Ophthalmic Lens Gap Formed by Particles for Aberration Correction
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Solution Overview
Problem
Existing ophthalmic lenses are ineffective in correcting high order aberrations, which significantly degrade image quality, and current methods for manufacturing wavefront aberrators are not efficient in reducing these aberrations.
Innovation Solution
The creation of a gap between two lens materials using particles, allowing for the injection and curing of a curable resin with a variable refractive index, which can correct high order aberrations by forming a refractive index profile across the lens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a monomer layer is used to create wavefront aberrators through controlled curing, then high order aberrations can be corrected, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The lens system is divided into multiple segments: base lens, cap lens, and a gap layer containing curable resin. This segmentation allows the wavefront correction function to be separated from the primary lens structures, enabling independent optimization of each component and simplifying the overall manufacturing process while maintaining high order aberration correction capability
Solution Approach 2:
The gap between base and cap lenses is pre-formed at a controlled size (less than 1 millimeter) using particles adhered to lens surfaces before the curable resin is injected. This preliminary structuring of the gap eliminates the need for complex post-manufacturing adjustments and streamlines the subsequent resin injection and curing processes
2Manufacturing precision
If particles are adhered to lens surfaces to form a gap, then a controlled gap for resin injection is achieved, but the manufacturing steps increase
Solution Approach 1:
The gap-forming particles are integrated into an adhesive composition that simultaneously performs two functions: forming the precise gap structure and bonding the base lens to the cap lens. This merging of gap formation and lens assembly operations reduces the total number of manufacturing steps while maintaining precise gap control
Solution Approach 2:
The adhesive composition containing particles serves multiple purposes: it acts as a bonding agent to join the lenses, a spacer to maintain the precise gap distance, and a template for the subsequent curable resin injection. This multi-functionality eliminates the need for separate components or operations for each function, simplifying the overall manufacturing process
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
This method effectively corrects high order vision aberrations by forming a refractive index profile across the lens, improving image quality and addressing the limitations of existing ophthalmic lens manufacturing techniques.
Implementation Method 1
A curable resin is then injected into the gap and then cured to have either a specific or a variable index of refraction
Data Source
AI summary
The present invention provides an ophthalmic lens comprised of two lens materials with a gap between them of less than about 5 mm. The gap is formed and maintained by particles on the perimeter of the surfaces of both lens materials. Methods are also provided for creating a gap between two lens materials and for producing an ophthalmic lens with a gap between two lens materials.