Multifocal lenses with ocular side lens segments

Systems and methods for creating and/or manufacturing progressive lenses (e.g., bifocal, multifocal, and so on) having ocular side (e.g., back side or surface) lens segments, are described. For example, the systems and methods may apply round lens segments to ocular sides or surfaces of progressive lenses, providing the lenses with specializing vision lens segments and/or power enhancement lens segments, which may combine with front surface power additions provided by the multifocal lens segments applied to the front surfaces of the lenses.

BACKGROUND

Typically, traditional multifocal lenses, such as progressive lenses, flat-top lenses, round lenses, and so on provide users with a seamless progression of powers, facilitating a clear vision of all viewing distances. However, lenses having a strong prescription (such as those having a small or short radii of curvature) are often bulky and inconvenient to a user wearing eyeglasses with such lenses. These users may suffer from a “coke bottle effect,” where the thickness of the lens causes the eyeglasses (and the user wearing them) to look unattractive at the periphery of the lenses.

Further, although such lenses may remove lines between lens segments, such as those visible in traditional bifocals, they are generally singularly purposed—to provide users with normal, clear vision at all distances. However, there may be times when users (e.g., golfers, pilots, and so on) require specialized powered segments, which cannot be accommodated or provided by traditional multifocal lenses. Further, such multifocal lenses often cannot provide power enhancements, such as large “add power” enhancements, required by users.

DETAILED DESCRIPTION

Introduction and Overview of Technology

Systems and methods for creating and/or manufacturing multifocal lenses (e.g., bifocal, progressive, flat-tops, round, and so on) having ocular side (e.g., back side or surface) lens segments, are described. For example, the systems and methods may apply round lens segments to ocular sides or surfaces of multifocal (e.g., progressive) lenses, providing the lenses with specializing vision lens segments and/or power enhancement or refinement lens segments at targeted locations, which may combine with front surface power additions provided by the multifocal lens segments applied to the front surfaces of the lenses.

In manufacturing such lenses having both front and back surface lens segments, the systems and methods may employ digital surfacing techniques to create and/or apply the lens segments to the lens surfaces. Digital surfacing, and other soft tool based surfacing, allows manufacturers to create an infinite number of surfaces on lenses, unlike traditional lathing and lapping techniques described herein.

For example, using digital surfacing, a diamond or other similar type of cutter produces a back surface segment of a lens according to a specified depth, at a precision of one tenth of a micron or less. Thus, digital surfacing, in some cases, enables manufacturers to create non-spherical surfaces on lenses, such as specialized digital round lens segments applied to ocular side surfaces.

Where previous techniques of creating lens segments onto a surface (e.g., using lathes and laps) could not achieve such specialized requirements, forming digitally created round (or other geometrically shaped) lens segments or sections on the back surfaces of lenses enables professionals to create lenses having patient specific optical and/or cosmetic benefits, specialized vision areas, and so on, while maximizing the optical quality of the lenses.

Therefore, in some embodiments, the systems and methods provide a lens for use with eyeglasses. The lens includes a front surface having a multifocal area, and a back surface having a lens segment. The back surface may include a lens segment positioned to enhance the power addition supplied by a front surface multifocal segment, and/or a lens segment positioned to provide a specialized bifocal segment, such as a golf segment that enables clear vision for objects in a specific area of vision, a pilot segment that enables clear vision for objects above a user's normal range of vision, or other such specialized or vision targeted segments.

Further, in some embodiments, the systems and methods provide a method of manufacturing a lens for use with eyeglasses. The systems and methods may receive a lens blank (such as a lens blank having a front side multifocal area), define a digital round segment to be applied to an ocular surface of the received lens blank, generate a digital surface map based on the defined round segment to be applied to the ocular surface of the received lens blank, and apply a round segment onto a specific area of the ocular surface of the lens blank based on the generated digital surface map.

Examples of a Suitable Lens Manufacturing System

As described herein, aspects of the systems and methods enable eyeglass manufacturers and other eye care professionals to apply various different lens segments to the back, or ocular, surfaces of lenses, such as multifocal lenses having front surface corrective areas.FIG. 1is a block diagram illustrating a suitable environment100for manufacturing a multifocal lens with an ocular side lens segment.

The environment100includes a digital surfacing system150. A digital surfacing system150performs soft tool based surfacing, allowing manufacturers to create an infinite number of surfaces on lenses. The system150may include various computer-controlled surfacing equipment or devices, which are generally more precise than conventional tools.

For example, the system150may receive a file, such as a digital surface map file130, which defines a lens surface (e.g., a surface having a round lens segment) to be applied to the back surface of a lens blank. A surface map component120, such as a surface map generator, may create the surface map (e.g., layout specifications of a lens segment) based on prescription information110for a patient.

In creating a job to manufacture a lens for the patient, the component120may receive various prescription information indicative of corrections or special lens segments to be applied to the lens. Using the prescription information, the surface map component may generate map surface information, such as add power information, segment size information, blend width information, and so on. Some or all of the information may also be input by an eye care professional or other user of the system150.

In some cases, the map component120accesses various data files to perform lens layout or location calculations and determine appropriate lens tool settings for manufacturing a custom lens. Examples of accessed data files include lens stock data, frame stock data, surfacing data, finishing data, and other miscellaneous data files.

Examples of lens stock data include style attributes, such as minimum fitting height for progressive lenses; material attributes, such as tintability and compatibility with various coatings; recommended lens base curve selection information for use with particular eyeglass prescriptions; lens technical information, such as lens blank dimensions and curve measurements; lens inventory in the laboratory; and lens selection criteria for which manufacturer's lens blank and which lens size to use for a given prescription, ranked according to the laboratory's preferences. Examples of frame stock data includes size and color availability; whether a frame is available for requested eye, bridge, and/or temple measurements; and technical details, such as the minimum lens edge thickness and compatible lens base curve. Examples of surfacing data include setup files for the generator (e.g., a surfacing machine); prism data that tells how much prism the generator is capable of producing in a generated lens; information about the dimensions of the blocks used to hold the lenses in the generator; information about the tools the generator uses to grind lenses and the pads placed on the tools, such as the diameter and curvature of the tools and thickness of the pads; and gauge data that provides the type of gauge used to measure the lens curves and thicknesses. Examples of finish data include the shape and circumference of a lens to fit into a frame; the location of the edge bevel or groove; and the position and shape of drill holes. Examples of other data files include information that flags preferences or warnings that are specific to a particular account and/or doctor, such as a doctor or patient/patient group specifying an anti-reflective coating on every order.

The system150utilizes the digital surface map130(and/or other information) as instructions, and directs a surfacing tool (e.g., a cutter tool) to apply (e.g., sculpt) the mapped surface to the back surface of the lens blank. In some cases, the tool may be a diamond or other similar type of cutter capable of producing a back surface segment of a lens according to a specified depth, at a precision of one tenth of a micron or smaller.

In some cases, the system150may perform a single job and directly apply both a front surface multifocal (e.g., progressive) area and a back surface round lens segment. However, in other cases, the system150may manufacture the lens160as a series of sequential jobs, a first job to receive and/or apply a front surface multifocal area, and a second job to apply the round segment to the back surface. For example, the system150may employ various 3D printing techniques to create segments on both surfaces of a lens. Once complete, the system150refines and finalizes the newly created lens160, which contains the round segment165on a back surface of the lens160.

FIG. 1and the discussion herein provide a brief, general description of a suitable computing environment in which the environment100can be supported and implemented. Although not required, aspects of the system are described in the general context of computer-executable instructions, such as routines executed by a general-purpose computer, e.g., mobile device, a server computer, or personal computer. Those skilled in the relevant art will appreciate that the system can be practiced with other communications, data processing, or computer system configurations, including: Internet appliances, hand-held devices (including tablet computers and/or personal digital assistants (PDAs)), all manner of cellular or mobile phones, multi-processor systems, microprocessor-based or programmable consumer electronics, network PCs, mini-computers, mainframe computers, voice-controlled devices, and so on.

Aspects of the system can be embodied in a special purpose computing device or data processor that is specifically programmed, configured, or constructed to perform one or more of the computer-executable instructions explained in detail herein. Aspects of the system may also be practiced in distributed computing environments where tasks or modules are performed by remote processing devices, which are linked through a communications network, such as a Local Area Network (LAN), Wide Area Network (WAN), or the Internet. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.

Aspects of the system may be stored or distributed on computer-readable media (e.g., physical and/or tangible computer-readable storage media, such as non-transitory media), including magnetically or optically readable computer discs, hard-wired or preprogrammed chips (e.g., EEPROM semiconductor chips), nanotechnology memory, biological memory, or other data storage media. Indeed, computer implemented instructions, data structures, screen displays, and other data under aspects of the system may be distributed over the Internet or over other networks (including wireless networks) or they may be provided on any analog or digital network (packet switched, circuit switched, or other scheme). Those skilled in the relevant art will recognize that portions of the system reside on a server computer, while corresponding portions reside on a client computer such as a mobile or portable device, and thus, while certain hardware platforms are described herein, aspects of the system are equally applicable to nodes on a network. In an alternative embodiment, the mobile device or portable device may represent the server portion, while the server may represent the client portion.

Any of the machines, databases, or devices shown inFIG. 1may be implemented in a general-purpose computer modified (e.g., configured or programmed) by software to be a special-purpose computer to perform the functions described herein for that machine, database, or device. For example, a computer system able to implement any one or more of the methodologies described herein. Moreover, any two or more of the machines, databases, or devices illustrated inFIG. 1may be combined into a single machine, and the functions described herein for any single machine, database, or device may be subdivided among multiple machines, databases, or devices.

Examples of Creating Multifocal Lenses with Ocular Side Lens Segments

As described herein, in some embodiments, the digital surfacing system150facilitates the creation and/or manufacture of multifocal lenses having ocular side lens segments, such as round segments.FIG. 2is a flow diagram illustrating a method200of manufacturing a multifocal lens with an ocular side lens segment. The method200may be performed by the digital surfacing system150and/or the surface map component120, and, accordingly, is described herein merely by way of reference thereto. It will be appreciated that the method200may be performed on any suitable hardware.

In operation210, the system150receives a lens blank with a front surface having an applied multifocal area. As described herein, the system150may apply a progressive or other multifocal segment (e.g., bifocal, trifocal, and so on), or area to the front surface during a job, or may receive a semi-finished lens blank with a modified front surface. Typically, the front surface includes an add power that is applied in 0.25 Diopter increments.

In operation220, the surface map component120defines a digital round segment to be applied to a back, or ocular, surface of the received lens blank. For example, the surface map component120may utilize information from a patient's prescription when defining the round segment. Example prescription information may include add power information, optical center information, and so on.

In operation230, the surface map component120generates a digital surface map that defines the round segment to be applied to the back surface of the lens. For example, the component120may determine and/or receive information identifying a block diameter of the lens blank, a base curve of the lens blank, layout information (such as based on optical center information), add power information, placement information, diameter information, height map information, size information, blend information, and so on.

In some embodiments, the surface map component120and/or the digital surfacing system150may include a user interface, such as an interface configured to facilitate the input of information, instructions, and/or other data useful in defining the digital surface maps and/or associated lens segments. The user interface may include a series of fields that define certain information, such as the information defining the round segment to be applied to the back surface of a lens.

As described herein, the fields may receive information defining a location or placement of the lens segment (e.g., with respect to a defined optical center), information indicating an enhanced add power for the lens segment, information defining a blending zone for the lens segment, information specifying a width of the lens segment, information specifying a shape or geometry (e.g., round, oval, and so on), of the lens segment, and so on.

In operation240, the digital surfacing system150places, sculpts, or otherwise applies a round segment onto a specific area of the back surface of the lens based on the generated surface map via digital surfacing techniques. For example, the system150applies, using the surface map information, a round segment to the back surface of a multifocal lens (e.g., a lens having a front surface with a multifocal lens). In some cases, the system150may apply the round segment in 0.01 Diopter increments, depending on what is prescribed for a user.

Thus, in some embodiments, the systems and methods generate, create, and/or manufacture a lens for use with eyeglasses. For example, the systems and methods utilize the digital surfacing system150to perform a method for creating a lens for use with eyeglasses, where the system150receives a digital surface map that defines a round segment to be applied to a back surface of a progressive lens, and instructs one or more digital surfacing tools of the digital surfacing system150to apply the defined round segment to the back surface of the progressive lens. The digital surface map is based on or includes information specifying an enhanced add power for the round segment, information defining a blending zone for the round segment, information specifying a width of the round segment, and so on.

FIG. 3illustrates a created multifocal lens with an ocular side lens segment. The lens300includes a progressive area315(e.g., a bifocal, trifocal, multifocal, and so on) applied to a front surface310of the lens, and a round segment325applied to a back, or ocular, surface320of the lens300.

As described herein, the systems and methods enable the application of a variety of different lens segment configurations, such as lens segments that enhance the optical power of a multifocal lens, and/or lens segments that provide specialized or targeted bifocal segments, such as bifocal segments useful in certain vocations (e.g., golf, aviation, woodworking, and so on).

As an example, an eye doctor orders a digital progressive lens with a600add power to be made for a patient. A typical digital processing system cannot create a lens with a progressive segment applied to a front side of lens having such a large add power. However, as described herein, the systems and methods receive a front surface progressive lens (e.g., a Varilux Comfort with300add power) as a lens blank, and create, using the techniques described herein, an add enhancer round segment having an add power of 300, at a specific location on the back surface, which aligns to the front surface, achieving a total add power of 600, as prescribed.

FIGS. 4A-4Eare diagrams illustrating example configurations of multifocal lenses having ocular side lens segments.FIG. 4Adepicts a traditional round seg bifocal lens400, with an enhanced round segment415applied to increase and/or refine the add power of a round seg bifocal410applied to a front surface of a lens400. The configuration enables, for example, a front-side multifocal lens, which normally is not available in an add power greater than 3.50 D (Diopters), to be enhanced with a back surface blended round segment to provide a total reading addition of 7.00 D or greater.

Further, such a configuration, in some embodiments, facilitates more specific, refined, and/or granular add powers to be applied to lenses, such as bifocals and other multifocal lenses. For example, a front side multifocal typically provides an add power in 0.25 Diopter increments. However, the systems describe herein can add the back surface segments in 0.01 Diopter increments. Therefore, the systems may provide for add powers that are within the typical 0.25 D increments (e.g., a 2.0 D front surface add power plus a 0.1 back surface add power provides for a 2.1 D combined add power for the lens).

FIG. 4Bdepicts an enhanced round segment435applied to a lens420, with a front surface progressive area430. The round segment435is placed as a vocational upper add power segment, providing a specific area for bifocal add power. The configuration enables, for example, airline pilots, plumbers and other users within work related situations to utilize upward positioned bifocals for close work above their heads. Traditional progressive lenses cannot provide such functionality. Thus, the systems and methods, in providing a back surface blended round segment, provides the specialized bifocal to a multifocal lens.

FIG. 4Cdepicts an enhanced round segment455applied to a lens440, with a progressive area450. The lens segment provides additional add power to a lens already providing 4.00 D via the front surface multifocal area450. In doing so, the lens segment455, in having a concentric, back surface blended round segment, enhances the add power of the lens440at the reading area of the lens, without typical cosmetic disadvantages of increasing the power on the front surface of the lens440.

FIG. 4Ddepicts a first enhanced round segment470and a second enhanced round segment475applied to a lens460that otherwise has no front side multifocal area. The round segments470,475are placed as vocational upper and lower add power segments, providing specific areas for bifocal add power.

FIG. 4Edepicts an enhanced round golf segment495applied to a lens480, with a progressive area490. The lens480is enhanced with a back surface blended round segment495positioned up and out in one eye, for use in reading score cards in golf (and useful in other similar pursuits), where a lower add power for a golfer is not designed for reading, but for intermediate distance (to the ball).

Thus, as depicted in the various embodiments described herein, the systems and methods facilitate the creation and manufacture of enhanced digital round segments (or segs) that can be placed on conventional front side multifocals (e.g., round segments, progressives, and/or lined multifocals).

Such lens segments, being placed on back surfaces of lens, may enhance, increase, and/or refine or incrementally adjust conventional lens style add powers. Further, the systems and methods, in utilizing digital surfacing techniques, provide for easy and specialized placement of rear side round segments for occupational, vocational, and/or other specialized uses, among other benefits.

CONCLUSION

As used herein, being above a threshold means that a value for an item under comparison is above a specified other value, that an item under comparison is among a certain specified number of items with the largest value, or that an item under comparison has a value within a specified top percentage value. As used herein, being below a threshold means that a value for an item under comparison is below a specified other value, that an item under comparison is among a certain specified number of items with the smallest value, or that an item under comparison has a value within a specified bottom percentage value. As used herein, being within a threshold means that a value for an item under comparison is between two specified other values, that an item under comparison is among a middle specified number of items, or that an item under comparison has a value within a middle specified percentage range.