted

Engineering Contradiction:

Improveencapsulation simplicityVSAvoidelectronic refractive index alteration

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent uses a thin film encapsulation structure that provides mechanical containment while allowing electrical signals to pass through to the liquid crystal material. The thin film approach maintains electronic controllability of the refractive index while preserving manufacturing simplicity.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The solid transparent optical material acts as an intermediary encapsulation layer that provides mechanical containment and structural integrity while being optically and electrically transparent to the liquid crystal material, allowing electronic refractive index modulation to function properly.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution provides a commercially viable electro-active lens with reduced visibility of the seal feature and preserved structural integrity, enabling successful processing and fitting into spectacle frames.

Implementation Method 1

the ability to alter the refractive index of the liquid optical material electronically

Methodology Applied

Scientific EffectElectro-optic effect: Electro-Optic Effects

Data Source

PatentUS8830408B2Electro-active diffractive lens and method for making the same

Publication Date: 2014.09.09 CARL ZEISS VISION INTERNATIONAL GMBH

AI summary

Aspects of the present invention provide an electro-active lens and method for manufacturing the same that encapsulates liquid crystal using solid transparent optical material using an improved liquid crystal seal feature. The seal feature greatly reduces the visibility of the liquid crystal seal feature in an assembled electro-active lens. The seal feature is also structurally robust such that the electro-active lens can be processed to fit a spectacle frame without disturbing containment of the liquid crystal and without disrupting electrical connectivity to the lens used to alter the refractive index of the liquid crystal, thereby ensuring fabrication of a commercially viable electro-active lens.