Optical Substrate Light-Blocking Composition Printing
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Solution Overview
Problem
Existing techniques for applying light-blocking compositions to optical articles, such as ophthalmic lenses, are limited in creating complex patterns and gradients, leading to inferior visibility and lens performance, and result in wastage of expensive materials during lens shaping. Additionally, photochromic materials are sensitive to temperature and have slow rise and decay rates.
Innovation Solution
A method of manufacturing optical articles with optical power gradients and applying photochromic compositions in specific patterns to form light-blocking zones with varying densities, allowing for complex light-blocking patterns and optimizing material usage, while also incorporating temperature-sensitive photochromic materials with controlled decay rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire surface of the lens blank is coated with light-blocking composition during manufacturing, then the lens receives uniform light-blocking protection, but expensive light-blocking composition is wasted on the removed portion of the lens blank
Solution Approach 1:
The patent applies light-blocking composition selectively to specific zones of the lens blank rather than uniformly across the entire surface. The composition is deposited in patterns corresponding to the final lens shape and optical power distribution, ensuring that material is only applied where needed in the finished product.
Solution Approach 2:
The patent performs edgeing (shaping) of the lens blank before applying the light-blocking composition. By pre-shaping the lens to its final form, the coating process only needs to cover the actual lens area, eliminating waste on portions that will be removed anyway.
2Adaptability or versatility
If photochromic materials are used for light-blocking, then the lenses can dynamically adjust to light conditions, but the materials have slow rise and decay rates and are sensitive to temperature
Solution Approach 1:
The patent creates zones with different photochromic composition densities corresponding to different optical power regions. High optical power zones receive higher concentrations of photochromic material, while low optical power zones receive lower concentrations, optimizing performance for each region's specific requirements.
Solution Approach 2:
The patent varies the concentration and distribution parameters of the photochromic composition across different lens zones. By adjusting the amount and density of photochromic material in different regions, the patent optimizes both the adaptation speed and light-blocking effectiveness for each optical zone.
3Ease of manufacture
If existing techniques are used to apply light-blocking compositions, then the application process is simple, but the ability to create complex patterns and gradients is limited
Solution Approach 1:
The patent replaces traditional mechanical coating methods with digital printing technology. This substitution enables precise control over composition deposition, allowing complex patterns, gradients, and variable densities to be created through digital design and automated printing processes rather than manual application.
Solution Approach 2:
The patent utilizes variable parameters in the printing process, including drop size, spacing, density, and composition concentration, to create complex light-blocking patterns. These parameter variations allow the system to produce gradients and non-uniform distributions that match the optical requirements of different lens zones.
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 enables the creation of optical articles with improved visibility and lens performance by optimizing light-blocking patterns and material usage, and addresses temperature sensitivity issues in photochromic materials, resulting in more efficient and effective light-blocking capabilities.
Implementation Method 1
applying a photochromic composition to the optical substrate in a pattern so that, upon exposure to an actinic energy, a first light-blocking zone is formed over the first optical region
Data Source
AI summary
Optical articles and methods of manufacturing the same are disclosed herein. In one aspect, the methods and optical articles formed include light-blocking compositions applied to optical substrates in accordance with the optical properties of the optical substrate. In another aspect, a method is disclosed in which the light-absorbing compositions are printed onto the optical substrate in the shape and size of the final lens that is to be formed from the optical substrate. In another aspect, the methods and optical articles utilize at least two different light-blocking compositions to achieve desired functionality of the optical article.