CURVED LENSES AND RELATED METHODS
First Claim
1. A method of making a formed lens, the method comprising:
- obtaining a lens blank comprising, in superposed relation, a linear polarizer layer laminated together with a plurality of polymeric layers, the linear polarizer layer having a polarization axis;
engendering rotational motion about a rotational axis of a roller having a forming surface thereon and lateral motion of a belt in contact with the forming surface, wherein the lateral motion is non-parallel to the rotational axis;
heating and pressing the lens blank between the belt and the forming surface at a pressure, the pressure being supplied by tension on the belt;
maintaining the pressure for a time sufficient to allow the lens blank to conform to the shape of the forming surface.
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Accused Products
Abstract
Curved lenses and methods for making curved lenses are described. One embodiment of a method of making a curved lens includes curving a lens blank made of a linear polarizer layer laminated together with a plurality of polymeric layers. The lens blank is curved by engendering rotational motion about a rotational axis of a roller having a forming surface thereon and lateral motion of a belt in contact with the forming surface. The lens blank is heated and pressed between the belt and the forming surface at a pressure, the pressure being supplied by tension on the belt. The pressure is maintained for a time sufficient to allow the lens blank to conform to the shape of the forming surface. Methods of the invention may be used to make curved lenses with different polarization properties and curvatures.
13 Citations
28 Claims
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1. A method of making a formed lens, the method comprising:
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obtaining a lens blank comprising, in superposed relation, a linear polarizer layer laminated together with a plurality of polymeric layers, the linear polarizer layer having a polarization axis; engendering rotational motion about a rotational axis of a roller having a forming surface thereon and lateral motion of a belt in contact with the forming surface, wherein the lateral motion is non-parallel to the rotational axis; heating and pressing the lens blank between the belt and the forming surface at a pressure, the pressure being supplied by tension on the belt; maintaining the pressure for a time sufficient to allow the lens blank to conform to the shape of the forming surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of making a formed lens, the method comprising:
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obtaining a lens blank comprising, in superposed relation, a linear polarizer layer laminated together with a plurality of polymeric layers, the linear polarizer layer having a polarization axis; placing the lens blank between a continuously rotating cylindrical roller and a belt; heating the lens blank to a forming temperature by pressing the lens blank at a pressure between the cylindrical roller and belt, the cylindrical roller being at the forming temperature; maintaining the pressure while heating at the forming temperature for allowing the lens blank to conform to the shape of the cylindrical roller; reducing the temperature to a reduced temperature while maintaining the pressure for allowing the lens blank to become a rigid lens having a convex side and a concave side; and removing the rigid lens from between the cylindrical roller and belt. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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28. A method of making eyewear, the method comprising:
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(a) obtaining a first lens and a second lens, the first lens and second lens comprising, in superposed relation, a linear polarizer layer laminated together with a plurality of polymeric layers, the linear polarizer layer having a polarization axis, the first lens and second lens being formed from lens blanks into a desired shape according to the following steps; (i) engendering rotational motion about a rotational axis of a roller having a forming surface thereon and lateral motion of a belt in contact with the forming surface, wherein the lateral motion is non-parallel to the rotational axis; (ii) heating and pressing the lens blanks separately between the belt and the forming surface at a pressure, the pressure being supplied by tension on the belt member; (iii) maintaining the pressure for a time sufficient to allow the lens blank to conform to the shape of the roller; and (b) placing the first lens and second lens into an eyeglass frame.
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Specification