Process and system for manufacturing an ophthalmic lens

Patent metadata

Field	Value
Publication number	US-2016114542-A1
Application number	US-201414895830-A
Country	US
Kind code	A1
Filing date	Jun 6, 2014
Priority date	Jun 7, 2013
Publication date	Apr 28, 2016
Grant date	—

Abstract

A process for manufacturing an ophthalmic lens having at least one optical function, includes the following steps: additively manufacturing ( 100 ) an intermediate optical element by depositing a plurality of preset volume elements of at least one material having a preset refractive index, the intermediate optical element including a target ophthalmic lens and a thickness allowance consisting of a portion of the plurality of volume elements; and subtractively manufacturing ( 300 ), by machining, the target ophthalmic lens from the intermediate optical element, the machining being carried out in a preset sequence, of at least one step, the preset sequence making it possible to subtract the thickness allowance, the additive manufacturing step ( 100 ) including a step of determining a manufacturing setpoint for the intermediate optical element in which the thickness allowance is determined depending on the preset sequence defined in the subtractive manufacturing step ( 300 ).

First claim

1 . A process for manufacturing an ophthalmic lens having at least one optical function, comprising the following steps:
additively manufacturing ( 100 ) an intermediate optical element ( 10 ) by depositing a plurality of predetermined volume elements of at least one material having a predetermined refractive index, said intermediate optical element comprising a target ophthalmic lens ( 30 ) adjoined to an extra thickness (Se) consisting of a portion of said plurality of volume elements; and subtractively manufacturing ( 300 ) by machining said target ophthalmic lens ( 30 ) from said intermediate optical element ( 10 ), the machining being carried out in a predetermined sequence, of at least one step, said predetermined sequence allowing said extra thickness to be subtracted, said additive manufacturing step ( 100 ) comprising a step ( 113 ) of determining a manufacturing settings for said intermediate optical element ( 10 ) in which said extra thickness (Se) is determined depending on said predetermined sequence defined in the subtractive manufacturing step ( 300 ).

2 . The process as claimed in claim 1 , wherein the extra thickness (Se) generated in the additive manufacturing step ( 100 ) leading to the intermediate optical element ( 10 ) and then subtracted in the subtractive manufacturing step ( 300 ) leading to the target ophthalmic lens ( 30 ) is comprised between 1 μm and 1000 μm inclusive and preferably comprised between 30 μm and 1000 μm inclusive.

3 . The process as claimed in claim 1 , wherein said predetermined sequence comprises at least one step chosen from a roughing step, a finishing step and a polishing step, alone or in combination.

4 . The process as claimed in claim 3 , wherein said predetermined sequence is chosen from:
a roughing step carried out on the intermediate optical element ( 10 ) leading to an intermediate optical element of state 2 , followed by a finishing step carried out on said intermediate optical element of state 2 leading to an intermediate optical element of state 3 , followed by a polishing step carried out on said intermediate optical element of state 3 leading to the target ophthalmic lens ( 30 ); or a finishing step carried out on the intermediate optical element ( 10 ) leading to an intermediate optical element of state 4 , followed by a polishing step carried out on said intermediate optical element of state 4 leading to the target ophthalmic lens ( 30 ); or a polishing step carried out on the intermediate optical element ( 10 ) leading to the target ophthalmic lens ( 30 ).

5 . The process as claimed in claim 3 , wherein said predetermined sequence is identical or different everywhere on the intermediate optical element ( 10 ).

6 . The process as claimed in claim 1 , wherein the step ( 100 ) of additively manufacturing an intermediate optical element ( 10 ) comprising the target ophthalmic lens ( 30 ) adjoined to an extra thickness (Se) is carried out by depositing a plurality of predetermined volume elements of a given constituent material of the target ophthalmic lens and extra thickness.

7 . The process as claimed in claim 1 , wherein the step ( 100 ) of additively manufacturing an intermediate optical element ( 10 ) comprising the target ophthalmic lens ( 30 ) adjoined to an extra thickness (Se) is carried out by depositing a plurality of predetermined volume elements of at least two different materials, the materials especially differing in their refractive index or in their intrinsic abradability.

8 . The process as claimed in claim 1 , wherein the additive manufacturing step ( 100 ) implements a three-dimensional printing, or stereolithography, or mask projection stereolithography process or a selective laser melting or sintering process, or a thermoplastic filament extrusion process.

9 . The process as claimed in claim 1 , wherein said step ( 113 ) of determining a manufacturing settings for said intermediate optical element ( 10 ) includes the following steps:
determining ( 105 ) target geometric characteristics for said ophthalmic lens from characteristics of said optical function to be given to said ophthalmic lens; determining ( 108 ) said extra thickness, from said determined target geometric characteristics and characteristics associated with said predetermined subtractive manufacturing sequence; and deducing ( 109 ) the geometric characteristics of said intermediate optical element ( 10 ) from said determined target geometric characteristics and from said determined extra thickness (Se).

10 . The process as claimed in claim 9 , wherein the step ( 108 ) of determining said extra thickness furthermore includes taking into account material physical data associated with said predetermined subtractive manufacturing sequence.

11 . The process as claimed in claim 9 , wherein said optical function to be given to said ophthalmic lens is characteristic of prescription values associated with a wearer of said ophthalmic lens and complementary fitting data of a predetermined frame and/or personalization data and/or frame-shape data.

12 . The process as claimed in claim 1 , in which the intermediate optical element ( 10 ) has an outline substantially equal to an outline configured to be inserted into a predetermined frame.

13 . A system for manufacturing an ophthalmic lens, including an additive manufacturing machine ( 1 ) and at least one subtractive manufacturing machine ( 21 ), in order to manufacture an ophthalmic lens, and at least one command/control unit ( 2 , 22 ) provided with system elements ( 3 , 4 , 5 , 23 , 24 , 25 ) configured to run a computer program comprising instructions configured to implement each of the steps of the process as claimed in claim 1 .

14 . The manufacturing system as claimed in claim 13 , furthermore comprising a varnishing machine configured to deposit a varnish on the element output by the subtractive manufacturing machine.

15 . The manufacturing system as claimed in claim 13 , in which the additive manufacturing machine comprises a manufacturing holder ( 12 ), which manufacturing holder is removable and configured to serve as a manufacturing holder for the subtractive manufacturing machine ( 32 ).

16 . The process as claimed in claim 2 wherein said predetermined sequence comprises at least one step chosen from a roughing step, a finishing step and a polishing step, alone or in combination.

17 . The process as claimed in claim 16 , wherein said predetermined sequence is chosen from:
a roughing step carried out on the intermediate optical element ( 10 ) leading to an intermediate optical element of state 2 , followed by a finishing step carried out on said intermediate optical element of state 2 leading to an intermediate optical element of state 3 , followed by a polishing step carried out on said intermediate optical element of state 3 leading to the target ophthalmic lens ( 30 ); or a finishing step carried out on the intermediate optical element ( 10 ) leading to an intermediate optical element of state 4 , followed by a polishing step carried out on said intermediate optical element of state 4 leading to the target ophthalmic lens ( 30 ); or a polishing step carried out on the intermediate optical element ( 10 ) leading to the target ophthalmic lens ( 30 ).

18 . The process as claimed in claim 4 , wherein said predetermined sequence is identical or different everywhere on the intermediate optical element ( 10 ).

19 . The process as claimed in claim 17 , wherein said predetermined sequence is identical or

Assignees

• Essilor Int

Inventors

• Quere Loic
• Gourraud Alexandre
• Allione Pascal
• Begon Cedric
• Le Saux Gilles

Classifications

• B29D11/00961

  using microprocessors or computers · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B29D11/00932

  Combined cutting and grinding thereof · CPC title

• B29D11/00009 Primary

  Production of simple or compound lenses · CPC title

• G02C2202/16

  Laminated or compound lenses · CPC title