Decentered noncorrective lens for eyewear

CA 02212341 1997-08-05

WO 97/21136 PCT/US96/19202

-1DECENTERED NONCORRECTIVE LENS FOR EYEWEAR

Field of the Invention

The present invention relates generally to lenses used in eyewear, and more particularly to a decentered, noncorrective lens configured and oriented to reduce optical distortion.

Background of the Invention

A wide variety of improvements have been made in recent years in the eyewear field, particularly with respect to eyewear intended for use in active sports or as fashion sunglasses. These improvements have been incorporated into eyewear having a unitary lens, such as the Blades® design (Oakley, Inc.) the M Frame® line (Oakley, Inc.), and the Zero® line also produced by Oakley, Inc. These eyewear designs accomplish a variety of functional advantages, such as maximizing interception of peripheral light, reducing optical distortion and increasing the wearer's comfort level, compared to previous active sport eyewear.

The unitary lens of the Blades® eyewear incorporates the cylindrical geometry disclosed, for example, in U.S. Patent No. 4,859,048, issued to Jannard. This geometry allows the lens to closely conform to the wearer's face and intercept light, wind, dust, etc. from directly in front of the wearer (anterior direction) and peripherally (lateral direction). See also U.S. Patent No. 4,867,550 to Jannard (toroidal lens geometry).

Although the early unitary lens systems provided a full side-to-side range of vision and good lateral eye protection, the potential for optical distortion still exists. In a unitary lens system, for example, the angle of incidence from the wearer's eye to the posterior lens surface changes as the wearer's sight line turns in either the vertical or horizontal planes. This results in disparate refraction between light entering closer to the front of the lens and peripheral light entering at the lateral ends. To address this source of prismatic distortion, U.S. Patent No. 4,853,048 discloses tapering the thickness of the lens from the medial portion toward the lateral edge.

Prior art eyewear has also employed dual lens systems in which two separate lenses are mounted along a front frame. In the early dual lens eyeglass systems, each of the right and left lenses were roughly co-planar in the as-worn configuration. Thus, the sight line of the wearer, when looking straight ahead, generally crossed the posterior surface of the lens at a normal to the lens surface in the optical zone. One of the disadvantages of this lens configuration was that the eyeglasses provided essentially no lateral eye protection without the use of special modifications, such as vertically elongated earstems or side attachments.

Dual lens systems were thereafter developed in which the lateral edge of each lens curved rearwardly from the frontal plane, and around the side of the wearer's head to provide a lateral wrap similar to that achieved by the high wrap unitary lens systems. Although the dual lens eyeglasses with significant wrap provided lateral eye protection, the lens curvature generally introduced measurable prismatic distortion through the wearer's angular range of vision. This was particularly pronounced in lenses comprising high index of refraction materials. In addition, although high base curvatures (e.g. base 6 or higher) are sometimes desirable to optimize wrap while maintaining a low profile, such lenses have not been practical in the past due to the relatively high level of prismatic distortion.

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Thus, there remains a need for a high base nonprescription lens for use in dual lens eyewear of the type exhibiting wrap and rake, which can intercept light throughout an angular range of vision while at the same time minimize optical distortion throughout that range.

Summary of the Invention

There is provided in accordance with one aspect of the present invention, an eyeglass lens for use in noncorrective dual lens eyewear. The eyeglass lens is utilized in combination with a frame to support the lens in the path of the wearer’s normal line of sight.

The lens comprises a lens body, having a front surface, a rear surface, and a thickness therebetween.

The front surface of the lens conforms to a portion of the surface of a solid geometric shape. In one embodiment, the front surface of the lens conforms substantially to a portion of the surface of a first sphere having a first center. The rear surface of the lens conforms substantially to a portion of the surface of a solid geometric shape, which may be the same or different than that conforming to the front surface. In one embodiment, the rear surface conforms substantially to a portion of the surface of a second sphere having a second center.

The first and second centers are offset from one another to taper the lens thickness. The lens is mounted in the frame in an orientation such that a line drawn through the first and second centers is maintained generally in parallel with a preselected reference such as the wearer's normal straight ahead line of sight.

The lens may be cut from a lens blank, or formed directly into its final configuration such as by injection molding or other techniques known in the art. Preferably, the lens is oriented on the head of a wearer by the eyeglass frame such that the normal sight line of the wearer crosses the anterior surface of the lens at an angle of greater than about 95°C, and preferably within the range of from about 100° to about 120°, while maintaining the optical centerline of the lens in a generally parallel relationship with the normal sight line of the wearer. The optical centerline of the lens may or may not pass through the lens.

Methods of making the lens of the present invention are also disclosed.

In accordance with another aspect of the present invention, there is provided an eyeglass, containing non-powered decentered eyeglass lenses which are optically corrected in an as-worn orientation with respect to the left and right normal lines of sight of a wearer, comprising:

a frame for suspending a non-glass left lens and a non-glass right lens, the lenses being spaced apart and independent from each other;

the left lens being attached to the frame and positioned by the frame in a predetermined orientation with respect to the wearer’s left normal line of sight to produce rake and wrap, said left lens having an outer surface conforming to a portion of the surface of a first sphere having a first center and an inner surface conforming to a portion of the surface of a second sphere having a second center, and a left optical centerline extending through the first and second centers;

wherein the frame maintains the left lens in an as-wom orientation such that the left optical centerline is maintained generally parallel to and spaced vertically and horizontally apart from the wearer’s left normal straight-ahead line of sight, and wherein the vertical distance between the left

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2a optical centerline and the left normal line of sight at the front left lens surface corresponds to the degree of rake in the left lens to correct for prism that would otherwise be induced by said rake;

the right lens being attached to the frame and positioned by the frame in a predetermined orientation with respect to the wearer’s right normal line of sight to produce rake and wrap, said right lens having an outer surface conforming to a portion of the surface of a first sphere having a first center and an inner surface conforming to a portion of the surface of a second sphere having a second center, and a right optical centerline extending through the first and second centers;

wherein the frame maintains the right lens in an as-worn orientation such that the right optical centerline is maintained generally parallel to and spaced vertically and horizontally apart from the wearer’s right normal straight-ahead line of sight, and wherein the vertical distance between the right optical centerline and the right normal line of sight at the front right lens surface corresponds to the degree of rake in the right lens to correct for prism that would otherwise be induced by said rake; and wherein the left and right optical centerlines are not coincident in the as-worn orientation.

In accordance with another aspect of the present invention, there is provided a method of cutting non-powered left lens for dual lens eyewear from a first spherical tapered lens blank and a nonpowered right lens for dual lens eyewear from a second spherical tapered lens blank, said left and right lenses for use in an eyeglass frame in which the lenses will exhibit both wrap and rake in an as-worn orientation on a standardized head form, and will minimize optical distortion in the as-worn orientation, comprising:

determining a desired degree of rake and a desired degree of wrap of the left and right lenses relative to the as-worn orientation, the rake and wrap resulting in a non-central orientation of the left and right lenses relative to the left and right normal lines of sight in the as-wom orientation;

obtaining a first spherical, vertically and horizontally tapered, non-glass lens blank having a first optical centerline passing through centers of curvature for anterior and posterior surfaces of the first lens blank;

selecting a first location on the first lens blank for cutting the first lens such that the first lens will have the optical centerline spaced vertically from the left normal line of sight in the as-wom orientation by an amount corresponding to the desired degree of rake;

cutting the first lens from said first location on the lens blank;

obtaining a second spherical, vertically and horizontally tapered, non-glass lens blank having a second optical centerline passing through centers of curvature for anterior and posterior surfaces of the second lens blank;

selecting a second location on the second lens blank for cutting the second lens such that the second lens will have the optical centerline spaced vertically from the right normal line of sight in the asworn orientation by an amount corresponding to the desired degree of rake; and cutting the second lens from said second location on the lens blank.

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2b

Further features and advantages of the present invention will become apparent from the detailed description of preferred embodiments which follows, when considered together with the attached claims and drawings.

Brief Description of the Drawings

Figure 1 is a perspective view of eyewear incorporating taper corrected lenses made in accordance with an embodiment of the present invention.

Figure 2 is a cross-sectional view taken along the lines 2-2 of Figure 1.

Figure 3 is a schematic horizontal cross-sectional view of a prior art untapered lens for a dual lens eyewear system.

Figure 4 is a schematic horizontal cross-sectional view of a tapered lens for a dual lens eyewear system.

Figure 5 is a cross-sectional view like that in Figure 2, showing taper corrected lenses having a greater base curvature, in accordance with another embodiment of the present invention.

Figure 6 is a perspective view of a lens blank conforming to a portion of the surface of a sphere, 15 showing a lens profile to be cut from the blank in accordance with a preferred embodiment of the present invention.

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-3Figure 7 is a perspective cutaway view of the hollow, tapered wall spherical shape, lens blank, and lens of Figure 6.

Figure 8 is a horizontal cross-sectional view of a lens constructed in accordance with a preferred embodiment of the present invention.

Figure 8A is a vertical cross-sectional view of a lens constructed in accordance with a preferred embodiment of the present invention.

Figure 9 is a top plan view of the lens of Figure 8 showing a high wrap in relation to a wearer.

Figures 10A-10C are right side elevational views of lenses of various configurations and orientations relative to a wearer.

Figure 10A illustrates the profile of a properly configured and oriented lens for use in an eyeglass having downward rake, in accordance with a preferred embodiment of the present invention.

Figure 10B illustrates the profile of a centrally oriented lens with no rake.

Figure 1ÛC illustrates a lens exhibiting downward rake but which is not configured and oriented to minimize prismatic distortion for the straight ahead line of sight.

Figure 11 schematically illustrates the projection of the lens horizontal profile from a desired orientation within an eyewear frame to the lens blank, in accordance with a preferred embodiment of the present invention.

Figure 11A schematically illustrates the projection of the lens vertical profile from a desired orientation within an eyewear frame to the lens blank, in accordance with a preferred embodiment of the present invention.

Figure 12 is a top plan view of the right lens and front (convex surface) of the lens blank of Figure 6, rotated to project the mechanical centerline of the blank normal to the page.

Figure 12A is a top plan view, like that of Figure 12, additionally showing the position from which a left lens could have been cut from the same lens blank.

Detailed Description of the Preferred Embodiments

Although the preferred embodiments will be discussed below in terms of lenses having ''spherical front and rear surfaces (surfaces which conform substantially to a portion of the surface of a sphere), it will be understood by those having ordinary skill in the art that the invention may also be applicable to lenses having different surface geometries. Additionally, it will be understood that the present invention has application to lenses of many front elevational shapes and orientations in the as-worn position beyond those illustrated herein.

Referring to Figures 1 and 2, there is illustrated an eyeglass 10, such as a sunglass having first and second lenses 12, 14 constructed in accordance with an embodiment of the present invention. Although the invention is illustrated as though it were incorporated into an eyeglass design marketed by Oakley under the Eye Jackets™ name, the present invention relates solely to the lens curvature, taper, and orientation on the head of the wearer. Therefore the particular lens or frame shape revealed in Figure 1 is not critical to the invention. Rather, lenses of many other shapes and configurations may be constructed which incorporate the configuration and orientation of the present invention, as will become apparent based upon the disclosure herein.

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-4Similarly, the mounting frame 16 having continuous orbitals is not essential to the present invention. The orbitals may bound only the bottom edge(s) of the lenses 12, 14, only the top edges, or the entire lenses as illustrated. Alternatively, the frame 16 can bound any other portions of the lenses as will be evident to those of skill in the art. Frameless eyeglasses can also be constructed in accordance with the present invention, as long as the lens orientation on the head of the wearer is substantially maintained in a predetermined relationship to a preselected sight line as will be discussed below. Preferably, though, the lenses 12, 14 are each mounted in an annular orbital as shown.

A pair of earstems 20, 22 pivotally attach to the frame 16. Alternatively, the earstems 20, 22 may attach directly to the lenses 12, 14. The frame may comprise any of a variety of metals, composites or relatively rigid, molded thermoplastic materials which are well known in the art, and may be transparent or any of a variety of colors. Injection molding, machining and other construction techniques are well known in the art.

Lenses in accordance with the present invention can be manufactured by any of a variety of processes well known in the art.

Typically, high optical quality lenses are cut from a preformed injection molded lens blank. Since the right and left lenses are preferably mirror images of each other, only the right lens will generally be described for most of the discussion below. In describing a method of cutting lenses from preformed lens blanks, however, the manner in which a left lens differs from the right lens will be related to the degree of rake and wrap chosen for the as-worn lens orientation. Alternatively, the lens can be molded directly into its final shape and size, to eliminate the need for post molding cutting steps.

Preferably, the lens, or the lens blank from which it is cut, is injection molded and comprises a relatively rigid and optically acceptable material, such as polycarbonate. Other polymeric lens materials can also be used, such as CR-39 and a variety of high index plastics which are known in the art. The decentered taper correction of the present invention may also be applicable to glass lenses, although the need for correction in the present context is generally more pronounced in currently popular nonglass materials.

If the lens is to be cut from a lens blank, the taper and curvature of a carefully preselected portion of the lens blank is transferred to the lens in accordance with a preferred orientation process described below. Preferably, the frame is provided with a slot or other attachment structure that cooperates with the molded curvature of the lens to minimize deviation from, and even improve retention of the as-molded curvature.

Alternatively, the lens or lens blank can be stamped or cut from generally planar tapered sheet stock and then bent into the curved configuration in accordance with the present invention. This curved configuration can then be maintained by the use of a relatively rigid, curved frame, or by heating the curved sheet to retain its curved configuration, as is well known in the thermoforming art.

Most preferably, the curvature of both surfaces of the lens are created in the lens blank molding and polishing processes, and the lens shape is cut from the blank in accordance with the invention as described below.

Referring to Figure 2, the lens 14 of the present invention is characterized in a horizontal plane by a generally arcuate shape, extending from a medial edge 24 throughout at least a portion and preferably substantially

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-5ail of the wearer's range of vision to a lateral edge 26. The arc length of the lens from the medial edge 24 to the lateral edge 26 in a dual lens system will generally be within the range of from about 1 1/2 inches to about 3 1/2 inches, and preferably within the range of from about 2 inches to about 3 inches. In one preferred embodiment, the arc length of the lens is about 2 3/8 inches.

Although the outer surfaces of the lenses 12,14 appear to be illustrated as lying on a common circle 31, the right and left lenses in a high wrap eyeglass will generally be canted such that the medial edge of each lens wffl fall outside of the circle 31 and the lateral edges wiB fall inside of the circle 31. Such canting of the lens increases the angle Θ (Fig. 2) and increases the deskabity of the optical correction achieved by the present invention.

When worn, the lens 14 should at least extend across the wearer's normal straight ahead Ena of sight 27, and preferably substantial across the wearer's peripheral zones of vision. As used herein, the wearer's normal line

I of sight shall refer to a fine projecting straight ahead of the wearer's eye, with substantially no angular deviatinn in either the vertical or horizontal planes as flustrated by fine 130 in Figs. 9 and 10. I ₍

The lens 14 is provided with an anterior surface 28, a posterior surface 30, and a varying thickness therebetween. The thickness of the tens 14 in the region of the medial edge 24 for a polycarbonate lens is generally within the range of from about 1mm to about 2.5mm, and preferably in the range of from about 1.5mm to about 1.8mm. In a preferred embodiment, the thickest portion of the tens 14 is at or about the intersection of the tens with the optical centerfine, and is about 1J5mm.

Preferably, the thickness of the lens 14 tapers smoothly, though not necessarily linearly, from the maximum thickness proximate the medial edge 24 to a relatively lesser thickness at the lateral edge 26. The thickness of the lens near the lateral edge 26 is generafiy within the range of from about .635mm to about 1.52mm, and, preferably, within the range of from about .762mm to about 127mm. In one preferred polycarbonate embodiment, the tens has a minimum thickness in the lateral zone of about 1.15mm. The minimum thickness at lateral edge 26 is generally governed by. the desired impact resistance of the tens.

Figure 3 schematically illustrates refraction in a prior art lens 41 with circular inside and outside surface horizontal cross-sections, having a uniform thickness 44. With such a lens 41, the angle of incidence of rays from the tens 41 to the eye 46 changes throughout the angular range of vision. For example, a ray which shaD be referred to for descriptive purposes as a medial fight ray 50 strikes the tens 41 at an angle a to the normal at the point of incidence. As is wen known in this art, bending of fight at transmitting surfaces depends m part upon the angle of incidence of light rays. The ray 50 is refracted or bent in opposite directions ot each of an outer surface 52 and an inner surface 54 of the tens 41, resulting in a transmitted ray 56 paraDei to the incident ray 50. The transmitted ray 56 is laterally displaced, relative to the path of the incident ray 50, by a distance 56. This displacement represents a first order source of (prismatic) optical distortion.

Furthennore, refractory displacement is even more pronounced ot a lateral end 60 due to a greater angle of incidence β. k peripheral incident ray 62 experiences greater displacement 64 than the medial incident ray 50, in accordance with Snell's Law, as wfil be understood by those of ordinary skiB in the optical arts. The discrepancy between the peripheral ray displacement 64 and the medial ray displacement 58 results in a second order of optical

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-6distortion. This second order of distortion may cause substantial warping of an image seen through relatively lateral portions of the lens 41.

Figure 4 schematically illustrates a lens 71 of tapered thickness, to compensate for the greater angle of incidence at the lateral ends 60 of the lens 41 (Figure 3), similar in ways to that disclosed in the context of unitary lens systems in U.S. Patent No. 4,859,048, issued to Jannard. Tapering produces a smaller lens thickness 74 at a lateral end 76, relative to a lens thickness 78 at a more medial point 80. This smaller thickness 74 reduces an amount of peripheral ray displacement 82, relative to the peripheral ray displacement 64 through the untapered lens 41 of Figure 4. In other words, lesser lens thickness 74 near the lateral end 76 of the tapered lens 71 compensates to some extent for a greater angle of incidence /3, relative to the thickness 78 and angle of incidence a at the more medial point 80.

The resulting difference between peripheral ray displacement 82 and medial ray displacement 84 on the same lens 71 is not as great as the corresponding difference in Figure 3, reducing the second order optical distortion. Note that the degree of correction of the second order distortion depends upon a relationship between the manner and degree of tapering from the apex 85 to each lateral end 76 and the manner in which the angle of incidence changes over the same range.

The lens 71 of Figure 4 is illustrated as though it were mounted within a frame (not shown) such that the wearer's normal line of sight 86 passes perpendicularly through the lens 71 at the lens apex or mechanical center 85. In other words, the angle of incidence to the lens normal is zero for the wearer's normal line of sight. The outer and inner surfaces of lens 71 in the cross-sectional illustration conform to offset, equal-radius circles represented by centerpoints 87 and 88, respectively. A line drawn through centerpoints 87 and 88, referred to herein as the optical centerline of the lens, is collinear with the normal line of sight in the as-worn orientation. This conventional configuration shall be defined as a centrally oriented lens, for ease of description. Circumferentially clockwise or counterclockwise of the normal line of sight 86, the angle of incidence to the lens normal increases in a regular fashion from zero at the lens apex 85.

A degree of wrap may be desirable for aesthetic styling reasons, for lateral protection of the eyes from flying debris, or for interception of peripheral light. Wrap may be attained by utilizing lenses of tight horizontal curvature (high base), such as small-radius spherical lenses, and/or by mounting each lens in a position which is canted laterally and rearwardly relative to centrally oriented dual lenses. Such canting shifts the normal line of sight 86 out of a collinear relationship with the optical centerline, and changes the optics of the lens. As a result, prior art dual lens eyewear with substantial wrap around the sides of a wearer's face has generally been accompanied by some degree of prismatic distortion.

Similarly, a high degree of rake or vertical tilting may be desirable for aesthetic reasons and for intercepting light, wind, dust or other debris from below the wearer's eyes. Just as wrap tends to shift the normal line of sight 86 out of a collinear relationship with a horizontal component of the optical centerline, mounting the lens with rake shifts the normal line of sight out of a collinear relationship with a vertical component of the optical centerline. Prior art dual lens eyewear with substantial rake generally also display a degree of prismatic distortion.

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-7ln accordance with the present invention, there is provided an improved optical configuration and method for minimizing prismatic distortion in a lens having rake and/or wrap in the as-worn orientation. Though the present invention may be applied to a wide variety of lens shapes and orientations, the invention has particular utility for dual lens eyewear using high base curvature and demonstrating a high degree of wrap and/or rake in the as-worn orientation.

Referring to Figures 2 and 5, the illustrated eyewear incorporates canted lenses 12 and 14 or 102 and 104, mounted in a position rotated laterally relative to conventional centrally oriented dual lens mountings. A canted lens may be conceived as having an orientation, relative to the wearer's head, which would be achieved by starting with conventional dual lens eyewear having centrally oriented lenses and bending the frame inwardly at the temples to wrap around the side of the head.

As a consequence of the increased wrap, the wearer's normal line of sight 27 no longer strikes the lens ?

perpendicularly, as illustrated in Fig. 4. Instead, the angle of incidence θ° (Figure 2} for the wearer's line of sight 27 is generally greater than 90°, and to achieve good wrap it may be greater than about 95°, preferably is within the range of from about 100° to about 135°, and in one 9.5 base embodiment is about 101.75°. Lower base lenses generally will exhibit a larger angle Θ in the as-worn orientation, and the angle Θ in an embodiment having a base of 6.5 was about 113.4°. In a base 4 embodiment having a pupillary distance of 2.8 inches, the angle Θ was about 119.864°.

Figure 5 illustrates the horizontal cross-section of an eyeglass 100 in accordance with an embodiment of the present invention, similar in style to that illustrated in Figure 2, except having lenses 102 and 104 of tighter curvature (higher base) as well as possibly greater wrap. When the eyeglass 100 is worn, a lateral edge 106 of the lens 104 wraps significantly around and comes in close proximity to the wearer's temple to provide significant lateral eye protection as has been discussed.

An anterior (front) surface 108 of the lens of the present invention will generally conform to a portion of the surface of a regular geometric solid, such as a sphere 110, shown here in horizontal cross-section. The front surfaces of spherical lenses 102 and 104 of the illustrated embodiment can, therefore, be characterized by a radius. By convention in the industry, the curvature may also be expressed in terms of a base value, such that the radius (R) in millimeters of the anterior surface of the lens is equal to 530 divided by the base curve, or

530 (i)

The present invention provides the ability to construct dual lens eyeglass systems having relatively high wrap using lens blanks having a base curve of 6 or greater, preferably between about 7-1/2 and 10-1/2, more preferably between about 8 and 9-1/2, and, in one embodiment between about 8-3/4 and 9. The radius of the circle conforming to the anterior surface of a base 8-3/4 lens, for example, is about 60.57 millimeters. For comparison, the radius of the circle which characterizes the anterior surface of a base 3 lens is about 176.66 miliimeters.

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-8The embodiment of the present invention illustrated in Figure 5 may be cut from a base 8 3/4 lens blank having a thickness of about 0.0649 inches at the optical centerline and about 0.053 inches at a reference point two inches along the outer circumference of the lens from the optical centerline. Alternatively, the lens can be molded directly into its final shape and configuration.

Figure 6 is a perspective view of a lens blank 122, a convex outside surface 136 of which generally conforms to a portion of the surface of a three-dimensional geometric shape 124. It will be understood by those of skill in this art that lenses in accordance with the present invention may conform to any of a variety of geometric shapes.

Preferably, the outside surface of the lens will conform to a shape having a smooth, continuous surface having a constant horizontal radius (sphere or cylinder) or progressive curve (ellipse, toroid or ovoid) or other aspheric shape in either the horizontal or vertical planes. The geometric shape 124 of the preferred embodiments herein described, however, generally approximates a sphere.

The sphere 124 illustrated in Figures 6 and 7 is an imaginary three-dimensional solid walled structure, a portion of the wall of which is suitable from which to cut a lens 120. As is known in the art, precision lens cutting is often accomplished by producing a lens blank 122 from which a lens 120 is ultimately cut. However, it should be clear to those of skill in the art from the illustrations of Figures 6 and 7, that the use of a separate lens blank is optional, and the lens 120 may be molded directly into its final shape and configuration if desired.

It can also be seen from Figures 6 and 7 that the lens 120 and/or the lens blank 122 can be positioned at any of a variety of locations along the sphere 124. For the purpose of the present invention, the optical centerline 132 operates as a reference line for orientation of the lens 120 with respect to the sphere 124. In the illustrated embodiment, wherein both the outside surface and the inside surface conform to a portion of a sphere, the optical centerline is defined as the line 132 which joins the two centers C1 and 02. The analogous reference line for the purpose of nonspherical lens geometry may be formed in a manner different than connection of the two geometric centers of the spheres, as will be apparent to one of skill in the art.

The lens 120 is ultimately formed in such a manner that it retains the geometry of a portion of the wall of the sphere as illustrated in Figure 7. The location of the lens 120 on the sphere 124 is selected such that when the lens 120 is oriented in the eyeglass frame, the normal line of sight 130 of the wearer through the tens will be maintained generally in parallel to the optical centerline 132 of the geometric configuration from which the tens 120 was obtained. In the illustration of Figures 6 and 7, the tens 120 is a right tens which has a significant degree of wrap, as well as some degree of downward rake (indicated by the as-worn normal line of sight crossing the sphere 124 below the optical centerline 130). A tens having a different shape, or a lesser degree of wrap may overlap the optical centerline 132 of the imaginary sphere 124 from which the tens was formed. However, whether the optical centerline of the imaginary sphere 124 crosses through the lens 120 or not is unimportant, so long as the line of sight 130 in the tens 120 is maintained generally in parallel in the as-worn orientation with the optical centerline 132.

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-9Similarly, if the fens is to have no rake or upward rake in the as-worn orientation, the normal line of sight (and the entire lens) would cross the sphere 124 at or above the central horizontal meridian which contains the optical centerline. The spatial distance and position of the ultimate normal line of sight 130 relative to the optical centerline 132 therefore indicates the degree of wrap (by horizontal distance) and rake (by vertical distance). However, regardless of the distances involved, the lens will exhibit minimal optical distortion as long as the normal line of sight 130 is offset from but maintained substantially parallel to the optical centerline 132 preferably in both the horizontal and vertical planes.

For purposes of the present invention, substantially parallel shall mean that the preselected line of sight 130 when the lens 120 is oriented in the as-worn position generally does not deviate within the horizontal or vertical plane by more than about ± 15° from parallel to the optical centerline 132. Preferably, the normal line of sight 130 should not deviate by more than about ±10° from the optical centerline 132, more preferably the normal line of sight 130 deviates by no more than about ± 5° and most preferably no more than about ± 2° from parallel to the optical centerline 132. Optimally, the line of sight 130 is parallel to the optical centerline in the as-worn orientation.

Variations from parallel in the horizontal plane generally have a greater negative impact on the optics than variations from parallel in the vertical plane. Accordingly, the solid angle between the line of sight 130 and optical centerline 132 in the vertical plane may exceed the ranges set forth above, for some eyewear, as long as the horizontal component of the angle of deviation is within the above-mentioned ranges of deviation from the parallel orientation. Preferably, the line of sight 130 deviates in the vertical plane no more than about ±10° and, more preferably, no more than about ± 3° from the optical centerline in the as-worn orientation.

Figure 7 is a cutaway view of the lens 120, lens blank 122, and geometric shape 124 of Figure 6. This view shows that the preferred geometric shape 124 is hollow with walls of varying thickness, as revealed by a horizontal cross-section 134 at the optical centerline of the geometric shape 124.

The tapered wails of the preferred geometric shape 124 result from two horizontally offset spheres, represented by their center points C1 and C2 and radii R1 and R2. An outer surface 136 of the preferred lens blank 122 conforms to one sphere (of radius R1) while an inner surface 138 of the lens blank 122 conforms to the other sphere (of radius R2). By adjusting the parameters which describe the two spheres, the nature of the taper of the lens hlank 122 may also be adjusted.

In particular, the parameters for the two spheres to which the lens blank outer surface 136 and inner surface 138 conform is preferably chosen to produce minimal or zero refractive power, or non-prescription lenses. Where CT represents a chosen center thickness (maximum thickness of the wall of the hollow geometric shape 124), n is an index of refraction of the lens blank material, R1 is set by design choice for the curvature of the outer surface 136, R2 may be determined according to the following equation:

CT/n represents the separation of the spherical centers C1 and C2. For example, where a base 6 lens is desired as a matter of design choice, the center thickness is chosen to be 3 mm, and the index of refraction of the preferred material (polycarbonate) is 1.586, R2 may be determined as follows:

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-10CT

1^=^-07+H = -3 4· ³ =87.225mm ² 6 1.586 (2) (3)

For this example, the radius R1 of the outer surface 136 is equal to 88.333 mm, the radius R2 of the inner surface 138 is equal to 87.225 mm, and the spherical centers C1 and C2 are separated by 1.892 mm. These parameters describe the curvature of the lens blank 122 of a preferred decentered spherical embodiment.

In the case of the preferred embodiment, the optical centerline 132 is that line which passes through both center paints C1 and C2 of the offset spheres. This happens to pass through the thickest portion of the preferred geometrical shape 124 walls at an optical center 140, though this may not be true for alternative nonspherical embodiments. The optical center line 132 happens to pass through surface 136 of the illustrated lens blank 122, although this is not necessary. The optical center 140 does not happen to lie on the iens 120, although it may for larger lenses or lenses intended to exhibit less wrap in the as-worn orientation.

Figure 8 illustrates a horizontal cross-section of a lens 120, showing in phantom the geometric shape 124 to which the outer surface 136 and inner surface 138 conform. The lens blank 122 is omitted from this drawing. In accordance with the present invention, the optical centerline 132 associated with the chosen orientation is aligned to be generally parallel to but offset from the straight ahead normal line of sight 130 of the wearer as the iens 120 is to be mounted in an eyeglass frame.

Figure 8A illustrates a vertical cross-section of the lens 120, also showing in phantom the geometric shape 124 to which the outer surface 136 and inner surface 138 conform. Unlike the horizontal view of Figure 8, the projection of the optical centerline 132 onto a vertical plane (i.e., the vertical component of the optical centerline 132) appears to pass through the vertical profile of the preferred lens 120. In any case, the vertical component of the optical centerline 132 associated with the chosen taper is also aligned to be generally parallel with the normal line of sight 130 of the wearer in the as-worn orientation.

Thus, in addition to providing optically correct lenses for dual lens eyewear with a high degree of wrap, the present invention may provide optically corrected tenses for eyewear characterized by a degree of rake. The terms rake and optically correct are further defined below.

In general, rake will be understood to describe the condition of a tens, in the as-worn orientation, for which the normal line of sight 130 (see Figure 8A) strikes a vertical tangent to the tens 120 at a non-perpendicular angle. For optically corrected eyewear in accordance with the preferred embodiment, however, the normal line of sight to a raked tens is generally parallel to and vertically offset from the optical centerline. Therefore, the degree

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-11of rake in a correctly oriented lens may be measured by the distance which the normal line of sight is vertically displaced from the optical centerline.

For a centrally oriented lens, as shown in Figure 10B, the wearer's line of sight coincides with the optical centerline, thus displaying no vertical displacement. While such a tens may be optically corrected (as defined below} in the as-worn orientation, the lens does not have rake, unlike the preferred embodiment of the present invention. Figure IOC shows a lens orientation which is downwardly tilted or raked, but for which the optical centerline and the normal line of sight are highly divergent such that no displacement could meaningfully be measured. While such a lens may have downward rake in a conventional sense, advantageously providing downward protection for the eye and conforming to the wearer's face, it is not optically corrected.

In contrast, the normal line of sight through a raked lens, made in accordance with the preferred embodiment, is characterized by a finite vertical displacement from the optical centerline, preferably a downward displacement for downward rake. Where the optical centerline diverges from the normal line of sight within the acceptable angular ranges set forth above, this displacement should be measured at or near the lens surface. The displacement may range from about any non-zero displacement to about 8.0 inches. Lenses of lower base curvature may require a greater displacement in order to achieve good rake. The vertical displacement for a lens of base 6 curvature, however, should be between about 0.1 inch and about 2.0 inches. More preferably, the vertical displacement is between about 0.1 inch and about 1.0 inch, particularly between about 0.25 inch and about 0.75 inch, and most preferably about 0.5 inch.

Optically correct, as that term has been used in the present description, refers to a lens which demonstrates relatively low distortion as measured by one or more of the following values in the as-worn orientation: prismatic distortion, refractive power and astigmatism. Raked lenses in accordance with the preferred embodiment demonstrate at least as low as 1/4 diopters or 3/16 diopters and typically less than about 1/8 diopters prismatic distortion, preferably less than about 1/16 diopters, and more preferably less than about 1/32 diopters. Refractive power and astigmatism for lenses in accordance with the present invention are also preferably low. Each of refractive power and astigmatism are also at least as low as 1/4 diopters or 3/16 diopters and preferably less than about 1/8 diopters, more preferably less than about 1/16 diopters and most preferably less than about 1/32 diopters.

It will be understood by the skilled artisan that the advantages in minimizing optical distortion apply to both the horizontal and the vertical dimensions. Particular advantage is derived by applying the principles taught herein to both vertical and horizontal dimensions of the lens, enabling the combination of lateral and lower peripheral protection of the eyes (through wrap and rake} with excellent optical quality over the wearer's full angular range of vision.

Furthermore, although the principal embodiments described herein are of constant radius in both the horizontal and vertical cross-section, a variety of lens configurations in both planes are possible in conjunction with the present invention. Thus, for example, either the outer or the inner or both surfaces of the lens of the present invention may generally conform to a spherical shape as shown in Figures 6 and 7. Alternatively either the outer or the inner or both surfaces of the lens may conform to a right circular cylinder, a frusto-conical, an elliptic cylinder.

CA 02212341 2005-03-22 an ellipsoid, an ellipsoid of revolution, other asphere or any of a number of other three dimensional shapes. Regardless of the particular vertical or horizontal curvature of one surface, however, the other surface should be chosen such as to minimize one or more of power, prism and astigmatism of the lens in the mounted and asworn orientation.

Figures 9-12 will aid in describing a method of choosing a location on the lens blank 122 from which to cut the right lens 120, in accordance with a preferred embodiment of the present invention. It will be understood that a similar method would be used to construct the left lens for the dual lens eyewear of the preferred embodiment.

As a first step, a desired general curvature of the lens inner or outer surface 138,136 may be chosen. For the preferred lens 120, this choice determines the base value of the lens blank 122. As noted elsewhere herein, a number of other curvatures may be utilized in conjunction with the present invention. A choice of lens thickness may also be preselected. In particular, the minimum thickness may be selected such that the lens will withstand a preselected impact force.

A desired lens shape may also be chosen. For example, Figure 12 illustrates an example of a front elevational shape for the lens 120. The particular shape chosen is generally not relevant to the oriented decentered lens optics disclosed herein.

A desired as-wom orientation for the lens should also be chosen, relative to the normal line of sight 130 of the wearer 126. As mentioned above, preferred orientations may provide significant lateral wrap for lateral protection and interception of peripheral light, and for aesthetic reasons, and also some degree of downward rake. For example, the embodiment Illustrated in Figures 6-12 uses a canted lens 120 to achieve wrap. Alternatively, wrap may be achieved through use of a higher base lens and a more conventional (non-canted) orientation. Figures 9 and 10A to 10C illustrate more plainly how the orientations may be related to the line of sight 130 of the wearer.

The eyewear designer may also choose a degree of rake, or vertical tilt, as will be understood from Figures 10A -10C, schematically illustrating various vertical as-wom orientations of a lens, relative to the head of the wearer 126. Figure 10A illustrates the preferred orientation of the lens 120 relative to the head of the wearer 126, and relative in particular to the straight ahead normal line of sight 130. A downward rake, as illlustrated in Figure 10A, is desirable for a variety of reasons, including improved conformity to common head anatomy. As will be apparent to those of skill in the art in view of the disclosure herein, a lens 120 having a mechanical center point which falls below the horizontal plane intersecting the optical centerline 132 (see Figure 7) will permit the lens to be oriented with a downward rake as illustrated in Figures 10A to 10C and yet preserve a generally parallel relationship between the optical centerline and the straight ahead line of sight. Since the orientation of the lens 120 to the optical centerline 132 in the imaginary sphere should be the same as the orientation between the lens 120 and a parallel to the normal line of sight 130 in the as-wom orientation any lens cut from this sphere below the optical centerline 132 can be mounted with a corresponding degree of downward rake and achieve the optical correction of the present invention.

Accordingly, the desired degree of rake may be chosen by specifying a vertical component of the displacement between the normal line of sight 130 and the optical centerline 132, as illustrated in Figure 10A.

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-13Either way, the greater the displacement, the greater the downward rake. In general, the vertical displacement in accordance with the present invention will be greater than zero. Generally it will be from about 0.1 inches to about 2 inches depending upon base curvature. Preferably, vertical displacement will be from about 0.1 inches to about one inch, or about 0.2 inches or greater. More preferably, it will be from about 0.25 inches to about 0.75 inches and in one embodiment it was about 0.5 inches.

Alternatively, a general profile may be chosen which fixes an orientation of the normal line of sight relative to the curvature of the lens (not accounting for the thickness of the lens). For instance, both Figure 10A provides reference points of a top edge 152 and a bottom edge 154 relative to the normal line of sight 130. This relationship may then be utilized to determine the position on a lens blank from which to cut the lens, as will be clear from the discussion of Figure 11A below.

Referring now to Figure 11, a mapping of the horizontal orientation of the lens 120 onto the lens blank 122 is illustrated. The normal line of sight 130, with respect to which the chosen orientation is measured, is maintained substantially parallel to and offset from the optical centerline 132. The horizontal component of the displacement will generally be within the range of from about 0.1 inches to about 8 inches for lower base curvatures.

Once the aesthetic design and desired rake and wrap orientation such as that illustrated in Figure 11 has been determined (such as by the chosen frame 150), and the lens blank 122 formed having a suitable base curvature for fitting within the aesthetic design, the aesthetic design may be projected graphically or mathematically onto the surface of the theoretical sphere or blank to reveal that portion of the sphere which is suitable for use as the lens 120. The projection of the lens shape onto the sphere should be moved about the surface of the sphere until it is positioned such that the lens cut from the sphere at that location will exhibit the appropriate wrap and rake for the aesthetic design without any rotation of the lens 120 out of its orientation in which the optical centerline of the sphere is generally parallel to the desired normal line of sight in the as-worn orientation.

A similar simultaneous projection may be performed for the vertical orientation chosen, as depicted in Figure 11 A. Figure 11A schematically represents the projection from the chosen frame 150 to a position on the lens blank 122. The frame 150 (or a conceptual configuration such as provided by Figure 10A) provides reference points in the form of the lens top edge 152 and bottom edge 154 in relation to the line of sight 130. The projection may then be shifted up or down until the top edge 152 and the bottom edge 154 are both simultaneously aligned with corresponding points on the outer surface 136 of the lens blank, while maintaining the line of sight 130 substantially parallel with the optical centerline 132.

Projection of both the horizontal profile and the vertical profile may be performed simultaneously, locating a unique position on the lens blank 122 corresponding to the desired three-dimensional shape of the lens (including the front elevational shape shown in Figure 12) at which the line of sight 130 is parallel to the optical centerline 132 or other reference line of the lens blank 122. Of course, it will be understood that the lines 130 and 132 may be substantially parallel, that is, within the acceptable range of angular deviation set forth above.

CA 02212341 2005-03-22

-14This shape may then be cut from the blank 122 or molded directly in the final lens configuration. The resultant lens 120 not only conforms to the desired shape, but also minimizes prismatic distortion when m the asworn orientation.

Figure 12 illustrates a lens blank 122, concave towards the page such as that shown conforming to a portion of the surface of the sphere in Figures 6 and 7. In Figure 12, the lens blank 122 has been formed on the theoretical sphere such that the mechanical center of the blank is illustrated in the center of the drawing on the central horizontal meridian. The illustrated lens profile 120 has a medial edge 148, a lateral edge 144, an upper edge 152 and a lower edge 154. The medial edge 148 of the right lens 120 Ges close to the optical center of the lens blank 122.

At feast a portion of the right fens 120 lies in the fewer left-hand (third) quadrant of the tens blank 122. Preferably, in an embodiment of the invention exhibitmg both wrap and downward rake, at least about half of the lens area will fad· within the third quadrant of the tens blank 122. Preferably aB or substantially all of the area of the tens 120 wiB Be below and to the left of the optical center as illustrated. Lenses exhibitmg a similar degree of rake but lesser wrap may be positioned on the tens blank 122 such that as much as 50% or more of the tens area is within the lower right (second) quadrant of the tens blank 122.

Figure 12A illustrates the position on the same tens blank 122 from which a left lens 120L could be cut. The left tens 120L has a medial edge 148L, a lateral edge 144L, an upper edge 152L and'a lower edge 154L The left tens 120L is drawn in phantom because both the right tens 120 and the left tens 120L for the illustrated profile cannot be cut from the same lens blank 122. Rather, the Bustrated left tens 120L would be cut from the position shown on a second tens blank which is identical to the first tens blank 122.

As the left lens 120L should be symmetrically opposite to the right lens 120, the left tens 120L is a mirror image of the right lens 120. For example, the image of the right lens 120 may be tripped across a vertical plane through which the optical centerline 130 and poles of the sphere 124 pass. The lens blank upon which that image would be projected may be identical to the illustrated tens blank 122, but rotated 180° about the mechanical center.

Alternatively, the left tens 120L position may also be considered the mirror image of the right tens 120 across an axis of vertical symmetry. As fllustrated in Figure 12A, the left tens 120L is upsidedown relative to the right tens 120. For the preferred tens blank 122, the axis of vertical symmetry is a central horizontal meridian 170 which divides the tens blank 122 into upper and lower halves, each of which conform to upper and lower hemispheres of the sphere 124 (Figures 6 and 7). Thus, the horizontal position (Le., distance from the medial or lateral edge of the lens blank 122) for each of the medial edge 148L, lateral' edge 144L, upper edge 152L and lower edge 154L, is the same for corresponding points of the right tens 120. Corresponding points on the left and right lenses are also the same vertical distance from the horizontal meridian 170, but m the opposite directions. For example, the upper edge 152L of the left lens 120L is about the same distance above the horizontal meridian 170 as the upper edge 152 of the right tens 120 is below the horizontal meridian 170.

Thus, the left tens 120L of any raked dual tens embodiment is cut substantially from the upper half of preferred tens blank 122, while the right tens 120 is cut substantially from the lower half of an identical tens blank.

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-15Preferably, where a dual lens embodiment displays both wrap and rake, the left lens 120L is cut substantially from the upper left (fourth) quadrant of the preferred lens blank 122, while the right lens is cut substantially from the third quadrant. Substantially, as used in this context, refers to more than 50% of the surface area of the lens 120 or 120L falling within the relevant half or quadrant of the preferred lens blank 122.

Of course, this description is limited to a lens blank 122, which is described by an optical centerline passing through the central horizontal meridian 170 (i.e., the lens blank 122 taper is vertically symmetrical) but not through the mechanical center (i.e., the lens blank 122 taper is horizontally asymmetrical). It will be understood that alternative lens blanks may utilize alternative tapering. The skilled artisan may adjust the positions from which to cut the right and left lenses such that the normal line of sight in the as-worn orientation is maintained substantially parallel to the optical centerline, regardless of the tapering symmetry.

The present invention thus provides a precise method of furnishing the correct correspondence between taper and the varying angle of incidence from the wearer's eye to the surface of a lens. By recognizing a novel relationship among the wearer's line of sight and the form of taper, the present invention allows use of any of a variety of lens designs while minimizing astigmatism, power and prismatic distortion. For example, a designer may choose a desirable orientation and curvature for the lens, relative to a wearer's line of sight. The orientation and curvature may be chosen from a wide range of rake, wrap, base value and proximity to a wearer's face. The form of taper and location of the lens profile on the theoretical sphere or other shape may then be chosen, by the method of the present invention, such that the prismatic distortion in the as-worn orientation is minimized.

Although the foregoing invention has been described in terms of certain preferred embodiments, other embodiments will become apparent to those of ordinary skill in the art in view of the disclosure herein. Accordingly, the present invention is not intended to be limited by the recitation of preferred embodiments, but is intended to be defined solely by reference to the appended claims.