Patent Description:
Conventionally, an electro-active lens is manufactured via a molding process, in which lens material (in liquid form) is poured or injected into a mold to form the lens. The electronics can be disposed in the mold such that the lens material, when cured or hardened, encapsulates the electronics. Unfortunately, molding electro-active lenses has several disadvantages. First, the electronics must be bulky enough to withstand the mechanical force exerted during the molding process (e.g., imposed by the lens material on the electronics). In other words, the electronics could be smaller if they didn't have to go through the molding process. Second, it can be challenging to apply the lens material conformally over the electronics during molding. In many cases, molding leaves gaps between the electronics and the optical parts of the resulting lens. The gaps can degrade the optical properties of the lens. Third, the molded lens may have to be ground, polished, machined, or otherwise finished to provide the desired prescription without breaking the embedded electronics. This means that the embedded electronics must be rugged enough to withstand finishing, which in turn implies that the embedded electronics must be large and heavy. These are just a few of the challenges associated with molding electro-active lenses.

<CIT> discloses a method for assembling a three-dimensional optical component from a base body, comprising loading the base body on a substrate into a printer, depositing droplets of printing ink on a first surface of the base body in a first printing step in order to build up an intermediate first pre-structure, depositing droplets of printing ink on a second surface of the base body in a second printing step in order to build up an intermediate second pre-structure, rotating the first pre-structure and arranging the first pre-structure on a support structure in a rearrangement step between the first printing step and the second printing step.

<CIT> discloses methods and apparatus for providing a variable optic insert into an ophthalmic lens. An energy source is capable of powering the variable optic insert included within the ophthalmic lens.

Systems, apparatus, and methods described herein are directed to manufacturing of electronic eyewear via three-dimensional (3D) printing technique. In one example, a method of manufacturing an optic includes disposing electronic circuitry on a substrate and the electronic circuitry has a first side and a second side opposite the first side. The method also includes depositing a first resin on the first side of the electronic circuitry and curing the first resin to form a first optical segment. The method further includes depositing a second resin on the second side of the electronic circuitry and curing the second resin to form a second optical segment. The first and second optical segments encapsulate the electronic circuitry.

In another example, a method of forming an electro-active ophthalmic lens includes depositing a first plurality of transparent resin droplets on a surface and curing the first plurality of transparent resin droplets to form a first portion of the electro-active ophthalmic lens. The first portion of the ophthalmic lens having an upward-facing surface. The method also includes disposing an electro-active element on the upward-facing surface of the first portion of the electro-active ophthalmic lens and the electro-active element has at least one of a variable transmittance or a variable optical power. The method also includes depositing a second plurality of transparent resin droplets on the electro-active element and on an exposed portion of the upward-facing surface of the first portion of the electro-active ophthalmic lens. The method further includes curing the second plurality of transparent resin droplets to form a second portion of the electro-active ophthalmic lens. The second portion of the electro-active ophthalmic lens has a radius of curvature selected to provide a predetermined optical power and forms, with the first portion of the electro-active ophthalmic lens, a hermetic seal about the electro-active element.

In yet another example, a method of three-dimensional (3D) printing includes printing a first layer of resin on a first side of electronic circuitry that has a second side opposite the first side and curing the first layer of resin to form at least a portion of a first optical segment. The method also includes printing a second layer of resin on the second side of the electronic circuitry curing the second layer of resin to form at least a portion of a second optical segment. The first optical segment, the second optical segment, and the electronic circuitry form electronic eyewear.

In yet another example, an apparatus includes electronic circuitry that includes an electro-active element. The electro-active element includes a first layer, an electro-active material disposed on the first layer, and a second layer disposed on the electro-active material. The first layer and the second layer substantially sealing the electro-active material without any adhesive. The apparatus also includes an optical element printed on the electronic circuitry and substantially enclosing the electronic circuitry. The optical element being in conformal contact with the electronic circuitry.

It should also be appreciated that terminology explicitly employed herein that also may appear in any document mentioned herein should be accorded a meaning most consistent with the particular concepts disclosed herein.

The skilled artisan will understand that the drawings primarily are for illustrative purposes and are not intended to limit the scope of the inventive subject matter described herein. The drawings are not necessarily to scale; in some instances, various aspects of the inventive subject matter disclosed herein may be shown exaggerated or enlarged in the drawings to facilitate an understanding of different features. In the drawings, like reference characters generally refer to like features (e.g., functionally similar and/or structurally similar elements).

To address the challenges of making electro-active lenses with conventional molding techniques, systems, apparatus, and methods described herein employ three-dimensional (3D) printing techniques. In some of these techniques, droplets of lens material (resin) are disposed on one or both sides of one or more electronic components to form an electronic lens. Since each droplet can be small (e.g., on the order of microns), each droplet exerts negligible mechanical force on the electronics. Therefore, electronics used in this technique can be thinner and more delicate than those used in conventional electronic eyewear. In addition, the small dimensions of the droplets also allow conformal contact between the electronics and the droplets (and accordingly the optical parts of the resulting lens). This conformal contact can reduce or eliminate gaps in the lens, thereby improving the optical quality of the lens. And the droplets can be deposited in almost arbitrary shapes, so they can be used to make custom surfaces for prescription lenses that don't need to be ground or finished.

<FIG> illustrate a method <NUM> of manufacturing an electro-active lens using a 3D printing technique. In this method <NUM>, electronic circuitry <NUM> is disposed on a substrate <NUM> as shown in <FIG>. The electronic circuitry <NUM> has a first side <NUM> and a second side <NUM> opposite the first side <NUM>. In <FIG>, a first optical segment <NUM> is formed on the first side <NUM> of the electronic circuitry <NUM>. The formation of the first optical segment <NUM> can be achieved by disposing resin onto the first side <NUM> of the electronic circuitry <NUM> in a layer-by-layer manner (see, e.g., <FIG> below). Each of these layers is very thin (e.g., with thicknesses on the order of microns), but in aggregate, they can form a thicker optical segment <NUM> (e.g., with a thickness on the order of millimeters or centimeters). The layers are cured, e.g., layer-by-layer with heat or UV light, to form the first optical segment <NUM>.

In <FIG>, the first optical segment <NUM> is cured and the electronic circuitry <NUM> is turned upside down, exposing the second side <NUM> for further processing. In <FIG>, a second optical segment <NUM> is formed on the second side <NUM> of the electronic circuitry <NUM> in a layer-by-layer fashion just like the first optical segment <NUM>. Once cured, the first optical segment <NUM> and the second optical segment <NUM> substantially encapsulate the electronic circuitry <NUM> and form an optical component <NUM> (e.g., a lens, prism, Fresnel lens, or other bulk optical component). Together, the optical component <NUM> and the electronic circuitry <NUM> form an electro-active lens <NUM>.

The substrate <NUM> in the method <NUM> can include any substrate that can support the processing of the electronic circuitry <NUM> via 3D printing. If desired, the substrate <NUM> can include or be coated with a non-stick material such that the assembly of the first optical segment <NUM> and the electronic circuitry <NUM> can be readily turned upside down for further processing (shown in <FIG>). For example, the substrate <NUM> can include silicone, polydimethylsiloxane (PDMS), polytetrafluoroethylene (PTFE), ceramic, or any other non-stick material. In another example, the substrate <NUM> can include a rigid material coated with a non-stick material on the surface. For example, the rigid material can include plastic, metal, or glass. If desired, a portion of the substrate <NUM> may be patterned or indented to hold the first optical segment <NUM> when it is flipped upside down as in <FIG>.

The substrate <NUM> can also have a dimple or depression for molding half of the bulk optic portion of the lens. Resin or other polymer may be deposited in the depression and cured to form a concave or convex surface facing down and a planar surface facing up. The electronic circuitry <NUM> can be placed on the planar surface and the remaining portion of the bulk optic portion of the lens can be deposited as described above with respect to <FIG> on the electronic circuitry <NUM> to fully or partially encapsulate the electronic circuity <NUM>. If desired, some resin can be deposited and cured on the planar surface to form a receptacle for the electronic circuity <NUM> before deposition and curing of the resin on top of the electronic circuity <NUM>. Once this resin has been cured, the completed lens can be released from the depression in the substrate.

The electronic circuitry <NUM> can include various electronic and/or electro-active components. For example, the electronic circuitry <NUM> can include an electro-active element, such as a liquid crystal element or electro-chromic element, which can change its optical properties (e.g., refractive index or transmittance) in response to an applied voltage. The electronic circuitry <NUM> can also include electronic components, such as a power supply (e.g., a thin-film battery or capacitor), antenna or inductive loop (e.g., for wireless communication and/or wireless charging), interconnect, processor, or controller. More details of the electronic circuitry <NUM> are described below with reference to <FIG>.

As described above, the 3D printing technique allows the use of very thin electronic circuitry <NUM> that likely wouldn't withstand the mechanical forces exerted in a conventional molding process. For example, the thickness of the electronic circuitry <NUM> can be substantially equal to or less than <NUM> (e.g., about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, or less, including any values and sub ranges in between).

In some cases, at least part of the electronic circuitry <NUM> can also be fabricated via 3D printing. For example, interconnects and conductive traces can be printed using conductive resin (or any other conductive ink). In this example, non-printed parts can be disposed on the substrate <NUM> and the connections between them can be printed to form the electronic circuitry <NUM>, after which the first optical segment <NUM> can be formed. In another example, the power supply in the electronic circuitry <NUM> can also be printed. More details on printing a power supply, interconnect, and/or other portions of the electronic circuitry <NUM> can be found below with reference to <FIG>.

If desired, the first optical segment <NUM> can be a portion of a first optical device and the second optical segment <NUM> can be a portion of another optical device. For example, the first optical segment <NUM> can be part of a convex lens and the second optical segment <NUM> can be part of a concave lens. In another example, the first optical segment <NUM> can include a flat surface and the second optical segment <NUM> can include a convex surface, i.e., the optical component <NUM> may form or include a plano-convex lens. In yet another example, the first optical segment <NUM> can include a flat surface and the second optical segment <NUM> can include a concave surface, i.e., the optical component <NUM> may form or include a plano-concave lens.

In yet another example, the first optical segment <NUM> can include a convex surface having a first radius of curvature or surface shape and the second optical segment <NUM> can include a convex surface having a second radius of curvature or surface shape different from the first radius of curvature or surface shape. In yet another example, the first optical segment <NUM> can include a concave surface having a first radius of curvature or surface shape and the second optical segment <NUM> can include a concave surface having a second radius of curvature or surface shape different from the first radius of curvature or surface shape. Any other combination of the first optical segment <NUM> and the second optical segment <NUM> can also be used to produce an aspherical surface, a surface with cylindrical power (e.g., to correct for astigmatism), or an arbitrarily shaped surface.

The resulting electro-active lens <NUM> (shown in <FIG>) can be configured for various applications. In one example, the electro-active lens <NUM> can be used in prescription spectacle lenses if it provides static and/or variable optical power. In another example, the eyewear <NUM> can be used in sunglasses if the electronic circuitry <NUM> includes an electro-active element, such as an electro-chromic element, that changes its transmittance in response to an applied voltage. In yet another example, the electro-active lens <NUM> can be used in a heads-up display (HUD). In this case, the electronic circuitry <NUM> can include a liquid-crystal display for virtual reality (VR), mixed reality (MR), and/or augmented reality (AR) applications. In yet another example, the electro-active lens <NUM> can be used in or as a contract lens or intra-ocular optic, such as an intra-ocular lens. In this example, the lens material can include silicone or another biocompatible, curable lens material.

<FIG> illustrate a method <NUM> of 3D printing of an electronic or electro-active lens by depositing droplets of lens material, such as a UV-curable resin, on and around one or more electronic components. In the method <NUM>, a first layer 230a of droplets 232a is disposed on component <NUM>, such as electronic circuitry or a liquid crystal element with variable refractive index, that is disposed on a substrate <NUM>, as shown in <FIG>. The first layer 230a includes multiple droplets 232a (e.g., resin droplets) in conformal contact with the component <NUM>. Adjacent droplets 232a can partially overlap each other or bleed into each other while viscous so as to substantially enclose the component <NUM>, thereby preventing the formation of gaps that could degrade the lens's optical and structural integrity.

The droplets 232a can be disposed on the component <NUM> using a nozzle connected to a tank including the lens material (e.g., an inkjet printer). The lens material is squeezed out of the nozzle using a piezoelectric actuator to form the droplets 232a. The nozzle moves relative to the component <NUM>, e.g., with a translation stage that moves the nozzle or the substrate supporting the component <NUM>. A computer or other controller actuates this stage and the droplet deposition by the nozzle such that the nozzle deposits drops in a desired pattern and order.

The diameter of the droplets 232a can depend on the diameter of the nozzle and the amount of lens material upon each actuation of the actuator. For example, the diameter of the droplets can be substantially equal to or less than <NUM> (e.g., about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, or less, including any values and sub ranges in between). If desired, the nozzle may be actuated to produce droplets of different sizes (e.g., larger in the middle of the electronic circuity and smaller around the edges) to produce a solid surface with a predetermined curvature once the droplets have been cured.

In <FIG>, electromagnetic radiation <NUM> cures the droplets 232a. In one example, the electromagnetic radiation <NUM> can be ultraviolet (UV) radiation, which can have a wavelength from about <NUM> to about <NUM>. The UV radiation can be emitted by, for example, a light-emitting diode (LED), a xenon lamp, a quartz tungsten halogen lamp, or any other appropriate UV light source. In another example, the electromagnetic radiation <NUM> can be infrared (IR) radiation, which can have a wavelength from about <NUM> to about <NUM>. The IR radiation can heat the droplets 232a and cure the droplets 232a via this heating. Alternatively, a heater can be used to heat and cure the droplets 232a. The curing temperature can be substantially equal to or less than <NUM> (e.g., about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, or less, including any values and sub ranges in between).

In one example, the droplets 232a can be cured after the entire layer 230a is disposed on the component <NUM>. In another example, each droplet 232a can be cured immediately after the droplet 232a is disposed on the component <NUM>. In this example, focusing optics can be used to focus the electromagnetic radiation <NUM> onto the individual droplets 232a to be cured. The curing time can be substantially equal to or less than <NUM> second for each droplet 232a (e.g., about <NUM> second, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, or less, including any values and sub ranges in between). Each droplet can be cured before the nozzle disposes the next droplet. Or the curing process and the disposition of the droplets 232a can be performed simultaneously or nearly simultaneously.

In yet another example, the droplets 232a can be cured after a sub-group in the first layer 230a is formed. For example, the droplets 232a can be cured after the surface of the first substrate <NUM> is covered with the droplets 232a. Similarly, the droplets 232a can be cured after the surface of the component <NUM> is covered with the droplets 232a. Or the droplets 232a can be cured after the contact region between the first substrate <NUM> and the component <NUM> is covered with the droplets 232a.

In some examples, all the droplets 232a in the first layer 230a have the same size. In another example, droplets 232a in the first layer 230a can have different sizes. For example, droplets 232a covering flat surfaces can have a larger diameter than droplets 232a covering uneven surfaces. In <FIG>, droplets 232a that cover the region right above the surface of the first substrate <NUM> can have a first diameter, and droplets 232a that cover the transition region from the first substrate <NUM> to the component <NUM> can have a second diameter less than the first diameter to ensure conformal contact with the edges and sidewalls of the electronics <NUM>.

In <FIG>, a second layer 230b of droplets 232b is disposed on the first layer 230a. The electromagnetic radiation <NUM> can be applied again to cure the droplets 232b before a third layer of droplets (not shown) is applied. The process can continue until an optical segment of a desired size and shape is formed by these multiple layers of droplets. The optical segment can be, for example, substantially similar to the first optical segment <NUM> shown in <FIG>. Similar steps can also be used to form the second optical segment and accordingly the entire optical component that encapsulates the component <NUM>. In one example, the droplets 232a and 232b have the same size. In another example, the droplets 232b can be smaller than the droplets 232a.

<FIG> illustrate optional additional steps for adding more components to the lens at different positions along the lens's optical axis (normal to the substrate <NUM>). The droplets 232a and 232b in <FIG> are cured or allowed to harden enough to form a supportive resin <NUM>. As shown in <FIG>, a second electronic or electro-active component <NUM>, such as an electrochromic or liquid crystal element with variable transmissivity, is placed on this resin <NUM>, possibly in alignment with the component <NUM> already partially encapsulated within the resin <NUM>. Then a nozzle (not shown) deposits additional droplets <NUM> on the second component <NUM> and the resin <NUM> as shown in <FIG>. These droplets <NUM> are cured or allowed to harden, thereby encapsulating the second component <NUM>.

The steps shown in <FIG> can be repeated as desired to form an electronic or electro-active lens with two, three, or more layers of components. The components can be stacked on top of each other, as shown in <FIG>, or partially or fully offset laterally from each other. If they are stacked on top of each other or appear to at least partially overlap when looking through the lens, they may be used to produce a combined effect. For example, if the components are orthogonally oriented cylindrical liquid crystal lens elements, they can focus light in orthogonal dimensions by different amounts. If the components are orthogonally oriented prismatic liquid crystal elements, they can steer light in orthogonal dimensions. And if the components are spherical liquid crystal lens elements, they can provide additive focusing power. If one element is an electrochromic element with variable transmissivity and the other element is a liquid crystal element with a variable refractive index, the elements can be used together to selectively attenuate and/or steer or focus incident light.

More details on 3D printing can be found in <CIT>, and entitled "3d printing method utilizing a photocurable silicone composition".

<FIG> illustrate a method <NUM> of 3D printing an electro-active lens with an embedded protective layer <NUM> to protect electronic circuitry <NUM>, which may include an electro-active element, from UV radiation used to cure the 3D printed lens material (resin). In <FIG>, a protective layer <NUM> is disposed on electronic circuitry <NUM> that is placed on a substrate <NUM>. In <FIG>, an optical segment <NUM> is formed on the protective layer <NUM> and substantially encloses the electronic circuitry <NUM>. In one example, the protective layer <NUM> is in conformal contact with the electronic circuitry <NUM> and may be deposited on the electronic circuitry <NUM> using 3D printing or any other suitable technique. In another example, the protective layer <NUM> substantially covers the top surface of the electronic circuitry <NUM>.

The protective layer <NUM> is opaque to the UV radiation (e.g., radiation <NUM> shown in <FIG>) employed to cure the optical segment <NUM> and therefore can protect the electronic circuitry <NUM> from potential damage caused by the UV radiation during curing. At the same time, the protective layer <NUM> transmits visible light, so it shouldn't affect the operation of the finished electro-active lens.

After the formation of the optical segment <NUM>, the assembly of the optical segment <NUM>, the electronic circuitry <NUM>, and the protective layer <NUM> can be turned upside down, exposing the bottom surface of the electronic circuitry <NUM> for further processing. Another protective layer can be disposed on the exposed surface of the electronic circuitry <NUM>, and another optical segment can be formed on the electronic circuitry <NUM> (e.g., similar to the processes shown in <FIG>).

In some cases, the protective layer <NUM> can be disposed on the electronic circuitry <NUM> via 3D printing and the ink can be cured thermally. Alternatively, the electronic circuitry <NUM> can be disposed within the protective layer <NUM> before being placed on the substrate <NUM>. For example, the electronic circuitry <NUM> can be vacuum packaged in a container (e.g., plastic bag) and then disposed on the substrate <NUM> for further processing.

<FIG> illustrate a method <NUM> of manufacturing an electro-active element <NUM> via 3D printing. The method <NUM> can be carried as a sub process for making part or all of the electronic circuitry in the methods <NUM>, <NUM>, and <NUM> described above. In <FIG>, a first layer 420a is printed on a first electrode 410a, which itself may be printed. For example, the first layer 420a can include multiple droplets that collectively form a thin film that covers the first electrode 410a. These droplets may be arranged and cured so that the first layer 420a includes ridges or other features that align the electro-active material <NUM>. The droplets may also be arranged and cured so that the first layer 420a includes ridges in diffractive or refractive structures, such as facets of a spherical or cylindrical Fresnel lens.

In <FIG>, an electro-active material <NUM> is disposed on the first layer 420a. The electro-active material <NUM> can include liquid crystal material whose refractive index changes in response to an applied voltage or electro-chromic material whose transmissivity varies in response to an applied voltage. Changing the refractive index in the electro-active material <NUM> can change the total optical power or transmissivity of the lens, thereby allowing dynamic adjustment of the optical power or transmissivity by the wearer. More information about electro-active elements can be found in <CIT> and in <CIT>.

In one example, the liquid crystal can be sprayed onto the first layer 420a. In this process, multiple droplets of liquid crystal may be disposed on the first layer 420a concurrently. In another example, the liquid crystal can be printed onto the first layer 420a. In this process, the liquid crystal can be disposed on the first layer 420a droplet by droplet. The liquid crystal can include bi-stable liquid crystal, which can maintain its orientation (and optical properties, including refractive index and transmissivity) after removal of the applied voltage, thereby reducing power consumption during use.

In <FIG>, a second layer 420b is printed on the electro-active material <NUM>. The first layer 420a and the second layer 420b form a housing <NUM> that substantially encapsulates the electro-active material <NUM>. Since both the first layer 420a and the second layer 420b are printed, the resulting housing <NUM> can be formed without using any adhesive. In <FIG>, a second electrode 410b is disposed on the second layer 420b. The first electrode 410a and the second electrode 410b can be configured to apply a voltage on the electro-active material <NUM> to adjust, for example, the refractive index and/or transmittance of the electro-active material <NUM>. The electro-active element <NUM> can be included in any of the electronic circuitry (e.g., <NUM>, <NUM>, or <NUM>) described herein to be part of an electronic eyewear.

The electrodes 410a and 410b can be fabricated before fabricating the rest of the electro-active element <NUM>, for example, via 3D printing using a conductive resin. The conductive resin can be prepared by adding carbon black filler (e.g., Ketjen black) to a standard resin (e.g., epoxy or polyurethane resins). In another example, the filler can be synthetic graphite powder. In yet another example, the filler material can include micro-scale metal structures, such as metal powder, metal flakes, or metal filaments. The metal can include, Ni, Ag, or Cu. For metal powders, the diameter of the powders can be, for example, about <NUM> to about <NUM> (e.g., about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, or about <NUM>, including any values and sub ranges in between). For metal filaments, the length of the filaments can be about <NUM> to about <NUM> (e.g., about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, or about <NUM>, including any values and sub ranges in between).

<FIG> shows a schematic of electronic eyewear <NUM> including a thin film battery <NUM> fabricated by additive manufacturing, such as 3D printing. The eyewear <NUM> includes a lens <NUM> disposed within a lens frame <NUM>. An electronic component <NUM>, such as an electro-active component or transparent display, is disposed in the lens <NUM> to provide additional functionality to the eyewear <NUM>.

The eyewear <NUM> includes a first coil <NUM> to receive electrical power from an external device (not shown in <FIG>). The received energy is transmitted wirelessly to a second coil <NUM> via, for example, inductive charging or magnetic resonance charging. A thin film battery <NUM> (also referred to as a power band) is disposed substantially around the electronic component <NUM> to store the electrical energy received by the second coil <NUM> and provide power to the electronic component <NUM>. Using two coils to relay energy to the battery <NUM> eliminates the need for a physical connection between the battery <NUM> and an antenna (e.g., the first coil <NUM>) that might otherwise obstruct the user's vision through part of the lens <NUM>.

The eyewear <NUM> can be manufactured via several methods. In one example, the first coil <NUM>, the second coil <NUM>, the thin film battery <NUM>, and the electronic component <NUM> can be disposed on a substrate, and the lens <NUM> can be formed using 3D printing around these electronic components (e.g., following the processes shown in <FIG>). In another example, these electronic devices, except the thin film battery <NUM>, can be disposed on a substrate, after which the thin film battery <NUM> can be printed (see details below). The lens <NUM> can then be printed around the thin-film battery <NUM> and other electronics.

In yet another example, the electronic component <NUM> can be disposed on a substrate and then the thin film battery <NUM> can be printed around the electronic component <NUM>. The first coil <NUM>, the second coil <NUM>, and/or any conductive traces connecting the components being embedded in the lens can then be printed using conductive resin (or any other appropriate conductive ink). The manufacturing can follow the processes shown in <FIG> to form the lens <NUM>. In yet another example, part of the electronic component <NUM>, such as an electro-active element, can also be printed, using the method <NUM> illustrated in <FIG>.

The thickness of the thin film battery <NUM> can be less than <NUM> (e.g., less than <NUM>, less than <NUM>, less than <NUM>, less than <NUM>, less than <NUM>, less than <NUM>, less than <NUM>, less than <NUM>, less than <NUM>, or less than <NUM>, including any values and sub ranges in between). Because the battery <NUM> can be so thin, it can have almost any shape. The thin film battery <NUM> can be embedded into the lens <NUM>. Alternatively, the thin film battery <NUM> can be disposed on the front surface or the back surface of the lens <NUM>.

Printing processes can be employed to fabricate the thin film battery <NUM>. In general, the fabrication process for a printed battery can start by selecting the printing tool, followed by tailoring the rheological properties (e.g., viscosity) of the inks used to print the battery's active layers, current collectors, and electrolyte. The non-printed components of the thin film battery <NUM> can serve as supports for the printed components.

In some cases, the thin film battery <NUM> can be fabricated using a dispenser printing technique, in which an ink syringe is employed to deposit ink over a substrate. The ink can be printed in the form of filaments or drops by modulating the pressure in an ink container (e.g., an ink barrel). The opening of the syringe can have a diameter from about <NUM> to about <NUM> (e.g., about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, or about <NUM>, including any values and sub ranges in between). The larger-diameter needles can be made of stainless steel and smaller-diameter needles can be made of pulled glass capillaries. The amount of pressure to force the ink through the syringe can depend on the diameter of the needle in the syringe and the viscoelastic behavior of the ink. The shear thinning behavior of the ink enables printing at considerably lower pressures.

Dispenser printing can be used to print inks over areas ranging from about <NUM><NUM> to <NUM><NUM> by drawing patterns in the form of repeated lines or drops. Dispenser printing large electrodes may be slower than other printing methods, but dispenser printing can be better for printing small electrodes over a defined location. Due to the non-contact nature of dispenser printing, the ink can be printed over uneven surfaces.

In practice, the dispenser printing technique can be used to fabricate the active layers and polymer electrolyte on glass substrates with pre-patterned current collectors formed by lithography. For example, the thin film battery <NUM> can include a 3D lithium-ion battery with interdigitated electrodes can be fabricated using the dispenser printing technique. In this example, a syringe can be employed to extrude concentrated inks of lithium iron phosphate (LFP) and LTO-based inks over lithographically patterned gold current collectors. Fine filaments of the concentrated inks can be formed by printing the ink through a glass needle (e.g., having a diameter of about <NUM>).

The shear thinning behavior of the inks can cause the flow of concentrated inks through small nozzles. A system of high-boiling-point solvent and volatile solvent can be used to control ink solidification and adhesion during patterning. The evaporation of the volatile solvent during the printing process can lead to partial solidification of the printed filament, and the remaining high-boiling-point solvent can function as a humectant to promote bonding between the individual layers.

The battery can be enclosed inside a plastic casing and the liquid electrolyte (e.g., <NUM>M LiClO<NUM> in <NUM>:<NUM> ratio of ethylene carbonate/dimethyl carbonate by volume) can be used to provide ionic contact to the anode and cathode. More information on this technique can be found in <NPL>).

In another example, the thin film battery <NUM> can include a Zn-MnO<NUM> battery printed with a solid polymer gel electrolyte containing an ionic liquid. The MnO<NUM> ink, polymer separator, and zinc ink can be printed sequentially onto a stainless-steel foil. The polymer gel electrolyte can include <NUM>:<NUM> mixture of PVDF-HFP and <NUM>M solution of zinc trifluoromethanesulfonate (Zn+Tf-) salt dissolved in BMIM+Tf-. The resulting cells can have a footprint of about <NUM><NUM> to about <NUM><NUM> and a total thickness of about <NUM> to about <NUM>. More information on this technique can be found in <NPL>).

In yet another example, the thin film battery <NUM> can include a Zn-AgO battery fabricated by a process where the ink can be forced through the needle with compressed gas. In this process, the low-viscosity nanoparticle silver ink can be disposed by dragging a meniscus of the ink over a glass substrate. Low vacuum can be applied inside the ink cartridge to control the meniscus of the ink. Once the silver ink is printed, the electrodes can be annealed to remove the dispersing solvent and assist with fusing of the nanoparticles. The Zn-AgO battery can be formed by electrodepositing Zn onto one electrode and oxidizing the other electrode. More information on this technique can be found in <NPL>).

In some cases, the thin film battery <NUM> can be fabricated using inkjet printing, which can have a high-resolution (e.g., about <NUM> drops per inch, or DPI). The resolution of the pattern depends on the quality of ink and characteristics of the print head. The drops (also referred to as droplets) can be formed by mechanically compressing the ink through a nozzle (e.g., using a piezoelectric head) or by heating the ink to increase its pressure. The final thickness of the printed electrode depends on the number of drops, the volume of the drop, the concentration of the ink and the footprint of the printed area.

For example, the thin film battery <NUM> can include a Zn-Ago battery fabricated using inkjet printing. Once the electrodes are printed and baked, they can be dipped in a bath with a KOH/ZnO electrolyte. Zn can be electrodeposited onto one electrode and the silver onto the counter electrode can be oxidized, forming a Zn-AgO battery. More details about this technique can be found in <NPL>).

In another example, the thin film battery <NUM> includes a lithium-ion battery, where the active electrodes (e.g., Lithium cobalt oxide or LCO, and lithium titanate or LTO) can be printed on current collector foils. Inkjet printable inks can be prepared by ball milling a mixture of active particles, carbon black, and polyvinylidene fluoride or polyvinylidene difluoride (PVDF) binder with a small fraction of surfactant (e.g., Tween-<NUM>/FC-<NUM>) in NMP/propylene carbonate (<NUM>:<NUM>) at <NUM> RPM for <NUM> hours. Ball milling the particles can reduce the particle size and the surfactants can reduce the coagulation rate by increasing the steric repulsion between the particles. The thicknesses of the active layers can be about <NUM> to about <NUM>.

<FIG> shows a schematic of electronic circuitry <NUM> suitable for encasing in resin or other curable material suitable for printing an ophthalmic lens. The electronic circuity <NUM> includes a first coil <NUM> that can be attached to the bulk lens component to receive wireless energy or power from an external device (not shown in <FIG>). A second coil <NUM> is attached to the bulk lens component <NUM> to receive wireless energy or power from the first coil <NUM> and transmit the received energy to an energy storage unit <NUM> (also referred to as an energy storage element <NUM>). The lens <NUM> can have optical power or not, depending on the application, which can range from vision correction to eye protection to virtual reality (VR), augmented reality (AR), or mixed reality (MR). The energy storage unit <NUM> provides at least part of the power for an electro-active element <NUM> (e.g., a liquid crystal element, an electro-chromic element, or other electro-active component).

The electronic circuitry <NUM> adds functions to the lens <NUM>. If the electronic component <NUM> includes an electro-active element, such as a liquid crystal or electrochromic element, it can provide a variable optical power or tint for the wearer. More information about electro-active elements can be found in <CIT>. The electronic element <NUM> could also include an electronically actuated filter, such as a band-reject filter that blocks IR light, UV light, or certain colors. A sensor embedded in the lens and connected to the filter may turn the filter on and off automatically in response to intense IR light, UV light, or certain color(s), e.g., to protect the user's eyes. If the electronic component <NUM> includes a UV sensor to detect the level of UV radiation, detection of a high level of UV light may trigger a decrease in the transmission of UV light to protect the wearer's eyes.

The electronic component <NUM> can include be coupled to other sensors as well. For example, the electronic component <NUM> can include an accelerometer to monitor the motion of the wearer. If the wearer moves, in a particular direction (e.g., he or she looks up or down), the accelerometer may trigger a change in the lens's optical power provided by an electro-active focusing element. If the sensors include a photodetector that detect ambient light, the detection of changes in ambient light by the photodetector can be used to control the refractive index or transmission of the embedded electro-active element.

The electronic component <NUM> can further include a range finder to measure distance between the wearer and an object of interest. This distance can be used to control the optical power (focal length) of the lens <NUM>. In yet another example, the electronic component <NUM> can further include an inter-pupil distance sensor to measure the distance between the two pupils of the wearer. The electronic component <NUM> can increase or decrease the optical power in response to the inter-pupil distance of the wearer. In yet another example, the electronic component <NUM> can further include a thermo-sensor to measure temperature, such as ambient temperature.

The electronic component <NUM> can further include one or more circuits, such as an application specific integrated circuit (ASIC) or other processor, to control the other components in or coupled to the lens. In another example, the electronic component <NUM> can include circuits for frequency modulation and demodulation. This circuit can allow the first coil <NUM>, the second coil <NUM>, and/or another antenna to receive and transmit modulated signals. In yet another example, the electronic component <NUM> can further include one or more resonance circuits to transmit and receive signals or power as discussed below. The electronic component <NUM> can further include a data storage unit, such as a memory or buffer, to store programs for the processor, sensor data, and status information.

<FIG> shows a schematic of an ophthalmic lens system <NUM> including a 3D printed lens <NUM> encasing the electronic circuitry <NUM> of <FIG>. The lens <NUM> is disposed in a lens frame <NUM> and can be manufactured by placing the electronic circuitry <NUM> of <FIG> on a substrate (e.g., the substrate <NUM> shown in <FIG>) and forming, via additive manufacturing, optical segments on both sides of the electronic circuitry <NUM>. These optical segments form a bulk lens component partially or completely surrounding the electronic circuitry <NUM>. A lens frame material can then be printed around the bulk lens component <NUM> to form the lens frame <NUM>. Part of the electronic circuitry <NUM> can be printed as well, including the electrical connections between components (e.g., the traces between the second coil <NUM> and the energy storage unit <NUM> and between the energy storage unit <NUM> and the electronic component <NUM>).

The ophthalmic lens system <NUM> can be used in various applications, including as a spectacle lens that provide dynamic vision correction. Other embodiments of the ophthalmic lens system <NUM> include electronic contact lenses, in which case the lens frame <NUM> can be made of or replaced by a soft material, such as a hydrogel. The ophthalmic lens system <NUM> can also be modified (e.g., by changing the shape of the lens <NUM>) for use in non-ophthalmic applications, including but not limited to electronic instrument lenses, electronic diagnostic lenses, electronic security lenses, and in electronic camera lenses (including those used for healthcare), manufacturing (e.g., in protective goggles), bar code scanning (e.g., the electronic component <NUM> can include a bar code reader), visual inspection, communications (e.g., for video calls or video conferences), and transportation (e.g., the electronic component <NUM> can provide drive directions to drivers).

The first coil <NUM> shown in <FIG> is disposed between the lens <NUM> and the lens frame <NUM>. In another example, the first coil <NUM> can be embedded in or affixed to the bulk lens component <NUM>. In this case, the first coil <NUM> can be made of transparent conductive material, such as ITO or another transparent conductive oxide (TCO). Alternatively, the first coil <NUM> can be disposed around a periphery of the bulk lens component <NUM> (i.e., substantially close to the lens frame <NUM>) to reduce interference with the wearer's vision. In this instance, the first coil <NUM> can also be used to define the 3D printing boundary. The first coil <NUM> (and other electronics) can be disposed on a substrate and the printer only disposes the lens material in the area within the first coil <NUM>. In yet another example, the first coil <NUM> can be around the thickness of the lens <NUM>. In yet another example, the first coil <NUM> can be disposed on the front or back surface of the lens <NUM>.

In yet another example, the first coil <NUM> can be integrated into the lens frame <NUM>. For example, the lens frame <NUM> can include hollow tubes and the first coil <NUM> can be disposed within the hollow tubes. In yet another example, the first coil <NUM> can be disposed at the front or back surface of the lens frame <NUM>.

The first coil <NUM> can also be disposed away from the lens <NUM>. For example, the first coil <NUM> can be disposed on the lens frame <NUM>, the temple portion of the lens frame <NUM>, or the eye wire portion of the lens frame <NUM>. In these cases, the second coil <NUM> can be disposed in or on the lens <NUM> and is electrically coupled to the electronic component <NUM> to power the electronic component <NUM> (e.g., the energy storage element <NUM> can be optional here). The second coil <NUM> can be also connected to a controller (not shown in <FIG>) to control the voltage transmitted to the electronic component <NUM>. The controller can also control the modulation, frequency, power, and/or other parameters of the signals sent to the electronic component. In yet another example, the external device controls the voltage, power, frequency, and other parameters of signals (including energy) transmitted to the first coil <NUM>. In this case, the number of components included in the lens <NUM> or the lens frame <NUM> can be reduced.

<FIG> shows that the first coil <NUM> and the second coil <NUM> each include a single loop. Alternatively, each of the first coil <NUM> and the second coil <NUM> can include multiple loops. In one example, the multiple loops are formed by the same conductive wire. In another example, the multiple loops are formed by multiple wires and can be substantially concentric with each other.

The first coil <NUM> can communicate with the external device in various ways. In one example, the first coil <NUM> receives energy from the external device, which can be a wireless charger or any other device that can transmit wireless energy. In another example, the first coil <NUM> can receive control signals from the external device so as to control the operation of the electronic component <NUM>. In yet another example, the first coil <NUM> can receive data from the external device. In this case, the external device can include a controller, a processor, a smartphone, a computer, a laptop, a tablet, or any other appropriate devices with a wireless transmitter.

The first coil <NUM> can also transmit signals to the external device. For example, the first coil <NUM> can transmit the operating status of the electronic component <NUM> to the external device, which can analyze the operating status and provide control signals based on the operating status of the electronic component <NUM>. In another example, the first coil <NUM> can transmit status information about the energy storage unit <NUM> to the external device. In response to an indication of low energy storage, the external device can initiate a charging process to charge the energy storage unit <NUM>.

Alternatively, the charging of the energy storage unit <NUM> can be automatic. For example, as long as the external device and the first coil <NUM> are within a threshold distance, the charging process can start. The threshold distance can be about <NUM> or less (e.g., about <NUM>, about <NUM>, about <NUM>, including any values and sub ranges in between). The charging can also be continuous or periodic. For example, the external device can include a docking station (also referred to as a dock) to receive and secure the first coil <NUM> (and the lens <NUM>) for charging.

The first coil <NUM> and the external device can communicate and/or transfer energy using various technologies. In one example, the first coil <NUM> and the external device can be inductively coupled. In this case, the external device can transmit energy to the first coil <NUM> via inductive charging.

In another example, the external device and the first coil <NUM> can be resonantly coupled. For example, the external device can function as a resonant transformer to transmit energy to the first coil <NUM> via magnetic resonance power transfer. Magnetic resonance power transfer is transmission of electrical energy between two coils that are tuned to resonate at the same frequency. Without being bound by any particular theory of mode of operation, based on the principles of electromagnetic coupling, resonance-based chargers can inject an oscillating current into a highly resonant coil (e.g., a coil included in the external device) to create an oscillating electromagnetic field. Another coil (e.g., the first coil <NUM>) with the same resonant frequency can receive power from the electromagnetic field and convert the power back into electrical current that can be used to power the electronic component <NUM> and/or charge the energy storage unit <NUM>.

Magnetic resonance wireless transfer is a non-radiative mode of energy transfer, relying instead on the magnetic near field. Magnetic fields usually interact weakly with biological organisms, including people and animals, and therefore are regarded as safe for biological application.

Resonance charging can offer unique advantages in spatial freedom, allowing the external device, which is also referred as the resonance charger, to be separated from the first coil <NUM>. In one example, the first coil <NUM> and the external device are coupled via near field resonant coupling. In this case, the distance between the external device and the first coil <NUM> can be substantially equal to or less than <NUM> times the diameter of the first coil <NUM>. Near field resonant coupling can have high efficiency, depending on the refractive orientation of the first coil <NUM> and the transmitting coil included in the external device.

In another example, the first coil <NUM> and the external device are coupled via mid-field resonant coupling, in which the distance between the external device and the first coil <NUM> can be about <NUM> times to about <NUM> times of the diameter of the first coil <NUM>. Power transmission efficiency in mid-field resonant coupling can depend on the relative angular orientation of the first coil <NUM> and the transmitting coil included in the external device.

In yet another example, the first coil <NUM> and the external device are coupled via far-field resonant coupling, in which the distance between the external device and the first coil <NUM> is greater than <NUM> times of the diameter of the first coil <NUM>. Far-field resonant coupling can be less sensitive to the angular orientation of the first coil <NUM> relative to the transmitting coil in the external device. The two coils (first coil <NUM> and the transmitting coil in the external device) can be impedance matched to increase the transmission efficiency. For example, the shapes, dimensions, and resistances of the two coils <NUM> and <NUM> can be configured to achieve impedance matching.

Other techniques can also be used to transfer energy from the external device to the first coil <NUM>. In one example, the first coil <NUM> can receive energy using radio frequency identification (RFID) technology, which allows the external device to transmit energy to the first coil <NUM> via RF waves. RFID technology also allows the external device to transmit and read data to and from the first coil <NUM>. In another example, the external device can transmit energy to the first coil <NUM> via microwaves. In yet another example, the external device can transmit energy to the first coil <NUM> via ultrasound waves.

In yet another example, the external device can communicate with the first coil <NUM> via WiFi signals. In yet another example, the external device can communicate with the first coil <NUM> via Bluetooth signals. In these cases, the communications between the external device and the first coil <NUM> can be two-way, i.e., the first coil <NUM> can also transmit data to the external device.

The first coil <NUM>, in response to receiving the electrical energy from the external device, excites and energizes the second coil <NUM>. This transfers the electrical energy to the second coil <NUM>. In this manner, the first coil <NUM> can function as a repeater or part of a repeater to relay the electrical energy from the external device to the second coil <NUM>. In one example, the energy transfer between the first coil <NUM> and the second coil <NUM> can be achieved using non-resonant inductive charging. Since the first coil <NUM> is close to the second coil <NUM>, the efficiency of this induction charging can be high. In another example, the energy transfer between the first coil <NUM> and the second coil <NUM> can be achieved using resonant charging as described above. Other than transferring energy, the first coil <NUM> can also function as an antenna to transmit controls signals or data to the second coil <NUM>.

The energy storage element <NUM> can use various techniques to store energy provided by the second coil <NUM>. In one example, the energy storage unit <NUM> includes a battery, such as a rechargeable battery. Due to convenient recharging using the wireless energy transfer techniques described above, the battery used in the ophthalmic lens system <NUM> can have a small size. For example, the lateral dimension (length) of the battery can be less than <NUM> (e.g., less than <NUM>, less than <NUM>, less than <NUM>, less than <NUM>, less than <NUM>, or less than <NUM>, including any values and sub ranges in between). The rechargeable battery can use a thin film battery (e.g., thin film lithium ion battery) to achieve a small form factor of the ophthalmic lens system <NUM>.

In another example, the energy storage element <NUM> can include a capacitor, supercapacitor, or ultra-capacitor. A supercapacitor can store up to <NUM>-<NUM> Watt-hours of electrical energy per kilogram of its weight.

In <FIG>, the energy storage element <NUM> is disposed away from the electronic component <NUM>. In another example, the energy storage element <NUM> can be disposed within the electronic component <NUM>. In yet another example, the energy storage element <NUM> can be disposed on the lens frame <NUM>. In yet another example, the energy storage element <NUM> can be disposed along a periphery of the lens <NUM>. In yet another example, the energy storage element <NUM> can be disposed along a periphery of the electronic component <NUM>. In yet another example, the energy storage element <NUM> can be disposed substantially parallel to the first coil <NUM>. An insulating layer can be disposed between the first coil <NUM> and the energy storage unit <NUM>.

Although various components are shown in <FIG>, some components are optional. For example, the ophthalmic lens system <NUM> can operate without the first coil <NUM>, in which case the second coil <NUM> receives energy directly from an external device. In another example, the ophthalmic lens system <NUM> can operate without the energy storage unit <NUM>. In this instance, the user can bring an external power supply during use and the external power supply can transmit wireless energy to the ophthalmic lens system <NUM>.

<FIG> shows a schematic of electronic eyewear <NUM> with electro-active lenses <NUM> made using 3D printing. The lenses <NUM> are disposed in a lens holder <NUM>, which is connected to a pair of temples 713a and 713b (collectively referred to as the temples <NUM>). The lens holder <NUM> and the temples <NUM> form a lens frame. The lenses <NUM> can include electronic circuitry (e.g., <NUM> in <FIG>) embedded in an optical element. The frame also includes various electronics. For example, the first temple 713a includes a first power supply 720a and a first electronic module 730a, and the second temple 713b includes a second power supply 720b and a second electronic module 730b. A removable electronic module <NUM> is also attached to the second temple 713b via a connector <NUM>. In addition, the temples <NUM> also includes wires 750a and 750b (collectively referred to as wires <NUM>) connected to two additional electronic modules 760a and 760b (collectively referred to as additional electronic modules <NUM>), which may contain conventional or bone conduction speakers.

The lens frame, including the lens holder <NUM> and the temples <NUM>, can be fabricated using 3D printing to fit around and connect to the lenses <NUM>. For example, all the electronics (e.g., power supply <NUM>, electronic modules <NUM>, connector <NUM>, wires <NUM>, and additional electronic modules <NUM>) can be disposed on a substrate, and a printer disposes droplets of lens frame material (e.g., resin, plastic, polymer, or any other appropriate material) around the electronics to form the lens frame, either piece-by-piece or as single integrated unit. In one example, the electronics in the lens frame can be connected to the electronics in the lenses <NUM> before printing the lens frame. In another example, the lens frame can be printed separately and then electrically and mechanically connected to the lenses <NUM>.

In one example, the electronics in the lens frame are connected to electronics in the lenses <NUM> via wires. These wires can be connected, for example, at the interface between the lens holder <NUM> and the temples <NUM>. In another example, the electronics in the lens frame are connected to the electronics in the lenses <NUM> via wireless connection. For example, the electronic modules <NUM> can include one or more wireless transceivers and the lenses <NUM> can include an antenna (see, e.g., <FIG>) to communicate with the electronics on the lens frame. The lenses <NUM> can also include an antenna to receive signals and/or electrical power from the power supply <NUM> disposed on the lens frame.

The removable electronic module <NUM> can be connected to or removed from the eyewear <NUM> during use. For example, the removable electronic module <NUM> can include a backup power supply that provides power to electronic components embedded in the lenses <NUM>. In another example, the removable electronic module <NUM> can include wireless transceivers to allow the eyewear <NUM> to communicate with external devices, such as a smartphone or electro-active lenses <NUM>.

The removable electronic module <NUM> can be coupled to the frame via a docking station in formed or mounted in the second temple 713b. More details of the docking station approach can be found in <CIT>, and entitled "EYEWEAR DOCKING STATION AND ELECTRONIC MODULE".

The electronic modules <NUM>, the removable electronic module <NUM>, and the additional electronic modules <NUM> can perform various types of functions, such as audio playback, audio recording, acoustic amplification, acoustic canceling, hearing aid, video playback, video recording, photography, fall detection, alertness monitoring, pedometer, geo-location, pulse detector, wireless communication, virtual reality, augmented reality, gaming, eye tracking, pupil monitoring, lens control, automated reminder, lighting, lasing, and alarm.

In some cases, the electronics in the lens frame include a controller (e.g., included in any of the electronic modules <NUM>, the removable electronic module <NUM>, and the additional electronic modules <NUM>) to control the operation of the electronic circuitry in the lens <NUM>. For example, the controller can control the focus, tint, or other optical properties of the lenses <NUM>. The control of the lens operation can be based on conditions sensed by one or more detectors in the electronics on the lens frame, such as lighting conditions, object distance, temperature, and humidity.

The power supply <NUM> can include, for example, one or more of a rechargeable battery, disposable battery, fuel cell, solar cell, or kinetic energy source whereby movement of the eyewear generates power. Although two power supplies <NUM> are illustrated in <FIG>, in practice, a single power supply can be used as well.

<FIG> show additional electronic eyewear with 3D printed lenses with embedded electronics. <FIG> shows an electronic eyewear system <NUM> including a repeater for wireless charging and fabricated by 3D printing. The system <NUM> includes a lens frame <NUM> to hold a lens <NUM>. A first coil <NUM> is disposed between the lens <NUM> and the lens frame <NUM> to receive energy wireless from an external device <NUM>. A repeater component <NUM> is operably coupled to the first coil <NUM> to form a repeater <NUM> so as to facilitate wireless energy transfer between the first coil <NUM> and the external device <NUM>. A second coil <NUM> is printed with conductive resin inside the lens <NUM> to receive electrical energy transmitted by the first coil <NUM> and transmit the received energy to an electronic component <NUM> (e.g., an electro-active element) via an internal electronic component <NUM> and a conductive path <NUM>, which may also be printed with conductive resin as described above.

The system <NUM> can be configured as spectacles that provide dynamic vision correction, dynamic tinting, and/or augmented reality. The conductive path <NUM> can be made of transparent conductive resin disposed within the lens <NUM> to reduce potential interference with the wearer's vision. The second coil <NUM> shown in <FIG> is disposed at a corner of the lens <NUM>. Alternatively, the second coil <NUM> can be disposed at a periphery of the electronic component <NUM> and can be substantially concentric with the first coil <NUM> so as to increase the efficiency of wireless energy transfer. In this case, the second coil <NUM> can also be made of transparent conductive resin and can be printed during the lens <NUM> fabrication process.

The system <NUM> can further include an optional energy storage element (not shown), such as the 3D printed battery shown in <FIG>, to store energy received by the second coil <NUM>. Alternatively, the electronic component <NUM> may be powered directly by the second coil <NUM>. In this case, the external device <NUM> can provide continuous charging to the first coil <NUM> to allow continuous operation of the electronic component <NUM>.

The system <NUM> can be manufactured in at least several ways. In one example, the individual electronic components, including the first coil <NUM>, the second coil <NUM>, the electronic component <NUM>, and the internal electronic component <NUM>, are placed on a substrate. The conductive path <NUM> is then printed using conductive resin to electrically connect the second coil <NUM> with the electronic component <NUM>. The lens <NUM> is then printed (e.g., using the process illustrated in <FIG>), followed by printing of the lens frame <NUM>. In another example, the lens frame <NUM> can be printed first to define the area of the lens <NUM>, after which the electronic components are disposed within the lens frame <NUM>. The lens <NUM> is then printed. In yet another example, all the electronic parts, including the conductive pathway <NUM>, can be prefabricated and then placed on a substrate to print the lens <NUM> and the lens frame <NUM>. In yet another example, the first coil <NUM> and the second coil <NUM> can also be fabricated via 3D printing.

<FIG> shows a schematic of a 3D printed optical system <NUM> including a resonator for wireless charging. The system <NUM> includes a lens frame <NUM> to hold a lens <NUM>. A first coil <NUM> is disposed along the periphery of the lens <NUM> to receive wireless energy from an external device <NUM>. One or more enabling resonator electrical components <NUM> are operably coupled to the first coil <NUM> to form a resonator <NUM>, which can increase the efficiency of energy transfer between the first coil <NUM> and the external device <NUM>. An electronic component <NUM> is embedded within the lens <NUM> and is powered by the resonator <NUM> via an embedded electronic component <NUM>. Placing the resonator electronic <NUM> and the internal electronic <NUM> close to each other can improve energy transfer efficiency.

In the system <NUM>, the electronic component <NUM> can include an electro-active element fabricated via a 3D printing process, e.g., like the one illustrated in <FIG>. The electronic parts, including the resonator <NUM> and the internal electronics <NUM>, can be placed adjacent to the electronic component <NUM> to form an assembly on which lens material can be deposited to form the lens <NUM>. The lens frame <NUM> can be printed before or after printing the lens <NUM>.

<FIG> shows a schematic of a printed ophthalmic system <NUM> with non-resonant coupling between an internal coil <NUM> (also referred to as a second coil or secondary coil) and a repeater coil <NUM> (also referred to as the first coil <NUM>). The system <NUM> includes an external device <NUM> to wirelessly transmit electrical energy to the first coil <NUM>, which is disposed between a lens <NUM> and a lens frame <NUM>. A repeater electronic component <NUM> is coupled to the first coil <NUM> to form a repeater <NUM> so as to facilitate energy transfer between the first coil <NUM> and the external device <NUM>. The second coil <NUM> is disposed close to the repeater electronic component <NUM> to receive energy efficiently from the first coil <NUM>. A conductive path <NUM> is disposed on or in the lens <NUM> to conduct the power from the second coil <NUM> to an electronic component <NUM>. Some or all of the components in ophthalmic system <NUM>, including the lens <NUM> and the conductive coils, can be formed using the 3D printing techniques disclosed herein.

Using two or more coils to relay energy from a wireless energy supply to an electronic component or battery in the lens alleviates problems associated with forming electrical connections between the frame <NUM> and the lens <NUM>. A molded electro-active lens may be "edged," or cut to fit in the frame. Edging could cut a wire extending from inside the lens to or beyond the lens's edge. For example, the edging process may smear plastic or debris over the wire, interfering with the electrical connection between the wire and the frame. A 3D printed lens (e.g., lens <NUM> in <FIG>) may not need to be edged - it can be printed to fit in the frame - but aligning a wire extending from a component embedded in the lens to the lens's edge for connection to the frame can still be challenging. Wirelessly coupling the component to the coil in the frame eliminates the need for these wires, simplifying alignment of the lens to the frame and removing potential obstructions from the wearer's field of view.

<FIG> shows a schematic of a printed ophthalmic system <NUM> with non-resonant coupling between an internal coil <NUM> and a resonator coil <NUM>. The system <NUM> includes a lens <NUM> disposed within a lens frame <NUM>. A first coil <NUM> is sandwiched between the lens <NUM> and the lens frame <NUM> to receive wireless energy from an external device <NUM>. A resonator electronic <NUM> is coupled to the first coil <NUM> to form a resonator <NUM>, which transmits the energy received by the first coil <NUM> to a second coil <NUM>. The second coil <NUM> and the resonator electronic <NUM> are disposed in close proximity to each other to increase energy transfer efficiency. The second coil <NUM> further transmits the electrical energy to an electronic component <NUM> via an internal electronic <NUM>.

<FIG> shows a schematic of a pair of printed spectacles <NUM> with electronic components that can be powered by wireless charging. The spectacles <NUM> include a pair of lenses 1230a and 1230b disposed in a lens frame <NUM>. Each lens 1230a and 1230b includes electronic components (not shown in <FIG>), such as electro-active elements as described above. A first group of coils 1210a is coupled to or embedded in the first lens 1230a and a second group of coils 1210b is coupled to or embedded in the second lens 1230b. The two groups of coils 1210a and 1210b may be formed of conductive resin and are configured to receive wireless energy from an external device <NUM>.

The spectacles <NUM> also include two energy storage units <NUM>, each of which is coupled to a respective group of coils 1210a and 1210b. The energy storage units <NUM> can include internal coils to receive energy from the coils 1210a and 1210b, in which case the coils 1210a and 1210b can function as repeaters and/or resonators. The system <NUM> further includes a sensor <NUM> that is operably coupled to the coils 1210b. The sensor <NUM> can include any of the sensors described above, including an accelerometer, a photo detector, a UV detector, a thermo-sensor, a range finder, or a combination thereof.

Each of the two groups of coils 1210a and 1210b, as shown in <FIG>, includes three loops. The three loops can be formed by one or more wires. Other numbers of loops can also be used in the coils 1210a and 1210b. For example, each of the two groups of coils 1210a and 1210b can include more than three loops (e.g., more than <NUM>, more than <NUM>, more than <NUM>, more than <NUM>, or more than <NUM>, including any values and sub ranges in between). The two groups of coils 1210a and 1210b include the same number of loops or different numbers of loops for powering electronic devices in each lens (1230a or 1230b).

The energy storage units <NUM> can include thin film batteries that are manufactured via 3D printing as described above with reference to <FIG>. The energy storage units <NUM> can also be manufactured by other methods and placed together with the coils <NUM> before the lenses 1230a and 1230b are printed. The coils <NUM> can also be printed.

<FIG> shows a schematic of a pair of printed spectacles <NUM> with wireless charging using coils 1310a and 1310b around the thickness of each lens (i.e., in a plane containing or parallel to the corresponding lens's optical axis). The spectacles <NUM> include a pair of lenses 1330a and 1330b disposed in a lens frame <NUM>. Each of the two lenses 1330a and 1330b includes a respective printed coil 1310a and 1310b to receive energy from an external device <NUM> so as to power a respective electronic optic 1350a and 1350b. The coils 1310a and 1310b are disposed on an upper portion of the respective lens 1330a and 1330b. The coils 1310a and 1310b are formed around the thickness of the lenses 1330a and 1330b, instead of along the periphery of the lenses as seen in, for example, <FIG>.

The spectacles <NUM> also include one or more energy storage elements <NUM> to store energy received by the coils 1310a and 1310b. The energy storage elements <NUM> can include internal coils (not shown in <FIG>) to receive energy from the coils 1310a and 1310b via, for example, non-resonant or resonant wireless charging.

The spectacles <NUM> further include a first sensor 1360a disposed on the temple portion of the lens frame <NUM> and a second sensor 1360b disposed in or on the rim portion of the lens frame <NUM>. The two sensors can include any of the sensors described above, including forward-facing photodetectors for measuring ambient light levels or backward-facing interpupillary distance sensors. Additional sensors may also be included in the spectacles <NUM>. The additional sensors can be disposed at any appropriate location, including in or on the rim, lens, temple, or bridge.

During the manufacturing, the coils 1310a and 1310b (as well as electronic parts) can be placed on a substrate and then the lenses 1330a and 1330b are printed. Alternatively, a portion of the lens 1330a (e.g., the portion above the coil 1310a) can be printed first, and then the coil 1310a can be printed on the printed portion of the lens 1330a, followed by printing of the rest of the lens 1330a. The portion of the lens 1330a printed before the printing of the coil 1310a can provide mechanical support for the coil 1310a during manufacturing. A similar process can be used to print the second lens 1310b.

<FIG> shows a schematic of a printed ophthalmic system <NUM> (e.g., a contact lens or an intra-ocular lens) including a repeater coil <NUM> and an internal coil <NUM> in a concentric configuration. The system <NUM> includes a lens <NUM> having an outer edge <NUM>. A first coil <NUM> (also referred to as an external coil or repeater coil) is disposed on the outer edge <NUM> of the lens <NUM> to receive wireless energy from an external device <NUM>. The first coil <NUM> can also transmit signals or data to the external device <NUM> (e.g., functioning as an antenna). Within the outer edge <NUM>, a second coil <NUM> (also referred to as an internal coil) is coupled to the lens <NUM> to receive energy transmitted by the first coil <NUM>. The first coil <NUM> and the second coil <NUM> are substantially concentric with each other to increase the efficiency of energy transfer between the two coils <NUM> and <NUM>.

The system <NUM> also includes an electro-active element <NUM> with electro-active material at the center of the lens <NUM>. The electro-active element <NUM> is powered by the second coil <NUM> via a conductive path <NUM> and an internal electronic <NUM>, which can include, for example, a voltage controller, frequency modulator and/or demodulator, and/or any other electronics.

The electro-active element <NUM> can be embedded within the lens <NUM> or disposed on the front or back surface of the lens <NUM>. The electro-active element <NUM> may include a liquid crystal layer disposed between two transparent electrodes. The liquid crystal can be embedded within the lens <NUM> and the electrodes can be disposed on respective surfaces of the lens <NUM> (i.e., one electrode on the front surface and the other electrode on the back surface).

The electro-active element <NUM> can be manufactured via the 3D printing technique described above with reference to <FIG>. The internal electronic <NUM> can be connected to the electro-active element <NUM> after the electro-active element <NUM> is fabricated. The internal electronic <NUM> can be predisposed on a substrate before the electro-active element <NUM> is printed. In either case, the conductive path <NUM> can be printed using conductive resin.

<FIG> illustrate a printed ophthalmic system <NUM> including a coil and a battery disposed between a lens and a lens frame. <FIG> shows a front view of the system <NUM> including a lens <NUM> disposed within a lens frame <NUM>. <FIG> shows a side view of the system <NUM>. <FIG> shows a magnified view of the portion of the system <NUM>. The magnified view shows that a first coil <NUM> (also referred to as an antenna), which is part of a repeater, disposed between the lens <NUM> and the lens frame <NUM>.

<FIG> shows a further magnified view of the printed ophthalmic system <NUM>. This view shows that the lens <NUM> has a beveled portion <NUM> with a wedge shape. A battery <NUM> (or any other energy storage element) is disposed on the wedge surface of the lens bevel <NUM>. An insulating layer <NUM> is disposed on the battery <NUM>. The first coil <NUM> is disposed substantially at the tip of the wedge surface of the beveled portion <NUM> and above the insulating layer <NUM>, which insulates the first coil <NUM> from the battery <NUM>.

The system <NUM> integrates the first coil <NUM> and the battery <NUM> into the space between the lens <NUM> and the lens frame <NUM>. This can securely fix the first coil <NUM> and the battery <NUM> into the system <NUM> without using any area on the lens <NUM>, thereby reducing interference with the vision of the wearer.

Claim 1:
A method of manufacturing an optic, the method comprising:
disposing electronic circuitry (<NUM>, <NUM>, <NUM>, <NUM>) on a surface, the electronic circuitry having a first side (<NUM>) and a second side (<NUM>) opposite the first side;
disposing a plurality of droplets (232a) of a first resin on the first side of the electronic circuitry;
curing the first resin to form a first optical segment (<NUM>);
turning the electronic circuitry upside down to expose the second side;
depositing a plurality of droplets (232b) of a second resin on the second side of the electronic circuitry; and
curing the second resin to form a second optical segment (<NUM>), the first optical segment and the second optical segment encapsulating the electronic circuitry, and
wherein at least one of:
(i) disposing the plurality of droplets of the first resin comprises depositing a first resin droplet having a first diameter to form a first portion of the first optical segment and depositing a second resin droplet having a second diameter different than the first diameter to form a second portion of the first optical segment, or
(ii) the electronic circuitry comprises an electro-active element (<NUM>, <NUM>, <NUM>), and the method further comprises printing a first layer (420a) on a first electrode (410a), disposing an electro-active material (<NUM>) on the first layer, printing a second layer (420b) on the electro-active material, the first layer and the second layer substantially encapsulating the electroactive material, and disposing a second electrode (410b) on the second layer, or
(iii) the method further comprises printing a thin film battery (<NUM>, <NUM>) in electrical communication with the electronic circuitry, or
(iv) the optic comprises a spectacle lens and the method further comprises printing at least a portion of a lens frame (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) to hold the spectacle lens (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>),
(v) the method further comprises disposing additional electronic circuitry (<NUM>) on the first resin, depositing a third resin (<NUM>) on the additional electronic circuitry, and curing the third resin to encapsulate the additional electronic circuitry between the first resin and the third resin.