Fabricating hybrid plastic-glass lens

Abstract

Fabricating a prescription optical element include providing a glass substrate layer and coupling an optical plastic layer to the glass substrate layer. A prescription surfaces is formed on an eyeward side of the optical plastic layer that is opposite an object side of the optical plastic layer. The object side is a planar surface that overlays the glass substrate layer and the glass substrate layer has a glass thickness to provide rigidity to the prescription optical element.

What is claimed is: 
     
         1 . A method of fabricating a prescription optical element, the method comprising:
 providing a glass substrate layer;   coupling an optical plastic layer to the glass substrate layer; and   forming a prescription surface on an eyeward side of the optical plastic layer that is opposite an object side of the optical plastic layer, wherein the object side is a planar surface that overlays the glass substrate layer, and wherein the glass substrate layer has a glass thickness to provide rigidity to the prescription optical element.   
     
     
         2 . The method of  claim 1 , wherein coupling the optical plastic layer to the glass substrate layer includes laminating the optical plastic layer to the glass substrate layer, wherein an intermediate layer adheres the glass substrate layer to the optical plastic layer. 
     
     
         3 . The method of  claim 1 , wherein coupling the optical plastic layer to the glass substrate layer includes roll-to-roll bonding of the optical plastic layer to the glass substrate layer. 
     
     
         4 . The method of  claim 1 , wherein coupling the optical plastic layer to the glass substrate layer includes casting, injection-molding, or over-molding the optical plastic layer to the glass substrate layer. 
     
     
         5 . The method of  claim 4 , wherein coupling the optical plastic layer to the glass substrate layer includes curing optical plastic layer with heat or ultraviolet radiation. 
     
     
         6 . The method of  claim 1 , wherein forming the prescription surface includes a subtractive process that includes at least one of grinding, diamond turning, or polishing the optical plastic layer to form the prescription surface of the optical plastic layer. 
     
     
         7 . The method of  claim 1  further comprising:
 forming a bevel or groove into the prescription optical element to aid in securing the prescription optical element into frames. 
 
     
     
         8 . The method of  claim 1 , wherein the glass thickness is 400 microns or less. 
     
     
         9 . The method of  claim 1 , wherein a plastic center thickness of the optical plastic layer is 200 microns or less after the prescription surface is formed.