Apparatus and method of fabricating a compensating element for wavefront correction using spatially localized curing of resin mixtures

Abstract

An optical wavefront correction plate incorporates a unique, three-dimensional spatial retardation distribution utilizing the index of refraction change of resin mixture in its cured state. The optical wave plate comprises a pair of transparent plates, containing a layer of a monomers and polymerization initiators, such as resin mixture. This resin mixture exhibits a variable index of refraction as a function of the extent of its curing. Curing of the resin mixture may be made by exposure to light, such as ultraviolet light, and may be varied across and through the surface of the resin mixture to create a particular and unique three-dimensional wavefront retardation profile. The optical wave plate provides improved performance in large area mirrors, lenses, telescopes, microscopes, and ophthalmic diagnostic systems.

1 . A correcting element, comprising: at least one first transparent element; and a layer of resin mixture juxtaposed with the transparent element and formed with a plurality of successive curing volumes, wherein the successive curing volumes establish a three-dimensional spatial distribution of an index of refraction profile within the resin mixture.  
     
     
         2 . The correcting element of  claim 1 , further comprising a second transparent element, wherein the first transparent element and the second transparent element hold the layer of resin mixture therebetween.  
     
     
         3 . The correcting element of  claim 2 , further comprising at least one barrier disposed between the first transparent element and the second transparent element to define a volume of resin mixture.  
     
     
         4 . An apparatus for manufacturing a correcting element having at least one transparent element and an adjacent resin mixture layer wherein the resin mixture is curable upon exposure to radiation having a wavelength to render cured resin mixture, and the cured resin mixture creates a predetermined three-dimensional spatial distribution of an index of refraction profile, the apparatus comprising: at least one scanning unit; at least one light source coupled to the scanning unit and emitting a light beam containing the wavelength, the light beam converging to a focal point; a means for controlling the scanning unit to position the focal point within the resin mixture layer; and a means for controlling the scanning unit to move the focal point through the resin mixture layer to cure the resin mixture, the cured resin mixture establishing the predetermined three-dimensional spatial distribution of an index of refraction profile.  
     
     
         5 . The apparatus of  claim 4 , wherein at least one of the scanning units is attached to a distal end of the light source.  
     
     
         6 . The apparatus of  claim 4 , wherein at least one of the scanning unit is attached to the correcting element.  
     
     
         7 . An apparatus for manufacturing a correcting element having at least one transparent element and an resin mixture layer wherein the resin mixture is curable upon exposure to radiation having a wavelength to establish a predetermined three-dimensional spatial distribution of index of refraction profile, the apparatus comprising: at least one optical fiber coupled to a radiation source, providing a suitable light source for curing the resin mixture; at least one optical relay imaging a target plane at an emitting end of the fiber to an image plane at the resin mixture layer; and at least one X-Y-Z translation mechanism attached to the fiber and positioning the fiber at the target plane such that the radiation emitted from the fiber is delivered by the optical relay to a corresponding image location at the image plane.  
     
     
         8 . An apparatus for manufacturing a correcting element having at least one transparent element and an adjacent resin mixture layer wherein the resin mixture is curable upon exposure to radiation having a wavelength, and the cured resin mixture creates a predetermined three-dimensional spatial distribution of index of refraction, the apparatus comprising: an optical fiber bundle; a plurality of radiation sources, each source being coupled to at least one optical fiber in the bundle; a plurality of control units controlling the radiation intensity and the duration of the radiation for each source; and at least one optical relay imaging light from emitting ends of the fiber bundle to a target plane in the resin mixture layer.  
     
     
         9 . The apparatus of  claim 8 , further comprising a translation mechanism attached to the fiber bundle providing translational positioning of the fiber bundle in at least one dimension in space.  
     
     
         10 . A method for improving the performance of an optical instrument, comprising: determining optical aberrations of the optical instrument; determining a three dimensional spatial distribution of an index of refraction profile that compensates for the aberrations; providing at least one correcting element having a layer of curable, refractive index changing material, the providing act including: (a) directing a focusing light beam to a first position within the layer of material to form a curing volume within the material; and (b) moving the focusing light beam to one or more subsequent positions within the layer of material to form one or more subsequent curing volumes, wherein the curing volume and the subsequent curing volumes collectively form the predetermined three-dimensional spatial distribution of an index of refraction; and inserting the wave plate in a predetermined location of the instrument.  
     
     
         11 . The method of  claim 10 , wherein the instrument is chosen from the group including telescopes, microscopes, confocal scanning microscopes, fundus cameras.  
     
     
         12 . A method of improving the performance of an optical element, comprising: making a correcting element having a first transparent element, and a layer of curable, refractive index changing polymer sandwiched between the first transparent element and a first surface of the optical element, the making act comprising: (a) determining optical aberrations of the optical element, the polymer layer, and the first transparent element; (b) determining a three dimensional spatial distribution of an index of refraction profile to compensate for the aberrations; (c) positioning a focusing light beam to a first position within the layer of polymer to form a curing volume within the polymer; and (d) moving the focusing light beam to one or more subsequent positions within the layer of polymer to form one or more subsequent curing volumes wherein the curing volume and the subsequent curing volumes collectively form the predetermined three dimensional spatial distribution of an index of refraction.  
     
     
         13 . The method of  claim 12 , wherein the optical element is selected from the group including mirrors and lenses.  
     
     
         14 . A method of manufacturing a customized ophthalmic lens for a patient, comprising: determining aberrations of the eye of a patient; determining a location of a center of an entrance pupil of the eye relative to a spectacle frame; manufacturing a correcting element comprising a first transparent element, and a layer of curable, refractive index changing resin mixture, the manufacturing act including: (a) determining a three dimensional spatial distribution of an index of refraction profile compensating for the aberrations; (b) positioning a focusing light beam to a first position within the layer of polymer to form a curing volume within the resin mixture; (c) moving the focusing light beam to one or more subsequent positions within the layer of polymer to form one or more subsequent curing volumes wherein the curing volume and the subsequent curing volumes collectively form the predetermined three dimensional spatial distribution of an index of refraction profile.  
     
     
         15 . The method of  claim 14 , comprising aligning an optical center of the correcting element with the center of the entrance pupil in the spectacle frame.  
     
     
         16 . The method of  claim 14 , comprising cutting the correcting element and fitting the correcting element into the spectacle frame.  
     
     
         17 . The method of  claim 14 , wherein the aberrations comprise refractive powers and higher order aberrations, the refractive powers comprising spherical power, cylindrical power and its orientation axis.  
     
     
         18 . The method of  claim 17 , wherein the corrective element comprising a second transparent element, sandwiching the index changing resin mixture between the first transparent element and the second transparent element.  
     
     
         19 . The method of  claim 18 , wherein at least one of the first and the second transparent element has a refractive power including a spherical and cylindrical power that closely matches corresponding components in the aberrations.  
     
     
         20 . The method of  claim 19 , wherein determining the three dimensional spatial distribution of an index of refraction profile comprises: determining a compensating wavefront of the patient's eye; determining a compensating wavefront of the corrective element; subtracting the compensation wavefront of the corrective element from the compensating wavefront of the patient's eye to render a residual compensating wavefront representing residual refractive power and high order aberrations of the eye.  
     
     
         21 . The method of  claim 19 , wherein the area on the ophthalmic lens correcting for the residual aberrations has a diameter in the range of 3 mm-70 mm.  
     
     
         22 . A method of manufacturing progressive ophthalmic lenses customized to a patient's eye comprising: imaging en face for measuring the patient's pupils, his spectacle, and pupilary distance of the patient when the patient is presented with targets at distant and at near viewing locations; imaging 90 degrees en face for measuring tilt angles of the patient's head, a distance between a corneal apex to an ophthalmic lens, and a location of targets when the patient is presented with targets at distant and near viewing locations; calculating locations of optical centers on the ophthalmic lens for the patient's distant and near vision; and designing a progressive addition lens using the locations of the optical centers of the distant and near vision of the patient.  
     
     
         23 . The method of  claim 22 , further comprising: determining a spatial distribution of an index of refraction profile from a progressive addition lens design; positioning a focusing light beam to a first position within the layer of resin mixture to form a curing volume within the resin mixture; and moving the focusing light beam to one or more subsequent positions within the layer of resin mixture to form one or more subsequent curing volumes wherein the curing volume and the subsequent curing volumes collectively form the three-dimensional spatial distribution of an index of refraction.  
     
     
         24 . The method of  claim 22 , wherein the targets at patient's near viewing positions comprise a display on a computer monitor or printed material at hand-held distance.  
     
     
         25 . A method for compensating for aberrations in a wavefront, comprising: measuring the aberrations in the wavefront; converting the aberrations to a compensating index of refraction profile; curing a substance to alter its index of refraction such that the index of refraction establishes a profile that matches the profile of the wavefront sought to be compensated for.  
     
     
         26 . An apparatus for curing at least one monomer in a resin mixture at a plurality of cure locations to thereby establish an index of refraction profile in the resin mixture, comprising: at least one light source useful for curing the monomer; means for passing light from the light source to at least one of the plurality of cure locations in the resin mixture; and means for moving the light from one cure location to another cure location.  
     
     
         27 . The apparatus claim of  26 , wherein the nearest neighbor cure locations have no overlap.  
     
     
         28 . The apparatus claim of  26 , wherein the nearest neighbor cure locations overlap not more than 80% of the beam waist of the light.  
     
     
         29 . The apparatus claim of  26 , wherein the nearest neighbor cure locations overlap between 40 to 60% of the beam waist of the light.