Method for mounting functional elements in a lens

Patent metadata

Field	Value
Publication number	US-11697257-B2
Application number	US-201917280166-A
Country	US
Kind code	B2
Filing date	Sep 25, 2019
Priority date	Sep 25, 2018
Publication date	Jul 11, 2023
Grant date	Jul 11, 2023

Abstract

A method for mounting functional elements in a lens includes mounting the functional elements on a foil, applying a closed contour alignment surface of an alignment tool having a central opening surrounded by the closed contour on the foil portion opposite to the mounted function elements, applying underpressure on the central opening to maintain the foil portion with the mounted functional elements on the alignment tool, cutting a flap including the foil portion and supporting the functional elements out of the foil, positioning and aligning the flap through actuator, fixing the position of the flap against the adjacent foil surface, embedding the foil with the mounted functional elements in a predetermined distance to the front surface of a mould, and casting and curing the lens with the embedded foil.

First claim

The invention claimed is:

1. A method for mounting a functional element in a lens, the method comprising:
mounting the functional element on a first portion of a foil;
applying a closed contour alignment surface of an alignment tool having a central opening on a second portion of the foil opposite to the functional element;
applying a pressure on the central opening of the alignment tool to maintain the second portion of the foil on the alignment tool;
cutting a hole in the foil to produce a cut-out including the functional element mounted thereon, or cutting the foil to create a flap in the foil containing the functional element;
aligning, via at least one actuator, the functional element on the foil of the cut-out or the flap, to a predetermined angle and position relative to a lens geometry;
fixing the position of the functional element on the foil of the cut-out against an adjacent foil surface or fixing the position of the flap with the functional element against an adjacent foil surface;
positioning the foil with the functional element at a predetermined distance from a front surface of a casting mould; and
casting and curing a polymer with the functional element and foil embedded therein.

2. The method of claim 1 , further comprising, before mounting the functional element on a first portion of a foil, mounting the functional element to a flexible printed circuit board.

3. The method of claim 2 , wherein mounting the functional element to the flexible printed circuit board comprises:
positioning the flexible printed circuit board on a surface of the mould having complementary recesses and at least one vacuum channel;
applying a vacuum pressure from a mould side through the least one vacuum channel; and
positioning the functional element via a functional element alignment tool through the vacuum channel on the flexible printed circuit board.

4. The method of claim 1 , wherein the functional element includes at least one of a camera, a light emitting element, or a passive element.

5. The method of claim 1 , wherein the functional element includes a camera; and
aligning, via at least one actuator, the functional element on the foil of the cut-out or on the flap, to a predetermined angle and position relative to a lens geometry, further includes:
connecting the camera to a visualizing unit configured to display images obtained by the camera;
providing a light source configured to emit a reference light; and
positioning and aligning the functional element based on the images displayed on the visualizing unit.

6. The method of claim 1 , wherein the functional element includes a light source; and
aligning, via at least one actuator, the functional element on the foil of the cut-out or on the flap, to a predetermined angle and position relative to a lens geometry, further includes:
providing a camera configured to receive light from the light source to produce an image;
providing a visualizing unit configured to display images obtained by the camera; and
positioning and aligning the functional element based on the images displayed on the visualizing unit.

7. The method of claim 1 , wherein the functional element includes a passive element configured to reflect or diffract incoming light; and
aligning, via at least one actuator, the functional element on the foil of the cut-out or on the flap, to a predetermined angle and position relative to a lens geometry, further includes:
providing a light source configured to illuminate the passive element;
providing a camera configured to receive light emitted by the passive element when illuminated by the light source;
providing a visualizing unit configured to display images obtained by the camera; and
positioning and aligning the functional element based on the images displayed on the visualizing unit.

8. The method of claim 7 , wherein the passive element includes a crystal, a mirror element, or a grating.

9. The method of claim 1 , further including:
capturing an image of the functional element positioned on the foil of the cut-out or an image of the flap with the functional element; and
adjusting the position of the functional element on the foil of the cut-out, or the position of the flap with the functional element, based on the captured image.

10. The method of claim 9 , further including displaying the captured image on a visualizing unit.

11. A method for mounting a functional element in a lens, the method comprising:
providing a prism on a foil;
positioning a functional element on the prism, the functional element including at least one of a camera, a light-emitting element, or a passive element;
fixing the position of the functional element on the prism;
positioning the foil with the functional element fixed to the prism a predetermined distance to a front surface of a mould;
casting and curing a polymer with the functional element and foil embedded therein.

12. The method of claim 11 , wherein positioning the functional element on the prism further includes:
mounting the functional element on a flexible printed circuit board; and
positioning the functional element on the flexible printed circuit board on the prism.

13. The method of claim 12 , wherein mounting the functional element on the flexible printed board circuit further includes:
providing an alignment tool having a vacuum channel configured to hold the flexible printed circuit board or functional element; and
holding the functional element via a vacuum through the vacuum channel before being positioned on the prism.

14. The method of claim 11 , wherein the functional element includes a camera; and
positioning the functional element on the prism, further includes:
connecting the camera to a visualizing unit configured to display images obtained by the camera;
providing a light source configured to emit a reference light; and
positioning the functional element on the prism and on the foil based on the images displayed on the visualizing unit.

15. The method of claim 11 , wherein the functional element includes a light source; and
positioning the functional element on the prism, further includes:
providing a camera configured to receive light from the light source to produce an image;
providing a visualizing unit configured to display images obtained by the camera; and
positioning the functional element on the prism and on the foil based on the images displayed on the visualizing unit.

16. The method of claim 11 , wherein the functional element includes a passive element configured to reflect or diffract incoming light, the passive element comprising at least one of a crystal, a mirror element, or a grating; and
positioning the functional element on the prism, further includes:
providing a light source configured to illuminate the passive element;
providing a camera configured to receive light emitted by the passive element when illuminated by the light source;
providing a visualizing unit configured to display images obtained by the camera; and
positioning the functional element on the prism and on the foil based on the images displayed on the visualizing unit.

17. A method for mounting a functional element in a lens, the method comprising:
mounting the functional element on a first side of a foil;
positioning a second side of the foil on a closed contour alignment surface of an alignment tool;
applying a pressure on a central opening of the alignment tool, the central opening surrounded by the closed contour alignment surface, to maintain the foil with the functional element on the

Assignees

• Metamaterial Inc
• Tobii Ab

Inventors

• Körner Lutz
• Hess Peter
• Greber Alexander
• Büttiker Urs
• Müller Reto
• Höglund Anders
• Ljunggren Daniel

Classifications

• H04N23/72

  Combination of two or more compensation controls · CPC title

• H04N23/55

  Optical parts specially adapted for electronic image sensors; Mounting thereof · CPC title

• B29D11/00009 Primary

  Production of simple or compound lenses · CPC title

• B29D11/00807 Primary

  Producing lenses combined with electronics, e.g. chips · CPC title

• G02B5/04

  Prisms · CPC title