Systems, devices, and methods for embedding a diffractive element in an eyeglass lens
View Patent ↗Systems, devices, and methods for embedding a diffractive element in an eyeglass lens are described. A method of embedding a diffractive element in an eyeglass lens includes applying a protective layer to a diffractive element, applying an interface layer to the protective layer, and applying a lens layer to the interface layer. The interface layer and the lens layer are each comprised of a resin material that hardens when cured. The interface layer is of a shape and thickness that adheres well to the protective layer after the interface layer is cured. The lens layer is of a shape and thickness that achieves the desired component shape of the lens after the lens layer is cured.
1. A method of embedding a diffractive element stack in an eyeglass lens, the method comprising:
coating the diffractive element stack with a first amount of resin;
at least partially curing the first amount of resin;
mounting the at least partially cured diffractive element stack in a mold;
filling the mold with a second amount of resin;
curing the second amount of resin to produce the eyeglass lens with the diffractive element embedded therein; and
removing the eyeglass lens from the mold.
2. The method of claim 1 , further comprising:
producing the diffractive element stack, wherein producing the diffractive element stack includes encasing a diffractive element with a protective material.
3. The method of claim 2 wherein encasing a diffractive element with a protective material includes encasing the diffractive element with a polycarbonate material.
4. The method of claim 1 wherein coating the diffractive element stack with the first amount of resin includes:
placing the diffractive element stack in a preliminary mold; and
filling the preliminary mold with resin; and
the method further comprising:
removing the diffractive element stack from the preliminary mold after at least partially curing the first amount of resin.
5. The method of claim 1 , further comprising: increasing a surface energy of the diffractive element stack before coating the diffractive element stack with a first amount of resin.
6. The method of claim 5 wherein increasing the surface energy of the diffractive element stack includes at least one process selected from a group consisting of: plasma treatment, UV-ozone treatment, and applying primer to the surface of the protective material.
7. The method of claim 1 , further comprising thermally annealing the eyeglass lens.
8. The method of claim 1 wherein mounting the at least partially cured diffractive element stack in a mold includes mounting the at least partially cured diffractive element stack in a transparent mold.
9. The method of claim 8 wherein at least one of at least partially curing the first amount of resin and curing the second amount of resin includes a photo-curing process.
10. The method of claim 8 wherein mounting the at least partially cured diffractive element stack in a mold includes adhering the at least partially cured diffractive element stack in the mold with a photo-curable adhesive.
11. The method of claim 1 wherein coating the diffractive element stack with a first amount of resin includes coating the diffractive element stack with a cross-linkable acrylic resin material.
12. The method of claim 1 wherein filling the mold with a second amount of resin includes filling the mold with a cross-linkable acrylic resin material.
13. The method of claim 1 , further comprising applying a curvature to the diffractive element.