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US-12623418-B2 - Functional layer application system

US12623418B2US 12623418 B2US12623418 B2US 12623418B2US-12623418-B2

Abstract

Systems and methods for adding a functional layer to a lens having a plurality of microlenses for inhibition of ametropia. The lens may include defocus incorporated multiple segments (DIMS) having a plurality of microlenses or lenslets producing refraction areas with different refraction forces. Injection molding may be utilized to add a functional layer to such a DIMS lens having a plurality of microlenses or lenslets. The functional layer may add a functional utility to the lens, including but not limited to photochromic functionality, polarization functionality, and the like.

Inventors

  • David Olund
  • Craig Drury
  • James Kunkel

Assignees

  • HOYA OPTICAL LABS OF AMERICA, INC.

Dates

Publication Date
20260512
Application Date
20231204

Claims (20)

  1. 1 . A method of fabricating a lens having microlenses with a functional layer, comprising the steps of: providing a mold having a first and a second side, wherein the first side includes a plurality of features configured to form a corresponding array of microlenses; setting the first side of the mold to a first temperature and the second side of the mold to a second temperature, wherein the second temperature is lower than the first temperature; providing a laminate having a functional layer at the first side of the mold; injecting a material into the mold at a velocity; applying a first pack pressure for a first duration of time; applying a second pack pressure for a second duration of time; and allowing the mold to cool thereby forming the lens having microlenses with a functional layer.
  2. 2 . The method of claim 1 , wherein the first temperature is between 280 degrees Fahrenheit and 300 degrees Fahrenheit.
  3. 3 . The method of claim 1 , wherein the first pack pressure is between 1250 PSI and 1750 PSI.
  4. 4 . The method of claim 3 , wherein the first duration of time is between 8 seconds and 12 seconds.
  5. 5 . The method of claim 4 , wherein the second pack pressure is between 3250 PSI and 3750 PSI.
  6. 6 . The method of claim 5 , wherein the second duration of time is between 13 seconds and 17 seconds.
  7. 7 . The method of claim 1 , wherein the first pack pressure is lower than the second pack pressure.
  8. 8 . The method of claim 1 , wherein the first duration of time is less than the second duration of time.
  9. 9 . The method of claim 1 , wherein the functional layer is comprised of a polarized functional layer or a photochromic functional layer.
  10. 10 . A method of fabricating a lens having microlenses with a functional layer, comprising the steps of: providing a mold having a first side and a second side, wherein the first side includes a plurality of features configured to form a corresponding array of microlenses; setting the first side of the mold to a first temperature and the second side of the mold to a second temperature, wherein the second temperature is lower than the first temperature; providing a laminate having a functional layer at the first side of the mold; injecting a material into the mold; applying a first pack pressure for a first duration of time; applying a second pack pressure for a second duration of time; applying a third pack pressure for a third duration of time; and allowing the mold to cool thereby forming the lens having microlenses with a functional layer.
  11. 11 . The method of claim 10 , wherein the step of injecting a material into the mold is repeated between two and five times.
  12. 12 . The method of claim 10 , wherein the first pack pressure is between 1250 and 1750 PSI.
  13. 13 . The method of claim 12 , wherein the first duration of time is between 8 and 12 seconds.
  14. 14 . The method of claim 13 , wherein the second pack pressure is between 3000 and 4000 PSI.
  15. 15 . The method of claim 14 , wherein the second duration of time is between 10 and 20 seconds.
  16. 16 . The method of claim 15 , wherein the third pack pressure is between 7000 and 10000 PSI.
  17. 17 . The method of claim 16 , wherein the third duration of time is between 30 and 50 seconds.
  18. 18 . The method of claim 10 , wherein the functional layer is comprised of a gray polarized functional layer, a brown polarized functional layer, or a photochromic functional layer.
  19. 19 . The method of claim 1 , wherein the first pack pressure is less than the second pack pressure.
  20. 20 . The method of claim 1 , wherein the first duration of time is less than the second duration of time.

Description

RELATED APPLICATIONS This application claims benefit of and priority to U.S. Provisional Application Ser. No. 63/385,911 filed Dec. 2, 2022 entitled Functional Layer Application System, and U.S. Provisional Application Ser. No. 63/385,916 filed Dec. 2, 2022 entitled Functional Layer Application System, both of which are hereby incorporated herein by reference in their entireties. BACKGROUND OF THE DISCLOSURE Various lenses known in the art to inhibit ametropia of the eye, and thus treat myopia, have been known to include a plurality of microlenses or lenslets which are positions on a curved lens. Such a configuration may be utilized to form two or more refracting areas, such as a first refraction area and a second refraction area. The first refraction area may have a first refraction force based on a prescription for correcting ametropia of the eyes. The second refraction area may have a refraction force different from the first refraction force so as to focus images on the positions except the retina of the eyes and thereby inhibit development of ametropia. In modern times, it is often desirable to add different functional layers to lenses. For example, a photochromic functional layer may be desirable on certain lenses to allow the lenses to darken on exposure to light. As another example, a polarized functional layer may be desirable on certain lenses to filter light, protect against ultraviolet rays, and minimize glare. It would be desirable to efficiently add a functional layer, such as a photochromic or polarized layer, to lenses for inhibiting ametropia, such as lenses having microlenses or lenslets. SUMMARY OF THE DISCLOSURE Disclosed herein are systems and methods for adding a functional layer to a lens for treating myopia and inhibiting ametropia. The lens may comprise a defocus incorporated multiple segments (“DIMS”) lens for inducing myopic defocus in the peripheral retina as an intervention to stop or slow myopic progression, such as in children. The lens for treating myopia and inhibiting ametropia may comprise a plurality of microlenses or lenslets producing refraction areas having different refraction forces. In an example embodiment, laminate technology may be utilized to deliver both a photochromic and a polarized solution by replicating DIMS features that are less than 2 microns or less in depth. The molding systems and processes shown and described herein may produce the same tight tolerances as a clear DIMS lens, while incorporating a functional layer. The molding systems and processes shown and described herein may produce a functional DIMS lens which has the same PSF performance (e.g., fit-defocus, stray light rate, and segment rate) as that of a clear DIMS lens. The functional layer may add a functional utility to the lens, including but not limited to photochromic functionality, polarization functionality, and the like. In an example embodiment, injection molding may be utilized to add a functional layer to a DIMS lens having a plurality of microlenses. In an example embodiment, the front mold temperature may be increased as compared to prior techniques, with the front mold temperature being between about 285 and 292 degrees Fahrenheit. In an example embodiment, the maximum amount of injected polycarbonate may be increased for fabricating a photochromic DIMS lens and decreased for fabricating a polarized DIMS lens, with the maximum amount of injected polycarbonate being about 3.720 inches, for example, with a four-cavity cold runner system. In an example embodiment, the speed of injection may be decreased as compared to prior techniques, with the speed of injection being about 0.1 inches per second. In an example embodiment, the transfer position may be decreased for fabricating a photochromic DIMS lens and increased for fabricating a polarized DIMS lens, with the transfer position being between about 0.52 inches and 0.58 inches. In an example embodiment, the cooling time of the mold may be decreased when compared to prior techniques, with the cooling time being between about 240 seconds and 260 seconds. In an example embodiment, a plurality of pack plastic pressures may be applied sequentially for a plurality of durations of time, rather than a single iteration of pack plastic pressure being applied for a single duration of time as used in prior techniques. In an example embodiment, a first pack plastic pressure of between about 1250 PSI and 1750 PSI may first be applied for a duration of between about 8 seconds and 12 seconds, a second pack plastic pressure of between about 3250 PSI and 3750 PSI may next be applied for a duration of between about 13 seconds and 17 seconds, and a third pack plastic pressure of between about 8250 PSI and 8750 PSI may next be applied for a duration of between about 38 seconds and 42 seconds. However, it should be appreciated that such values are optimized for a four cavity molding and may differ when used in connection with a two cavity or single cavi