Method of creating ophthalmic lenses using modulated energy

• US 20070023942A1
• Filed: 10/19/2005
• Published: 02/01/2007
• Est. Priority Date: 07/30/2004
• Status: Active Grant

• Current Assignee: Alcon Incorporated
• Original Assignee: Novartis Ag
• Inventors: Domschke, Angelika, Morgan, Courtney, Andino, Rafael, Lindacher, Joseph
• Granted Patent: US 8,454,862 B2
• Time in Patent Office: Days
• US Class Current: 264/1.320
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 35/0894 provided with masks or diaphragms
• CPC Class Codes: B29D 11/00134 Curing of the contact lens material
• CPC Class Codes: B29D 11/00355 with a refractive index gradient
• CPC Class Codes: B29D 11/00442 Curing the lens material
• CPC Class Codes: B29K 2105/243 Partially cured
• CPC Class Codes: B29L 2011/0016 Lenses
• CPC Class Codes: B29L 2011/0033 Multifocal lenses
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

This invention is related to lenses and the associated processes used to manufacture lenses. In particular, the present invention is related to a process for designing and creating bifocal, multifocal, and single vision ophthalmic lenses by modulating an energy source.

Claims

1. A method for making an ophthalmic lens comprising

Providing a fluid optical material;

Providing a mold;

Injecting said fluid optical material into said mold;

Exposing said mold and fluid optical material to an energy source; and

modulating said energy source to create at least one index of refraction in the optical zone of the lens.

2. The method of claim 1, wherein said energy source is selected from the group consisting of UV light.

3. The method of claim 1 and wherein said modulating step source further comprises varying light intensity according to an illumination scheme.

4. The method of claim 3, wherein said variation is accomplished by creating a gray-scale mask.

5. The method of claim 4, wherein said gray scale mask is created using stereo lithography.

6. The method of claim 4 wherein said gray scale mask is created by a computer-generated hologram.

7. The method of claim 4 wherein said gray scale mask masks said energy source in an illumination scheme, wherein said scheme corresponds to a desired lens geometry.

8. The method of claim 7, wherein said desired lens geometry has more than one optical zone.

9. The method of claim 1, wherein said exposing step further comprises curing said fluid optical material into a lens.

10. The method of claim claim 1 wherein said ophthalmic lens is selected from the group consisting of:

a bifocal lens, a multifocal lens, a toric lens, a customized lens and a single vision lens.

11. The method of claim 1, wherein said ophthalmic lens is designed to correct one or more of the following defects:

myopia, hypermetropia, presbyopia, defocus, and astigmatism.

12. The method of claim 1, wherein said fluid optical material comprises a prepolymer and a photoinitiator.

13. The method of claim 12, wherein said fluid optical material further comprises a sensitizer.

14. The method of claims 12, wherein said fluid optical material comprises an additive.

15. The method of claim 12, wherein said fluid optical material comprises NaCl.

16. The method of claim 3, wherein said varying light intensity further comprises providing a uniform light source in optical connection with a DMD.

17. The method of claim 16 wherein said DMD is in optical connection with said fluid optical material.

18. The method of claim 17, wherein one or more MEMS devices drives one or more DMDs.

19. The method of claim 3, wherein said illumination scheme corresponds to a desired lens geometry.