U.S. patent application number 13/854877 was filed with the patent office on 2013-11-07 for contour form control.
This patent application is currently assigned to Johnson & Johnson Vision Care, Inc.. The applicant listed for this patent is Johnson & Johnson Vision Care, Inc.. Invention is credited to Jonathan P. Adams, Michael Widman, Christopher Wildsmith.
Application Number | 20130297057 13/854877 |
Document ID | / |
Family ID | 48045290 |
Filed Date | 2013-11-07 |
United States Patent
Application |
20130297057 |
Kind Code |
A1 |
Wildsmith; Christopher ; et
al. |
November 7, 2013 |
CONTOUR FORM CONTROL
Abstract
This invention describes methods and apparatus for implementing
a Convergence Process to Converge a Lens Design wherein a previous
DMD Show may be modified for a subsequent Iteration. In preferred
embodiments, an Iterative Loop may be initiated during a
Convergence Process wherein one or more of various: techniques,
modalities, and thickness correction methods may be
implemented.
Inventors: |
Wildsmith; Christopher;
(Jacksonville, FL) ; Widman; Michael;
(Jacksonville, FL) ; Adams; Jonathan P.;
(Jacksonville, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson & Johnson Vision Care, Inc.; |
|
|
US |
|
|
Assignee: |
Johnson & Johnson Vision Care,
Inc.
Jacksonville
FL
|
Family ID: |
48045290 |
Appl. No.: |
13/854877 |
Filed: |
April 1, 2013 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61618073 |
Mar 30, 2012 |
|
|
|
Current U.S.
Class: |
700/97 |
Current CPC
Class: |
B29C 2035/0827 20130101;
B29D 11/00951 20130101; B29C 2035/0833 20130101; B29C 35/0894
20130101 |
Class at
Publication: |
700/97 |
International
Class: |
G05B 15/02 20060101
G05B015/02 |
Claims
1. An apparatus for modifying a DMD Show to create a Contour Form
Ophthalmic Lens that Converges a Lens Design, the apparatus
comprising: a computer processor in digital communication with a
Contour Forming device; a digital media storage device in
communication with the computer processor and storing executable
software code which is executable upon demand and operative with
the processor and the Contour Lens Forming device to: store digital
data descriptive of an inventory of data wherein said data comprise
one or both of Lens Design data and DMD Show data; receive a
digital data input descriptive of said data; create said DMD Show
wherein a DMD Show instruction is based upon said Lens Design;
determine if said Lens conforms to an Acceptance Criteria of said
Lens Design; and create a subsequent DMD Show instruction wherein
said subsequent DMD Show instruction comprises one or more of a
Convergence masking technique.
2. The apparatus of claim 1 wherein said Convergence masking
technique comprises one or more of said DMD Show covering one or
more of a selected masking region.
3. The apparatus of claim 2 wherein said selected masking region
comprises one or more of a radius, a sector, a segment, and an
area.
4. The apparatus of claim 1 wherein one or more of said Convergence
masking technique comprises one or more of a Blend Zone.
5. The apparatus of claim 4 wherein said Blend Zone comprises one
or more specified zones connecting said selected masked region to
one or more of a non-masked region.
6. An apparatus for modifying a DMD Show to create a Contour Form
Ophthalmic Lens that Converges a Lens Design, the apparatus
comprising: a computer processor in digital communication with a
Contour Forming device; a digital media storage device in
communication with the computer processor and storing executable
software code which is executable upon demand and operative with
the processor and the Contour Lens Forming device to: store digital
data descriptive of an inventory of data wherein said data comprise
one or both of Lens Design data and DMD Show data; receive a
digital data input descriptive of said data; create said DMD Show
wherein a DMD Show instruction is based upon said Lens Design;
determine if said Lens conforms to an Acceptance Criteria of said
Lens Design; and create a subsequent DMD Show instruction wherein
said subsequent DMD Show instruction comprises one or more of a
Convergence modality.
7. The apparatus of claim 6 wherein said Convergence modality
comprises a one-sided modality.
8. The apparatus of claim 7 wherein said one-sided modality
comprises adjusting one or more parameters of one or more
instructions of said previous DMD Show by either of decreasing a
value of said instruction, and increasing said value of said
instruction.
9. The apparatus of claim 7 wherein said one-sided modality
comprises a thickening ratchet instruction.
10. The apparatus of claim 9 wherein said thickening ratchet
instruction comprises an increased said value of said instruction
in one or more portions of said previous DMD Show.
11. The apparatus of claim 7 wherein said one-sided modality
comprises a thinning ratchet instruction.
12. The apparatus of claim 11 wherein said thinning ratchet
instruction comprises a decreased said value of said instruction in
one or more of said portion of said previous DMD Show.
13. The apparatus of claim 7 wherein said one-sided modality
comprises a piston-shifting technique.
14. The apparatus of claim 13 wherein said piston-shifting
technique comprises performing a uniform shift of an equal amount,
of one or more of a selected portion of said previous DMD Show
instruction.
15. The apparatus of claim 7 wherein said one-sided modality
comprises an apex-locking technique.
16. The apparatus of claim 15 wherein said apex-locking technique
comprises a locked I.sub.CT wherein said I.sub.CT is set to a
specified value, that remains constant during said subsequent
Iteration.
17. The apparatus of claim 6 wherein said Convergence modality
comprises a two-sided modality.
18. The apparatus of claim 17 wherein said two-sided modality
comprises adjusting one or more said parameters of one or more said
instructions of said previous DMD Show by both of decreasing said
value of said instruction, and increasing said value of said
instruction.
19. The apparatus of claim 17 wherein said two-sided modality
comprises a piston-shifting technique.
20. The apparatus of claim 19 wherein said piston-shifting
technique comprises performing a uniform shift of an equal amount,
of one or more of said selected portion of said previous DMD Show
instruction.
21. The apparatus of claim 17 wherein said two-sided modality
comprises an apex-locking technique.
22. The apparatus of claim 21 wherein said apex-locking technique
comprises a locked I.sub.CT wherein said I.sub.CT is set to a
specified value, that remains constant during said subsequent
Iteration.
23. An apparatus for modifying a DMD Show to create a Contour Form
Ophthalmic Lens that Converges a Lens Design, the apparatus
comprising: a computer processor in digital communication with a
Contour Lens Forming device; a digital media storage device in
communication with the computer processor and storing executable
software code which is executable upon demand and operative with
the processor and the Contour Lens Forming device to: store digital
data descriptive of an inventory of data wherein said data comprise
one or both of Lens Design data and DMD Show data; receive a
digital data input descriptive of said data; create said DMD Show
wherein a DMD Show instruction is based upon said Lens Design;
determine if said Lens conforms to an Acceptance Criteria of said
Lens Design; and create a subsequent DMD Show instruction wherein
said subsequent DMD Show instruction comprises one or more of a
thickness correction method.
24. The apparatus of claim 23 wherein said thickness correction
method comprises one or more of a percentage method, an arithmetic
method, and a secant method.
25. The apparatus of claim 23 wherein said thickness correction
method comprises a Filtering process of one or more of a data
point.
26. The apparatus of claim 25 wherein said Filtering process
comprises one or more of defining, detecting, removing, and
correcting errors in given data.
27. The apparatus of claim 23 wherein said thickness correction
method comprises a Surface Fitting process of one or more of said
data point.
28. The apparatus of claim 27 wherein said Surface Fitting process
comprises constructing one or both of a surface and a mathematical
function that has a best fit to a series of said data points by
implementing one of either interpolation and smoothing.
29. The apparatus of claim 23 wherein said thickness correction
method comprises a uniform spatial gain method.
30. The apparatus of claim 29 wherein said uniform spatial gain
method provides for one or more of a same said thickness correction
method to be applied across said Training Region wherein a gain
magnitude factor is equal at each pixel location.
31. The apparatus of claim 23 wherein said thickness correction
method comprises a non-uniform spatial gain method.
32. The apparatus of claim 31 wherein said non-uniform spatial gain
method comprises one or more of same said thickness correction
method applied across said Training Region wherein said gain
magnitude factor may be different at each pixel location.
33. The apparatus of claim 31 wherein said non-uniform spatial gain
method comprises a function-based non-uniform spatial gain
method.
34. The apparatus of claim 33 wherein said function-based
non-uniform spatial gain method comprises relating said gain
magnitude factor to a radial location of said pixel.
35. The apparatus of claim 31 wherein said non-uniform spatial gain
method comprises a direct mapping non-uniform spatial gain
method.
36. The apparatus of claim 35 wherein said direct mapping
non-uniform spatial gain method comprises leveraging corresponding
data from a Training Region derived from one or more of said
previous DMD Shows, said measured Lens, and said Lens Design
wherein desired said gain magnitude factor may be calculated at
each pixel location.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to the U.S. Provisional
Application No. 61/618,073, filed Mar. 30, 2012, the contents of
which are relied upon and incorporated herein.
FIELD OF USE
[0002] The present invention describes methods and apparatus to
control manufacture of an article via contour forming apparatus.
More specifically, in some embodiments, a contour forming apparatus
may be controlled based upon a Convergence Process to manufacture a
series of Contour Form Lenses until a Lens Design meets an
Acceptance Criteria.
SUMMARY OF THE INVENTION
[0003] Accordingly, one aspect of this invention provides for
implementing a Convergence Process to create a contour form contact
Lens that meets an Acceptance Criteria of a Lens Design. For
example, a DMD Show may create a Lens that does not meet an
Acceptance Criteria wherein a Convergence Process may be initiated
for a subsequent Iteration. In some embodiments of the present
invention, there may be a variety of one or more of a masking
technique, a Convergence modality, and a thickness correction
method used during a Convergence Process.
[0004] In some other embodiments, a masking technique may include
one or more of a radial masking technique, a sector masking
technique, a segment masking technique, and an area masking
technique, wherein Blend Zones may be applied if necessary. In some
additional embodiments, a modality may include one or more of a
one-sided Convergence modality and a two-sided Convergence
modality. Accordingly, in related embodiments, one or both of an
apex-locking technique and a piston-shifting technique may be used
when performing one or both of a one-sided Convergence Modality and
a two-sided Convergence modality.
[0005] Furthermore, in some embodiments, a thickness correction
method may include one or more of a percentage thickness correction
method, an arithmetic thickness correction method, and a secant
thickness correction method. In some other embodiments, one of
either of a uniform spatial gain method and a non-uniform spatial
gain method may be applied when utilizing a thickness correction
method. In yet some further embodiments, there may be multiple
types of a non-uniform spatial gain method including a
function-based non-uniform spatial gain method and a direct mapping
non-uniform spatial gain method.
BRIEF DESCRIPTION OF DRAWINGS
[0006] FIG. 1 illustrates methods steps that may be used to
implement some embodiments of the present invention.
[0007] FIG. 2a illustrates an example of a radial masking technique
that may be used to implement some embodiments of the present
invention.
[0008] FIG. 2b illustrates an example of a sector masking technique
that may be used to implement some embodiments of the present
invention.
[0009] FIG. 2c illustrates an example of a segment masking
technique that may be used to implement some embodiments of the
present invention.
[0010] FIG. 2d illustrates an example of an area masking technique
that may be used to implement some embodiments of the present
invention.
[0011] FIG. 2e illustrates an example of Blend Zones that may be
used to implement some embodiments of the present invention.
[0012] FIG. 3 illustrates a graphical representation in flat space
of a two-sided Convergence modality that may be used to implement
some embodiments of the present invention.
[0013] FIG. 4 illustrates a graphical representation in flat space
of a one-sided Convergence modality utilizing a thickening ratchet
procedure that may used to implement some embodiments of the
present invention.
[0014] FIG. 5 illustrates a graphical representation in flat space
of a one-sided Convergence modality utilizing a thinning ratchet
procedure that may be used to implement some embodiments of the
present invention.
[0015] FIG. 6 and FIG. 7 illustrate graphical representations in
flat space of an apex locking technique that may be used to
implement some embodiments of the present invention.
[0016] FIG. 8 illustrates a graphical representation in flat space
of a piston-shifting technique that may be used to implement some
embodiments of the present invention.
[0017] FIG. 9 illustrates a display of data generated by utilizing
an arithmetic thickness correction method with application of
various gain magnitude factors that may be used to implement some
embodiments of the present invention.
[0018] FIG. 10 illustrates a display of data generated by utilizing
a percentage thickness correction method with application of
various gain magnitude factors that may be used to implement some
embodiments of the present invention.
[0019] FIG. 11 illustrates a processor that may be used to
implement some embodiments of the present invention.
DETAILED DESCRIPTION OF INVENTION
[0020] The present invention provides for methods and apparatus for
one or both of creating and modifying a DMD show to create a Lens
that Converge a Lens Design. In the following sections detailed
descriptions of embodiments of the invention will be given. The
description of both preferred and alternative embodiments though
thorough are exemplary embodiments only, and it is understood that
to those skilled in the art that variations, modifications and
alterations may be apparent. It is therefore to be understood that
said exemplary embodiments do not limit the broadness of the
aspects of the underlying invention. Method steps described herein
are listed in a logical sequence in this discussion however this
sequence no way limits the order in which they may be implemented
unless specifically stated.
GLOSSARY
[0021] In this description and claims directed to the presented
invention, various terms may be used for which the following
definitions will apply:
[0022] "Acceptance Criteria" as used herein, refers to one or both
of specified parameter ranges and specified parameter values, such
that if measured parameters of a fabricated Lens or Lens Precursor
fall within a range or meet a value of one or both a Lens Design
and a Desired Target File, the fabricated Product may be deemed
acceptable.
[0023] "Blend Zone" as used herein means a contiguous area that
blends one or both of a portion of a Lens to another adjoining
portion of a Lens, and a portion of a DMD Show to another adjoining
portion of a DMD Show.
[0024] "Catalog Item" as used herein, refers to a file, feature,
component, design, data or descriptor that may temporarily or
permanently stored in various embodiments, such as libraries or
databases, and may be recalled for use without having to recreate
them.
[0025] "Contour Forming Device" as used herein, refers to equipment
and methods for fabricating one or more of a Lens Precursor Form, a
Lens Precursor, and a Lens wherein the device may involve, for
example, the use of actinic radiation, Reactive Mixture, and DMD
devices.
[0026] "Convergence" (also sometimes referred to herein as:
"Convergence Process" or "Converge" with the same meaning as
"Convergence Process") as used herein, refers to the process of
modifying DMD Files and using the modified DMD Files in an
Iterative Loop until subsequent fabricated Lens parameters satisfy
one or both of a specified Acceptance Criteria and a Desired Target
File.
[0027] "Curved Space" as used herein, refers to a coordinate
mapping space (e.g., Cartesian, polar, spherical, etc) where
curvature of a design has not been removed.
[0028] "Custom Product" as used herein, refers to a Product
including one or more parameters that may be available in other
than incremental steps. Custom Product parameters allow for more
precise sphere power, cylinder power, and cylinder axis (e.g.,
-3.125D/-0.47D.times.18.degree.) than Standard Product parameters,
and may include base curves, diameters, and stabilization profiles,
and thickness profiles based upon a particular use of a Product
offered.
[0029] "Desired Target File" as used herein, "Desired Target File"
or "Target File" refers to data that may represent one or more of a
Lens Design, a Thickness Map, a Lens Precursor design, a Lens
Precursor Form design, a Lens Precursor Feature design, and
combinations of the above. A Desired Target File may be represented
in either a hydrated or un-hydrated state, in Flat or Curved Space,
in 2-dimensional or 3-dimensional space, and by methods including
but not limited to, geometric drawings, power profile, shape,
features, thicknesses etc. Desired Target Files may contain data on
a regularly or irregularly spaced grid.
[0030] "Digital Core Break" as used herein, refers to a range of
Product where select Lens Precursor Features or control parameters
or other features may be identical and may remain constant within a
specified Product range.
[0031] "DMD" as used herein, refers to a digital micromirror device
that is a bistable spatial light modulator consisting of an array
of movable micromirrors mounted over a CMOS SRAM. Each mirror may
be independently controlled by loading data into the memory cell
below the mirror to steer reflected light, spatially mapping a
pixel of video data to a pixel on a display. The data
electrostatically controls the mirror's tilt angle in a binary
fashion, where the mirror states are either +X degrees ("on") or -X
degrees ("off"). For example, with current devices, X may be either
10 degrees or 12 degrees (nominal); future devices may have
different tilt angles. Light reflected by the "on" mirrors is
passed through a projection Lens and onto a screen. Light reflected
by the "off" mirrors creates a dark field, and defines the
black-level floor for the image. Images are created by gray-scale
modulation between "on" and "off" levels at a rate fast enough to
be integrated by the observer. Each mirror may receive a number of
instructions from one, none, or a plurality of DMD Shows. Select
mirrors may be turned "on" during the Lens fabrication process.
DMDs (digital micromirror device) may be found in DLP projection
systems.
[0032] "DMD Control Software" as used herein, refers to software
that organizes and utilizes DMD Files and DMD Shows that may enable
fabrication of Lens Precursors, or Lens Precursor Features.
[0033] "DMD Show" as used herein "DMD Show" or "DMD File" refers to
a collection of one or both of time based instructional data points
and thickness based instructional data points that may be used to
activate mirrors on a DMD, and enable a Lens or Lens Precursor or
Lens Precursor Form or Lens Precursor Feature(s) to be fabricated.
A DMD Show may have various formats, with (x, y, t), and (r,
.theta., t) being the most common where, for example "x" and "y"
are Cartesian coordinate locations of DMD mirrors, "r" and
".theta." are Polar coordinate locations of DMD mirrors, and "t"
represents time instructions controlling DMD mirror states. DMD
Shows may contain data on a regularly or irregularly spaced
grid.
[0034] "Fabrication Process Conditions" as used herein, refers to
settings, conditions, methods, equipment and processes used in
fabrication of one or more of a Lens Precursor, a Lens Precursor
Form, and a Lens.
[0035] "Filtering" as used herein, refers to the process including
one or more of defining, detecting, removing, and correcting errors
in given data, in order to minimize the impact of errors in input
data on succeeding analyses.
[0036] "Flat Space" as used herein, refers to coordinate mapping
space (e.g., Cartesian, polar, spherical, etc) where curvature of a
design being considered has been removed.
[0037] "Fluent Lens Reactive Media" as used herein, means a
Reactive Mixture that is flowable in either its native form,
reacted form, or partially reacted form and may be formed upon
further processing into a part of an ophthalmic Lens.
[0038] "Free-form" as used herein "free-formed" or "free-form",
(also sometimes referred to herein as: "contour formed" or "contour
form" with the same meaning as "contour formed"), refers to a
surface that is formed by crosslinking of a Reactive Mixture via
exposure to actinic radiation on a voxel by voxel basis, with or
without a fluent media layer, and is not shaped according to a cast
mold, lathe, or laser ablation. Detailed description of Free-form
methods and apparatus are disclosed in U.S. patent application Ser.
No. 12/194,981 (VTN5194USNP) and in U.S. patent application Ser.
No. 12/195,132 (VTN5194USNP1).
[0039] "Iteration" as used herein, refers to the creation of a
subsequent DMD File/DMD Show that is subsequently, used in the
Convergence Process to satisfy Acceptance Criteria.
[0040] "Iterative Loop" as used herein, refers to one, or a series
of process steps that may enable one or more of a Lens, a Lens
Precursor, and a Lens Precursor Feature fabrication such that each
time through a loop, one or more of a Lens, Lens Precursor, and a
Lens Precursor Feature may be more conformal to a desired Lens
Design, than its predecessor. A Convergence Process may contain one
or more Iterative Loops wherein one or both of DMD Shows and
Fabrication Process Conditions may be modified.
[0041] "Lens" as used herein, "Lens" or "lens" refers to any
ophthalmic device that resides in or on the eye. These devices may
provide optical correction or may be cosmetic. For example, the
term Lens may refer to a contact Lens, intraocular Lens, overlay
Lens, ocular insert, optical insert or other similar device through
which vision is corrected or modified, or through which eye
physiology is cosmetically enhanced (e.g., iris color) without
impeding vision. In some embodiments, the preferred Lenses of the
invention are soft contact Lenses and are made from silicone
elastomers or hydrogels, which include but are not limited to
silicone hydrogels, and fluorohydrogels.
[0042] "Lens Design" as used herein, refers to form, function or
both of a desired Lens, which if fabricated, may provide optical
power correction, acceptable Lens fit (e.g., corneal coverage and
movement), acceptable Lens rotation stability, etc. Lens Designs
may be represented in either a hydrated or un-hydrated state, in
Flat or Curved Space, in 2-dimensional or 3-dimensional space, and
by a method including one or more of, geometric drawings, power
profile, shape, features, thicknesses etc. Lens Designs may contain
data on a regularly or irregularly spaced grid.
[0043] "Lens Precursor" as used herein, means a composite object
consisting of a Lens Precursor Form and Fluent Lens Reactive Media
in contact with a Lens Precursor Form that may be rotationally
symmetrical or non-rotationally symmetrical. For example, in some
embodiments Fluent Lens Reactive Media may be formed in the course
of producing a Lens Precursor Form within a volume of Reactive
Mixture. Separating a Lens Precursor Form and Fluent Lens Reactive
Media from a volume of Reactive Mixture used to produce a Lens
Precursor Form may generate a Lens Precursor. Additionally, a Lens
Precursor may be converted to a different entity by either the
removal of an amount of Fluent Lens Reactive Media or the
conversion of an amount of Fluent Lens Reactive Media into
non-fluent incorporated material.
[0044] "Lens Precursor Feature", also referred to as "feature", as
used herein, refers to a non-fluent substructure of a Lens
Precursor Form, and acts as an infrastructure for a Lens Precursor.
Lens Precursor Features may be defined empirically or described
mathematically by control parameters (height, width, length, shape,
location, etc.,) may be are fabricated via DMD Show instructions.
Examples of Lens Precursor Features may include one or more of the
following: a Lens Edge feature, a Stabilization Zone feature, a
Smart Floor Volumator feature, an Optic Zone feature, a Moat
feature, a Drain Channel feature, etc. Lens Precursor Features may
be fabricated using Actinic Radiation Voxels and may be
incorporated into an ophthalmic Lens upon further processing.
[0045] "Lens Precursor Form" as used herein, refers to a non-fluent
object, which may be consistent with being incorporated upon
further processing into an ophthalmic Lens.
[0046] "Product" as used herein, refers to one or more of a Lens, a
Lens Precursor, and a Lens Precursor Form and may include either
"Standard Product" or "Custom Product".
[0047] "PV" (Peak to Valley) as used herein, refers to the
difference between the highest point and the lowest point on a
surface of one or more of a measured Lens Precursor, a measured
Lens Precursor Form, and a measured Lens for one or both of a whole
surface, and a specified region, (e.g., an optic zone), and may be
part of an Acceptance Criteria.
[0048] "RMS" (Root Mean Square) as used herein, refers to the
smoothness of one or more of a measured Lens Precursor, a measured
Lens Precursor Form, and a measured Lens for one or both of a whole
surface, and a specified region, (e.g., an optic zone), and may be
part of an Acceptance Criteria.
[0049] "Standard Product" as used herein, refers to a Product with
limited Product parameter availability, such as those offered in
discrete steps. For example, sphere power parameters may only be
available in 0.25D steps (e.g., -3.00D, 3.25D, -3.50D, etc.);
cylinder power parameters may only be available in 0.50D steps
(e.g, -0.75D, -1.25D, -1.75D, etc.); and cylinder axis parameters
may only be available in 10.degree. steps (e.g., 10.degree.,
20.degree., 30.degree., etc.). Other Standard Product parameters
and features offered in discrete steps include but are not limited
to base curve radii, diameter, stabilization profiles and thickness
profiles.
[0050] "Substrate" as used herein, refers to a physical entity upon
which other entities may be placed or formed.
[0051] "Surface Fitting" as used herein, refers to the process of
constructing a surface or mathematical function that has the best
fit to a series of data points, possibly subject to constraints.
Surface Fitting can involve either interpolation, where an exact
fit to the data is required, or smoothing, in which a "smooth"
function is constructed that approximately fits the data.
[0052] "Thickness Map" as used herein, refers to a 2-dimensional or
3-dimensional thickness profile representation of a desired
Product, Lens Precursor Form, or Lens Precursor. Thickness Maps may
either be in Flat or Curved Space coordinate space and may contain
data on a regularly or irregularly spaced grid.
[0053] "Training Region" as used herein, refers to one or both of a
whole Lens, and one or more portions of a Lens, that may be
iterated upon during a Convergence Process.
[0054] "Voxel" as used herein, also referred to as "Actinic
Radiation Voxel" is a volume element, representing a value on a
regular or irregular grid in 3-dimensional space. A Voxel may be
viewed as a three dimensional pixel, however, wherein a pixel
represents 2D image data a Voxel includes a third dimension. In
addition, wherein Voxels are frequently used in the visualization
and analysis of medical and scientific data, in the present
invention, a Voxel is used to define the boundaries of an amount of
actinic radiation reaching a particular volume of Reactive Mixture,
thereby controlling the rate of crosslinking or polymerization of
that specific volume of Reactive Mixture. By way of example, Voxels
are considered in the present invention as existing in a single
layer conformal to a 2-D mold surface wherein the Actinic Radiation
may be directed normal to the 2-D surface and in a common axial
dimension of each Voxel. As an example, specific volume of Reactive
Mixture may be crosslinked or polymerized according to
768.times.768 Voxels.
[0055] In some embodiments, a Lens may be fabricated based upon a
desired Lens Design, via the use of DMD Shows. Furthermore, a
fabricated Lens may not conform to an Acceptance Criteria of a Lens
Design wherein an Iteration of a previous DMD Show may have to
occur. For example, an Iteration of a previous DMD Show may enable
closer Convergence of a desired Lens Design.
[0056] Referring now to FIG. 1, a flowchart illustrates method
steps that may be followed to implement some embodiments of the
present invention. At 101, in some embodiments, a Lens surface may
be examined for surface anomalies (e.g., blobs, dirt, etc), that
may be present on a Lens surface. At 102, upon determination that
surface anomalies are present on a Lens surface, a Lens may be
discarded and a new Lens remade for example, by utilizing the same
settings of a previous DMD Show. At 103, upon determination that
surface anomalies are not present on a Lens surface, a PV value may
be determined. If a PV is not acceptable, at 104, parameters for a
subsequent Iteration of a DMD Show may be created and a new Lens
made. If a PV is acceptable, at 105, a determination may be made of
whether a RMS is in a desired optic zone. If a RMS is not
acceptable, at 104, parameters for a subsequent DMD Show may be
created and a new Lens made. If a RMS is acceptable, at 106, a
determination may be made of whether a measured Lens meets other
thickness specifications (e.g., peripheral geometries). If other
thickness specifications are not acceptable, at 104, parameters for
a subsequent Iteration of a DMD Show may be created and an
Iteration of a Lens made. If other thickness specifications are
acceptable, at 107, a Lens may be released for post processing.
[0057] As discussed in the aforementioned method steps, there may
be cases when a previous DMD Show creates a Lens that does not
conform to an Acceptance Criteria of a Lens Design and a subsequent
Iteration may be needed.
[0058] In some embodiments, there may be a variety of one or more:
techniques, modalities, and methods utilized during a Convergence
Process. In other related embodiments, when performing a
Convergence Process, a subsequent DMD Show instruction for a
subsequent Iteration may be one or both of an altered previous DMD
Show instruction, a combination of a previous show instruction and
one or more of another DMD Show instruction, and a combination of
two or more DMD Shows. For example, two or more portions from one
or multiple DMD Shows may be combined together for a subsequent
Iteration. Accordingly, an Iterative Loop of a Convergence Process
may be continuously repeated until a Lens meets an Acceptance
Criteria of a Lens Design.
[0059] In some aspects of the present invention, a masking
technique may be implemented during a Convergence Process. In some
embodiments, a masking technique may include one or more of a
radial masking technique, a sector masking technique, a segment
masking technique, and an area masking technique. In some related
embodiments, one or more of a masking technique may be applied to
either: one DMD Show, and two or more DMD Shows that may be used in
a subsequent Iteration. Additionally, in some other embodiments,
one or more of a masking technique may be applied to a Training
Region of a Lens that may include one or both of a whole Lens, and
one or more of a portion of a Lens.
[0060] Furthermore, in some additional embodiments, performing a
masking technique may be used to further Converge a Lens Design
even if a measured Lens already meets a desired Acceptance
Criteria. For example, a PV of a measured Lens may be acceptable,
but performing a masking technique in a subsequent Iteration may
cause Convergence of a Lens Design even more closely and therefore,
enable better performance of a Lens such as improving vision with
even more precision than it may have been without using a masking
technique.
[0061] Referring now to FIGS. 2a-2d, illustrate various examples of
different masking techniques, in flat space. In some embodiments,
when implementing a masking technique a user may specify one or
more of a boundary inside of which a DMD Show may be used, and
outside of which a different DMD Show may be used.
[0062] Referring now to FIG. 2a, illustrates an example of a radial
masking technique applied to a DMD Show. In some embodiments, for
example, when using a radial masking technique for a subsequent
Iteration, one or more portions of one or more DMD Shows, may be
specified to occur within a certain radius. Additionally, one or
more portions of one or more different DMD Shows may be specified
to occur within one or both of one or more radii of a Lens Design,
and an entire remaining portion of a Lens Design.
[0063] Referring now to FIG. 2b, illustrates an example of a sector
masking technique applied to a DMD Show. In some embodiments, for
example, when using a sector masking technique for a subsequent
Iteration, one or more portions of one or more DMD Shows, may be
specified to occur within a certain sector. Additionally, one or
more portions, of one or more different DMD Shows may be specified
to occur within one or both of one or more sectors of a Lens
Design, and an entire remaining portion of a Lens Design.
[0064] Referring now to FIG. 2c, illustrates an example a segment
masking technique applied to a DMD Show. In some embodiments, for
example, when using a segment masking technique for a subsequent
Iteration, one or more portions of one or more DMD Shows, may be
specified to occur within a certain segment. Additionally, one or
more portions, of one or more different DMD Shows may be specified
to occur within one or both of one or more segments of a Lens
Design, and an entire remaining portion of a Lens Design.
[0065] Referring now to FIG. 2d, illustrates an example an area
masking technique applied to a DMD Show. In some embodiments, for
example, when using an area masking technique for a subsequent
Iteration, one or more portions of one or more DMD Shows, may be
specified to occur within a certain area. Additionally, one or more
portions, of one or more different DMD Shows may be specified to
occur within one or both of one or more areas of a Lens Design, and
an entire remaining portion of a Lens Design.
[0066] In some other embodiments, one or more of a Blend Zone may
be specified when using a masking technique. For example, one or
more of a Blend Zone may be applied when implementing a masking
technique and two or more portions taken from either one DMD Show
or two or more DMD Shows, do not connect to one another when they
are combined together in a subsequent DMD Show, as illustrated in
FIG. 2e.
[0067] In some additional aspects of the present invention, there
may be different Convergence modalities implemented during a
Convergence Process either, by one or both of a one-sided
Convergence modality, and a two-sided Convergence modality. In some
embodiments, a two-sided Convergence modality may be used when
performing an Iteration of a previous DMD Show to Converge a Lens
Design in a subsequent DMD Show. For example, a previous show may
create parts of a Lens that may be either one or both of thicker
than a Lens Design, and thinner than a Lens Design. In some related
embodiments, when performing a two-sided Convergence modality, an
Iteration for a subsequent DMD Show may occur by adjusting one or
more of a parameter of both of an instruction that resulted in a
Lens with both one or more thicker areas and one or more thinner
areas, than called for in a Lens Design. Adjustments may occur at
each pixel of a previous show for a subsequent show.
[0068] In some further embodiments, a one-sided Convergence
modality may also be implemented to Converge a Lens Design in a
subsequent DMD Show. In other related embodiments, when performing
an Iteration of a previous DMD Show, a one-sided Convergence
modality may be performed by utilizing either one or both of a
thickening ratchet instruction, and a thinning ratchet instruction.
For example, a previous DMD Show may create areas of a Lens that
may be either one or both of thicker than a Lens Design, and
thinner than a Lens Design. Iterations for a subsequent show
instruction may occur by one of either adjusting one or more
parameters of an instruction that needs to be decreased in value,
and of an instruction that needs to be increased in value.
Accordingly, adjustments may occur at each pixel of selected areas
for a subsequent show instruction.
[0069] Referring now to FIG. 3, illustrates a graphical
representation in flat space, of implementing a two-sided
Convergence modality. In this example, the previous DMD instruction
301 created the measured Lens 303 with areas of the Lens that were
both thinner than the target thickness 302, and thicker than the
target thickness 302 of the desired Lens Design.
[0070] At 300, illustrates applying a two-sided Convergence
modality to the subsequent DMD instruction 304. The subsequent DMD
Show instruction 304 results in decreasing instruction in areas of
the previous DMD Show instruction 301 that created regions that
were too thick on the measured Lens 303, in comparison to the
target thickness value 302. Additionally, the subsequent DMD Show
instruction results increasing instruction in areas of the previous
DMD Show instruction 301 that created regions that were too thin on
the measured Lens 303, in comparison to the target thickness value
302.
[0071] Referring now to FIG. 4, illustrates a graphical
representation in flat space, of implementing a one-sided
Convergence modality by utilizing a thickening ratchet instruction.
In this example, the previous DMD instruction 401 created the
measured Lens 403 with areas that were both thicker than the target
thickness and thinner than the target thickness 402 of the Lens
Design.
[0072] At 400, illustrates applying a one-sided Convergence
modality by utilizing a thickening ratchet instruction 405 in the
subsequent DMD Show instruction 404. The subsequent DMD instruction
404 results in an increasing instruction only in areas of the
previous DMD Show instruction 401 that created regions that were
too thin on the measured Lens 403, in comparison to the target
thickness value 402. Additionally, the subsequent DMD instruction
404 remains unchanged from the previous show instruction 401 that
created regions of the measured Lens 403 that were too thick, in
comparison to the target thickness value 402. Therefore, for the
subsequent Iteration, adjustments occur only to portions of the
previous show that resulted in regions that were too thin on the
measured Lens 403 while other areas remain unchanged in the
subsequent DMD instruction 404.
[0073] Referring now to FIG. 5, illustrates a graphical
representation in flat space, of a one-sided Convergence technique
by utilizing a thinning ratchet instruction. In this example, the
previous DMD instruction 501 created the measured Lens 503 with
areas that were both, thicker and thinner than the target thickness
502 of the Lens Design.
[0074] At 500, illustrates applying a one-sided Convergence
modality by utilizing a thinning ratchet instruction 505 for in
subsequent DMD Show instruction 504. The subsequent DMD instruction
504 results in only decreasing instruction of the previous DMD Show
instruction 501 that created regions that were too thick on the
measured Lens 503, in comparison to the target thickness 502.
Additionally, the subsequent DMD instruction 504 remains unchanged
from the previous show instruction 504 that created areas of the
measured Lens 503 that were too thin, as compared to the target
thickness value 502. Therefore, for the subsequent Iteration,
adjustments occur only to portions of the previous show that
resulted in regions that were too thick on the measured Lens 503
while other areas remain unchanged in the subsequent DMD
instruction 504.
[0075] In some further aspects of the present invention, various
techniques including one or both of an Apex locking technique and a
piston-shifting technique may be applied when implementing one or
more the aforementioned Convergence modalities. In some
embodiments, when performing an apex-locking technique an
instruction at an apex from a previous DMD Show may be adjusted up
to a target thickness value. Furthermore, other selected areas of a
previous instruction may be adjusted up uniformly by a same amount
as an apex value and an apex may be locked so that it may be kept
constant for other subsequent DMD Shows.
[0076] For example, when locking an apex control, instruction at an
apex (I.sub.CT) may be adjusted up to a target thickness apex value
and kept the same; this measured distance between an I.sub.CT and a
target thickness apex is a lock CT value. Furthermore, in some
embodiments, a lock CT value (.DELTA..sup.th), may be calculated by
taking the difference between an I.sub.CT of a previous show and a
target thickness apex value of that same show. Subsequently,
.DELTA..sup.th may be added to every point of an entire measured
Lens surface, and may become a "modified" Lens thickness file for a
subsequent DMD Show. Consequently, a subsequent DMD Show
instruction may create a "modified" measured Lens and subsequently,
be compared to a Lens Design.
[0077] Additionally, in some other embodiments, performing an apex
locking technique may be used to further Converge a Lens Design
even if a measured Lens already meets a desired Acceptance
Criteria. For example, a PV of a measured Lens may be acceptable,
but performing an apex locking technique in a subsequent Iteration
may cause Convergence of a Lens Design even more closely and
therefore, enable better performance of a Lens such as improving
vision with even more precision than it may have been without using
an apex locking technique.
[0078] Referring now to FIG. 6 and FIG. 7, FIG. 6, illustrates a
graphical representation in flat space, of utilizing an apex
locking technique when a Lens center thickness is too thin, and
FIG. 7, illustrates a graphical representation in flat space, of
utilizing an apex locking technique when a Lens center thickness is
too thick. Additionally, both FIG. 6 and FIG. 7, are examples in
flat space, of a comparison between a subsequent locked apex DMD
instruction wherein the I.sub.CT remains the same as in the
previous show instruction 601 and 701, and a subsequent non-locked
apex DMD instruction 606 and 706, wherein the I.sub.CT may not
remain the same as in the previous show instruction 601 and 701.
Referring now again to FIG. 6, in this example, the previous DMD
instruction 601 created the measured Lens 603, where the I.sub.CT
is thinner than the target thickness 602 apex value of the desired
Lens Design. Referring now again to FIG. 7, in this example, the
previous DMD instruction 701 created the measured Lens 703, where
the I.sub.CT is thicker than the target thickness 702 apex value of
the desired Lens Design.
[0079] Referring now again to both FIG. 6, at 605, and FIG. 7, at
705, the temporary adjusted measured Lens profile is created by
comparing the difference between the I.sub.CT value of the measured
Lens 603 and 703, and the target thickness apex value 602 and 702,
and adjusting the subsequent instruction by .DELTA..sup.th. At 606
and at 706, the subsequent non-locked apex instruction is
calculated by adding .DELTA..sup.th to every point on the entire
measured Lens 603 and 703, surface of a temporary adjusted measured
Lens profile 605 and 705, plus any selected additional amount and
thereby, adjusting a subsequent instruction by that total amount.
At 604 and 704, the apex lock instruction is calculated by taking
the difference of the non-locked apex instruction 606 and 706, and
the .DELTA..sup.th, and subsequently, adding the difference to
every point on the measured Lens 603 and 703, surface except to the
I.sub.CT. Accordingly, the I.sub.CT remains the same as in the
previous DMD instruction 601 and 701, and is kept constant during
subsequent Iterations when going through an Iterative Loop of a
Convergence Process.
[0080] In some other additional aspects of the present invention,
when performing a piston-shifting technique a uniform shift of a
previous DMD Show instruction may be done to one or more selected
portions of a previous instruction by a selected amount.
Additionally, in some other embodiments, performing a piston
shifting technique may be used to further Converge a Lens Design
even if a measured Lens already meets a desired Acceptance
Criteria. For example, a PV of a measured Lens may be acceptable,
but performing a piston shifting technique in a subsequent
Iteration may cause Convergence of a Lens Design even more closely
and therefore, enable better performance of a Lens such as
improving vision with even more precision than it may have been
without using a piston shifting technique.
[0081] Referring now to FIG. 8, illustrates a graphical
representation in flat space, of utilizing a piston-shifting
technique. Additionally, at 800, is an example in flat space of a
comparison between a subsequent piston shifted DMD instruction,
wherein a uniform shift of one or more selected portions of the
instruction of the previous show are adjusted by a same amount, and
a subsequent non-piston shifted DMD instruction. In this example,
the previous DMD instruction 801 created the measured Lens 803,
with areas of the Lens that were both thicker and thinner than the
target thickness 802 of the desired Lens Design. At 804, the
subsequent non-piston-shifting instruction results by non-uniformly
adjusting one or more of a selected portion of the previous DMD
instruction 801 by one or more of various selected amounts. At 805,
the subsequent piston-shift instruction results by uniformly
shifting one or more of a selected portion of the previous DMD Show
instruction 801 by a same selected amount.
[0082] In some aspects of the present invention, various thickness
correction methods may be utilized in a Convergence Process to
calculate a subsequent DMD Show instruction including one or more
of an arithmetic thickness correction method, a percentage
thickness correction method, and a secant thickness correction
method. In cases where a Lens may not meet an Acceptance Criteria,
a thickness correction method may be selected based upon
observation made by someone skilled in the art.
[0083] In some embodiments, adjustments may be made at each pixel
of a previous DMD Show using a selected thickness correction method
to calculate a DMD Show instruction for a subsequent Iteration. In
some related embodiments, selected data points of a previous show
may go through one or both of a Filtering process and a Surface
Fitting process for a subsequent DMD Show prior to applying a
thickness correction method. In additional embodiments, a DMD Show
may be Iterated to affect certain or specific areas of a Lens.
Accordingly, for example, subsequent Iterations of a previous DMD
Show may result in one or more of changing a whole Lens, one or
both of reducing certain apertures of a Lens and increasing certain
apertures of a Lens (e.g., optic zone, peripheral zone), and
changing select regions of a Lens.
[0084] Additionally, in some embodiments, various gain magnitude
factors may be applied to a calculation of a subsequent DMD Show
instruction. Furthermore, a gain magnitude factor may be changed
mid-stream during subsequent Iterations. For example, a gain factor
of 200% applied to Iteration 3 may be dropped down to 150% at
Iteration 5.
[0085] In some embodiments, if a DMD Show creates a Lens that does
not meet an Acceptance Criteria, an arithmetic thickness correction
method may be used to calculate instructions for an Iterative DMD
Show. Referring now to FIG. 9, illustrates a display of data
generated by utilizing an arithmetic thickness correction method to
calculate subsequent DMD Show instructions at different iterations
and applying various gain magnitude factors.
[0086] In some related embodiments, to calculate an Iteration value
for a subsequent DMD Show instruction set using an arithmetic
thickness correction method, a Delta thickness value may have to be
calculated. For example, a Delta thickness value may be equal to a
target thickness value of a target design minus a measured Lens
thickness value created from a previous DMD Show. Subsequent to a
calculation of a Delta thickness value, a Delta thickness value may
be multiplied with an applicable gain magnitude factor amount
selected and divided by 100, to determine a scaled Delta thickness
value. A scaled Delta thickness value may be added to a value of a
previous show instruction. In some embodiments, use of the
aforementioned formula may occur at each pixel of a previous show
to calculate a new value for each pixel for a subsequent DMD
Show.
[0087] More specifically, at 902, is an example of utilizing an
arithmetic thickness correction method and applying a 200% gain
magnitude factor to subsequent Iterations of the previous show,
wherein the target thickness value of the Lens Design is 0.0900
.mu.m and the measured Lens thickness is 0.0750 .mu.m. In this
example, the Delta thickness value is 0.0150 .mu.m, which is
calculated by subtracting the measured Lens thickness of 0.0750
.mu.m from the target thickness value of 0.0900 .mu.m. Furthermore,
the scaled Delta thickness value is 0.0300 .mu.m, which is
calculated by multiplying the Delta thickness value of 0.0150 .mu.m
by the gain magnitude factor of 200%, and dividing that value by
100. Subsequently, the scaled Delta thickness value of 0.0300 .mu.m
is added to the previous show value of 0.1250 .mu.m, giving the
subsequent show instruction value of 0.1550 .mu.m.
[0088] In yet, some further embodiments, if a DMD Show creates a
Lens that does not meet desired Acceptance Criteria a percentage
thickness correction method may be used to calculate instructions
for an Iterative DMD Show. Referring now to FIG. 10, illustrates a
display of data generated by utilizing a percentage thickness
correction method to calculate subsequent DMD Show instructions at
different iterations and applying various gain magnitude
factors.
[0089] In some related embodiments, to calculate an Iteration value
for a subsequent DMD Show instruction set utilizing a percentage
thickness correction method, a Delta instruction value may have to
be calculated. For example, a Delta instruction value may be equal
to taking a previous show value and multiplying it by an applicable
gain magnitude factor followed by, multiplying the resulting value
by a target thickness value minus a measured Lens value.
Furthermore, the preceding value is divided by a measured Lens
value, followed by multiplying the resulting value by 100 and
subsequently, adding the value to a previous show value. In some
embodiments, use of the aforementioned formula may occur at each
pixel of a previous show to calculate a new value for each pixel
for a subsequent DMD Show.
[0090] More specifically, at 1002, is an example of utilizing a
percentage thickness correction method calculation and applying a
200% gain magnitude factor to subsequent Iterations of an initial
show, wherein the initial show is 0.125 .mu.m, the target thickness
is 0.090 .mu.m, and the measured Lens thickness is 0.0750 .mu.m. In
this example, the subsequent DMD Show instruction is calculated by
multiplying the initial show value of 0.125 .mu.m by 200%, followed
by multiplying this value by 0.015 .mu.m, which is value of the
difference of the target thickness value of 0.090 .mu.m, and the
measured Lens value of 0.075 .mu.m, equaling the value of 0.00375
.mu.m. Subsequently, the Delta instruction a value of 0.05 .mu.m is
calculated by dividing the value of 0.00375 .mu.m by the measured
Lens value of 0.075 .mu.m. Furthermore, the previous show value of
0.125 .mu.m is subsequently added to the Delta instruction value of
0.05 .mu.m, resulting in the subsequent DMD Show instruction value
of 0.175 .mu.m.
[0091] In some additional embodiments, an Iteration value for a
subsequent DMD Show instruction set may be determined by utilizing
a secant thickness correction method, which may be calculated by
using a secant method algorithm. A secant method is a root-finding
algorithm that uses a succession of roots of secant lines to better
approximate a root of a function f, and is known to those skilled
in the art.
[0092] In some other related embodiments of the present invention,
various spatial gain methods may be applied when using one or more
of the aforementioned thickness correction methods. In some
embodiments, spatial gain methods may include one or both of a
uniform (linear) spatial gain method, and a non-uniform spatial
gain method. Furthermore, a non-uniform spatial gain method may
consist of two types including one or both of a function based
non-uniform spatial gain method, and a direct mapping spatial gain
method.
[0093] In some other embodiments, when applying a uniform (linear)
spatial gain method, a same thickness correction method be applied
across a designated Training Region wherein a gain magnitude factor
is equal at each pixel location. For example, all pixels within an
optic zone may be modified by the arithmetic method using a 100%
gain magnitude factor. In some additional embodiments, when
applying a non-uniform spatial gain method, a same thickness
correction method may be applied across a designated Training
Region wherein a gain magnitude factor may be different at each
pixel location. For example, pixels lying on a diameter of 4 mm may
have a gain magnitude factor of 200% whereas pixels lying a
diameter of 2 mm may have a gain magnitude factor of 150%.
[0094] Furthermore, in some related embodiments, when applying a
function based non-uniform spatial gain method, a gain magnitude
factor may be related to a radial location of a pixel. In some
other related embodiments, when applying a direct mapping
non-uniform spatial gain method, corresponding data may be
leveraged from a Training Region of one or more previous DMD Shows,
a measured Lens, and a Lens Design, to calculate a desired gain
magnitude at each pixel location.
[0095] Referring now to FIG. 11, illustrates a controller 1100 that
may be used to implement some aspects of the present invention. A
processor unit 1101, which may include one or more processors,
coupled to a communication device 1102 configured to communicate
via a communication network. The communication device 1102 may be
used to communicate, for example, with one or more controller
apparatus or manufacturing equipment components.
[0096] A processor 1101 may also be used in communication with a
storage device 1103. A storage device 1103 may comprise any
appropriate information storage device, including combinations of
magnetic storage devices (e.g., magnetic tape and hard disk
drives), optical storage devices, and/or semiconductor memory
devices such as Random Access Memory (RAM) devices and Read Only
Memory (ROM) devices.
[0097] A storage device 1103 may store an executable software
program 1104 for controlling a processor 1101. A processor 1101
performs instructions of a software program 1104, and thereby
operates in accordance with the present invention such as, for
example, the aforementioned method steps. For example, a processor
1101 may receive information descriptive of a desired Lens Design.
A storage device 1103 may also store ophthalmic related data in one
or more databases 1105 and 1106. A database may include one or more
of files containing DMD Show instruction data, customized Lens
Design data, metrology data, defined Lens parameter data for
specific Lens Designs.
CONCLUSION
[0098] The present invention, as described above and as further
defined by the claims below, provides an apparatus for implementing
a Convergence Process.
CALCULATIONS
Arithmetic Method:
[0099] .DELTA. th value = ( Target Thickness - Measured Lens
Thickness ) ##EQU00001## Scaled .DELTA. th value = ( .DELTA. th
value .times. Gain Factor ) 100 ##EQU00001.2## Subsequent D M D
Show Instruction = Previous Instruction + Scaled .DELTA. th value
##EQU00001.3##
Percentage Method:
[0100] Subsequent D M D Show Instruction = ( ( ( Previous
Instruction + Gain Factor ) .times. ( Target Thickness - Measured
Lens Thickness ) ) ( Measured Lens Thickness .times. 100 ) )
##EQU00002##
* * * * *