METHOD OF MAKING AN ARBITRARY SURFACE OPTICAL ELEMENT

• US 20070152359A1
• Filed: 03/07/2007
• Published: 07/05/2007
• Est. Priority Date: 09/23/2005
• Status: Abandoned Application

• Current Assignee: Charles Chuang, David Poppell, Kathleen Davies, Paul Frey, Qing Guo, William Burnett
• Original Assignee: Charles Chuang, David Poppell, Kathleen Davies, Paul Frey, Qing Guo, William Burnett
• Inventors: Guo, Qing, Burnett, William, Poppell, David, Davies, Kathleen, Frey, Paul, Chuang, Charles
• Application Number:
  US11/682,891
• Publication Number:
  US 20070152359A1
• Time in Patent Office: Days
• US Class Current: 264/1.340
• CPC Class Codes: B29C 45/1418 the inserts being deformed or preformed, e.g. by the injection pressure
• CPC Class Codes: B29C 45/14778 the article consisting of a material with particular properties, e.g. porous, brittle
• CPC Class Codes: B29D 11/00865 Applying coatings; tinting; colouring printing, marking or copying processes B41M; identification in general G09F3/00; producing decorative effects in general B44C; positioning or marking of lenses B24B13/0055
• CPC Class Codes: G02B 5/10 with curved faces
• CPC Class Codes: G02B 7/008 with means for compensating for changes in temperature or for controlling the temperature; thermal stabilisation
• CPC Class Codes: G03B 21/28 Reflectors in projection beam in illumination beam G03B21/2066
• CPC Class Codes: H04N 9/3141 Constructional details thereof details not peculiar to the presence of an electronic spatial light modulator G03B21/14

Abstract

An arbitrary surface optical element, such as a mirror for use in a rear projection television, includes a non-optical portion and an optical portion. The non-optical portion circumscribes the optical portion and has a thickness greater than the optical portion. Accordingly, the two portions cool at approximately the same rate, thereby minimizing warpage from differential cooling.

Claims

1. A method of forming an optical element, comprising:

molding a resin into a part with a mold, the part having a non-optical portion and an optical portion, the non-optical portion having a thickness greater than the optical portion;

cooling the part; and

applying thin film onto the part.

2. The method of claim 1, wherein the applying thin film includes applying one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter, via evaporation.

3. The method of claim 1, wherein the applying thin film includes applying one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter via lamination.

4. The method of claim 3, wherein the resin includes a thermoplastic material and wherein the lamination includes laminating a protective film to the part.

5. The method of claim 4, further comprising using a pressure sensitive or thermo set adhesive that has a higher melt temperature than either the film or part to ensure adhesion during the lamination.

6. The method of claim 4, wherein the lamination includes applying a protective coating to the reflective film.

7. The method of claim 1, wherein the molding includes using a mold that becomes part of the optical element.

8. The method of claim 1, wherein the molding includes applying vacuum from a first side of the mold and pressure from a second side of the mold.

9. The method of claim 1, wherein the non-optical portion includes at least one rib.

10. The method of claim 1, wherein the non-optical portion extends outward from the optical portion with a dimension that is at least about twice the thickness of the optical portion.