Variable optical arrays and variable manufacturing methods

• US 7,268,950 B2
• Filed: 11/18/2004
• Issued: 09/11/2007
• Est. Priority Date: 11/18/2003
• Status: Expired due to Fees

• Current Assignee: Temeku Technologies Incorporated
• Original Assignee: Merlin Technology Limited Liability Company
• Inventors: Poulsen, Peter D.
• Primary Examiner(s): THOMPSON, TIMOTHY J
• Application Number:
  US10/993,423
• Publication Number:
  US 20050134965A1
• Time in Patent Office: 1,027 Days
• Field of Search: 359/624, 359/847, 359/853, 359/896, 359/900
• US Class Current: 359/624
• CPC Class Codes: B29D 11/00278 Lenticular sheets B29D11/00269 takes precedence
• CPC Class Codes: G02B 3/005 arranged along a single direction only, e.g. lenticular sheets G02B3/0043 takes precedence
• CPC Class Codes: G02B 3/0056 arranged along two different directions in a plane, e.g. honeycomb arrangement of lenses G02B3/0043 takes precedence; miniaturised objectives for electronic devices employing wafer level optics G02B13/0085
• CPC Class Codes: G02B 3/0062 Stacked lens arrays, i.e. refractive surfaces arranged in at least two planes, without structurally separate optical elements in-between
• CPC Class Codes: G02B 3/06 with cylindrical or toric faces

Abstract

The invention divides the lens focusing process into two or more surfaces that incorporate multiple curved axial optic elements on each surface. The axial optics may be manufactured by molding, machining, or by suspended film. If suspended film is used, then both sides of an optic may have a suspended film that is transparent. Alternatively, one side of the suspend film optic may use a reflective film.

Claims

1. An array of independent axial optical elements, comprising:

a film having a shape which conforms to the shape of an array of optical elements, said film comprised of a flexible sheet of material displaced into said shape; and

solidified fill material affixed to said film

wherein said fill material secures said film in said shape.

2. An array of independent axial optical elements according to claim 1, wherein said array of independent axial optical elements has a profile selected from the following group:

sinusoidal;

curved;

baffled;

flat;

apex-forming; and

non-uniform curved.

3. An array of independent axial optical elements according to claim 1, wherein:

said film is a reflective film.

4. An array of independent axial optical elements according to claim 3, wherein said array of independent axial optical elements has a profile selected from the following group:

sinusoidal;

curved;

baffled;

flat;

apex-forming; and

non-uniform curved.

11. An array of independent axial optical elements according to claim 1, wherein:

said film is a transparent film.

12. An array of independent axial optical elements according to claim 11, wherein said array of independent axial optical elements has a profile selected from the following group:

sinusoidal;

curved;

baffled;

flat;

apex-forming; and

non-uniform curved.

5. A method of manufacturing an optical array, comprising:

suspending a film on a tool;

applying a differential pressure to said film, said differential pressure moving portions of said film into a shape which conforms to the shape of an array of axial optical elements; and

applying a filler material to one side of said film to form an optical array having said shape.

6. A method of manufacturing an optical array according to claim 5, wherein said optical array has a profile selected from the following group:

sinusoidal, curved;

baffled;

flat;

apex-forming; and

non-uniform curved.

7. A method of manufacturing an optical array according to claim 5, wherein said film suspended on said tool is transparent.

8. A method of manufacturing an optical array according to claim 7, wherein said optical array has a profile selected from the following group:

sinusoidal;

curved;

baffled;

flat;

apex-forming; and

non-uniform curved.

9. A method of manufacturing an optical array according to claim 5, wherein said film suspended on said tool is reflective.

10. A method of manufacturing an optical array according to claim 9, wherein said optical array has a profile selected from the following group:

sinusoidal;

curved;

baffled;

flat;

baffled;

flat;

apex-forming; and

non-uniform curved.

13. An array of independent axial optical elements, comprising:

a flexible sheet of material displaced into a shape which conforms to the shape of a curved axial optic by application of a differential pressure to said flexible sheet of material; and

a fill material applied to one side of said displaced sheet of flexible material, said fill material solidifying to permanently secure said sheet of flexible material displaced into said shape, thereby forming an array of independent axial optical elements.

14. An array of independent axial optical elements according to claim 13, wherein said array of independent axial optical elements has a profile selected from the following group:

sinusoidal;

curved;

baffled;

flat;

apex-forming; and

non-uniform curved.

15. An array of independent axial optical elements according to claim 14, wherein said flexible sheet of material is a reflective film.

16. An array of independent axial optical elements according to claim 14, wherein said flexible sheet of material is a transparent film.

17. A method of manufacturing an optical array, comprising:

suspending a sheet of flexible material on a tool;

applying a differential pressure to said sheet of flexible material to move portions of said sheet of flexible material into a curved position relative to said tool; and

applying a filler material to one side of said sheet of flexible material to form an optical array comprised of an array of axial optical elements.

18. A method of manufacturing an optical array according to claim 17, and further comprising:

selecting a profile from the following group;

sinusoidal;

curved;

baffled;

flat;

apex-forming and non-uniform curved; and

applying said differential pressure such that said sheet of flexible material is moved into said selected profile relative to said tool.

19. A method of manufacturing an optical array according to claim 18, wherein said sheet of flexible material suspended on said tool is a transparent film.

20. A method of manufacturing an optical array according to claim 19, wherein said sheet of flexible material suspended on said tool is a reflective film.

21. A method of manufacturing an optical array, comprising:

suspending a film on a tool;

applying a differential pressure to said film to move a portion of said film into a desired shape, said desired shape conforming to the shape of an array of axial optical elements; and

securing said film in said desired shape by applying a filler material to one side of said film;

wherein said film secured in said desired shape and said solidified material securing said film in said desired shape collectively form an optical array comprised of an array of axial optical elements.

22. A method of manufacturing an optical array according to claim 21, wherein said film is a sheet of transparent material.

23. A method of manufacturing an optical array according to claim 21, wherein said film is a sheet of reflective material.