SYSTEMS, DEVICES, AND METHODS FOR EMBEDDING A DIFFRACTIVE ELEMENT IN AN EYEGLASS LENS
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 fabricating an eyeglass lens with a diffractive element embedded therein, the method comprising:
applying a protective layer to the diffractive element;
applying an interface layer to the protective layer, wherein the interface layer comprises a resin material; and
applying a lens layer to the interface layer, wherein the lens layer comprises the resin material, and wherein the interface layer provides adhesion between the protective layer and the lens layer.
2 . The method of claim 1 wherein applying the protective layer to the diffractive element includes applying a polycarbonate layer to the diffractive element.
3 . The method of claim 1 wherein applying the interface layer to the protective layer comprises:
coating the protective layer with a first amount of the resin material; and
at least partially curing the first amount of the resin material.
4 . The method of claim 1 wherein applying the lens layer to the interface layer comprises:
mounting the diffractive element in a mold;
filling the mold with a second amount of resin; and
curing the second amount of resin to produce the eyeglass lens with the diffractive element embedded therein.
5 . The method of claim 1 wherein mounting the diffractive element in a mold includes mounting the diffractive element in a transparent mold.
6 . The method of claim 5 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.
7 . The method of claim 5 wherein mounting the diffractive element in a mold includes adhering the diffractive element to the mold with a photo-curable adhesive.
8 . The method of claim 1 , further comprising: increasing a surface energy of the protective layer before applying the interface layer to the protective layer.
9 . The method of claim 8 wherein increasing the surface energy of the protective layer 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.
10 . The method of claim 1 , further comprising thermally annealing the eyeglass lens.
11 . The method of claim 1 wherein applying the interface layer to the protective layer includes applying a cross-linkable acrylic resin to the protective layer.
12 . The method of claim 1 wherein applying the lens layer to the interface layer includes applying a cross-linkable acrylic resin to the interface layer.
13 . The method of claim 1 , further comprising applying a curvature to the diffractive element.