Abstract:
The present invention provides for an optical assembly using two ultra-thin optical pieces/parts defining the outer bound of the assembly with a solid or liquid core and methods of forming said assembly. In particular, the present in invention discloses the handling and arrangements of said ultra-thin optical pieces to prevent deformation and loss of optical quality of said ultra-thin optical pieces. The ultra-thin optical pieces can be from 25-200 microns and their structural integrity can be preserved through uninterrupted support throughout the encapsulation of one or more fluids, e.g., a saline solution and an oil solution, which can be used to form a liquid meniscus lens. In some embodiments, interlocking features included in the ultra-thin optical parts can be included in order to help create the seal and/or provide structural support to the liquid lens assembly. In another embodiment, the supporting pieces to the ultra-thin optical components have an interlocking or centering mechanism, to aid in the assembly and sealing of said optical assembly.

Description:
TECHNICAL FIELD 
     The disclosure relates to ophthalmic lenses and, in particular, methods for molding and assembling ultra-thin optical parts for use as or in ophthalmic devices. 
     BACKGROUND OF THE INVENTION 
     Contact lenses have been used to improve vision for many years. Early designs of contact lenses were fashioned from hard materials, such as polymethyl methacrylate (PMMA). However, these lenses were uncomfortable and caused various problems for patients because of their relatively low permeability to oxygen. Soft contact lenses which were oxygen-permeable were later developed using materials based on hydrogels. Although hydrogel lenses are extremely popular today, the industry is continuously looking to improve the design of lenses or develop lenses specific to a certain condition. 
     For example, presbyopia is typically an age-related condition in which the eye&#39;s ability to focus on near objects progressively diminishes. The result for many people is the need for varifocal or bifocal glasses. Some of these glasses incorporate lenses that attempt to correct both near and far vision with the same lens. With respect to contact lenses, some people choose contact lenses to correct one eye for near and one eye for far, although side effects can include an interference with depth perception due to the loss of concurrent focusing of one eye in relation to the other eye. 
     Liquid lens technology has been gaining momentum with respect to use in medical imaging devices, microcameras, and fiber-optic telecommunication systems. A liquid lens uses one or more fluids to create a variable focus lens without any moving parts. In most cases, two immiscible fluids, one an electrically conducting aqueous solution and a nonconducting oil, are provided in a closed device. A hydrophobic coating may be applied to interior portions of the device, for example, to force the aqueous solution into a hemispherical lens-shaped configuration toward a portion of the device not having the hydrophobic coating. In a process called electrowetting, application of very minute direct current voltages across the hydrophobic coating decreases the repellency of the coating. The liquid&#39;s surface tension is changed through the process, which changes the radius of curvature in the meniscus, which in turn changes the focal length of the lens. A liquid lens is thus capable of transitioning from a convex (convergent) to a concave (divergent) lens shape with voltages as little as 0.1 microjoules and in just a few milliseconds. 
     A solution for presbyopia may rest on the ability to create a multiple state liquid meniscus lens that allows a person to control, for example, the zoom in and zoom out capability of the lens. However, the ability to manufacture this type of ophthalmic lens depends on the ability to create and assemble ultra-thin optical quality parts that are not deformed during manufacturing. 
     Designs of ophthalmic devices in accordance with aspects of the present disclosure rely on using ultra-thin materials that require extreme care in the shaping and handling of component parts. Even if handled with care, ultra-thin parts can often warp, curl, or irreversibly deform. Methods and systems are needed to enable assembly of, for example, a liquid filled ophthalmic device using ultra-thin parts that will not deform during shaping, handling, and assembly. 
     SUMMARY OF THE INVENTION 
     The present disclosure includes methods and apparatus for assembling ultra-thin component optical quality parts/pieces using a mold assembly with ejectable mold parts. The mold parts are designed to support and maintain the integrity of the fragile ultra-thin parts throughout the assembly process. 
     The present invention includes disclosure of an ophthalmic lens constructed from a plurality of ultra-thin parts, wherein each of the ultra-thin parts are maintained in contact with a support surface of a mold part throughout the assembly process. Separate mold parts, each with an ultra-thin part secured therein, are ejected from a molding apparatus prior to entering a liquid lens assembly station. The mold parts can be configured to mate inside an aqueous solution in the liquid lens assembly station in a manner that facilitates final assembly of the liquid lens prior to removal from the substrate. 
     According to some aspects of the present disclosure, an ophthalmic liquid lens device capable of being worn on an anterior surface of an eye is disclosed. The ophthalmic liquid lens device including: a liquid lens assembly including, a first ultra-thin optical part defined by a concave substrate surface of a first mold block, a second ultra-thin optical part defined by a convex substrate surface of a second mold block, one or more fluids contained between a cavity formed by the first ultra-thin optical part and the second ultra-thin optical part; a seal containing the one or more fluids in the cavity between the first ultra-thin optical part and the second ultra-thin optical part, the seal including interlocking features included in the periphery regions of said first ultra-thin optical part and said second ultra-thin optical part; and a hydrogel portion configured to support said liquid lens assembly. 
     In yet additional aspects of the present disclosure, a method of manufacturing a liquid lens suitable for an ophthalmic device is disclosed. The method including: defining a first ultra-thin optical part on a concave or convex substrate surface of a first mold block; defining a second ultra-thin optical part on a concave or convex substrate surface of a second mold block; containing one or more fluids between a cavity formed by the first ultra-thin optical part supported by the concave substrate surface of the first mold block and the second ultra-thin optical part supported by the convex substrate surface of the second mold block; creating a seal containing the one or more fluids in the cavity between the first ultra-thin optical part supported by the concave or convex substrate surface of the first mold block and the second ultra-thin optical part supported by the concave or convex substrate surface of the second mold block; and removing one or both of said first ultra-thin optical part from the supporting concave substrate surface of the first mold block and said second ultra-thin optical part from the supporting convex substrate surface of the second mold block. 
     Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description and drawings. Moreover, it is noted that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a cross-sectional view A of an exemplary ultra-thin optical piece  102  on a concave substrate  101  and an enlarged section B of an edge of the ultra-thin optical piece  102  resting upon the substrate  101  according to aspects of the present disclosure; 
         FIG. 2  illustrates a cross-sectional view of an exemplary convex substrate  201  supporting an ultra-thin optical piece  202  according to aspects of the present disclosure; 
         FIG. 3  illustrates the exemplary concave substrate  101  of  FIG. 1  and the exemplary convex substrate  201  of  FIG. 2  being assembled under a fluid according to aspects of the present disclosure; 
         FIG. 4  illustrates ultra-thin optical pieces  102  and  202  assembled and sealed together containing one or more liquids therebetween according to aspects of the present disclosure; 
         FIG. 5  illustrates a liquid lens  500  released from a mold assembly  400  after assembly of the ultra-thin optical pieces  102  and  202  in accordance with aspects of the present disclosure; and 
         FIG. 6  illustrates method steps that can be used to manufacture ultra-thin optical parts for a liquid lens according to aspects of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The disclosure will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. 
     Various aspects of a method and apparatus for molding ultra-thin optical parts may be illustrated by describing components that are coupled, sealed, attached, and/or joined together. As used herein, the terms “coupled”, “sealed”, “attached”, and/or “joined” are used to indicate either a direct connection between two components or, where appropriate, an indirect connection to one another through intervening or intermediate components. In contrast, when a component is referred to as being “directly coupled”, “directly sealed”, “directly attached”, and/or “directly joined” to another component, there are no intervening elements present. 
     Relative terms such as “lower” or “bottom” and “upper” or “top” may be used herein to describe one element&#39;s relationship to another element illustrated in the drawings. It will be understood that relative terms are intended to encompass different orientations in addition to the orientation depicted in the drawings. By way of example, if aspects of a mold assembly shown in the drawings are turned over, elements described as being on the “bottom” side of the other elements would then be oriented on the “top” side of the other elements. The term “bottom” can therefore encompass both an orientation of “bottom” and “top” depending on the particular orientation of the apparatus. 
     Various aspects of a method and apparatus for molding ultra-thin optical pieces/parts may be illustrated with reference to one or more exemplary embodiments. As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments of the methods and devices disclosed herein. 
     GLOSSARY 
     In this description and claims directed to the disclosed invention, various terms may be used for which the following definitions will apply: 
     “Contact Angle” as used herein, may refer to the angle at which the oil/saline solution interface, also referred to as the liquid meniscus boundary, meets the meniscus wall. In the case of a linear meniscus wall, the contact angle is measured as the angle between the meniscus wall and the line tangent to the liquid meniscus boundary at the point where the liquid meniscus boundary meets the meniscus wall. In the case of a curved meniscus wall, the contact angle is measured as the angle between the lines tangent to the meniscus wall and the liquid meniscus boundary at the point where they meet. 
     “Interlocking Features” as used herein, may refer to structural features located along the peripheral zone of the ultra-thin optical parts used to contain the one or more fluids in a Meniscus Cavity formed between two or more ultra-thin optical parts. In some embodiments, the structural features along the periphery can include a series of extending protrusions that can be made from the same material as the ultra-thin parts or from another material that can be rigid. The structural features can add structural rigidity to the overall optical assembly formed by the ultra-thin optical parts. In some embodiments, the structural features may be mated with corresponding sections of one ultra-thin optical piece to another ultra-thin optical piece using an aligning feature on the mold blocks. Mold blocks can include one or more substrate forming surfaces on which the optical ultra-thin parts can be formed and remain until the assembly is put together to thereby prevent deformation of the parts. 
     “Liquid Meniscus Boundary” as used herein, may refer to the arcuate surface interface between the saline solution and the oil. Generally, the surface will form a lens that is concave on one side and convex on the other. 
     “Media Insert” as used herein, may refer to a formable or rigid substrate capable of supporting an Energy Source within an Ophthalmic Lens. In some embodiments, the Media Insert can include one or more variable optic lenses. 
     “Meniscus Cavity” as used herein, may refer to the space in an arcuate liquid meniscus lens between the front curve lens and the back curve lens in which oil and saline solution are maintained. 
     “Meniscus Wall” as used herein, may refer to a specific area on the interior of the front curve lens, such that it is within the meniscus cavity, along which the liquid meniscus boundary moves. 
     “Ophthalmic Lens” as used herein, may refer to any ophthalmic device that is capable of residing in or on the eye. These devices can provide one or more of: optical correction, therapy, and may be cosmetic. For example, the biomedical ophthalmic device can refer to an energized contact lens, intraocular lens, overlay lens, ocular insert, optical insert, punctal plug, or other similar ophthalmic device through which vision is corrected or modified, an eye condition is enhanced or prevented, and/or through which eye physiology is cosmetically enhanced (e.g., iris color). In some embodiments, the ophthalmic device of the invention can include soft contact lenses made from silicone elastomers or hydrogels, which include but are not limited to silicone hydrogels, and fluorohydrogels. 
     “Optical Zone” as used herein, may refer to an area of an ophthalmic lens through which a wearer of the ophthalmic lens sees. 
     “Peripheral Zone” as used herein, the term “peripheral zone” or “non-optic zone” may refer to an area of an ophthalmic lens and/or liquid lens assembly outside of the optic zone of the ophthalmic lens, and therefore outside of a portion of the ophthalmic lens through which a lens wearer sees while wearing the ophthalmic lens on, near or in the eye in a normally prescribed fashion. 
     “Released from a mold” as used herein, may refer to a liquid lens assembly being either completely separated from one or more mold surfaces, or being only attached so that it can be removed with mild agitation or by a device without further mold movement. Examples of removal techniques can include, but are not limited to, pushed off with a swab, grabbed by a suction cup, or the use of another handling device. 
     “Sharp” as used herein, may refer to a geometric feature of an internal surface of either a front curve or back curve lens piece sufficient to contain the location of a contact line of two predefined fluids on the optic. The sharp is usually an outside corner rather than an inside corner. From a fluid standpoint it is an angle greater than 180 degrees. 
     “Substrate Forming Surface” as used herein, may refer to a surface that is used to mold lens pieces. In some embodiments, any such surface can include an optical finish, which indicates that it is sufficiently smooth and formed so that a lens surface fashioned by the polymerization of a lens forming material in contact with the molding surface can be optically acceptable. Further, in some embodiments, the substrate forming surface can have a geometry that is necessary to impart to the lens piece surface the desired optical characteristics, including without limitation, spherical, aspherical and cylindrical power, wavefront aberration correction, corneal topography correction and the like as well as any combinations thereof. 
     “Substrate” as used herein, the term Substrate, Mold, Block, or Mold Block may refer to a physical entity upon which other entities may be placed or formed. 
     Referring now to  FIG. 1 , a cross-sectional view A of an exemplary ultra-thin optical piece  102  on a Substrate  101  and an enlarged section B of an edge of the ultra-thin optical piece  102  resting upon the substrate  101  are illustrated. In some embodiments, the Substrate  101  can preferably be an ejectable mold part having at least one optical quality forming surface  105 . Substrates  101  and  201  (shown in  FIG. 2 ) materials can include any standard mold making materials, such as but not limited to steel, aluminum, high conductivity alloys like brass. More generally, these substrates can be of any material that can maintain precisely the shape of the ultra-thin optical piece  102  and  202 . In the case of cross-linked ultra-thin optical parts, the substrates  101  and  201  can be adapted from further series of material that do not have the temperature resistance for metallic alloys, such as molded polymers, or other molded cross-linked structures. 
     In some embodiments, the Substrate  101  can include alignment features  110  that can correspond to alignment features on a second Substrate or mold piece, e.g. Substrate  201  (shown in  FIG. 2 ). In some aspects, the alignment features  110  can be used to assemble a liquid lens assembly  500  (shown in  FIG. 5 ) using the ultra-thin optical piece  102  supported by the concave Substrate Forming Surface  105 . In some embodiments, the alignment features  110  can include mechanical features, such as a kinematic mount, as well as additional electromechanical means. 
     The formed ultra-thin optical piece  102  can be, for example, between 200 and 25 microns and preferably about 100 microns thick. As a result, without the support from the Substrate  101 , the ultra-thin optical piece  102  can deform losing its optical properties if it was to be released from the optical quality forming surface  105  before forming the liquid lens assembly  500 . For example, in conventional mold systems, the cured ultra-thin optical piece  102  would typically be ejected from or physically removed from the optical quality forming surface  105  of the Substrate  101 . The removed or ejected ultra-thin optical piece  102  would then be assembled with the other ultra-thin optical piece  202  separate from the molds. However, when dealing with such ultra-thin components as is the case with the ultra-thin optical pieces  102  and  202  (shown in  FIG. 2 ), ejection by any means or handling of the ultra-thin optical piece  102  outside of the Substrates  101  or  102  can inevitably lead to warping, curling, or deformation in many cases. 
     Therefore, in accordance with various aspects of the present disclosure, to avoid the problems noted above with respect to the ejection or removal of the ultra-thin optical pieces  102  and  202  from their respective Substrates  101  and  201 , the ultra-thin optical pieces  102  and  202  are never removed from their respective optical quality forming surface, e.g.,  105 , until the liquid lens assembly  500  is completely assembled. Rather, the substrates  101  and  201  can be responsible for maintaining the structural integrity of each ultra-thin optical piece  102  and  202  during assembly after they are themselves ejected from the ejectable block used to form the ultra-thin optical pieces  102  and  202 . Accordingly, each of the ultra-thin optical pieces  102  and  202  remains structurally supported by at least a portion of the Substrate  101  or  201  that is ejected from the mold assembly, such as by the concave forming surface  105 . 
     In some exemplary embodiments, the mold parts may include a back surface Substrate  101  and a front Surface substrate  201 . As used herein, the term “front surface mold part” refers to the mold part whose concave optical quality forming surface  105  may be used to form the front surface of the ultra-thin optical piece  102 . Similarly, the term “back surface mold part” refers to the substrate  201  whose convex optical quality forming surface  205  may form the back surface of the ultra-thin optical piece  202  (shown in  FIG. 2 ). In some embodiments, Substrates  101  and  201  can be of a concavo-convex shape, including planar annular flanges which can surround the circumference of the uppermost edges of the concavo-convex regions of the Substrate  101  and/or  201 . 
     Referring now to the enlarged section B of  FIG. 1 , an edge of the ultra-thin optical piece  102  supported by the substrate  101  is illustrated. In particular, Interlocking Features  115  located along the Peripheral Zone of the ultra-thin optical pieces  102  are depicted. In some embodiments, the Interlocking Features  115  can be used to help the structural integrity of the liquid lens assembly  500  (shown in  FIG. 5 ), by helping to provide a seal once they are interlocked or “joined”. The seal can be used to contain one or more liquids between two or more ultra-thin optical pieces, e.g.  102  and  202 . The Interlocking Features  115  may be formed of the same material as the rest of the ultra-thin optical piece  102  or of a different material that is also rigid or semi-rigid. Materials can include, for example, polyolefins, Zenor, Topas, Polystyrene, and the like. 
     In some embodiments, the Interlocking Features  115  can add structural rigidity to each of the ultra-thin optical pieces  102  and  202  and to the overall liquid lens assembly  500  (shown in  FIG. 5 ) formed. The Interlocking Features  115  may be radially symmetrical or non-symmetrical requiring radial alignment as well as overall alignment in relation with one another. Alignment of the ultra-thin optical pieces  102  and  202  may be accomplished, for example, using corresponding alignment features  110  and  210  of the Substrates  101  and  201  respectively, the use of kinematic mounts, electromechanical alignment means, and the such. 
     Referring now to  FIG. 2 , a cross-sectional view of an exemplary convex Substrate  201  supporting an ultra-thin optical piece  202  according to aspects of the present disclosure is illustrated. The convex Substrate  201  may include similar aspects to the previously described exemplary concave Substrate  101 . For example, convex Substrate  201 , like concave Substrate  101 , may be part of a block assembly (not shown) used to form the ultra-thin optical piece  202  so that after formation of the ultra-thin optical pieces  102  and  202 , the Substrates  101  and  201  may be ejected from the mold assemblies with each of the ultra-thin optical pieces  102  and  202  supported on an optical quality forming surfaces  105  and  205  respectively. Accordingly, the ultra-thin optical piece  202  can remain structurally supported by optical quality Substrate Forming Surface  205  after Substrate  201  is ejected from the mold assembly (not shown) to prevent any deformation and loss of optical quality of the ultra-thin optical piece  202 . As previously mentioned, deformation and loss of optical quality of the ultra-thin optical piece  202  can occur due to the extremely thin nature of the ultra-thin optical pieces  102  and  202 , as independent handling of either part can resemble the handling of a flexible, film-like material. 
     Because conventional tooling mechanisms and handling means in typical mold systems are not capable of handling the individual ultra-thin optical pieces  102  and  202  during assembly without warping, curling, or deforming the delicate structures of these parts. Constant structural support is required throughout the tooling process to maintain shape integrity and the material properties of the ultra-thin optical pieces  102  and  202  during production of the liquid lens assembly  500 . Only when fully assembled into the liquid lens assembly  500  are the combined parts structurally capable of performing in an acceptable manner without the issues experienced by the parts individually. 
     Ultra-thin optical piece  202  can be formed in similar fashion to that for ultra-thin optical piece  102 , except that the substrates  101  and  201  may be configured differently. In this manner, a second mold assembly for ultra-thin optical piece  202  may be used that is configured differently from that disclosed for ultra-thin optical piece  102  in order to impart the necessary optical qualities required for the back optic portion of the liquid lens assembly  500 . For example, the amount of curvature imparted to ultra-thin optical piece  202  can be different compared to that imparted to ultra-thin optical piece  102 . Accordingly, although some aspects of the present disclosure may be described only with respect to ultra-thin optical piece  102  and/or with respect to the mold assembly (not shown) or substrates  101  and  201 , it should be understood that substantially the same methods, parts or devices will be apparent to those skilled in the art. 
     In some embodiments, aspects of the removable Substrate  201  may be specifically formed to assist in positioning of the Substrate  201  during the forming of the liquid lens and/or to ease ejection of the Substrate  201  from the mold assembly (not shown) after formation of the ultra-thin optical piece  202 . For example, the Substrate&#39;s alignment features  210  can include mechanical features, such as a kinematic mount, as well as additional electromechanical means. 
     Referring now to  FIG. 3 , the exemplary concave Substrate  101  of  FIG. 1  and the exemplary convex Substrate  201  of  FIG. 2  are illustrated being assembled under a fluid  301  according to aspects of the present disclosure. As previously presented, ejectable substrates  101  and  201  can support ultra-thin optical pieces  102  and  202  for the formation of a liquid lens assembly  500  under one or more fluids. For example, a saline solution  301  and an oil  305  may be contained in an arcuate shaped cavity formed between the two ultra-thin optical pieces  102  and  202 . In some preferred embodiments, a volume of saline solution  301  contained within the cavity is greater than the volume of oil  305  contained within the cavity. Additionally, some preferred embodiments can include the saline solution  301  in contact with essentially an entirety of an interior surface of the back curve ultra-thin optical piece  202 . Some embodiments may include a volume of oil  305  that is about 66% or more by volume as compared to an amount of saline solution  301 . Some additional embodiments may include an arcuate liquid meniscus lens assembly  500  wherein a volume of oil  305  is about 90% or less by volume as compared to an amount of saline solution  301 . 
     In accordance with aspects of the present disclosure, the substrates  101  and  201  may be immersed in the aqueous solution  301  and, while in the aqueous solution, the Substrates  101  and  201  may be mated, as shown in  FIG. 4 . Thus, as described, Substrates  101  and  201  are removable components of a block used to form the ultra-thin optical pieces  102  and  202 . The substrates  101  and  201  may be arrayed as a “sandwich” in a mold assembly  400  (shown in  FIG. 4 ). The front surface mold Substrate  101  is on the top, with the concave forming surface  105  of the mold part facing downwards. The back surface Substrate  201  can be disposed symmetrically on the bottom of the front surface Substrate  101 , with the convex forming surface  205  of the back surface substrate  101  projecting partially into the concave region of the front surface Substrate  101 . Preferably, the back surface Substrate  201  can be dimensioned such that the convex surface  205  thereof engages the outer edge of the concave surface  105  of the front curve substrate  101  throughout its circumference, thereby cooperating to form a sealed cavity containing the saline solution  301  and the oil  305 . 
     Referring now to  FIG. 4 , ultra-thin optical pieces  102  and  202  assembled and sealed together containing one or more liquids therebetween according to aspects of the present disclosure are depicted. The front curve Substrate  101  and the back curve Substrate  201  are assembled together forming the mold assembly  400  used to join the ultra-thin optical pieces  102  and  202  with the saline solution  301  and the oil solution  305  therein. In some embodiments, the mold assembly  400  may include a groove  401  in one of the Substrates  201  or  202  that can be used to deliver an adhesive used to seal the saline solution  301  and the oil solution  305  between the ultra-thin optical pieces  102  and  202 . In alternative embodiments, the mold assembly may include a means to heat stake the ultra-thin optical pieces  102  and  202  together. In yet additional embodiments, the seal may be created by polymerizing the edges of the two ultra-thin optical pieces  102  and  202  or by joining Interlocking Features  115  forming part of the ultra-thin optical piece  102  with Interlocking Features of another ultra-thin optical piece or the piece itself, e.g. ultra-thin optical piece  202 . In some embodiments, detents, protrusions, channels, or other formations, may be provided to assist with positioning the released substrates  101  and  201  to enable coordination with the adhesive delivery system or heat bonding system, for example. 
     Because the liquid lens assembly  500  (shown in  FIG. 5 ) can be assembled inside the aqueous solution, once the ultra-thin optical pieces  102  and  202  are bonded/joined to each other, preferably about an outer periphery of each part, the one or more aqueous solution  301  and  305  can be compressed and trapped between the ultra-thin optical pieces  102  and  202  increasing the structural integrity of the part. 
     Referring now to  FIG. 5 , a liquid lens  500  released from the mold assembly  400  after joining the ultra-thin optical pieces  102  and  202  encapsulating the one or more liquids  301  and  305  is depicted. The structural integrity of the ultra-thin optical pieces  102  and  202  being exponentially greater due to the liquids  301  and  305  contained therein. The exponentially greater structural strength which can allow for some manipulation of the liquid lens  500  so that it can be incorporated and/or used as an ophthalmic lens without affecting the optical quality of the ultra-thin optical pieces  102  and  202 . Accordingly, the liquid lens assembly  500  can have sufficient structure so that any further handling, cleaning, and/or packaging of the liquid lens assembly  500  will be resilient to irreversibly warp, curl or deform the lens surfaces of the individual ultra-thin optical pieces  102  and  202 . 
     The flexural modulus of the first ultra-thin optical piece  102 , for example, combined with the flexural modulus of the second ultra-thin optical piece  202 , increases the structural stability of the device as a whole. Moreover, as the liquid lens assembly  500  can be forced into a state of deflection, such as by squeezing diametrically opposed portions of the periphery, quadratic momentum of the liquid trapped between the ultra-thin optical pieces  102  and  202  exponentially increases the resistance of liquid lens assembly  500  to continued deflection. The liquid lens assembly  500  thus tends to resist deflection in order to retain the preformed shape of each of the ultra-thin optical pieces  102  and  202  by virtue of the sealed solution between the ultra-thin optical pieces  102  and  202 . 
     The liquid lens may be used to provide for an energized variable power liquid meniscus ophthalmic lens. For example, the ultra-thin optical pieces  102  and  202  can be transparent and the center may include a first liquid  301 , which may be an insulative liquid, and a second liquid  305 , which is an electrically conductive liquid. The first liquid  301  and the second liquid  305  are generally non-miscible liquids having different optical indices. An annular electrode (not shown), which is open facing a recess, may be positioned on a rear face of ultra-thin optical piece  202 . Another electrode may be placed in contact with the conductive liquid  305 . Application of a voltage across the electrodes is utilized to create electrowetting and modify the curvature of the interface between the two liquids, according to the voltage applied between the electrodes. A beam of light passing through the cell normal to the upper plate and the lower plate and in the region of the drop will be focused to a greater or lesser extent according to the voltage applied to the electrodes. The conductive liquid is typically an aqueous saline liquid, e.g.  301 , and the insulating liquid is typically an oily solution, e.g.  305 . However, in other embodiments within the scope of the disclosure, the center can include other types or combinations of non-gaseous media. 
     In some embodiments, the lens material may be any suitable polymer material, such as a hydrogel, silicone hydrogel, silicone acrylate, or fluoro-silicone acrylate. The lens material may initially be in a molten state and direct injected into the mold cavity, for example. The ultra-thin optical pieces  102  and  202  may be molded according to the same or other techniques, including, for example, spin-casting, lathing, diamond turning, or laser cutting. Although described herein with respect to a front optic portion and a rear optic portion, the methods and apparatus for molding and assembling ultra-thin optical pieces  102  and  202  may be used for molding any multiple molded parts conventionally requiring separate handling and assembly. 
     Referring now to  FIG. 6  method steps  600  that can be used to manufacture ultra-thin optical parts for a liquid lens  500  according to aspects of the present disclosure are illustrated. Beginning at step  601 , a first ultra-thin optical piece can be formed on a concave optical quality forming surface  105  of a first Substrate  101 . At step  605 , a second ultra-thin optical piece can be formed on a convex optical quality forming surface  205  of a second Substrate  201 . Said first and second Substrates  101  and  201  can each form part of a block used to form each of the and a convex optical quality forming surface  205  respectively. The optical quality surfaces can be part of two different Substrates  101  and  201  each forming part of a block used to form the ultra-thin optical pieces  102  and  202 . As previously mentioned, the ultra-thin optical pieces  102  and  202  may be formed and/or molded using techniques, including, for example, injection molding, spin-casting, lathing, diamond turning, or laser cutting. 
     At step  610 , said first and second Substrates  101  and  201  supporting the first and second ultra-thin optical pieces  102  and  202  respectively can be aligned with each other. As discussed in the present disclosure, alignment may occur using alignment features  110  and  210  of the Substrates  101  and  201 . As previously discussed, alignment features  110  and  210  can include electromechanical alignment means, mechanical means and the such. 
     At step  615 , one or more liquids can be contained between the first and the second ultra-thin optical parts  102  and  202  without separating the ultra-thin optical pieces  102  and  202  from their respective Substrates  101  and  201 . The one or more liquids can include a saline solution and an oil solution, e.g.,  301  and  205  respectively, and be used to form a liquid lens assembly  500 . In some embodiments, this step can take place by emerging both Substrates  101  and  201  into the solution. The oil  305  may be included through a structure of one of the Substrates  101  and  102  or by adding a drop of oil solution  305  after the Substrates  101  and  201  have been immersed into the saline solution  301 . At step  620 , the one or more solutions can be sealed therebetween forming a liquid lens assembly  500 . The seal may be provided using the interlocking structures on the one or more ultra-thin optical pieces  102  and  202 , the use of an adhesive, heat stacking, and other suitable techniques known to assemble optical parts in the art. At step  625 , the liquid lens assembly  500  can be removed from at least one of the Substrates  101  and/or  201  to form part of an ophthalmic lens. In some embodiments, the liquid lens assembly  500  may be placed onto a hydrogel skirt. In alternative embodiments, the liquid lens assembly  500  may be encapsulated by hydrogel. 
     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, because numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention.