Abstract: A method of fabricating an optical assembly includes providing a first mold having a first curved mold surface; placing a substantially flat reflective polarizer; on the first curved mold surface and applying at least one of pressure and heat to at least partially conform the reflective polarizer to the first curved mold surface; providing a second mold comprising a second mold surface, the first and second mold surfaces defining a mold cavity therebetween; substantially filling the mold cavity with a flowable material having a temperature greater than a glass transition temperature of the reflective polarizer; and solidifying the flowable material to form a solid optical element bonded to the reflective polarizer. A maximum variation of an orientation of a pass polarization state across the bonded reflective polarizer is within about 3 degrees of a maximum variation of the orientation of the pass polarization state across the substantially flat reflective polarizer.

Abstract: Optical systems for displaying an image are described. The optical systems include spaced apart first and second optical lenses. A partial reflector is disposed on and conforms to a major surface of the first optical lens where the major surface can have a best-fit spherical radius of curvature in a range from 20 mm to 200 mm. A reflective polarizer is disposed on and conforms to a major surface of the second optical lens where the major surface can have a best-fit spherical radius of curvature in a range from 14 mm to 250 mm. A retarder layer is disposed between the reflective polarizer and the partial reflector. The first optical lens can have an optical birefringence of less than 15 nm/cm and the second optical lens can have an optical birefringence of greater than 15 nm/cm. A method of fabricating an optical assembly is described.

Abstract: An optical system including one or more optical lenses, at least one retarder layer, a reflective polarizer, and a partial reflector is provided. The at least one retarder layer may include first and second retarder layers having different wavelength dispersion curves. The at least one retarder layer may include a first retarder layer having a non-uniform fast axis orientation and/or a non-uniform retardance.

Abstract: An optical assembly including an optical element insert molded directly onto an optical stack is provided. The optical stack includes an optical film and may include a liner with the optical film being disposed between the optical element and the liner. The liner, if included, is removable from the optical film without substantial damage to the optical film. An outermost layer of the optical film may be diffusion bonded to a major surface of the optical element. The optical film includes a protective coating having an average thickness of no more than 30 micrometers. The protective coating includes an at least partially cured composition. The composition includes 70 to 96 weight percent of urethane (meth)acrylate compound having an average (meth)acrylate functionality of 2 to 9.5, and 2 to 20 weight percent of (meth)acrylate monomer having a (meth)acrylate functionality of 1 to 2.

Abstract: An optical system including one or more optical lenses, at least one retarder layer, a reflective polarizer, and a partial reflector is provided. The at least one retarder layer may include first and second retarder layers having different wavelength dispersion curves. The at least one retarder layer may include a first retarder layer having a non-uniform fast axis orientation and/or a non-uniform retardance.

Abstract: A display system includes an optical system and a curved display disposed to emit light toward the optical system. The optical system includes at least a first optical lens, a partial reflector and a reflective polarizer. The optical system has an optical axis such that a light ray propagating along the optical axis passes through the first optical lens the partial reflector and the reflective polarizer without being substantially refracted. At least one major surface of the optical system can be rotationally asymmetric about the optical axis. A major surface of the optical system may have a first portion defined by a first equation and a second portion adjacent the first portion defined by a different equation. The first optical lens may have a contoured edge adapted to be placed adjacent an eye of a viewer and substantially conform to the viewer's face.

Abstract: An optical assembly including an optical element insert molded directly onto an optical stack is provided. The optical stack includes an optical film and may include a liner with the optical film being disposed between the optical element and the liner. The liner, if included, is removable from the optical film without substantial damage to the optical film. An outermost layer of the optical film may be diffusion bonded to a major surface of the optical element.

Abstract: Optical films having a curved shaped and methods of shaping optical films are described. A method of shaping an optical film includes the steps of disposing the optical film adjacent first and second rollers spaced apart along a first direction, securing opposing first and second ends of the optical film, providing a curved mold surface, and shaping the optical film by contacting the optical film with the curved mold surface while stretching the optical film along the first direction and keeping a threshold distance between closest points on the optical film contacting the first roller and contacting the curved mold surface less than the width of the optical film to reduce buckling of the optical film.

Abstract: Polymer composites and methods of making wherein the polymer composites include a continuous matrix phase and a reinforcing phase, with varying properties (material and/or physical).

Abstract: A reflective polarizing imaging lens includes at least one optical film having an active area that is curved in two orthogonal directions. Edges of the optical film are arranged to form seams between segments of the optical film in the active area of the reflective polarizing imaging lens.

Abstract: An optical system including one or more optical lenses, at least one retarder layer, a reflective polarizer, and a partial reflector is provided. The at least one retarder layer may include first and second retarder layers having different wavelength dispersion curves. The at least one retarder layer may include a first retarder layer having a non-uniform fast axis orientation and/or a non-uniform retardance.

Abstract: An optical system including a first optical element having a curved first major surface and an optical stack bonded and conforming to the curved first major surface of the first optical element is described. The optical stack includes a reflective polarizer substantially transmitting light having a first polarization state and substantially reflecting light having an orthogonal second polarization state and a non-adhesive flexible optical layer bonded to the reflective polarizer and comprising substantially parallel opposing first and second major surfaces. At least one location on the non-adhesive flexible optical layer has an optical retardance of less than about 100 nm or greater than about 200 nm at a wavelength of about 550 nm.

Abstract: An optical element includes an optical surface configured to receive light at a predetermined wavelength in a range from about 400 nm to about 1000 nm. The optical surface is defined by a vertical axis and a horizontal axis defining four Cartesian quadrants sequentially numbered in a counter-clockwise direction. A first longitudinal section of the optical surface is centered on the vertical axis and a second longitudinal section of the optical surface is centered on the horizontal axis. The first and second longitudinal section each extend across opposite edges of the optical surface and have a same substantially uniform retardance for substantially normally incident light. The optical element includes four discrete retarder sections. Each retarder section is disposed on a respective Cartesian quadrant of the optical surface and has a retardance difference from the substantially uniform retardance of the optical surface that is greater than zero.

Abstract: A container is provided. The container includes a body, a first plug, and a second plug. The body has a first end, a second end, and a bypass with a length L disposed between the ends. The first and second plugs are slideably disposed in the body and define a first compartment. A second compartment is in the body between the second plug and the second end. The second plug has a first edge; a second edge; and a plurality of primary conduits, each primary conduit extending from first openings in the side wall to second openings in the bottom surface. The bottom surface does not define a plane oriented substantially orthogonal to the longitudinal axis. A distance D extends longitudinally from the first edge to the second edge. A distance E extends longitudinally from the first edge to the first opening. D?L and E<L.

Abstract: A patterned optical retarder including non-overlapping first (21) and second (27) regions with respective first and second major surfaces having different RMS surface roughnesses. For substantially normally incident light over a wavelength range from about 400 nm to about 1000 nm, the optical retarder has different retardances in the respective first and second regions.

Abstract: Shaped optical films and methods of shaping optical films are described. The method includes securing at least portions of a perimeter of the optical film in a first plane so that the secured portions do not move relative to one another; and stretching the optical film by displacing a portion of the optical film along at least a first direction perpendicular to the first plane such that one of a radial and circumferential stretching of the optical film is substantially constant from a center to the perimeter of the optical film, and the other one of the radial and circumferential stretching of the optical film substantially changes from the center to the perimeter of the optical film. The optical film is a reflective polarizer including a plurality of alternating polymeric layers.

Abstract: An optical system including at least a first lens, a partial reflector and a reflective polarizer is described. The optical system has an optical axis such that a light ray propagating along the optical axis passes through the first lens the partial reflector and the reflective polarizer without being substantially refracted. At least one major surface of the optical system is rotationally asymmetric about the optical axis. A major surface of the optical system may have a first portion defined by a first equation and a second portion adjacent the first portion defined by a different equation. The first lens may have a contoured edge adapted to be placed adjacent an eye of a viewer and substantially conform to the viewer's face.

Abstract: Optical systems for displaying an image are described. The optical systems include spaced apart first and second optical lenses. A partial reflector is disposed on and conforms to a major surface of the first optical lens where the major surface can have a best-fit spherical radius of curvature in a range from 20 mm to 200 mm. A reflective polarizer is disposed on and conforms to a major surface of the second optical lens where the major surface can have a best-fit spherical radius of curvature in a range from 14 mm to 250 mm. A retarder layer is disposed between the reflective polarizer and the partial reflector. The first optical lens can have an optical birefringence of less than 15 nm/cm and the second optical lens can have an optical birefringence of greater than 15 nm/cm. A method of fabricating an optical assembly is described.

Abstract: An optical system including at least a first lens, a partial reflector and a reflective polarizer is described. The optical system has an optical axis such that a light ray propagating along the optical axis passes through the first lens the partial reflector and the reflective polarizer without being substantially refracted. At least one major surface of the optical system is rotationally asymmetric about the optical axis. A major surface of the optical system may have a first portion defined by a first equation and a second portion adjacent the first portion defined by a different equation. The first lens may have a contoured edge adapted to be placed adjacent an eye of a viewer and substantially conform to the viewer's face.

Abstract: A container and methods for storing and mixing a two-component composition is provided. The container includes a body, a first plug and a second plug. The body has a first end, a second end, and a bypass with a length L disposed between the first and second ends. The first and second plugs are slidably disposed in the body and define a first compartment. A second compartment is disposed in the body between the second plug and the second end. The second plug has a first edge, a second edge, and a plurality of spaced-apart primary conduits extending through the second plug. Each primary conduit has a separate first opening. A distance D extends longitudinally from the first edge to the second edge and a distance E extends longitudinally from the first edge to the first opening that is nearest the first edge. D?L and E<L.