Hermetically Sealed Cell Optical Elements for Custom Ametropia
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Solution Overview
Problem
Existing methods for producing ophthalmic lenses with varying optical properties are not well-suited for mass production and customization, as they often require re-forming operations that compromise their appeal and adaptability to different spectacle frames or eyes with specific ametropia corrections.
Innovation Solution
A process involving the production of transparent optical elements with hermetically sealed cells containing substances with optical properties, allowing for cutting and customization to fit various frames, while maintaining flexibility and optical functionality, including refractive index variation, light absorption, and polarization properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional methods are used to manufacture ophthalmic lenses with varying refractive indices, then customization for specific ametropia is achieved, but mass production capability is poor and re-forming operations are required
Solution Approach 1:
The lens is divided into multiple zones with different refractive indices, each zone being manufactured separately and then assembled. This allows standardization of the manufacturing process for mass production while maintaining customization capability through selective assembly of different lens zones according to patient needs.
Solution Approach 2:
The invention creates a universal lens manufacturing system that can produce lenses for various ametropia types using the same base process. The standardized lens zones can be combined in different configurations to serve multiple optical correction needs, eliminating the requirement for separate re-forming operations.
2Adaptability or versatility
If ink-jet heads are used to deposit polymer solutions onto lens surfaces to modulate refractive index, then surface-level optical property variation is achieved, but control of physical phenomena makes practice difficult and large-scale use problematic
Solution Approach 1:
The refractive index modulation function is extracted from the lens surface and transferred to separate lens zones. Instead of attempting to control complex physical phenomena during surface deposition, the patent uses simpler zone-based assembly where different refractive indices are pre-established in discrete regions and combined as needed.
Solution Approach 2:
The patent changes the approach from continuous surface modulation to discrete zone-based modulation. By establishing different refractive indices in separate lens zones during manufacturing, the system avoids the need to control complex physical phenomena during final assembly while still achieving the desired optical property variation.
3Speed
If photochromic lenses with liquid or gel dyes are used, then superior speed of reaction to luminosity variations is achieved, but the lens cannot be cut or adapted to different frames
Solution Approach 1:
The photochromic lens is segmented into multiple zones with different photochromic properties. Each zone can be independently optimized for its optical function while the overall lens structure remains cuttable and adaptable to different frames. The segmentation allows the lens to maintain fast photochromic response in each zone while being flexible enough for customization.
4Manufacturing precision
If lenses are manufactured for specific spectacle frames, then optimal optical properties for that frame are achieved, but re-forming operations are required to adapt to different frames or eyes
Solution Approach 1:
The lens design incorporates dynamic configurability through modular zones that can be assembled in different arrangements. This allows the same base lens structure to be adapted to different frames and eye prescriptions without requiring re-forming operations, as the zones can be reconfigured to match specific optical requirements.
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
Enables the production of flexible, modular optical elements that can be adapted to different frames and eyes, offering high fill factors and reduced diffractive effects, thus improving adaptability and image quality without cosmetic defects.
Implementation Method 1
The structure of such a lens incorporates a layer whose light absorption spectrum depends on the light received. The photochromic dye of this layer is usually solid, although it is known that liquids or gels have superior properties
Implementation Method 2
These techniques generally make use of liquid crystals or electrochemical systems
Implementation Method 3
Ametropia-correcting lenses are conventionally manufactured by the forming of a transparent material having a refractive index higher than that of air. The shape of the lenses is chosen so that the refraction at the material/air interfaces causes suitable focussing onto the retina
Implementation Method 4
each cell being hermetically sealed and containing a substance having an optical property
Data Source
AI summary
To produce a transparent optical element, the process starts with the production of an optical component having at least one transparent array of cells that are juxtaposed parallel to one surface of the component, each cell being hermetically sealed and containing a substance having an optical property. This optical component is then cut along a defined contour on its surface, corresponding to a predetermined shape of the optical element. Preferably, the array of cells constitutes a layer having a height of less than 100 μm perpendicular to the surface of the component.