Curved lenses and related methods
First Claim
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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;
placing a lens blank on a flat flexible member of elastomer, the flat flexible member contacting an entirety of, and supporting, the lens blank, wherein the lens blank and the flat flexible member are each initially and essentially planar, and wherein the flat flexible member of elastomer has;
a thickness between about 0.5 mm and about 5.0 mm;
a shore hardness A between about 25 and about 70;
a tensile strength between about 5 MPa and about 30 MPa;
an elongation at break between about 100% and about 1000%; and
a resistance to tearing between about 50 N/cm to about 1000 N/cm;
heating and applying a pressure to the lens blank by pressing the lens blank between a curved rigid member and the flat flexible member, causing the flat flexible member to assume a shape of the curved rigid member while supporting the lens blank therebetween; and
maintaining the pressure for a time sufficient to allow the lens blank to conform to the shape of the curved rigid member and the flat flexible member.
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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 heating and pressing the lens blank between a curved rigid member and a flexible member at a pressure and maintaining the pressure for a time sufficient to allow the lens blank to conform to the shape of the curved rigid member. Methods of the invention may be used to make curved lenses with different polarization properties and curvatures.
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Citations
30 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; placing a lens blank on a flat flexible member of elastomer, the flat flexible member contacting an entirety of, and supporting, the lens blank, wherein the lens blank and the flat flexible member are each initially and essentially planar, and wherein the flat flexible member of elastomer has; a thickness between about 0.5 mm and about 5.0 mm; a shore hardness A between about 25 and about 70; a tensile strength between about 5 MPa and about 30 MPa; an elongation at break between about 100% and about 1000%; and a resistance to tearing between about 50 N/cm to about 1000 N/cm; heating and applying a pressure to the lens blank by pressing the lens blank between a curved rigid member and the flat flexible member, causing the flat flexible member to assume a shape of the curved rigid member while supporting the lens blank therebetween; and maintaining the pressure for a time sufficient to allow the lens blank to conform to the shape of the curved rigid member and the flat flexible member. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A method of making a formed lens, the method comprising:
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obtaining a flexible 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 flexible lens blank on a flexible member of elastomer, the flexible member contacting an entirety of, and supporting, the flexible lens blank, wherein the flexible lens blank and the flexible member are each initially and essentially planar, and wherein the flexible member of elastomer has; a thickness between about 0.5 mm and about 5.0 mm; a shore hardness A between about 25 and about 70; a tensile strength between about 5 MPa and about 30 MPa; an elongation at break between about 100% and about 1000%; and a resistance to tearing between about 50 N/cm to about 1000 N/cm; heating the flexible lens blank to a forming temperature by pressing the flexible lens blank at a pressure between a curved rigid member and the flexible member, while the flexible member supports the flexible lens blank, the curved rigid member being at the forming temperature; maintaining the pressure while heating at the forming temperature for allowing the flexible lens blank to assume a shape of the curved rigid member; reducing the temperature to a reduced temperature while maintaining the pressure for allowing the flexible lens blank to maintain a convex side and a concave side once the pressure is removed; and removing the flexible lens blank from between the curved rigid member and the flexible member. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29)
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30. A method of making eyewear, the method comprising:
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obtaining a first lens and a second lens, the first lens and the 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 the second lens being formed from lens blanks into a desired shape according to the following steps; placing a lens blank on a flexible member of elastomer, the flexible member contacting an entirety of, and supporting, the lens blank, wherein the lens blank and the flexible member are each initially and essentially planar; and
wherein the flexible member of elastomer has;
a thickness between about 0.5 mm and about 5.0 mm;
a shore hardness A between about 25 and about 70;
a tensile strength between about 5 MPa and about 30 MPa;
an elongation at break between about 100% and about 1000%; and
a resistance to tearing between about 50 N/cm to about 1000 N/cm;heating and applying a pressure to the lens blank separately by pressing the lens blanks between a curved rigid member and the flexible member, while the flexible member supports the lens blank, causing the flexible member to assume a shape of the curved rigid member; maintaining the pressure for a time sufficient to allow the lens blank to conform to the shape of the curved rigid member and the flexible member, the curved rigid member responsible for a force to form a concave side of the lens blank and the flexible member responsible for a responsive force to form a convex side of the lens blank; and placing the first lens and the second lens into an eyeglass frame.
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Specification