Method of manufacturing an optical lens

Abstract

A method of manufacturing an optical lens that is configured to correct high order aberrations. One embodiment is a method of customizing optical correction in an optical system. The method includes measuring optical aberration data of the optical system. The method further includes calculating a lens definition based on the optical aberration data. Calculating the lens definition may include calculating a correction of at least one high order optical aberration. The method further includes fabricating a correcting lens based on the lens definition.

1 . A method of customizing optical correction in an optical system comprising: 
 measuring optical aberration data of the optical system;    determining, based on the optical aberration data, a lens definition comprising a correction of at least one high order optical aberration; and    fabricating a correcting lens based on the lens definition.    
     
     
         2 . The method of  claim 1 , wherein measuring optical aberration data in the optical system comprises measuring optical parameters of at least one human eye.  
     
     
         3 . The method of  claim 1 , wherein fabricating a correcting lens comprises fabricating a lens configured for use in an optical path of at least one of a camera, a telescope, binoculars, or a microscope.  
     
     
         4 . The method of  claim 1 , wherein fabricating a correcting lens comprises fabricating an eyepiece configured for use in an optical path of at least one of a camera, a telescope, binoculars, or a microscope.  
     
     
         5 . The method of  claim 1 , wherein a correcting lens is fabricated to adjust at least one low order aberration.  
     
     
         6 . The method of  claim 1 , wherein determining a lens definition comprises determining at least one of a low order aberration, a high order aberration, a high order correction zone, a transition zone, a swim zone, a channel, or a blend zone.  
     
     
         7 . The method of  claim 1 , wherein determining the lens definition is based at least in part on at least one of a patient's vertex distance, pupil size, pupil distance, gaze, or x-y tilt.  
     
     
         8 . The method of  claim 1 , wherein the correcting lens is fabricated to adjust at least one high order aberration.  
     
     
         9 . The method of  claim 1 , wherein fabricating a lens correcting lens comprises curing a photosensitive component within said lens.  
     
     
         10 . The method of  claim 1 , wherein fabricating a correcting lens comprises depositing one or more monomers each having a different refractive index in quantities to achieve a pattern of refraction determined by the lens definition.  
     
     
         11 . The method of  claim 1 , wherein fabricating a correcting lens comprises depositing at least one monomer layer having a varying thickness so as to define a pattern of refraction determined by the lens definition.  
     
     
         12 . The method of  claim 1 , wherein fabricating a correcting lens comprises defining a pattern of refraction in a photosensitive gel portion of an optical element.  
     
     
         13 . The method of  claim 1 , wherein fabricating a correcting lens comprises exposing a photosensitive gel portion of an optical element to a pattern of radiation so as to define a pattern of refraction therein.  
     
     
         14 . The method of  claim 1 , wherein fabricating a correcting lens comprises a cast molding process.  
     
     
         15 . The method of  claim 1 , wherein fabricating a correcting lens comprises contouring at least one surface of an optical element.  
     
     
         16 . The method of  claim 15 , wherein the act of contouring comprises grinding the surface.  
     
     
         17 . The method of  claim 16 , wherein the act of contouring comprises polishing the surface.  
     
     
         18 . The method of  claim 15 , wherein the act of contouring comprises freeform shaping the surface.  
     
     
         19 . The method of  claim 15 , wherein the act of contouring comprises laser ablating the surface.  
     
     
         20 . A method of manufacturing a customized lens, the method comprising: 
 measuring optical parameters of an optical system, wherein the optical parameters comprise measured optical aberrations; and    forming a lens having at least one optical element, wherein forming the lens comprises: 
 correcting a portion of the measured optical aberrations in the at least one optical element, wherein the portion comprises at least one low order aberration; and  
 correcting at least one remaining optical aberration in the lens and wherein the at least one remaining optical aberration comprises a high order aberration.  
   
     
     
         21 . The method of  claim 20 , wherein forming the lens further comprises measuring the at least one of the remaining optical aberration.  
     
     
         22 . The method of  claim 20 , wherein measuring optical parameters of the optical system comprises measuring vision parameters of a human eye.  
     
     
         23 . The method of  claim 22 , wherein the vision parameters comprise at least one of the patient's vertex distance, pupil size, pupil distance, frame information, gaze, or x-y tilt.  
     
     
         24 . The method of  claim 20 , wherein measuring optical parameters of the optical system comprises measuring optical parameters of an optical instrument.  
     
     
         25 . The method of  claim 25 , wherein the optical instrument comprises at least one of a microscope, a telescope, binoculars, or a camera.  
     
     
         26 . The method of  claim 20 , further comprising correcting another at least one remaining optical aberration comprising a low order aberration.  
     
     
         27 . The method of  claim 20 , wherein correcting the portion of the measured optical aberrations comprises contouring at least one surface of the at least one optical element.  
     
     
         28 . The method of  claim 27 , wherein the act of contouring comprises grinding the surface.  
     
     
         29 . The method of  claim 28 , wherein the act of contouring comprises polishing the surface.  
     
     
         30 . The method of  claim 27 , wherein the act of contouring comprises freeform shaping the surface  
     
     
         31 . The method of  claim 27 , wherein the act of contouring comprises laser ablating the surface.  
     
     
         32 . The method of  claim 20 , wherein correcting a portion of the measured optical aberrations comprises correcting at least one low order aberration.  
     
     
         33 . The method of  claim 20 , wherein correcting a at least one of the remaining optical aberration comprises correcting at least one high order aberration.  
     
     
         34 . The method of  claim 20 , wherein correcting at least one of the remaining optical aberration comprises correcting at least one low order aberration.  
     
     
         35 . The method of  claim 20 , wherein correcting at least one of the remaining optical aberration comprises correcting at least a portion of the measured optical aberrations.  
     
     
         36 . The method of  claim 20 , wherein correcting at least one of the remaining optical aberrations comprises changing a refractive index in a material sandwiched between optical elements to correct low order aberrations.  
     
     
         37 . The method of  claim 20 , wherein correcting at least one of the remaining optical aberrations comprises changing a refractive index in a material sandwiched between optical elements to correct high order aberrations.  
     
     
         38 . The method of  claim 20 , wherein correcting at least one of the remaining optical aberrations comprises performing controlled deposition of one or more formulations on the at least one optical element and curing of the formulations to correct low order aberrations.  
     
     
         39 . The method of  claim 38 , wherein performing controlled deposition of one or more formulations comprises performing controlled deposition of a layer varying in thickness so as to define the pattern of refraction.  
     
     
         40 . The method of  claim 39 , wherein the pattern of refraction is defined by the surface height variation of the layer.  
     
     
         41 . The method of  claim 20 , wherein correcting the at least one of the remaining optical aberrations comprises performing controlled deposition of two or more formulations on the at least one optical element and curing of the formulations to correct high order aberrations.  
     
     
         42 . The method of  claim 20 , wherein forming a lens comprises forming an ophthalmic lens.  
     
     
         43 . The method of  claim 20 , wherein forming a lens comprises forming at least one of a spherical, aspheric, single vision, bifocals, multifocal, progressive addition lens, atoric, or contact lens.  
     
     
         44 . A method of making an optical lens comprising: 
 applying a spacer having a predetermined thickness to a first optical element;    applying a curable material to the first optical element;    debubbling the curable material;    positioning a portion of the curable material onto an off-center location of a second optical element; and    mating the second optical element and the first optical element such that the curable material forms a layer having a thickness defined by the predetermined thickness of the spacer.    
     
     
         45 . The method of  claim 44 , wherein debubbling the filler material comprises placing the filler material into a vacuum chamber.  
     
     
         46 . The method of  claim 44 , wherein at least one of the first and second optical elements comprises a thick optical element.  
     
     
         47 . The method of  claim 44 , wherein at least one of the first and second optical elements comprises a thin optical element.  
     
     
         48 . The method of  claim 44 , wherein at least one of the first and second optical elements comprises a lens.  
     
     
         49 . The method of  claim 44 , further comprising contouring a surface of at least one of the first and second optical element.  
     
     
         50 . The method of  claim 49 , wherein the act of contouring comprises grinding the surface.  
     
     
         51 . The method of  claim 50 , wherein the act of contouring comprises polishing the surface.  
     
     
         52 . The method of  claim 49 , wherein the act of contouring comprises freeform shaping the surface.  
     
     
         53 . The method of  claim 44 , further comprising at least partially curing the curable material to form a semi-cured material.  
     
     
         54 . The method of  claim 53 , wherein the semi-cured material is configured to be further selectively cured so as to define a pattern of refraction index in the optical element.  
     
     
         55 . The method of  claim 53 , wherein at least partially curing the curable material comprises forming a gel.  
     
     
         56 . The method of  claim 53 , further comprising further curing the curable material to define a pattern of refractive index which corrects at least one high order aberration in an optical path through the optical lens.  
     
     
         57 . The method of  claim 56 , wherein further curing the curable material comprises exposing the curable material to a pattern of radiation.  
     
     
         58 . The method of  claim 44 , wherein applying the curable material comprises: 
 depositing a matrix polymer having a monomer mixture dispersed therein, the matrix polymer being selected from the group consisting of polyester, polystyrene, polyacrylate, thiol-cured epoxy polymer, thiol-cured isocyanate polymer, and mixtures thereof; and    the monomer mixture comprising a thiol monomer and at least one second monomer selected from the group consisting of ene monomer and yne monomer.    
     
     
         59 . A method of making an optical lens, the method comprising: 
 dispensing a curable material to form a substantially planar sheet;    curing the curable material to form a semi-cured material wherein the index of refraction of said semi-cured material can be selectively varied;    applying at least a portion of the sheet to a first optical element;    affixing a second optical element to the first optical element; and    sealing the curable material therebetween.    
     
     
         60 . The method of  claim 59 , further comprising: 
 curing the semi-cured material to define a pattern of refractive index which corrects at least one high order aberration in an optical path through the optical lens.    
     
     
         61 . The method of  claim 60 , wherein curing the semi-cured material comprises exposing the semi-cured material to a pattern of radiation.  
     
     
         62 . The method of  claim 59 , wherein the first optical element comprises a lens.  
     
     
         63 . The method of  claim 59 , wherein the second optical element comprises a lens.  
     
     
         64 . A method of making a lens blank, the method comprising: 
 mating a first optical element at a predetermined distance from a second optical element so as to form a cavity therebetween;    filling the cavity with a curable material; and    at least partially curing the curable material to form a semi-cured material.    
     
     
         65 . The method of  claim 64 , wherein the act mating further comprises clamping the first and second optical element at the predetermined distance.  
     
     
         66 . The method of  claim 64 , wherein the semi-cured material is configured to be further selectively cured so as to define a pattern of refraction index in the optical element.  
     
     
         67 . The method of  claim 64 , wherein the act of mating further comprises applying a tape around the circumference of the first and second optical element so as to seal the cavity.  
     
     
         68 . The method of  claim 67 , wherein the filling comprises: 
 forming a passage through the tape; and    dispensing the curable material through the passage.    
     
     
         69 . The method of  claim 64 , further comprising forming at least one passage in the first optical element and wherein filling the cavity comprises dispensing the curable material through the at least one passage.  
     
     
         70 . The method of  claim 64 , wherein the act of mating comprises sandwiching a spacer between the first and second optical element.  
     
     
         71 . The method of  claim 70 , further comprising forming at least one passage in the spacer and wherein filling the cavity comprises dispensing the curable material through the at least one passage.  
     
     
         72 . The method of  claim 70 , wherein the spacer comprises an adhesive spacer.  
     
     
         73 . The method of  claim 64 , further comprising forming at least one passage in the first optical element and wherein filling the cavity comprises injecting the curable material through the at least one passage.  
     
     
         74 . The method of  claim 64 , wherein at least partially curing comprises performing thermal curing.  
     
     
         75 . The method of  claim 64 , wherein at least partially curing comprises curing at an ambient temperature.  
     
     
         76 . The method of  claim 64 , wherein at least partially curing comprises exposing the curable material to radiation.  
     
     
         77 . The method of  claim 64 , wherein the curable material comprises a photosensitive material.  
     
     
         78 . The method of  claim 64 , wherein the curable material comprises: 
 a matrix polymer having a monomer mixture dispersed therein, the matrix polymer being selected from the group consisting of polyester, polystyrene, polyacrylate, thiol-cured epoxy polymer, thiol-cured isocyanate polymer, and mixtures thereof; and;    the monomer mixture comprising a thiol monomer and at least one second monomer selected from the group consisting of ene monomer and yne monomer.    
     
     
         79 . The method of  claim 64 , further comprising contouring a surface of at least one of the first and second optical element.  
     
     
         80 . The method of  claim 79 , wherein the act of contouring comprises grinding the surface.  
     
     
         81 . The method of  claim 80 , wherein the act of contouring comprises polishing the surface.  
     
     
         82 . The method of  claim 79 , wherein the act of contouring comprises freeform shaping the surface.  
     
     
         83 . The method of  claim 79 , wherein the act of contouring comprises performing laser abrasion.  
     
     
         84 . A method of making an optical lens, the method comprising: 
 forming a substantially planar sheet of gel;    applying at least a portion of the substantially planar sheet of gel to the at least one surface of the mold to form a first layer of material having a selectively variable index of refraction; and    forming a second layer of material within the mold.    
     
     
         85 . The method of  claim 84 , further comprising curing the first layer of material to define a pattern of refractive index which corrects at least one high order aberration in an optical path through the optical lens.  
     
     
         86 . The method of  claim 85 , wherein curing the first layer of material comprises exposing the material to a pattern of radiation.  
     
     
         87 . The method of  claim 84 , wherein the curable material comprises: 
 a matrix polymer having a monomer mixture dispersed therein, the matrix polymer being selected from the group consisting of polyester, polystyrene, polyacrylate, thiol-cured epoxy polymer, thiol-cured isocyanate polymer, and mixtures thereof; and    the monomer mixture comprising a thiol monomer and at least one second monomer selected from the group consisting of ene monomer and yne monomer.    
     
     
         88 . The method of  claim 84 , further comprising applying an optical coating to the mold.  
     
     
         89 . The method of  claim 88 , wherein the optical coating comprises a layer of scratch-resistant material.  
     
     
         90 . A method of making an optical lens, the method comprising: 
 forming a first layer of curable material within a mold, wherein the curable material comprises a mixture of materials having low and high refractive indices;    exposing the layer of curable material to a first pattern of radiation to define a first pattern of refractive index in the layer which corrects at least one high order optical aberration in an optical path through the optical lens; and    exposing the layer of curable material to a second pattern of radiation to define a second pattern of refractive index in the layer which corrects at least one low order optical aberration in an optical path through the optical lens.    
     
     
         91 . The method of  claim 90 , wherein exposing the layer of curable material to the first and second patterns of radiation comprises exposing the layer of curable material to first and second two-dimensional grayscale patterns of irradiation.  
     
     
         92 . The method of  claim 90 , wherein exposing the layer of curable material to the first and second patterns of radiation comprises frontal-polymerization.  
     
     
         93 . The method of  claim 90 , wherein exposing the layer of curable material to the first pattern of radiation comprises exposing the layer to spatially modulated high intensity light.  
     
     
         94 . The method of  claim 90 , wherein exposing the layer of curable material to the second pattern of radiation comprises exposing the layer to spatially modulated low intensity light.  
     
     
         95 . The method of  claim 90 , wherein exposing the layer of curable material to the first pattern of radiation comprises exposing the layer to spatially modulated high intensity light, and wherein exposing the layer of curable material to the second pattern of radiation comprises exposing the layer to spatially modulated low intensity light.  
     
     
         96 . The method of  claim 90 , wherein the high refractive index material comprises acrylate components.  
     
     
         97 . The method of  claim 90 , wherein the high refractive index material comprises at least one material selected from the group consisting of vinyl and allyl components.  
     
     
         98 . The method of  claim 90 , wherein the low refractive index material comprises acrylate components.  
     
     
         99 . The method of  claim 90 , wherein the low refractive index material comprises at least one material selected from the group consisting of vinyl and allyl components.  
     
     
         100 . The method of  claim 90 , wherein the curable material comprises: 
 a matrix polymer having a monomer mixture dispersed therein, the matrix polymer being selected from the group consisting of polyester, polystyrene, polyacrylate, thiol-cured epoxy polymer, thiol-cured isocyanate polymer, and mixtures thereof, and    the monomer mixture comprising a thiol monomer and at least one second monomer selected from the group consisting of ene monomer and yne monomer.    
     
     
         101 . The method of  claim 90 , further comprising applying an optical coating to the mold.  
     
     
         102 . The method of  claim 101 , wherein the optical coating comprises a layer of scratch-resistant material.  
     
     
         103 . A method of making an optical lens, the method comprising: 
 filling a mold with a curable material;    determining a pattern of refractive index to correct at least one optical aberration;    irradiating the curable material with a two dimensional grayscale pattern so as to form a first layer defined therein the pattern of refractive index;    removing uncured material from the mold;    filling the mold with a second layer of curable material; and    curing the second layer of curable material within the mold.    
     
     
         104 . The method of  claim 103 , wherein first layer of material has a varying thickness that defines the pattern of refractive index.  
     
     
         105 . The method of  claim 103 , further comprising forming a scratch resistant layer.  
     
     
         106 . The method of  claim 103 , further comprising determining a second pattern of refraction to correct at least one remaining optical aberration and wherein curing the second layer comprises irradiating the second layer of curable material with a two dimensional grayscale pattern so as to define the second pattern of refractive index in the second layer.  
     
     
         107 . A method of making an optical lens, the method comprising: 
 depositing a first layer of material on to at least one surface of a mold so as to define a pattern of refractive index which corrects at least one high order aberration in an optical path through the optical lens; and    forming a second layer of material within the mold.    
     
     
         108 . The method of  claim 107 , wherein depositing the layer of material comprises depositing a varying thickness of the layer of material to define a pattern of varying thickness and wherein the pattern of varying thickness comprises the pattern of refractive index.  
     
     
         109 . The method of  claim 107 , wherein depositing the first layer of material comprises depositing a mixture of at least two materials and wherein the mixture of the at least two materials is varied to define the pattern of refractive index.  
     
     
         110 . The method of  claim 107 , further comprising applying an optical coating to the mold.  
     
     
         111 . The method of  claim 110 , wherein the optical coating comprises a layer of scratch-resistant material.  
     
     
         112 . A method of making a customized lens, the method comprising 
 applying a layer of curable polymer to an optical element; and    selectively curing the layer to vary the thickness of the layer so as to define a pattern of refraction that corrects at least one optical aberration.    
     
     
         113 . The method of  claim 112 , further comprising substantially uniformly curing the layer.  
     
     
         114 . The method of  claim 112 , wherein the pattern of refraction corrects at least one high order aberration.  
     
     
         115 . The method of  claim 112 , wherein the pattern of refraction corrects at least one low order aberration.  
     
     
         116 . The method of  claim 112 , wherein the pattern of refraction corrects at least one low order aberration and at least one high order aberration.  
     
     
         117 . The method of  claim 112 , wherein the act of selectively curing comprises: 
 exposing the layer to a two-dimensional grayscale pattern of radiation.    
     
     
         118 . The method of  claim 117 , wherein the radiation comprises high intensity radiation.  
     
     
         119 . The method of  claim 113 , wherein substantially uniformly curing comprises exposing the layer to substantially uniform radiation.  
     
     
         120 . The method of  claim 119 , wherein the radiation comprises low intensity radiation.  
     
     
         121 . The method of  claim 119 , wherein applying a layer of curable material comprises vacuum forming the layer of curable material.  
     
     
         122 . The method of  claim 119 , wherein the optical element comprises a framed lens.  
     
     
         123 . A method of making a customized lens, the method comprising: 
 applying a layer of curable material to an optical element;    vacuum forming the layer of curable material to the optical element;    at least partially curing the layer of curable material; and    selectively curing the layer of curable material to define a pattern of refraction in the layer that corrects at least one high order optical aberration in an optical path through the lens.    
     
     
         124 . The method of  claim 123 , wherein selectively curing a layer of curable material comprises exposing the layer to a two-dimensional grayscale pattern of radiation.  
     
     
         125 . The method of  claim 123 , wherein applying a layer of curable material comprises: 
 forming a layer of semi-cured material;    applying a curable material to the optical element; and    applying at least a portion of the layer of semi-cured material to the optical element, the curable material being substantially uniformly distributed between the layer of semi-cured material and the optical element.    
     
     
         126 . The method of  claim 123 , wherein the optical element comprises a framed lens.  
     
     
         127 . The method of  claim 126 , further comprising removing the framed lens from the frame.  
     
     
         128 . A method of making a customized lens, the method comprising: 
 applying a layer of semi-cured material to an optical element;    vacuum forming the layer of semi-cured material to the optical element;    selectively curing the layer of curable material to define a pattern of refraction in the layer that corrects at least one high order optical aberration in an optical path through the lens.    
     
     
         129 . The method of  claim 128 , wherein applying a layer of semi-cured material comprises applying a layer of primer.  
     
     
         130 . The method of  claim 128 , wherein applying a layer of semi-cured material comprises applying an adhesive semi-cured material.  
     
     
         131 . A system for customizing optical correction in an optical system, the system comprising: 
 means for measuring optical aberration data of the optical system;    means for determining, based on the optical aberration data, a lens definition comprising a correction of at least one high order optical aberration; and    means fabricating a correcting lens based on the lens definition.