OPHTHALMIC LENSES HAVING A PHOTOPOLYMER LAYER WITH GRIN ELEMENTS
20230036893 · 2023-02-02
Assignee
Inventors
- Paul CHAMBERLAIN (Livermore, CA, US)
- Sourav Saha (Pleasanton, CA, US)
- Arthur Bradley (Bloomington, IN)
- Baskar ARUMUGAM (Dublin, CA, US)
Cpc classification
G02B1/10
PHYSICS
B29D11/00865
PERFORMING OPERATIONS; TRANSPORTING
B29D11/00317
PERFORMING OPERATIONS; TRANSPORTING
G02C7/086
PHYSICS
G02C7/022
PHYSICS
International classification
Abstract
Ophthalmic lenses are described that have a layer, which has a base refractive index, provided on a surface of the lens. The layer includes at least one gradient index optical element. The ophthalmic lens may be a spectacle lens or a contact lens.
Claims
1. An ophthalmic lens the lens having a layer having a base refractive index provided on a surface of the lens, and the layer including at least one gradient index optical element.
2. The ophthalmic lens according to claim 1, wherein the layer is provided on an anterior surface of the lens.
3. The ophthalmic lens according to claim 1, wherein the layer is a film that has been applied to a surface of the lens.
4. The ophthalmic lens according to claim 1, wherein the layer is a coating provided on a surface of the lens.
5. The ophthalmic lens according to claim 1, wherein the lens is a spectacle lens.
6. The ophthalmic lens according to claim 1, wherein the lens is a contact lens.
7. The ophthalmic lens according to claim 6, wherein the lens is a rigid contact lens.
8. The ophthalmic lens according to claim 1, wherein the layer comprises a plurality of gradient index optical elements that are distributed across an area of the layer.
9. The ophthalmic lens according to claim 8, wherein the plurality of gradient index optical elements are distributed on lattice points of a triangular lattice across an area of the layer.
10. The ophthalmic lens according to claim 1, wherein the layer is a photopolymer layer, wherein each of the at least one gradient index optical element is a photocured gradient index optical element.
11. The ophthalmic lens according to claim 1, wherein each of the at least one gradient index optical element has a radially varying refractive index profile defined by a quadratic function.
12. The ophthalmic lens according to claim 1, wherein each of the at least one gradient index optical element has a diameter or width of between 10 μm and 2 mm.
13. The ophthalmic lens according to claim 8, wherein the plurality of gradient optical elements occupy between 20% and 80% of a surface area of the layer.
14. The ophthalmic lens according to claim 1, having a central region and an annular region surrounding the central region, wherein the layer that includes each of the at least one gradient index optical element covers a portion of the annular region.
15. The ophthalmic lens according to claim 14, wherein a plurality of gradient index optical elements are arranged periodically around the annular region.
16. The ophthalmic lens according to claim 14, wherein the layer includes a plurality of concentric annular regions, each annular region including at least one gradient index optical element.
17. The ophthalmic lens according to claim 16, wherein at least one gradient index optical element in a first annular region is out of phase with at least one gradient index optical element in an adjacent second annular region.
18. The ophthalmic lens according to claim 16, wherein the annular regions radially separated by a region of the layer having the base refractive power.
19. The ophthalmic lens according to claim 16, wherein the annular regions are adjacent to each other.
20. The ophthalmic lens according to claim 1, wherein the layer has a thickness of between 1 μm and 70 μm.
21. The ophthalmic lens according to claim 1, further comprising an adhesive provided between the layer and the surface of the lens.
22. The ophthalmic lens according to claim 1, further comprising a protective layer provided on an anterior surface of the layer that includes at least one gradient index optical element.
23. A method of manufacturing an ophthalmic lens, the method comprising: providing an ophthalmic lens; and forming a layer on a surface of the lens, wherein the layer has a base refractive index and includes at least one gradient index optical element.
24. The method according to claim 23, wherein forming the layer comprises applying a coating or film to the surface of the lens.
25. The method according to claim 24, wherein the layer is a film and wherein the step of applying the film to the lens comprises adhering the film to the lens using an adhesive.
26. The method according to claim 24, wherein the layer is a coating, and wherein plasma coating is used to apply the layer to the lens.
Description
DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0029] According to a first aspect, the present disclosure provides an ophthalmic lens. The lens has a layer having a base refractive index provided on a surface of the lens. The layer includes at least one gradient index optical element.
[0030] The lens may be for preventing or slowing the development or progression of myopia. The lens may be a lens for correcting or improving vision associated with presbyopia, hyperopia, astigmatism, keratoconus or another refractive anomaly.
[0031] The layer may cover an entire lens surface, or substantially all of a surface of the lens. Alternatively, the layer may cover a portion of a lens surface. The layer may cover a central portion of a lens surface, for example, a portion that is configured to be situated in front of a lens wearer's eye. The layer may cover an annular region surrounding the centre of the lens. There may be a peripheral region of the lens that is not covered by the layer.
[0032] The base refractive index of the layer may be constant. The base refractive index of the layer may be between 1.3 and 1.8, preferably about 1.5. Each of the at least one GRIN optical elements may have an average refractive power that is greater than the base refractive power. Alternatively, each of the at least one GRIN optical elements may have an average refractive power that is less than the base refractive power.
[0033] In the context of the present disclosure, each of the at least one gradient index (GRIN) optical elements is an element that has a varying refractive index. The variation in refractive index may be a transverse variation in refractive index across the element. i.e., in a direction that runs parallel to a surface of the layer. The variation in refractive index may be a radial variation in refractive index, i.e., the refractive index may vary extending radially outwardly from a point. The variation in refractive index may be an axial variation in refractive index, i.e., in a direction that runs normal to a surface of the layer. Each of the at least one GRIN optical elements may have a transverse variation in refractive index and an axial variation in refractive index. The variation in refractive index of each of the at least one GRIN optical elements may be a linearly varying gradient in refractive index, or a gradient that has a varying profile defined by a quadratic function.
[0034] The GRIN elements may be lenses. Advantageously, the GRIN elements may provide defocusing. It is believed that defocusing may help to prevent or slow of the worsening of myopia. It is believed that defocusing may help to correct or improve vision associated with presbyopia, hyperopia, astigmatism, keratoconus or other refractive anomalies.
[0035] Each of the at least one GRIN optical elements may give rise to additional scattering of light that falls incident on the GRIN optical element, compared to light falling incident on the remainder of the layer. Alternatively, each of the at least one GRIN optical elements may give rise to reduced scattering of light that falls incident on the GRIN optical element, compared to light falling incident on the remainder of the layer. Each of the at least one GRIN optical elements may have a minimum change in refractive index, compared to the base refractive index, of at least 0.001, preferably at least 0.005. Each of the at least one GRIN optical elements may have a minimum refractive index that is 0.001 greater than the base refractive index. Each of the at least one GRIN optical elements may have a minimum refractive index that is 0.005 greater than the base refractive index. Each of the at least one GRIN optical elements may have a maximum refractive index that is 0.005 less than the base refractive index. Each of the at least one GRIN optical elements may have a maximum refractive index that is 0.001 less than the base refractive index. Each of the at least one GRIN optical elements may have a maximum change in refractive index, compared to the base refractive index of less than 0.1, preferably less than 0.025. Each of the at least one GRIN optical elements may have a maximum refractive index that is 0.1 greater than the base refractive index. Each of the at least one GRIN optical elements may have a maximum refractive index that is 0.025 greater than the base refractive index. Each of the at least one GRIN optical elements may have a minimum refractive index that is 0.1 less than the base refractive index. Each of the at least one GRIN optical elements may have a minimum refractive index that is 0.025 less than the base refractive index. Each of the at least one GRIN optical elements may have a minimum refractive power that is between −25 D and 25 D, preferably between −0.25 D and 25 D.
[0036] Each of the at least one GRIN optical elements may extend through the thickness of the layer. Each of the at least one GRIN optical elements may extend partway through the thickness of the layer. Each of the at least one GRIN optical elements may be embedded within the layer.
[0037] The layer may be a cross-linked polymeric layer including at least one GRIN optical element. The layer may have been formed from a matrix of uncross-linked polymers.
[0038] The layer may be provided on an anterior surface of the lens. In the context of the present disclosure, the anterior surface of the lens is the forward facing, or exterior surface of the lens when the lens is being worn by a lens wearer.
[0039] The layer may be a film that has been applied to a surface of the lens. The layer may comprise a Bayfol® HX film. The layer may be a film that is applied to the lens during manufacture of the lens. The layer may be permanently adhered or otherwise applied to the lens. The layer may be releasably adhered or otherwise applied to the lens, i.e., it may be readily removable from the lens. The layer may be re-usable, such that layer can be easily removed and reapplied to the same lens or to a different lens.
[0040] The layer may be a coating provided on a surface of the lens. The coating may be applied to the lens during the lens manufacture process. The coating may bond to a surface of the lens. The coating may be irreversibly applied to the lens, for example, bonding between the coating and the lens may be permanent bonding.
[0041] The lens may be a spectacle lens. The lens may be circular in shape. The lens may be elliptical in shape. The lens may be oval in shape. The lens may be rectangular in shape. The lens may be square in shape. The anterior surface of the lens may have an area of between 1200 mm.sup.2 and 3000 mm.sup.2. The lens may be formed from transparent glass or rigid plastic such as polycarbonate. The lens may be substantially planar and may have at least one curved surface providing a lens power.
[0042] The lens may be a contact lens. As used herein, the term contact lens refers to an ophthalmic lens that can be placed onto the anterior surface of the eye. It will be appreciated that such a contact lens will provide clinically acceptable on-eye movement and not bind to the eye or eyes of a person. The contact lens may be in the form of a corneal lens (e.g., a lens that rests on the cornea of the eye). In embodiments where the lens is a contact lens, the lens may have a surface area of between 60 mm.sup.2 and 750 mm.sup.2. The lens may have a circular shape. The lens may have an oval shape. The lens may have an elliptical shape. The lens may have a diameter of between 10 mm and 15 mm.
[0043] The lens may be a rigid contact lens. The lens may be a rigid, gas permeable contact lens.
[0044] The contact lens may be a toric contact lens. For example, the toric contact lens may include an optic zone shaped to correct for a person's astigmatism.
[0045] The lens may be a soft contact lens, such as a hydrogel contact lens or a silicone hydrogel contact lens.
[0046] The lens may comprise an elastomer material, a silicone elastomer material, a hydrogel material, or a silicone hydrogel material, or combinations thereof. As understood in the field of contact lenses, a hydrogel is a material that retains water in an equilibrium state and is free of a silicone-containing chemical. A silicone hydrogel is a hydrogel that includes a silicone-containing chemical. Hydrogel materials and silicone hydrogel materials, as described in the context of the present disclosure, have an equilibrium water content (EWC) of at least 10% to about 90% (wt/wt). In some embodiments, the hydrogel material or silicone hydrogel material has an EWC from about 30% to about 70% (wt/wt). In comparison, a silicone elastomer material, as described in the context of the present disclosure, has a water content from about 0% to less than 10% (wt/wt). Typically, the silicone elastomer materials used with the present methods or apparatus have a water content from 0.1% to 3% (wt/wt). Examples of suitable lens formulations include those having the following United States Adopted Names (USANs): methafilcon A, ocufilcon A, ocufilcon B, ocufilcon C, ocufilcon D, omafilcon A, omafilcon B, comfilcon A, enfilcon A, stenfilcon A, fanfilcon A, etafilcon A, senofilcon A, senofilcon B, senofilcon C, narafilcon A, narafilcon B, balafilcon A, samfilcon A, lotrafilcon A, lotrafilcon B, somofilcon A, riofilcon A, delefilcon A, verofilcon A, kalifilcon A, lehfilcon A, and the like.
[0047] Alternatively, the lens may comprise, consist essentially of, or consist of a silicone elastomer material. For example, the lens may comprise, consist essentially of, or consist of a silicone elastomer material having a Shore A hardness from 3 to 50. The Shore A hardness can be determined using conventional methods, as understood by persons of ordinary skill in the art (for example, using a method DIN 53505). Other silicone elastomer materials can be obtained from NuSil Technology or Dow Chemical Company, for example.
[0048] The lens may have an optic zone. The optic zone encompasses parts of the lens that have optical functionality. The optic zone is configured to be positioned over or in front of the pupil of an eye when in use. The optic zone may be surrounded by a peripheral zone. The peripheral zone is not part of the optic zone, but sits outside the optic zone. For a contact lens, the peripheral zone may sit above the iris when the lens is worn. The peripheral zone may provide mechanical function, for example, increasing the size of the lens thereby making the lens easier to handle. For a contact lens, the peripheral zone may provide ballasting to prevent rotation of the lens, and/or providing a shaped region that improves comfort for the lens wearer. The peripheral zone may extend to the edge of the lens. In embodiments of the present disclosure the layer including at least one GRIN optical element may cover the optic zone, but it may be that it does not cover the peripheral zone.
[0049] The layer may have a uniform thickness. For a contact lens, the layer may have a thickness of between 1 μm and 100 μm, preferably between 10 μm and 20 μm, and more preferably between 14 μm and 18 μm. For a spectacle lens, the layer may have a thickness of between 1μm and 1000 μm, preferably between 10 μm and 20 μm, and more preferably between 14 μm and 18 μm.
[0050] In embodiments of the present disclosure, the layer may comprise a plurality of GRIN elements distributed across an area of the layer. The plurality of GRIN optical elements may be distributed across the whole area layer. The plurality of GRIN optical elements may be distributed across a portion of the layer. The plurality of GRIN optical elements may be randomly distributed across all or a portion of the layer. The GRIN optical elements may be arranged in a regular pattern across all or a portion of the layer. For a spectacle lens, it may be advantageous to provide a plurality of GRIN distributed across an area of the lens, as this may enable defocus (caused by the GRIN elements) to be maintained as the lens wearers eye moves relative to the lens. A plurality of GRIN elements distributed across a spectacle lens may enable a consistent myopic defocus to be maintained.
[0051] The GRIN optical elements may be positioned at regular intervals across the whole layer or a portion of the layer. The GRIN optical elements may be arranged on lattice points of a triangular lattice. The GRIN optical elements may be arranged on lattice points of a square or rectangular lattice. The GRIN optical elements may be arranged to form an annular pattern on the layer. The annular pattern may leave a central region of the lens free from GRIN optical elements. The lens may have a central region having a diameter of up to 8 mm may be free from GRIN optical elements. The annular pattern may comprise a single annulus or a plurality of concentric annuli.
[0052] The layer may be a photopolymer layer. Each of the at least one gradient index optical elements may be a photocured gradient index optical element. Each GRIN optical element may have been formed using photocuring.
[0053] Each of the at least one gradient index optical elements may have a radially varying refractive index profile defined by a quadratic function. Each of the at least one GRIN optical elements may have varying refractive index profile defined by a higher order polynomial function. Each of the at least one GRIN optical elements may have varying refractive index profile defined by a Gaussian function.
[0054] Each of the plurality of GRIN elements may have the same variation in refractive index. Each of the plurality of GRIN elements may have a different variation in refractive index. Some of the GRIN elements may have the same variation in refractive index, and other elements may have a different variation in refractive index. A plurality of GRIN optical elements may be distributed such that GRIN optical elements having the same or a similar variation in refractive index may be grouped in clusters or in an ordered arrangement. The film may be dividable into a plurality of distinct portions, with each portion comprising GRIN optical elements having a different variation in refractive index.
[0055] Each of the at least one gradient index optical elements may have a width of between 10 μm and 5 mm. Each of the at least one GRIN optical elements may have a volume of between 100 μm.sup.3 and 3 mm.sup.3. The plurality of GRIN optical elements may occupy between 5% and 80% of the volume of the layer. The plurality of gradient index optical elements may cover between 20% and 80% of a surface area of the layer. The layer may include between 2 and 5000 gradient index optical elements.
[0056] Each of the at least one GRIN optical elements may extend through the thickness of the layer. Each of the at least one GRIN elements may extend through part of the thickness of the layer. Each of the at least one GRIN elements may be dispersed within the layer. Each of the at least one GRIN elements may be approximately cuboidal or spherical in shape.
[0057] The lens may have a central region and an annular region surrounding the central region. The layer that includes each of the at least one gradient index optical elements may cover a portion of the annular region. It may be that the layer does not cover the central region, and the central region may therefore be free from GRIN optical elements. The layer may cover all of the annular region, or part of the annular region. As used herein, the term annular region refers to a region that may extend around the entire outer edge of the central region, or may extend partially around the outer edge of the central region. The annular region may be circular, oval or elliptical in shape. The annular region may include a plurality of GRIN optical elements. The plurality of GRIN optical elements may be distributed around the entire annular region, or may be distributed across a portion of the annular region. The plurality of gradient index optical elements may be arranged periodically around the annular region. The layer may include a plurality of concentric annular regions, and each of the concentric annular regions may include at least one GRIN optical element. Each concentric annular region may include a plurality of GRIN elements. A plurality of GRIN optical elements may cover a portion of each annular region. Using the angle θ to define the position around the annular region, wherein θ varies between 0° and 360, a plurality of GRIN optical elements may cover the same range of θ angles for each annular region (i.e. the GRIN elements may be in phase for each annular region, with maxima and minima at the same θ values for each annular region), or may occupy different ranges of θ angles (i.e. the GRIN elements may be out of phase for each annular region, with maxima and minima at different θ values for each element). At least one GRIN element in a first annular region may therefore be out of phase with at least one GRIN element in an adjacent second annular region. At least one GRIN element in a first annular region may be in phase with at least one GRIN element in an adjacent second annular region.
[0058] If the layer includes a plurality of concentric annular regions, the variation in refractive index around each of the annular regions may be in phase, or out of phase.
[0059] The layer may include a plurality of concentric annular regions that are radially separated by a region of the layer having the base refractive index. Alternatively, the layer may include a plurality of concentric annular regions that are adjacent to each other, such that there is not a region having the base refractive index between the annular concentric gradient index optical elements.
[0060] The layer may have a thickness of between 1 μm and 70 μm.
[0061] The lens may further comprise an adhesive provided between the layer and the surface of the lens. The adhesive may comprise a transparent adhesive such as an epoxy-based adhesive. The adhesive may be an adhesive layer. The adhesive layer may be applied to an anterior surface of the lens during manufacture of the lens. The adhesive layer may be applied to a posterior surface of the layer during manufacture of the lens. The adhesive may permanently adhere the layer to the surface of the lens. Alternatively, the layer may be bonded to the surface of the lens. The layer may be permanently, or irreversibly bonded to the surface of the lens.
[0062] The lens may further comprise a protective layer provided on an anterior surface of the layer that includes at least one gradient index optical element. The anterior surface of the layer that includes at least one GRIN optical element is the forward facing, or exterior surface of the layer when the lens is in normal use and being worn by a lens wearer. The protective layer may cover all or part of the anterior surface of the layer that includes at least one GRIN optical element. The protective layer may be a transparent layer. The protective layer may comprise polycarbonate (PC). The protective layer may comprise polyethylene terephthalate (PET) or cellulose triacetate (TAC). The protective layer may comprise a substance that has negligible birefringence. The protective layer may be impermeable to water. The protective layer may be scratch resistant. The protective layer may have the base refractive index. The protective layer may offer a degree of UV protection. The protective layer may be adhered to layer including at least one GRIN optical element using an adhesive.
[0063] According to a second aspect, the present disclosure provides a method of manufacturing an ophthalmic lens. The lens has a layer provided a surface of the lens. The layer has a base refractive index and includes at least one gradient index optical element. The method comprises providing an ophthalmic lens and applying a coating or film to the lens to form the layer. The lens may include any of the features set out above. Providing the lens may comprise manufacturing the lens. Manufacturing the lens may comprise forming a female mold member with a concave lens forming surface and a male mold member with a convex lens forming surface. The method may comprise filling a gap between the female and male mold members with bulk lens material. The method may further comprise curing the bulk lens material to forms the lens.
[0064] The lens may be a molded contact lens. The lens can be formed by cast molding processes, spin cast molding processes, or lathing processes, or a combination thereof. As understood by persons skilled in the art, cast molding refers to the molding of a lens by placing a lens forming material between a female mold member having a concave lens member forming surface, and a male mold member having a convex lens member forming surface.
[0065] The layer may be a film. The step of applying the film to the lens may comprise using an adhesive to adhere the layer to the lens. The adhesive may be a transparent adhesive. The adhesive may be applied to a posterior surface of the layer including at least one GRIN element. The adhesive may be applied to an anterior surface of the lens prior to application of the layer including at least one GRIN element.
[0066] Alternatively, the layer may comprise a coating. A coating may be applied directly onto a lens surface by various coating methods, such as spray coating, spin coating, solution casting, liquid phase surface deposition, or gas phase surface deposition. Prior to applying the coating to a lens surface, the lens surface may be treated, for example, using plasma treatment, to improve the bonding or adhesion with the coating layer.
[0067] The step of forming the layer may comprise photocuring at least one region of a photocurable layer, thereby producing at least one photocured gradient index optical element. A digital light projection system may be used to photocure at least one region of the photocurable layer. Alternatively, a direct laser writing system may be used to photocure at least one region of the photocurable layer. Alternatively, a collimated LED/laser light source may be used to photocure at least one region of the photocurable layer. A high resolution 3D photocurable system, such as a two photon confocal microscope based laser illumination system may be used to photocure at least one region of the photocurable layer.
[0068] In the example embodiments described below, the lens may be a spectacle lens or a contact lens. The lens may have a circular shape. The lens may have an oval shape. The lens may have an elliptical shape. In the case of a spectacle lens, the lens may have an area between 300 mm.sup.2 and 5000 mm.sup.2, preferably between 1000 mm.sup.2 and 3000 mm.sup.2. In the case of a contact lens, the lens may have a surface area of between 60 mm.sup.2 and 750 mm.sup.2. A contact lens may have a diameter of between 6 mm and 20 mm, preferably between 9 mm and 16 mm.
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[0081] Whilst the present disclosure has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the disclosure lends itself to many different variations not specifically illustrated herein. By way of example only, certain possible variations will now be described.
[0082] In example embodiments of the present disclosure, each GRIN element may have an average refractive index that is higher than the base refractive index. In other example embodiments, each GRIN element may have an average refractive index that is lower than the base refractive index.
[0083] Whilst in the foregoing description, integers or elements are mentioned which have known obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present disclosure, which should be construed as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the disclosure that are described as advantageous, convenient or the like are optional, and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the disclosure, may not be desirable and may therefore be absent in other embodiments.