Abstract:
A curved circularly polarized lens is used in a passive 3D system to view 3D multimedia. The lens is created in an advanced delicate process whereby two lens pieces are combined with a special glue and molded to a specific conformation. This unique method of production of curved circularly polarized lenses retains the molecular arrangement of the lens, reduces or eliminates optical distortion and physical warping, and eliminates movement between the lens layers.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. provisional application Ser. No. 61/393,281 filed on Oct. 14 2010 and U.S. provisional application Ser. No. 61/393,284 filed on Oct. 14 2010, the disclosures of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Technical Field 
         [0003]    The present invention pertains to special lenses used for viewing 3D multimedia. 
         [0004]    In particular, the present invention pertains to the use of curved circularly polarized lenses which are produced in a unique process that retains the molecular structure and alignment of the lens, reduces or eliminates optical distortion, and eliminates physical warping. The lenses are used in passive 3D systems to view still and moving images. 
         [0005]    2. Discussion of Related Art 
         [0006]    One of the greatest challenges facing multimedia producers is the balance of comfort, optical integrity, and user adaptability of 3D glasses. Several competing formats of 3D glasses offer distinct advantages and disadvantages due to the production methods for the lenses and the physical characteristics and capabilities of the lenses. One example of a less effective competing 3D lens format is the linearly polarized lens. 
         [0007]    Linearly polarized glasses allow a user to view stereoscopic pictures when two images are superimposed onto a screen through orthogonal polarizing filters in an image projector. The filters are usually positioned at 45 degrees and 135 degrees. The viewer wears linearly polarized glasses which also contain a pair of orthogonal polarizing filters in the same orientation as the projector. With this method, each filter passes only light which is similarly polarized and blocks orthogonally polarized light. Each of the user&#39;s eyes can only see one of the projected images, and thus, the 3D effect is achieved. However, when using linearly polarized glasses, the user must constantly maintain his head position in order to consistently experience the 3D effect. Should the user tilt his head while wearing the 3D glasses, the tilting of the filters in the glasses will cause the images of the left and right channels to bleed over into the opposite channel. Moreover, tilting of the user&#39;s head while wearing linearly polarized 3D glasses also causes failure of the polarization, ghosting, and both eyes seeing both images of the stereoscopic media. This characteristic of linearly polarized glasses causes discomfort to users over prolonged viewing periods because the user cannot move his head in order to maintain a consistent 3D effect. 
         [0008]    Accordingly, a need in the art exists to improve the user comfort, user mobility during 3D media viewing, and optical clarity of 3D glasses. No current 3D lens technology exists that allows a user to tilt and rotate his head during 3D media viewing while maintaining a consistent 3D effect. 
       OBJECTS OF THE INVENTION 
       [0009]    Accordingly, it is the object of the invention to provide a comfortable 3D media viewing experience for short or prolonged viewing periods. 
         [0010]    It is another object of the invention to provide 3D glasses that allow for normal user head movement during viewing of 3D media without causing optical distortion or interruption of the 3D effect. 
         [0011]    Yet another object of the invention is to provide 3D glasses with structural integrity thanks to a unique lens binding process. 
         [0012]    Another object of the invention is to prevent optical distortion and increase structural integrity in the 3D glasses through a unique lens shape conformation process. 
         [0013]    Another object of the invention is to enhance optical clarity and reduce or eliminate optical distortion in the 3D lenses by employing a special process of producing the 3D lenses such that the molecular alignment is retained throughout the process. 
         [0014]    The present invention may be used in conjunction with televisions, computer monitors, theater projection screens, and other media. 
         [0015]    The present invention may utilize lens tint to enhance color perception, depth perception, and optical clarity. 
         [0016]    The above and still further features, objects, and advantages of the present invention will become apparent upon consideration of the following detailed description of specific embodiments thereof, especially when considered in conjunction with accompanying drawings wherein in like reference numerals in the various figures designate like components. 
       SUMMARY OF THE INVENTION 
       [0017]    In one aspect, the invention discloses a method to form 3D glasses lens comprising: providing a retarder film, providing a polarized film, providing a high adhesion glue having a peel adhesion rate of at least 600 g/cm, applying the glue to a first surface to the retarder film, attach the polarized film to the first surface of the retarder film to form a circular polarized film, applying heat to the circular polarized film until it is soft, applying pressurized air to the circular polarized film and vacuuming the pressurized air as the pressurized air passes through the circular polarized film. 
         [0018]    In one embodiment, the invention further comprising cutting the circular polarized into lens shape to form circular-polarizer3D lens. In yet another embodiment, it further comprising adding a substrate layer to the circular-polarizer3D lens using glue with lamination method. 
         [0019]    In yet another embodiment it further comprising adding a substrate to the circular polarized using a casting method. In yet another embodiment the casting method is comprised of: providing a bottom casting mold, providing a top casting mold, providing a o-ring, placing the o-ring around the edges of the bottom casting mold, placing a first quantity of liquid epoxy on to the bottom casting mold, placing the circular-polarizer3D lens over the first liquid epoxy, applying a second quantity of epoxy liquid on to the circular-polarizer3D lens, applying the top casting mold onto the second liquid epoxy, allowing the first and second liquid epoxy to dry to form epoxy-circular-polarizer3D lens wherein the epoxy-circular-polarizer3D lens&#39; thickness is determined by hight of the o-ring, removing the epoxy-circular-polarizer3D lens from the casting molds after a duration of time. 
         [0020]    In yet another embodiment, the casting method is comprised of providing a bottom casting mold, providing a top casting mold, providing a supporter, placing the supporter around the edges of the bottom casting mold, placing a first quantity of liquid epoxy on to the bottom casting mold, placing the circular-polarizer3D lens over the first liquid epoxy, applying a second quantity of epoxy liquid on to the circular-polarizer3D lens, applying the top casting mold onto the second liquid epoxy wherein the top casting mold rests on the supporter, allowing the first and second liquid epoxy to dry to form epoxy-circular-polarizer3D lens wherein the epoxy-circular-polarizer3D lens&#39; thickness is determined by height of the supporter, removing the epoxy-circular-polarized 3D lens from the casting molds. 
         [0021]    In yet another embodiment, casting method is disclosed comprised of providing a rim-lock like apparatus wherein the apparatus is comprised of a bottom rim-lock mold, a top rim-lock mold, a divider and a clipping apparatus, placing a first quantity of liquid epoxy on to the bottom rim-lock mold, placing the circular-polarizer3D lens over the first liquid epoxy, applying a second quantity of epoxy liquid on to the circular-polarizer3D lens, applying the top rim-lock mold onto the second liquid epoxy wherein the the top rim-lock mold sits on the divider, clipping the top rim-lock mold with the bottom rim-lock mold with the clipping apparatus wherein the, allowing the first and second liquid epoxy to dry to form epoxy-circular-polarizer3D lens wherein the epoxy-circular-polarizer3D lens&#39; thickness is determined by height of the divider, removing the epoxy-circular-polarizer3D lens from the top and bottom rim-lock molds. 
         [0022]    In yet another embodiment, the casting method further comprises an injection tube where in the liquid epoxy is applied using the injection tube. In yet another embodiment, the adhesion glue is selected from the group consisted of acrylonirile, acrylic, polymer, polyacrylamide, epoxy, eva and polyurethane. 
         [0023]    In yet another embodiment, the application of heat further comprises pre-heating the circular polarized film for approximately 20-30 seconds. In yet another embodiment the heat is approximately 120-200 degree fahrenheit. In yet another embodiment, the pressurized air is pressured at approximately 2 kg/cm to 5 kg/cm. 
         [0024]    In yet another embodiment, the method is carried using an apparatus for assembly of layered lens disclosed in this disclosure. In yet another embodiment, the duration time is approximately 10-30 hours. In yet another embodiment, the liquid epoxy can be replaced by other compatible liquid film materials. 
         [0025]    In yet another embodiment, the retarder can be replaced by polymer sheet to be attached to the polarized film using the same above methods to create a linear polarized film for use for 3D lenses. 
         [0026]    In another aspect of the present invention, an apparatus for assembly of layered lens is disclosed comprising, a first mold comprising one or more holes in the mold, a second mold comprising one or more holes in the mold, the first mold capable of closing onto the second mold in a sealed manner and holding one or more polymer films within the first and second molds in a sealed manner, an air input providing external pressurized air through the first mold holes wherein the pressurized air further passes through the polymer films, a vacuum pump vacuuming the external pressurized air through the second mold holes, a heating source to heat the first and second molds. 
         [0027]    In yet another embodiment, the heating source pre-heats the first or second molds before the polymer films are placed in the first or second molds. In yet another embodiment, the method, the heating source heats pre-heats the first or second molds for 20-30 seconds. In yet another embodiment, the method the heat is approximately 120-200 degree Celsius. In yet another embodiment, the method the pressurized air is pressured at approximately 2 kg/cm to 5 kg/cm. In yet another embodiment, the id pressurized air is heated to 250-300 degree Celsius. 
         [0028]    In yet another embodiment, the vacuum pump is built as one unit with the second mold. In yet another embodiment, the input is built as one unit with the first mold. 
         [0029]    In yet another embodiment, the apparatus further including a cylinder capable of moving the first mold vertically to close onto the second mold. In yet another embodiment, the, the apparatus further including a cylinder capable of moving the second mold vertically to close onto the first mold. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0030]      FIG. 1  is a diagram showing the procedural steps of combining layers of retarder and polarized film. 
           [0031]      FIG. 2  is a diagram showing the placement of various layers of polymer. 
           [0032]      FIG. 3  is a diagram showing the placement of various layers of polymer and additives in the succeeding step of the procedure. 
           [0033]      FIG. 4  is a diagram showing the placement of various layers of polymer and additives in the succeeding step of the procedure. 
           [0034]      FIG. 5  is a diagram of a molding apparatus with a vacuum chamber for shaping the lens. 
           [0035]      FIG. 6  is a diagram of the pre-heating stage of forming the lens. 
           [0036]      FIG. 7  is a diagram of the succeeding step in the procedure of forming the lens within the apparatus, wherein air is vacuumed out and pumped in simultaneously. 
           [0037]      FIG. 8  is a diagram of die-cutting of the lens. 
           [0038]      FIG. 9  is a diagram of the laminate substrate method of adding a substrate lens. 
           [0039]      FIG. 10  is a diagram of the casting method. 
           [0040]      FIG. 11  is a diagram of the O-ring controller for a mold. 
           [0041]      FIG. 12  is a continuation of the above diagram. 
           [0042]      FIG. 13  is a continuation of the sequential steps of the above diagram. 
           [0043]      FIG. 14  is a diagram of the supporter. 
           [0044]      FIG. 15  is a diagram of the next step of the procedure involving the supporter. 
           [0045]      FIG. 16  is a diagram of procedural steps in the rim-lock method with epoxy drops. 
           [0046]      FIG. 17  is a diagram of the next step of the rim-lock method. 
           [0047]      FIG. 18  is a diagram of the next step of the rim-lock method. 
           [0048]      FIG. 19  is the rim-lock method with epoxy injection procedural diagram. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0049]    Referring to  FIG. 1 , which is a visual flow diagram of the method of laminating retarder film  101  and polarized film together  104 . To laminate the retarder film  101  and polarized film  104  together, a special glue  102  with adhesive index above 600 g/cm 2  is used in order to prevent movement or uneven stretching between the layers. The retarder film  101  is combined with the polarized film  104  to create a polarized lens. 
         [0050]    Now referring to  FIG. 2 , which is a continuation of the above visual flow diagram sequentially tracing the process of laminating retarder film. Here it illustrates (pressure sensitive adhesive) PSA  103  as on top of the retarder  101 . PSA is usually provided and applied to the commercially available retarder films. Its quality is similar to adhesive tapes and has poor adhesive rating and not able to keep the layer in place. In this diagram, it is shown that the top layer PSA  103  is applied already to the retarder  101  and the bottom surface of the retarder  101  is re-treated with glue  102 . 
         [0051]    Referring to  FIG. 3 , which is a continuation of the above visual flow diagram sequentially tracing the process of laminating retarder film, the combined layers now include the retarder  101 , an applied layer of glue  102 , (pressure sensitive adhesive) PSA  103 , and a polarized film layer  104 . As stated earlier, while PSA  103  are typically applied and included to commercially available retarder, PSA  103  is also applied and included to commercially available polarized film  104 . In this embodiment, it is shown that the glue  102  can applied directly on to PSA  103  which is attached to the polarized film. The glue  102  is added for immediate use or after heat application and hardening of the layers. Examples of glue used include but are not limited to acrylonirile, acrylic, polymer, polyacrylamide, epoxy, EVA, and polyurethane. The glue must have peel adhesive value of no less than 600 g/cm. 
         [0052]    Now, referring to  FIG. 4 , in another embodiment, the retarder  101  is combined with a layer of special glue  102 , and then with a commercially available polarized film which includes a first layer of TAC (Triacetate)  104 , a layer of PVA (Polyvinyl alcohol Film)  105 , and another layer of TAC  104  are added below. 
         [0053]    Referring to  FIG. 5 , which a diagram of an apparatus for molding the lens in a vacuum chamber, the cylinder  110  is moved upwards and downwards along a vertical axis, which moves the top mold chamber  111  having the top mold  14  so it can close onto the bottom mold chamber  113  having a bottom mold  112 . An input of air for external air can in incorporated into the bottom mold chamber  113  and introduce pressurized air, preferably at 250-300 Degree Celsius and at 2-5 kg/cm pressure, into the bottom mold  112  wherein the mold  112  would have one more many holes to channel the air upwards. An air vacuum pump can be built into the top mold chamber  111  and sucks up the pressurized and heated air. Once the retarder and polarized lens are combined, they are introduced into this apparatus. The apparatus is preferably pre-heated for 20-30 seconds and at preferably 120-200 degree C. When the retarder and circularly polarized layers are soft, the top half of the apparatus vacuums air out, while the bottom half of the apparatus introduces 250-300 degree Celsius heat and pressure onto the lens. 
         [0054]    Best way for good quality is to have vacuum air out and compress air in at the same time. Ideal amount of time to do this is approximately 5-20 seconds. 
         [0055]      FIG. 6  is a diagram illustrates one embodiment of the pre-heating stage of the mold process for making curved circularly polarized lens before pressurized air is introduced. Here, the top mold  201  chamber is stabilized at 90 degrees Celsius as indicated by  203 , and the bottom mold  202  is stabilized at 180 degrees Celsius as indicated by  204 . 
         [0056]    Now referring to  FIG. 7 , which is a continuation of the process in  FIG. 6 . After the circular polarized lens becomes soft, hot air is vacuumed out  205  of the top mold  201 . Compressed hot air  206  is pumped into the bottom mold  202  at the rate of 3 kg/cm 2 . These processes are carried out simultaneously for optimal results. 
         [0057]    Referring to  FIG. 8 , which is a diagram of die-cutting,  207  the lens must be pressed firmly to hold it stationary and prevent movement in order to ensure a high quality and precise cut. After the die-cut  208 , the polymer sheet on the convex side  209  is retrieved. 
         [0058]    Referring to  FIG. 9 , which is a diagram of the laminate substrate method of adding a substrate lens, epoxy  210  is added to a layer of polarized film  211 , glue  212 , and pre-formed substrate  213  (including but not limited to epoxy, PU, PC, AC, nylon, CR39). 
         [0059]    Referring to  FIG. 10 , which is a diagram of the casting method which there are four types to control the thickness of the substrate. Here, epoxy  220  is added to polarized film  221  and pre-formed substrate  222  (including but not limited to epoxy, PU, PC, AC, nylon, CR39). 
         [0060]    Referring to  FIG. 11 , which is a diagram of the  0 -ring controller for a mold, the circularly polarized film  301  is placed upon epoxy liquid  303  applied to the bottom mold  304 . The O-ring  302  is constructed of PU (polyurethane) or silicon may be adjusted to control the thickness of the lens. 
         [0061]    Referring to  FIG. 12 , which is a continuation of the above diagram, the top mold  305  is placed upon the circularly polarized film  301  which rests above a layer of epoxy  303  upon the bottom mold  304 . 
         [0062]    Referring now to  FIG. 13 , which is a continuation of the sequential steps of the above diagram,  306  the molds are pressed together in order to shape the circularly polarized lens  307 . A waiting period  308  occurs, during which the curing process occurs. The mold may be removed after 10-30 hours. After 30-72 hours, the lens will be fully set and the finished product  309  is hardened and removed. 
         [0063]    Referring to  FIG. 14 , which is a diagram of the supporter, the circularly polarized lens  310  is placed upon a layer of epoxy liquid  312  on top of the bottom mold  313 . A leg  311  on either end of the mold lends support in the vertical direction. In the following step  314 , the circular polarized layer  310  is placed upon the readied mold. 
         [0064]    Referring to  FIG. 15 , which is a diagram of the next step of the procedure involving the supporter, the polarized layer  310  has been placed atop the epoxy layer  312  on the mold. In the following step  316 , the two molds are pressed together with the polarized layer  310  sandwiched in between. Then, in the next step  318 , the polarized layer is sandwiched between two layers of epoxy  312 . A waiting period of 10-30 hours commences  317 . The curing process occurs and the mold may then be removed. The lens will then be fully set. 
         [0065]    Referring to  FIG. 16 , which is a diagram of procedural steps in the rim-lock method with epoxy drops, a rim-lock  401  is attached on either side of a bottom glass mold  402 . In the following step  403 , epoxy  404  is added on top of the glass mold. 
         [0066]    Referring now to  FIG. 17 , which is a diagram of the next step of the rim-lock method, a curved circularly polarized layer  405  is added on top of the epoxy  404 . 
         [0067]    Referring now to  FIG. 18 , which is a diagram of the next step of the rim-lock method, an upper glass mold  406  is pressed downwards upon an additional layer of epoxy  404  over the circularly polarized layer  405 . In the following step, clippers  407  are used to secure the combined layers together firmly. The layers now include a circularly polarized layer  405  sandwiched in between layers of epoxy  404 . Following a waiting period of 48 hours, the finished product is removed from the mold and includes a cured circularly polarized layer  405  sandwiched between layers of epoxy  404 . 
         [0068]    Referring now to  FIG. 19 , which is the rim-lock method with epoxy injection procedural diagram, a rim lock  506  is attached to either side of a bottom glass mold  505 . Epoxy  505  is introduced into the system above the bottom mold  505  via an epoxy injection tube  503 . Then, a circularly polarized layer  502  is placed upon the epoxy  504 , and a top glass mold  501  is pressed down upon the entire combination of layers. In the following sequential diagram, a clamp  507  secures the combination of layers, which now include the top mold  501 , two layers of epoxy  504  surrounding a circularly polarized layer  502 , and a bottom mold  505 . The epoxy was injected into the system via a dropper or syringe-like device  508  in the preceding step  509 . A cap  510  plugs the epoxy injection port after epoxy injection.