# US 12,005,632 B2 · Eyewear lens creation using additive techniques with diffuse light

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- Number: US 12,005,632 B2
- Document ID: US12005632B2
- Status: Granted
- Kind: B2
- Application number: 18/183,089
- Filed: 2023-03-13
- Published: 2023-07-20
- Granted: 2024-06-11
- Earliest claimed: 2020-10-16
- Assignees: Indizen Optical Technologies S.L.
- Applicants: Indizen Optical Technologies S.L.
- Inventors: Eduardo Pascual; José Alonso Fernández; Ignacio Canga; Juan Antonio Quiroga Mellado; Daniel Crespo Vázquez
- Web page: https://patentgrep.com/patent/US12005632B2

## CPC

- B29C 64/124: using layers of liquid which are selectively solidified
- B29C 33/0011: {thin-walled moulds}
- B29C 39/42: Casting under special conditions, e.g. vacuum
- B29C 64/255: Enclosures for the building material, e.g. powder containers
- B29C 64/264: Arrangements for irradiation
- B29C 64/364: Conditioning of environment
- B29C 64/386: Data acquisition or data processing for additive manufacturing
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B29D 11/00009: {Production of simple or compound lenses}
- B29D 11/00442: {Curing the lens material}
- B29D 11/0048: {Moulds for lenses (moulds for plastic articles in general B29C33/00)}
- B29D 11/0073: {Optical laminates}
- B29D 11/00865: {Applying coatings; tinting; colouring (printing, marking or copying processes B41M; identification in general G09F3/00; producing decorative effects in general B44C; positioning or marking of lenses B24B13/0055)}
- B29D 11/00951: {Measuring, controlling or regulating}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- B33Y 80/00: Products made by additive manufacturing
- G02B 1/041: {Lenses}
- G02B 1/14: Protective coatings, e.g. hard coatings
- G02B 3/0081: {having one or more elements with analytic function to create variable power (variable magnification in general G02B15/00)}
- G02B 27/0012: {Optical design, e.g. procedures, algorithms, optimisation routines}
- G02C 7/02: Lenses; Lens systems {; Methods of designing lenses}
- B29C 64/35: Cleaning
- B29K 2105/0002: {monomers or prepolymers}
- B29K 2105/0005: {containing compounding ingredients (releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26)}
- B29L 2011/0016: {Lenses}
- B33Y 40/20: Post-treatment, e.g. curing, coating or polishing
- G02B 1/11: Anti-reflection coatings
- G02B 5/23: Photochromic filters
- G02B 2003/0093: {characterised by the shape}
- Y02P 20/582: Recycling of unreacted starting or intermediate materials
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02C: SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES (trial frames for testing the eyes A61B3/04; goggles or eyeshields not having the same features as spectacles A61F9/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Systems and methods for lens creations are disclosed. The method includes initiating light transmission from a light source through a diffuser into a container holding resin and a substrate. The light transmission is performed according to an irradiation pattern wherein each point in the resin is illuminated by at least 10% of the diffuser. This causes a lens to be formed. To achieve this illumination, at least 15% of the diffuser receives light from the light source. Further, a diameter of the diffuser is greater than or equal to a diameter of the substrate. The system performing the methods includes a polymerization apparatus and may include a resin conditioning and reservoir apparatus, a metrology unit, a resin drainage apparatus and an optional postcuring apparatus.

## Claims

### Claim 1

A system for lens creation comprising:
a resin conditioning and reservoir apparatus to hold and maintain a resin;
a polymerization apparatus coupled with the resin conditioning and reservoir apparatus, the polymerization apparatus to:
receive input information including a lens prescription and wearer information;
calculate creation instructions based on the input information, the creation instructions including: 1) an irradiation pattern, 2) an exposure time to use a light transmission of the irradiation pattern to form a lens having the lens prescription and the wearer information, and 3) a resin composition;
create a spectacle lens by initiating the light transmission of the irradiation pattern from a light source onto and through a diffuser into a chamber in the polymerization apparatus containing the resin and a substrate such that each point in a thickness of the resin sufficient to form the lens is illuminated by light from at least 10% of an area of the diffuser; and
stop the light transmission after the exposure time to form the spectacle lens, wherein the spectacle lens meets the creation instructions, wherein a single polymerization front has the shape of a target surface of the spectacle lens that meets the creation instructions, wherein the substrate is selected from the group including poly(allyl diglycol carbonate), polycarbonate, polyurethane-based plastic or glass.

### Claim 2 (depends on 1)

The system of claim 1 wherein at least 15% of the diffuser receives light from the light source.

### Claim 3 (depends on 1)

The system of claim 1 wherein a diameter of the diffuser is greater than or equal to a diameter of the substrate.

### Claim 4 (depends on 1)

The system of claim 1 further comprising: a drainage apparatus including a spinning machine to remove remaining resin from the formed lens.

### Claim 5 (depends on 4)

The system of claim 4 further comprising: a post-curing apparatus including at least one selected from the group including a heater and a light emitter.

### Claim 6 (depends on 5)

The system of claim 5 wherein the post-curing apparatus further comprises an inner chamber and is configured to create a vacuum in the inner chamber.

### Claim 7 (depends on 1)

The system of claim 1 wherein the resin conditioning and reservoir apparatus comprises a mixing apparatus to stir and/or mix the resin.

### Claim 8 (depends on 1)

The system of claim 1 wherein the resin conditioning and reservoir apparatus comprises a controller and venting components to control the gaseous atmosphere within a chamber included in the resin conditioning and reservoir apparatus.

### Claim 9 (depends on 1)

The system of claim 1 wherein the resin conditioning and reservoir apparatus includes at least one of a heater and an oxygen scavenger mechanism.

### Claim 10 (depends on 1)

The system of claim 1 wherein the resin conditioning and reservoir apparatus includes at least one sensor to measure physical and chemical parameters including temperature, oxygen concentration, and/or nitrogen concentration.

### Claim 11 (depends on 1)

The system of claim 1 wherein the resin conditioning and reservoir apparatus includes a filtering apparatus to remove particles in the resin that could interfere with lens formation and/or lens quality.

### Claim 12 (depends on 1)

The system of claim 1 wherein the polymerization apparatus is configured with venting components to create a vacuum in the chamber and maintain a desired gaseous atmosphere in the chamber.

### Claim 13 (depends on 1)

The system of claim 1 further comprising a metrology apparatus coupled with the polymerization apparatus, the metrology apparatus including at least one camera and/or thermal sensor to make real time measurements of light and/or heat during lens formation, the measurements used by the controller in the polymerization apparatus to correct or improve the light input pattern during the polymerization process.

### Claim 14 (depends on 1)

The system of claim 1 wherein the formed lens further comprises a spun on hard coating.

### Claim 15 (depends on 1)

The system of claim 1 wherein the exposure time is a single period of time, and wherein the irradiation pattern is a single irradiation pattern that coincides with forming a lens having the lens prescription and the wearer information.

### Claim 16 (depends on 1)

The system of claim 1 wherein the lens includes the thickness of the illuminated resins but not the substrate.

### Claim 17

A system for lens creation comprising:
a resin conditioning and reservoir apparatus to hold and maintain a resin;
a polymerization apparatus coupled with the resin conditioning and reservoir apparatus, the polymerization apparatus to:
receive input information including a lens prescription and wearer information;
calculate creation instructions based on the input information, the creation instructions including: 1) an irradiation pattern, 2) an exposure time to use a light transmission of the irradiation pattern to form a lens having the lens prescription and the wearer information, and 3) A resin composition;
create a spectacle lens by initiating the light transmission of the irradiation pattern from a light source onto and through a diffuser into a chamber in the polymerization apparatus containing the resin and a substrate such that each point in a thickness of the resin sufficient to form the lens is illuminated by light from at least 10% of an area of the diffuser; and
stop the light transmission after the exposure time to form the spectacle lens, wherein the spectacle lens meets the creation instructions, wherein a single polymerization front has the shape of a target surface of the spectacle lens that meets the creation instructions, wherein the substrate includes embedded electronic circuits or embedded image formation systems.

### Claim 18

A system for lens creation comprising:
a resin conditioning and reservoir apparatus to hold and maintain a resin;
a polymerization apparatus coupled with the resin conditioning and reservoir apparatus, the polymerization apparatus to:
receive input information including a lens prescription and wearer information;
calculate creation instructions based on the input information, the creation instructions including: 1) an irradiation pattern, 2) an exposure time to use a light transmission of the irradiation pattern to form a lens having the lens prescription and the wearer information, and 3) a resin composition;
create a spectacle lens by initiating the light transmission of the irradiation pattern from a light source onto and through a diffuser into a chamber in the polymerization apparatus containing the resin and a substrate such that each point in a thickness of the resin sufficient to form the lens is illuminated by light from at least 10% of an area of the diffuser; and
stop the light transmission after the exposure time to form the spectacle lens, wherein the spectacle lens meets the creation instructions, wherein a single polymerization front has the shape of a target surface of the spectacle lens that meets the creation instructions, wherein the substrate is polarized or photochromic.

### Claim 19

A system for lens creation comprising:
a resin conditioning and reservoir apparatus to hold and maintain a resin;
a polymerization apparatus coupled with the resin conditioning and reservoir apparatus, the polymerization apparatus to:
receive input information including a lens prescription and wearer information;
calculate creation instructions based on the input information, the creation instructions including: 1) an irradiation pattern, 2) an exposure time to use a light transmission of the irradiation pattern to form a lens having the lens prescription and the wearer information, and 3) a resin composition;
create a spectacle lens by initiating the light transmission of the irradiation pattern from a light source onto and through a diffuser into a chamber in the polymerization apparatus containing the resin and a substrate such that each point in a thickness of the resin sufficient to form the lens is illuminated by light from at least 10% of an area of the diffuser; and
stop the light transmission after the exposure time to form the spectacle lens, wherein the spectacle lens meets the creation instructions, wherein a single polymerization front has the shape of a target surface of the spectacle lens that meets the creation instructions, wherein the substrate includes a convex surface, and the substrate incorporates an antireflective coating or a hard coating treatment on the convex surface.

### Claim 20

A system for lens creation comprising:
a resin conditioning and reservoir apparatus to hold and maintain a resin;
a polymerization apparatus coupled with the resin conditioning and reservoir apparatus, the polymerization apparatus to:
receive input information including a lens prescription and wearer information;
calculate creation instructions based on the input information, the creation instructions including: 1) an irradiation pattern, 2) an exposure time to use a light transmission of the irradiation pattern to form a lens having the lens prescription and the wearer information, and 3) a resin composition;
create a spectacle lens by initiating the light transmission of the irradiation pattern from a light source onto and through a diffuser into a chamber in the polymerization apparatus containing the resin and a substrate such that each point in a thickness of the resin sufficient to form the lens is illuminated by light from at least 10% of an area of the diffuser; and
stop the light transmission after the exposure time to form the spectacle lens, wherein the spectacle lens meets the creation instructions, wherein a single polymerization front has the shape of a target surface of the spectacle lens that meets the creation instructions, and wherein the spectacle lens includes the substrate and the thickness of the illuminated resins.