Abstract: Microfabricated lenses, e.g., solid immersion lens (SIL) structures, are provided along with techniques for constructing these lens structures, as well as selected applications of such lens structures.

Abstract: The present invention provides a method for forming microstructure optical elements. The method comprises providing a mold and forming a cavity in the mold according to the shape of microstructure optical elements. The cavity is formed a sealed space, which is vacuumed through an extraction opening arranged near the end of the cavity. Filling material into the cavity is to be formed the microstructure optical elements. Due to an extraction opening arranged near the end of filling process, the filling process is smooth so as to improve the element quality, manufacturing efficiency and transferability.

Abstract: An apparatus for manufacturing a lens with a predetermined prescription from a number of lens molds, a gasket, and a source of a fluid material. The apparatus includes a device for selecting a first lens mold and a second lens mold based upon the prescription, a device for positioning the lens molds within the gasket, a device for inserting an amount of the fluid material within the gasket and between the molds, a device for curing the fluid material so as to form the lens, and a device for advancing the lens molds along a predetermined path through the selecting device, the positioning device, the fill device, and the cure device.

Abstract: Microlens arrays (105) having high focusing efficiencies are provided. The high focusing efficiencies are achieved by accurately producing the individual microlenses making up the array at high fill factors. Arrays of positive microlenses are produced by forming a master having a concave surface-relief pattern (101) in a positive photoresist (21) using direct laser writing. Through this approach, the problems associated with the convolution of a finite laser beam with a desired profile for a microlens are overcome. The microlens arrays of the invention have focusing efficiencies of at least 75%.

Abstract: An apparatus and method for holding a mold assembly and molding an optical lens using the same. In one aspect, the present invention provides an apparatus for holding a mold assembly, wherein the mold assembly includes a front mold, a back mold and a strip wrapping around the edges of the front mold and back mold to form a sleeve. In one embodiment, the apparatus includes a first portion and a second portion. The first portion has a top part, a bottom part, and a middle part connecting the top part and the bottom part, the middle part including a base and a holder coupled to the base. The second portion has a top part, a bottom part, and a middle part connecting the top part and the bottom part, the middle part including a base and a holder coupled to the base.

Abstract: The present invention provides a polarizer manufacturing method. Dichroic molecule material is printed over the polarizer substrate by microcontact printing. A shear force generated from the microcontact printing process can arrange the Dichroic molecule in a particular direction.

Abstract: The present provides deformable molds and methods for manufacturing ophthalmic lenses using deformable molds. The molds of the invention may be used in the custom manufacture of ophthalmic lenses.

Abstract: Tools and methods for making molded an optical integrated circuit including one or more waveguides are disclosed. In one embodiment, a molding die is provided that includes a substrate that has a topographically patterned first surface. A conformal protective film is provided over the first surface of the substrate. The substrate may be formed of silicon or gallium arsenide, and may be patterned using conventional semiconductor patterning techniques, such as plasma etching. The protective film may be metal (e.g., nickel or titanium), diamond, or some other hard material. Typically, a plurality of such molding dies are formed from a wafer of the substrate material. The die is pressed into a moldable material, such as thermal plastic, to form the wave guide(s) of the optical integrated circuit. A plurality of the dies may be mounted around the curved surface of a heated roller, and a heated tape of the waveguide material may be fed under the roller in a mass production process.

Abstract: A method for making a lens molding replica die for molding a lens made of glass or a synthetic resin comprises the steps of: (1) making a master die having a reference surface; (2) forming a separating film on the master die; (3) forming an SiC film on the reference surface; (4) machining a surface of the die base member into a prescribed shape and machining the SiC film into a shape in conformity of the surface of the die base member; (5) bonding a die base member onto the SiC film; and (6) separating the SiC film bonded onto the die base member from the master die.

Abstract: A shape memory polymer contact lens mold is formed from a sheet of a shape memory polymer in a press, an agile tool or by an agile tool formed by an inert gas at a temperature at or above the glass transition temperature which is thereupon cooled to below the glass transition temperature and removed therefrom.

Abstract: The invention is a mold and method for using the mold to make a multi-stage intraocular lens. The mold is provided with a gate in fluid communication with a lens portion and/or haptic portion of the mold core. In addition, a gasket is provided around the mold core. As molding material is introduced into the mold via the gate, a vacuum is drawn around and through the gasket to evacuate air trapped in the mold core and to help pull the material through the mold core.

Abstract: An object of the present invention is to enable to use a common transfer machine for transferring performs to and for transferring products from a press-forming system for glass having a plurality of press units. The press-forming system for glass has a plurality of press units. A linear moving stage is arranged in the proximity of the press units. A transfer robot is mounted on the linear moving stage. A pallet changer is arranged in the proximity of an end of the linear moving stage. A tray presently in use is mounted on a first mount and a new tray on standby is mounted on a second mount on the pallet changer. The inner space of the tray is partitioned into sections so as to correspond to press units in number. In each section, a plurality of pockets is arranged for storing preforms or products one by one.

Abstract: The invention is concerned with the problem that with known plastic casting moulds, especially those of polypropylene, the lenses produced with these moulds have a slippery surface. The invention solves this problem through the use of polymers which are notable for their very low oxygen permeability.

Abstract: A method for molding an optical lens by using two moulding shells and a closing element acting in the periphery thereof. The moulding shells are placed in holding elements. If necessary, one of the holding elements is made to rotate around a centering axis which is common to the unit. The moulding shells are removed from the holding elements using removing elements. The possible inclination of the moulding shells is verified in relation to a reference plane. If necessary, their position is adjusted in relation to the removing elements which bear them. Both of the moulding shells are moved towards each other using the removing elements while maintaining their position in relation thereto. The closing element is placed around the moulding shells and the moulding cavity thus formed is filled. The invention can be used with optical lenses which are made of a polymerizable material.

Abstract: In one embodiment, the method for producing a stamper, comprises: forming a nickel plated substrate having desired surface features on one side; disposing a managed heat transfer layer on a second side of said substrate; forming a thickness of said managed heat transfer layer having a variation of less than about 5%; and altering said exposed surface of said managed heat transfer layer. Also disclosed are a method and apparatus for producing data storage media.

Abstract: An optical disk and a method of producing it, particularly a stamper for molding a semiconductor disk base capable of forming an optical disk sufficiently compatible with commercially available CD (Compact Disk) players, a method of producing a stamper, a method of producing an optical disk base, a method of producing an optical disk, and an optical disk base and optical disk are disclosed. The present invention improves both of transferability and tact of an optical disk base molding cycle, allows a fine pattern to be formed in a transfer surface, and makes it needless to change existing molding equipment. In addition, when guide grooves formed in the optical disk are filled with a pigment by spin coating, the guide grooves have a substantially uniform configuration in the radial direction of the disk. The optical disk is sufficiently compatible with various CD players available on the market.

Abstract: There is disclosed a method of making an intraocular lens having first and second viewing elements. The viewing elements are interconnected by a plurality of translation members extending from a periphery of the first viewing element. At least one of the translation members comprises a plurality of arms, and at least one of the viewing elements includes an optic having refractive power. The method comprises providing a first outer mold and a second outer mold, and an inner mold therebetween. The first outer mold and the inner mold define a first mold space, and the second outer mold and the inner mold define a second mold space. The method further comprises molding the viewing elements, the plurality of arms and the optic as a single piece by filling the first and second mold spaces with a material, such that the first viewing element and the plurality of arms are formed in the first mold space and the second viewing element is formed in the second mold space.

Abstract: A method for molding an optical attenuator having a unitary lens portion and supporting portion includes the steps of: providing a mold having cavity and core elements which together define a space in which the optical attenuator can be molded including a movable core pin having a proximal end defining a surface of the lens portion, and a core pin motor coupled to the core pin for adjusting the thickness of the lens portion; injecting a suitable polymer into the space to form the optical attenuator; separating the cavity and core elements to extract the optical attenuator from the mold; optically measuring the thickness of the lens portion; and providing a signal indicative of the thickness of the lens to a controller having an output coupled to the core pin motor, the controller providing a signal to the core pin motor specifying any movement necessary to retain the thickness of the lens portion within a desired range before repeating the injecting step.

Abstract: The invention relates to methods for making mold tools. More particularly, the mold tools are used for molding a resin substrate which has fine pits, i.e., concavities and protuberances. The invention also pertains to a method for manufacturing a resin substrate. Such resin substrates may be used as an optical disk, a magnetic disk, a hard disk, etc., for recording data. According to a preferred embodiment of the invention, a first metallic (Ni) mold tool (father) is made which is a duplicate of a master substrate, then a resin mold tool (mother) is made which is a duplicate of the first metallic mold tool and finally a second metallic (Ni) mold tool (son) is made which is a duplicate of the resin mold tool. Both the father and son may be referred to a “stamper”. The invention also relates to methods of manufacturing a mold tool for molding the base of an optical disk having at least one signal recording region and at least one non-signal recording region.

Abstract: A processing apparatus is provided with a diamond tool. When a first edge portion is made as X axis, a tip end peak point of a rake face is made as an intercept (0, y) on Y axis, and the rake face is projected in the first quadrant on an X-Y plane, a shape between an end portion of a first edge portion and an end portion of a second edge portion is asymmetric around a straight line which passes at the intercept and is parallel to X axis and the shape is shaped to be not a straight line such that Y value of a point on the shape increases as X value of the point increases.

Abstract: A production process of an optical disk, wherein when a layer of an ultra violet rays curing resin which constitutes a portion of the optical disk is formed, a comi-transparent film of a metal is formed an a molded substrate on which a pattern was transcribed and this molded substrate is used as a semi-transparent stamper, and the production of an optical disk with two layers at one side is made easy thereby.

Abstract: Screen apparatuses are provided which include a first lens or holographic optical element layer and a second mask layer. The first layer substantially collimates image light rays to impinge on the mask layer. The mask layer provides an array or matrix of projecting members. Each of the projecting members receives and focuses the substantially collimated light rays to corresponding focal points. The mask layer includes a mask that blocks light transmission except where openings are located. The openings allow the light focused through the focal joints to substantially pass through the mask to form an image. The screen apparatuses can be advantageously employed in display apparatuses.

Abstract: A method of forming a replica of a diffraction grating from a master grating is disclosed, wherein the method includes the steps of: depositing a release layer including a self-assembled monolayer (SAM) on an upper surface of the master diffraction grating; depositing a reflective layer (e.g., aluminum) over the release layer; providing an adhesive layer (e.g., epoxy) and a glass substrate over the reflective layer; and, separating the substrate, the adhesive layer, and the reflective layer from the master diffraction grating, thereby producing a replica of diffraction grating. The SAM release layer may be durable and a plurality of diffraction grating replicas may be produced from a master grating.

Abstract: An apparatus and method for fabricating the light guide panel reduces the thickness of the stamper and fixes it firmly in place. The apparatus and method for fabricating the light guide panel according to the present invention has a stamper for forming patterns on the light guide panel and first and second side mold frames which are separable so as to hold the stamper in place during the formation of the light guide and so as to easily eject the finished light guide after it has formed and hardened.

Abstract: Disclosed is a manufacturing method of a complex lens for a tandem scanning optical system that includes a step for preparing molding dies for forming a cavity to form the complex lens as a single-piece element, and a step for injecting lens material into the cavity. The molding dies include a pair of single-piece mirror surface cores that form a plurality of lens surfaces of the complex lens at an incident side and a plurality of lens surfaces at an exit side, respectively. The complex lens has a plurality of stacked lens portions and the lens portions converging a plurality of light beams, which are modulated independently and deflected by a deflector, onto a surface to be scanned, respectively, for forming a plurality of scanning lines at the same time.

Abstract: There is described a method for depicting a predetermined diffraction structure on a substrate by scanning an electron beam onto the substrate. The method includes the steps of: measuring a contour of the substrate so as to detect height errors in surface heights in comparison with specified values of a surface height distribution of the substrate; adjusting a depicting mode for depicting each of diffraction gratings, which constitute the predetermined diffraction structure, in response to the height errors detected in the measuring step, so as to compensate for a phase change of diffracted light caused by each of the height errors corresponding to each of the diffraction gratings; and depicting each of the diffraction gratings by scanning the electron beam onto the substrate, according to the depicting mode adjusted in the adjusting step. The depicting mode represents each spacing between the diffraction gratings or a dose of the electron beam.

Abstract: A method for making a double-sided microlens mold and microlens array mold is described which utilizes a spinning half radius diamond cutting member operated in a plunge cut in a technique similar to milling to cut the optical surface into a diamond turnable material. The method can be used to make high sag lens molds with high accuracy. Microlens array molds can be made with a high degree of uniformity and a nearly 100% fill factor.

Abstract: An apparatus and method for filling a mold for casting optical lens. Two molding shells and a closure member form a mold with a molding cavity. To fill the mold a fluid lens-forming material is introduced into the molding cavity through a casting opening formed in the closure member. Air is venting out during the filling process through a venting opening also formed in the closure member. Both the casting opening and the venting opening are located in the upper portion of the molding cavity but spaced apart from each other at an acute angle.

Abstract: A method and a system for fabricating articles made from thermoset resins using an ionic mold release agent. The invention uses a mold having a metal oxide surface with enhanced mold release characteristics. The release agent is applied internally in the resin composition or externally on the metal oxide surface. The method includes providing a mold, forming a metal oxide surface on the mold, providing an ionic release agent, providing the acid or base conjugate of the release agent at the metal oxide surface, providing a thermoset resin in the mold, and curing the resin in the mold. A method of using float glass having a SnO2 enriched surface, wherein the method includes the steps of providing an ionic release agent externally to the tin oxide surface, is also disclosed.

Abstract: The present invention provides a method for producing a light transmitting plate, comprising the steps of: using a molding equipment composed of an injection equipment and a mold for producing a light transmitting plate wherein a cavity of the mold communicates with a cylinder in the injection equipment; feeding a transparent resin into the cylinder; melting the transparent resin in the cylinder; and injecting the molten resin into the cavity of the mold from the cylinder; wherein a viscosity of the molten resin at the inlet of the mold is about 50 to about 5,000 Pa·sec and an injection rate is about 1 to about 15 cm3/sec, which method can be produce excellent light transmitting plate, specially large-size ones, further ones with a reflection layer pattern or a light diffusion pattern transferred, in transparency and dimensional stability.

Abstract: Retroreflective prism sheeting is formed in a mold with textured facets and/or windows thereon. Smaller prisms are formed adjacent larger prisms. Optionally, the optical axis of the prisms may be tilted with respect to one another, preferably in a negative direction. The textured facets or windows provide more uniform retroreflected light intensity distribution and whiteness of the sheeting.

Abstract: A retroreflective structure includes a retroreflective sheeting having an array of transparent prisms formed into pairs of prisms. Each prism includes a base aperture and three intersecting lateral faces meeting at an apex. Each of the lateral faces includes a base edge which forms a portion of the perimeter of the base aperture. The base edge of each lateral face intersects the base edge of a contiguous lateral face to form a base point, the first face of at least one prism in the array including a first face first planar surface and a first face second planar surface. The first face first planar surface and the first face second planar surface are contiguous along an edge having a first and second end points, wherein the apex, the first end point, and a first base point are coplanar and form a continuous edge from the first base point to the apex.

Abstract: The method involves cutting or forming one or more patterns of optical element shapes in the exterior surface of a sleeve or one or more curved substrates or films on a roll during rotation of the roll. Then at least a portion of the sleeve or substrates or films containing at least one pattern of optical element shapes is removed from the roll and the pattern of optical element shapes or a copy or inverse copy thereof is used to form a corresponding pattern of optical elements on or in an optical substrate.

Abstract: The method includes the step of forming a solid epoxy member on a substrate, the epoxy member having an upper surface of desired configuration. A first metal layer is deposited on the epoxy member with the upper surface thereof conforming to the desired configuration. A layer of epoxy is deposited on the first metal layer and epoxy material from the epoxy layer is removed to create a well, exposing the metal layer on the epoxy member. A metal impression layer is then deposited in the well. The metal impression layer is then removed from the well and affixed to a mounting member as a mold component for injection molding of small structures.

Abstract: A process for forming a preform for use in compression molding an optical lens is provided. A heated reservoir desirably a thermoplastic extruder is filled with a thermoplastic material. The heated reservoir has a fluid outlet which is located in close proximity to the concave mold. The thermoplastic material, for example, polycarbonate pellets is fluidized in the heated reservoir. A predetermined amount of a fluid thermoplastic material is dispensed from the reservoir outlet onto the outside the edge of a heated concave mold prior to the fluid solidifying so that the fluid makes point or line contact as it first contacts the concave molds. The fluid flows down the sloping wall of the concave mold into the concave mold and forms a blob of material having a greater thickness at the center of the concave mold than at the periphery of the mold. The thermoplastic blob is then allowed to cool below its melting temperature.

Abstract: A method and a mask have been optimized to reduce seam lines in replicated structures using lithographic processes. Multiple exposures and sweeps across a substrate using the mask results in the reduction of seam lines in the final developed photosensitive or micro formed structures.

Abstract: A method for manufacturing ophthalmic lenses using reusable thermoplastic molds is provided. The invention permits the production of a full prescriptive range of lenses while reducing the number of mold inserts required. Further, the method of the invention may be used in a method for the delivery of customized ophthalmic lenses to a lens wearer.

Abstract: A method of forming a transferring surface onto a producing die to produce an optical element, wherein the transferring surface transfers an optical surface onto the produced optical element, the method comprising the steps of: cutting a material so as to form the transferring surface with a curvature; wherein the material has a hardness not smaller than Rockwell hardness HRA 80 or Vickers hardness Hv 1000 and the cutting step is conducted with a critical cutting-in depth of 5 &mgr;m or less for the material.

Abstract: A method of forming a contact lens within a mold is provided. A coating of a polyionic material(s) is applied to the mold before forming a lens therein. The coating can be applied by spraying or dipping the mold within a solution(s) of polyionic materials. Various other additives can also be applied to the mold. The coating can then be transferred to a contact lens formed within the mold such that the resulting lens has altered surface properties.

Abstract: A process of fabricating a non-gap 3-D microstructure array mold core comprises a first step in which a buffer layer is coated on a substrate. A photomask layer is then coated of the buffer layer. A pattern is subsequently formed on the photomask by photo-lithography. The patterned photomask layer is subjected to a reflow by which a microstructure array is formed on the photomask layer. The microstructure array is coated with a metal conductive layer. The microgaps of the microstructure array are eliminated by an electrocasting layer which is coated on the microstructure array. The non-gap microstructure array mold core so fabricated is made into a metal molding tool by microinjection molding or microthermo-pressure molding.

Abstract: A method of cast moulding toric contact lenses is provided in which each lens has a ballast and a toric central zone having a cylindrical axis, the cylindrical axis having an axis of orientation at a desired rotational angle with respect to the axis of the ballast, said method comprising the steps of: (a) providing male and female mould halves wherein the surface of one mould half defines said cylindrical axis and the other defines said ballast axis; (b) loosely assembling the mould halves and transporting the loosely assembled moulds to a filling station under conditions in which the mould halves are free to move relatively to each other in a rotational sense and are subjected to a joggling action during said transport or while being held prior to entry into the filling station; (c) lifting the male mould halves at the filling station, introducing a flowable polymerisable composition into the female mould halves and closing the male mould fully into the female mould halves and curing the polymerisable compos

Abstract: A method for casting an ophthalmic lens having a toric surface includes the step of providing a casting cell that includes a conventional front mold, a novel gasket, and a novel toric back mold. An annular carrier ring is integrally formed with or attached to the toric back mold. The gasket has a first annular flat step against which the front mold squarely abuts and a second annular flat step against which the annular carrier ring squarely abuts. The gasket includes no toric annular seat against which the front surface of a toric back mold abuts. This eliminates the need for a lens maker to maintain a large inventory of toric back molds and gaskets. The square seating enhances the sealing capability of the mold, reduces leaks, and produces lenses having fewer bubbles and flash on the edge of the lens.

Abstract: A Fresnel lens has a plurality of pitch areas in which a plurality of hybrid type prism portions are arranged. Each hybrid type prism portion has a refraction type prism portion and a total reflection type prism portion. In the refraction type prism portion, a ray of incident light Li1 of an incident angle “an” is refracted twice and goes out as a ray of outgoing light Lo1 of an outgoing angle “f”. In the total reflection type prism portion, a ray of incident light Li2 of the incident angle “a” is refracted, totally reflected and refracted in that order and goes out as a ray of outgoing light Lo2 parallel to the ray of outgoing light Lo1.

Abstract: The invention provides a mold assembly for manufacturing contact lenses. The mold assembly comprises a plurality of identical molds which are stacked one on another. Each pair of neighboring molds cooperate with each other to define a molding cavity having a configuration of a desired contact lens. The present invention also provide a method for casting contact lenses in a mold assembly composed of multiple identical molds that are stacked one on another.

Abstract: A production method of a light guide and a stamper, combining anisotropic etching and isotropic etching. First a plurality of microstructures is formed on a back surface and a front surface of the substrate. By electroforming, rear and front stampers are made from the back and front surfaces of the substrate. Light guides are produced using the rear and front stampers. Anisotropic etching is performed on the front surface of the substrate, forming V-shaped, U-shaped or pyramid like microstructures. Isotropic etching is performed on the back surface of the substrate, forming quadratic, bowl like, oval or semicircular microstructures. If a transparent substrate is used, then after finishing the etching of microstructures, a light source, a reflector, a diffusion sheet and a prism sheet are added, simulating a back light module for performing a test of luminosity, uniformity of light intensity and light emission angle, so that optical properties are known before proceeding with inverse-forming of the stampers.

Abstract: Systems and methods of the present invention are directed to an optical element that includes a diffraction grating, an inclined surface, good optical characteristics, and an optical element manufacturing metal die. The optical element manufacturing metal die is capable of injection molding of an optical element having a complex structure. Further, the optical element manufacturing metal die includes nestings that have a plurality of mirror surface forming portions. The pluralilty of mirror surface forming portions include a plurality adjoining pairs of mirror surfaces. The plurality of mirror surface forming portions are molded by two adjoining pairs of the plurality of adjoining pairs of mirror surface forming portions, which are formed on the same nesting. At least one of the plurality of mirror surface forming portions are formed by a mirror surface grinding method.

Abstract: This invention relates to a method for preparing at least one mold part of a two-part mold useful for transferring a hydrophobic top coat from a mold onto an optical substrate. Further, the invention relates to a method for easily transferring a hydrophobic top coat from a mold onto the anti-reflecting coating of a coated optical substrate. Additionally, the invention relates to a method which provides improved adhesion of the hydrophobic top coat onto an optical substrate and in particular onto an anti-reflecting coating of a coated optical substrate. The invention also discloses a mold part useful in such methods.

Abstract: In order to eliminate post-molding mounting of a bulb 3 and a terminals 7 using a socket, when molding of a side turn signal blinker 1 in a manner of die slide injection, a process to mount the bulb 3 and the terminals 7 to a housing 4 is provided between a process to separate a first and second dies 9 and 10 from each other, which has carried out a primary injection molding of a lens portion 2 and the housing 4 as semi-finished products, and a process in which the dies are slid, the lens portion 2 and the housing 4 are butted and the secondary injection is carried out; thereby post-molding mounting of the bulb and the terminals is eliminated and the side turn signal blinker 1 in which the bulb 3 and the terminals 7 have been inserted, is obtained.

Abstract: An optical coupler arrangement which is employed for replicating surface features of diverse types of optical devices. Also disclosed is to a novel method of accurately replicating surface features of optical devices; particularly through the utilization of the novel optical coupler arrangement.

Abstract: A cavity 22 in an injection molding assembly includes a lower mold insert 21 for shaping a lens convex surface and an upper mold insert 20 for shaping a lens concave surface. When the heated injection molding assembly is cooled and a lens is ejected after a molten resin is pressurized by the upper mold insert 20, the temperature of the lower mold insert 21 is lowered below the temperature of the upper mold insert 20, which prevents the molded lens from bending at a central portion and enable high transfer precision of insert shapes.