Process for producing a transparent optical element, optical component involved in this process and optical element thus obtained

Abstract

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.

1 . Process for producing a transparent optical element, comprising the following steps: 
 producing 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; and    cutting the optical component along a defined contour on said surface, corresponding to a predetermined shape of the optical element.    
     
     
         2 . Process according to  claim 1 , wherein the array of cells constitutes a layer having, perpendicular to said surface, a height of less than 100 μm.  
     
     
         3 . Process according to  claim 1 , which furthermore includes a step of drilling through the optical component in order to fasten the optical element to a holding support.  
     
     
         4 . Process according to  claim 1 , wherein the production of the optical component comprises the formation of the array of cells on a rigid transparent substrate.  
     
     
         5 . Process according to  claim 1 , wherein the production of the optical component comprises the formation of the array of cells within a flexible transparent film followed by the transfer of said film onto a rigid transparent substrate.  
     
     
         6 . Process according to  claim 1 , wherein the substance having an optical property contained in at least some of the cells is in the form of a liquid or gel and the production of the optical component comprises the formation, on a substrate, of a grid of walls for defining the cells parallel to said surface of the component, the collective or individual filling of the cells with the substance having an optical property in the form of a liquid or gel, and the closing of the cells on their opposite side from the substrate.  
     
     
         7 . Process according to  claim 1 , wherein the optical property is chosen from a coloration, photochromism, polarization or refractive-index property.  
     
     
         8 . Process according to  claim 1 , wherein different cells contain substances having a different refractive index.  
     
     
         9 . Process according to  claim 8 , wherein the substances having a different refractive index comprise photopolymers, liquid crystals or mesoporous materials.  
     
     
         10 . Process according to  claim 9 , wherein the production of the optical component comprises the formation, on a substrate, of a grid of walls for defining the cells parallel to said surface of the component, the collective filling of the cells with a solution or a suspension of monomers or liquid crystals, the closing of the cells on their opposite side from the substrate, and the selective curing of said solution or suspension in the presence of differentiated electromagnetic radiation parallel to said surface of the component.  
     
     
         11 . Process according to  claim 8 , wherein the refractive index of the substances contained in the cells are adapted in order to vary said index over the surface of the component according to the estimated ametropia of an eye to be corrected.  
     
     
         12 . Process according to  claim 1 , wherein the array of cells includes several groups of cells containing different substances.  
     
     
         13 . Process according to  claim 12 , wherein the production of the optical component comprises the formation, on a substrate, of a grid of walls for defining the cells parallel to said surface of the component, the differentiated filling of the cells with the substances having an optical property, using ink-jet heads, and the closing of the cells on their opposite side from the substrate.  
     
     
         14 . Process according to  claim 1 , wherein several arrays of cells are stacked on the thickness of the component.  
     
     
         15 . Process according to  claim 14 , wherein each array of cells has identical optical properties, or each array of cells has different optical properties, or the cells within each array of cells have different optical properties.  
     
     
         16 . Process according to  claim 1 , wherein the fill factor τ is greater than 90%, parallel to the surface of the component.  
     
     
         17 . Process according to  claim 1 , wherein the cells of the array are arranged in a hexagonal-type lattice.  
     
     
         18 . Process according to  claim 1 , wherein the cells have dimensions of greater than 1 μm parallel to the surface of the component.  
     
     
         19 . Process according to  claim 1 , wherein the cells are separated by walls having dimensions of between 0.10 μm and 5 μm parallel to the surface of the component.  
     
     
         20 . Process according to  claim 19 , wherein the walls ( 18 ) have dimensions of less than 0.35 μm.  
     
     
         21 . Process according to  claim 19 , wherein the cells are separated by walls made of a material that does not reflect light and have dimensions of between 0.40 μm and 3.00 μm.  
     
     
         22 . Process according to  claim 21 , wherein the walls have dimensions of between 0.40 μm and 1.00 μm.