Abstract:
Curved lenses configured to decode three dimensional content and method of fabricating the same. The lenses decode three-dimensional content displayed on televisions or computer monitors. Sheets from which the lenses are cut have either (i) a polarizing axis of 0 degrees relative to horizontal and one sheet has a retarder axis at −45 degrees relative to horizontal and the other sheet has a retarder axis of +45 degrees relative to horizontal; (ii) a polarizing axis of −45 degrees relative to horizontal and one sheet has a retarder axis at 0 degrees relative to horizontal and the other sheet has a retarder axis of 90 degrees relative to horizontal; or (iii) a polarizing axis of +45 degrees relative to horizontal and one sheet has a retarder axis at 0 degrees relative to horizontal and the other sheet has a retarder axis of 90 degrees relative to horizontal.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    This application is a continuation U.S. patent application Ser. No. 13/323,725, filed Dec. 12, 2011; which is a continuation of U.S. patent application Ser. No. 12/973,620, filed Dec. 20, 2010, now U.S. Pat. No. 8,100,525; which is a continuation of U.S. patent application Ser. No. 12/604,155, filed Oct. 22, 2009, now U.S. Pat. No. 7,854,506; which is a continuation-in-part of U.S. patent application Ser. No. 12/495,754, filed Jun. 30, 2009, now U.S. Pat. No. 7,946,703; which is a continuation-in-part of U.S. patent application Ser. No. 12/350,092, filed Jan. 7, 2009, now U.S. Pat. No. 7,950,798; which claims the benefit of U.S. patent application Ser. No. 61/019,545, filed Jan. 7, 2008, which are commonly assigned, the disclosures of which are hereby incorporated by reference in their entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The embodiments of the present invention relate to lenses designed to decode three dimensional content displayed on television, movie, computer or similar screens or monitors. 
       BACKGROUND OF THE INVENTION 
       [0003]    Three dimensional movies for theatres have been around for decades. With technological advances, three dimensional content is being developed for television, computer monitors and home projectors. In the past, and even today, special glasses allow users to view three dimensional content. Flat paper eyeglasses using red and green film for lenses are the primary glasses being used today. However, flat paper eyeglasses are not very effective for facilitating the desired three dimension effect. In addition, the flat paper eyeglasses are not comfortable and are generally viewed as a novelty. Other flat lenses suffer from the same drawbacks. 
         [0004]    One advancement has been the development of linear and circular polarization for decoding three dimensional content. Despite the advancement, the lens and eyeglass technology has not advanced significantly. 
         [0005]    Thus, there is a need for lenses that take advantage of the linear and circular polarization technologies while more effectively creating the desired three dimensional effect. Advantageously, the lenses and eyeglasses should provide improved optics and contrast while providing user comfort and versatility. It is also beneficial if the lenses may be mounted into stylish frames. 
       SUMMARY OF THE INVENTION 
       [0006]    Accordingly, one embodiment of the present invention is a curved lens configured to decode three dimensional content comprising: a polarizing layer laminated with a polymeric material layer on one or both sides; a retarder layer laminated to a front of the polarizer layer directly or to the polymeric material to form a sheet, said retarder layer aligned to decode a desired circular polarization; and wherein a blank cut from the sheet is curved using a thermoforming process or high pressure process into a lens configured to decode three dimensional content. 
         [0007]    Another embodiment is a lens configured to decode three dimensional content comprising: a polarizing layer laminated with a polymeric material layer on one or both sides; a retarder layer laminated to a front of the polarizer layer directly or to the polymeric material to form a sheet, said retarder layer aligned to decode a desired circular polarization; wherein a blank cut from the sheet is curved using a thermoforming process or high pressure process into an optical element configured to decode three dimensional content; and wherein said optical element is utilized in an injection molding process whereby one or more thickness layers are added to the optical element to form said lens. 
         [0008]    Another embodiment of the present invention is a method of fabricating a curved lens configured to decode three dimensional content comprising: cutting lens blanks from sheets of material comprising: a polarizing layer laminated with a polymeric material layer on one or both sides; a retarder layer laminated to a front of the polarizer layer directly or the polymeric material, said retarder layer aligned to decode a desired circular polarization, and wherein said blanks are cut to maintain a specified alignment of a polarizing axis associated with said sheet; curving said blanks into lenses by: a. heating the blanks to a deformation temperature; and applying a vacuum suction and/or pressure; or b. applying high pressure. 
         [0009]    In one embodiment, the retarder is a norbornene copolymer resin such as an Afton film (manufactured by JSR Corp.) or Zenor film (manufactured by Zeon corp.). Conventional adhesives (e.g., pressure sensitive adhesives) are used to bond the layers forming the lens. In one embodiment, a hard coating is applied to the front and back surfaces of the lens to allow for normal cleaning and extended life. In one embodiment, a lens thickness is between 750 and 1500 microns. In another embodiment, the lens thickness is between 250 and 1500 microns. 
         [0010]    In an embodiment intended to decode 3D content displayed on computer screens or monitors, the blanks are cut from the sheet at a plus or minus 45 degree angle to correctly align the polarizing axis with the display of content on the television or computer screen. 
         [0011]    Other variations, embodiments and features of the present invention will become evident from the following detailed description, drawings and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIGS. 1 and 2  illustrate an exemplary specification sheet for a first lens embodiment of the present invention; 
           [0013]      FIGS. 3 and 4  illustrate an exemplary specification sheet for a second lens embodiment of the present invention; 
           [0014]      FIG. 5  illustrates a flow chart detailing one embodiment of manufacturing the lenses according to the embodiments of the present invention; 
           [0015]      FIG. 6  illustrates a flow chart detailing a second embodiment of manufacturing the lenses according to the embodiments of the present invention; and 
           [0016]      FIGS. 7   a - 7   c  illustrate various television and computer screen shots showing content parameters and polarizing axis alignment of corresponding 3D lenses. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0017]    For the purposes of promoting an understanding of the principles in accordance with the embodiments of the present invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive feature illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention claimed. 
         [0018]    Traditionally flat lenses and frames have been used in 3D glasses. One problem with the flat 3D glasses is that the lenses are distanced from the user&#39;s face and more particularly the user&#39;s eyes. Thus, light is able to enter the user&#39;s eyes from the top, bottom and side of the lenses reducing the visual acuity and contrast thereby reducing the effectiveness and comfort of the 3D experience. This is especially true at home or other locations outside of dark movie theatres. Moreover, the current one-size-fits-all approach to flat 3D eyeglasses reduces the quality of the 3D experience and in many cases results in an uncomfortable fit for most users. Accordingly, the embodiments of the present invention seek to overcome the disadvantages of the prior art flat 3D eyeglasses by creating 3D lenses and eyeglasses which are more akin to normal curved lenses and eyeglasses. Consequently, the lenses described herein are generally thicker than traditional flat 3D lenses and curved to prevent ambient light from interfering with the 3D experience and allow for better fitting glasses. Conventional flat 3D paper lenses are 0.3 to 0.4 mm thick while the embodiments of the present invention are substantially in a range of 0.75 mm to 1.5 mm. In an alternative embodiment, the lenses may be in range of 0.25 mm to 0.75 mm for use with an injection molding process as described below. The curvature further enables a better fit on the user&#39;s head. In addition, the thicker lenses enable them to be mounted into stylish frames to which people are more accustomed. 
         [0019]      FIGS. 1-4  show specifications associated with lenses made utilizing the embodiments of the present invention.  FIGS. 1 and 2  depict charts  100  and  105  listing lens specifications according to a first embodiment. The charts  100  and  105  depict dimensions, including width  110  and length  115 , polarization angle  120 , retardation angle  125 , transmittance percentage  130 , polarizing efficiency  135 , thickness  140  and retardation  145 . As shown in charts  100  and  105 , the width ranges from 495 mm to 505 mm; length from 700 mm to 710 mm; polarization angle from −1.0 degree to 1.0 degree; retardation angle from 44.0 degrees to 46.0 degrees (or 134 degrees to 136 degrees); transmittance percentage from 37.5% to 42.5% v; polarizing efficiency of 99% or greater; thickness of 1020 microns to 1080 microns (or 1.02 mm to 1.08 mm) and retardation of 110 to 150 nm. Larger ranges are possible for each of the aforementioned categories. Charts  101  and  106  shown in  FIGS. 3 and 4 , respectively, depict similar lens specifications according to a second embodiment of the present invention. 
         [0020]    Fabrication of the lenses is accomplished using lamination and thermoforming techniques.  FIG. 5  shows a flow chart  200  detailing one method of fabricating lenses according to the embodiments of the present invention. At  205 , sheets are formed and, at  210 , lens blanks are cut from the sheets of material comprising: polyvinylalcohol polarizer film, polyethylene terephthalate or similar material laminated with triacetate on one or both surfaces (i.e., linear polarized film) and a retarder film laminated on a front surface thereof creating a circular polarized film. While triacetate is one material that can be used, others include polycarbonate, poly (methyl methacrylate), polystyrene, polyamide, cellulose acetate butyrate (CAB), cellulose acetate, cellulose diacetate (DAC) or cellulose triacetate (TAC), diacetate and similar stress-free (no birefringence) materials. The triacetate, diacetate or other materials may also be laminated onto the back (bottom) of the polarizer film to eliminate any unwanted retardation effects. A laminator machine forms the sheets of materials such that the axis of the polarizing film and retarder film are aligned properly to small tolerances. In one embodiment, the retarder is an Arton film (manufactured by JSR Corp.) or Zenor (manufactured by Zeon corp.). Other materials, such as polyurethanes, cellulose diacetate and polycarbonates, may also be used as the retardation film. Adhesives bind the materials together. The size of the blanks is dictated by the intended frame size. A typical size is 50 mm×70 mm. At  215 , the blanks are placed into a thermoforming machine which heats the blanks to a deformation temperature (e.g., 90° C. to 130° C.). At  220 , the heated blanks are curved using thermoforming techniques to an optically correct curved surface utilizing vacuum suction and/or pressure. To generate the desired base curve (e.g., 4, 6 and 8), a different combination of unique temperatures and times may be required. Once formed, at  225 , the curved blanks are cooled and removed from the machine. At  230 , the blanks, now lenses, can be finished with conventional lens dry cutting machines. At  235 , a hard coating is applied over the curved lenses. The hard coating allows normal cleaning and extended use while protecting the operational materials forming the lenses. The hard coat may also be applied prior to the thermoforming process by using a thermoformable hard coat material. At  240 , protective, removable sheets are applied to protect the lenses during subsequent operations including installation into frames, packaging and shipping. The protective sheets may also be applied to the sheets of the material prior to thermoforming process. 
         [0021]    While thermoforming techniques are referenced in the flow chart  200 , extreme pressures may also be used to create the curved lenses. A machine known as the Wheel or similar machines generate extreme pressures and can be used to curve a blank into a lens. The process is known as press polishing whereby heat and pressure are applied to the blank via both sides of highly polished molds. 
         [0022]    The triacetate and diacetate may comprises multiple layers themselves and have qualities, including transparency, low birefringence, lightweight and strength. Moreover, triacetate and diacetate are responsive to lamination and thermoforming processes and techniques as disclosed herein. 
         [0023]    For the circular polarized lenses utilized in the embodiments of the present invention the polyvinylalcohol polarizer film is tinted and stretched in a linear direction to orient the polymer molecules. Polyiodine molecules are commonly used to allow polarizing efficiency and transmission to reach acceptable levels (e.g., &gt;99% and &gt;35%, respectively). Alternatively, dichroic dyes can be used to provide improved resistance to heat and humidity, but may have slightly lower polarizing efficiency and transmission. Both embodiments can produce the desired 3D decoding effect. 
         [0024]    The curved lenses disclosed herein have numerous advantages over the flat 3D glasses of the prior art. The curved lenses provide a clearer and natural vision of 3D images with greater acuity and contrast. More particularly, the curved lenses reduce light entering the user&#39;s eyes from the side, top or bottom of the eyeglass frames thereby increasing the comfort and contrast associated with the viewed 3D images. The curved lenses can be fitted into commercial eyeglass frames to create a stylish pair of eyeglasses. 
         [0025]    In another embodiment, as shown in the flow chart  300  of  FIG. 6 , an optical element is made using the aforementioned process for use in an injection molded lens. Steps  305 - 330  coincide with steps  205 - 230  described above except that the resultant blanks are thinner than the lenses formed using the steps of flow chart  200 . At  335 , the blank becomes part of the final thicker lenses via an injection molding process. In other words, a thinner version of the lens described above is used as an optical element to make low cost injection molded polycarbonate (or polymethylmethacrylate and polymide) lenses. In this embodiment, the thermoformed optical elements are in a range of about 250-750 microns with a final injected 3D lens in a range of about 1000 to 2200 microns. Such lenses can be optically corrected with increased thickness and rigidity. In one embodiment, a back polymer layer of the lens is the same material as the injected material to provide good adhesion and reliability. 
         [0026]      FIGS. 7   a - 7   c  show various television and computer screens depicting content and polarizing axis orientation or alignment for corresponding 3D lenses.  FIG. 7   a  shows a television  400  displaying 3D content on a screen  401  configured with a vertical polarizing axis  402  and retarder axes  403 ,  404  aligned at −45 and +45 degrees, respectively, relative to horizontal. Lenses  405 ,  410  have a polarizing axis  415  aligned at 0 degrees (i.e., horizontal). A retardation axis  406  associated with the left lens  405  is at −45 degrees (i.e., rotated clockwise) relative to horizontal and a retardation axis  411  associated with the right lens  410  is at +45 degrees (i.e., rotated counter-clockwise) relative to horizontal. Accordingly, the left lens  405  and right lens  410  each allow only similarly polarized content emitted by the television screen to pass through thus creating the 3D effect. The configuration of lenses  405 ,  410  is the same as the configuration of the movie lenses discussed above. 
         [0027]      FIG. 7   b  shows a first computer  450  displaying 3D content on a screen  451  with a polarizing axis  452  at +45 degrees from the horizontal and retarder axes  453 ,  454  aligned at 0 degrees (horizontal) and 90 degrees (vertical), respectively, from the horizontal. Lenses  455 ,  460  have a polarizing axis  465  aligned at −45 degrees from the horizontal. A retardation axis  456  associated with the left lens  455  is at 90 degrees and a retardation axis  461  associated with the right lens  460  is at 0 degrees relative to horizontal. 
         [0028]      FIG. 7   c  shows a second computer  480  displaying 3D content on a screen  481  with a polarizing axis  482  at −45 degrees from the horizontal and retarder axes  483 ,  484  aligned at 0 degrees (horizontal) and 90 degrees (vertical), respectively, from the horizontal. Lenses  485 ,  490  have a polarizing axis  495  aligned at +45 degrees from the horizontal. A retardation axis  486  associated with the left lens  485  is at 0 degrees and a retardation axis  491  associated with the right lens  490  is at 90 degrees relative to horizontal. 
         [0029]    Although the invention has been described in detail with reference to several embodiments, additional variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.