3D Printed Spectacle Lens with Location-Dependent Refractive Index

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Solution Overview

Problem

Conventional spectacle lenses rely solely on the interplay of optically active surfaces for dioptric power, limiting design flexibility and production efficiency, particularly in achieving complex optical corrections like multifocality.

Innovation Solution

A spectacle lens comprising components A, B, and C, where A includes an ultrathin lens or functional layer, B features a polymeric material with a location-dependent refractive index, and C has a functional layer or ultrathin lens, produced using a 3D printing process involving UV-curable inks and subsequent curing, machining, and bonding to achieve desired optical corrections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional spectacle lenses rely solely on the interplay of optically active surfaces for dioptric power, then the production process is simple, but design flexibility and ability to achieve complex optical corrections is limited

Engineering Contradiction:

Improvedesign flexibilityVSAvoidproduction process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent introduces a polymeric material component with location-dependent refractive index distribution within the spectacle lens. This allows different regions of the lens to have different optical properties, enabling complex optical corrections such as multifocality without requiring complex surface geometries. The local variation in refractive index provides design flexibility while maintaining a relatively simple production process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The spectacle lens is constructed as a composite structure combining a polymeric material with location-dependent refractive index and ultrathin lens components. This composite approach enables the integration of multiple optical functions within a single lens structure, achieving complex optical corrections while simplifying the overall production process compared to traditional multi-component assemblies.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If conventional spectacle lenses rely solely on the interplay of optically active surfaces for dioptric power, then the manufacturing process is efficient, but ability to achieve complex optical corrections like multifocality is limited

Engineering Contradiction:

Improveoptical correction capabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent changes the refractive index parameter of the polymeric material to create location-dependent optical properties. By varying the refractive index throughout the lens volume rather than relying solely on surface geometry, the lens can achieve complex optical corrections such as multifocality. This parameter change enables enhanced optical correction capability while maintaining manufacturing efficiency through additive or injection molding processes.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If spectacle lenses are produced by mechanically abrasive machining of spectacle lens blanks, then the process is well-established, but neither the front face nor the reverse face already corresponds to the ultimate optically effective target faces

Engineering Contradiction:

Improveoptical face precisionVSAvoidproduction simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent incorporates the final optical face geometries directly into the lens during the initial forming process using polymeric material with location-dependent refractive index. This preliminary action eliminates the need for subsequent mechanically abrasive machining to achieve the ultimate optically effective target faces. The optical faces are precision-formed in advance, maintaining manufacturing precision while simplifying the overall production process.

Inventive Principle:

Principle #10Preliminary action

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 creation of spectacle lenses with customizable dioptric power distributions and complex optical corrections, such as multifocality, through precise control of refractive index and surface topography, enhancing optical performance and manufacturing efficiency.

Implementation Method 1

B features a polymeric material with a location-dependent refractive index

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

produced using a 3D printing process involving UV-curable inks and subsequent curing

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11614640B2Spectacle lens and method, in particular 3D printing method, for the production thereof

Publication Date: 2023.03.28 CARL ZEISS VISION INTERNATIONAL GMBH

AI summary

A spectacle lens has, starting from the object-sided front surface of the spectacle lens to the opposite rear-side of the spectacle lens, at least a) one component A including at least one functional layer FA and/or an ultrathin glass, b) one component B including at least one polymer material and, c) one component C, including at least one functional layer F and/or an ultrathin glass. A method, in particular a 3D printing method, for producing the spectacle lens is also disclosed.