Patent Publication Number: US-2021178710-A1

Title: Methods, apparatuses, and systems for edge sealing laminate wafers containing a soft deformable inner film

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to optical article and, more particularly but without limitation, to the manufacture of optical articles for use with an eyewear apparatus. 
     BACKGROUND 
     Optical articles, such as lenses, are typically made by functional wafers. Theses wafers may be subject to various manufacturing processes during the formation of an optical article. For example, flat wafers are typically transformed (e.g., thermoformed) from a flat circular wafer to a concave dome-shaped functional wafer to correspond to a base curve of the optical article. The thermoformed functional wafers are then often used in an injection overmolding process to produce corrective or non-corrective eyeglass lenses. Often, the wafer includes a thick center layer of soft thermoplastic material (e.g., soft thermoplastic layer or soft adhesive layer) as it offers certain advantages, such as soft polymer segment, ductility, and chemical compatibility during the formation of the wafers and optical articles. However, there are several complications that arise from using the soft thermoplastic layer in both thermoforming and injection molding processes. 
     To illustrate, to maintain the desired ductility of the wafer, the soft thermoplastic layer of the wafer typically has a glass transition temperature well below that of the injection molding temperature that results in outflow (e.g., edge bleeding) of the soft layer. This edge bleeding creates unwanted contamination of the insert, mold cavity and/or space between the outer side surface of the insert and the mold cavity walls. This contamination may prevent removal of the insert from the mold block and/or create buildup of unwanted material on the molding surfaces which affects product yields, increases down time due to mold cleaning, and leads to imperfections in subsequent lens formation such as, for example, non-uniform thickness of the soft thermoplastic layer which may result in optical distortions or cosmetic issues in the lenses. Some conventional approaches to preventing edge bleeding have included using outer layers that have a larger diameter than the soft, central layer to prevent the central layer from bleeding into the mold cavity. However, such wafer geometry is difficult to produce on a large scale and the soft layer is still visible after injection molding. Accordingly, such solutions offer little help in reducing manufacturing time and produce lenses with undesirable cosmetic properties. 
     SUMMARY 
     The present disclosure is generally related to systems, devices, and methods for manufacturing an optical article. For example, a method of manufacturing an optical article may include sealing and cutting a laminate to form a functional wafer. Sealing the laminate may include liquefying at least a portion of a thermoplastic layer of a laminate and displacing the liquefied portion of the thermoplastic layer to produce a wafer having an inner layer that includes a central portion having a first thickness that is greater than a second thickness at an edge portion of the inner layer. The reduced thickness of the inner layer at the edge portion of the wafer may prevent molten material from bleeding out of the wafer during subsequent manufacturing steps to produce the optical article. In another example, a system may include one or more tools for producing a non-contaminating optical wafer for use in manufacture of the optical article. The one or more tools may include an imprinting apparatus and a cutting apparatus. To illustrate, the imprinting apparatus is configured to form an imprint in the laminate and the cutting apparatus is configured to cut out wafers from the laminate. In this way, imprinting apparatus and cutting apparatus may operate in conjunction to efficiently produce a plurality of non-contaminating wafers in a timely and reproducible manner. In some implementations, the imprinting apparatus may operate on a laminate prior to operation of the cutting apparatus on the laminate. In other implementations, the cutting apparatus may operate on a laminate to form a wafer prior to an operation of the imprinting apparatus on the wafer. Consequently, the disclosed system, apparatuses, and methods enable mass production of a non-contaminating optical wafer capable of preventing edge bleed and subsequent contamination of the mold cavity without sacrificing the cosmetic appearance of the lenses. 
     In some of the foregoing implementations of the present methods (e.g., of forming a wafer for use in an optical article), a method includes liquefying at least a portion of a thermoplastic layer of a laminate. The method also includes displacing the liquefied portion of the thermoplastic layer. The method further includes cutting a wafer from the laminate. In some such implementations, liquefying the at least the portion of the thermoplastic layer of the laminate may include heating the at least the portion of a thermoplastic layer of the laminate. Additionally, or alternatively, cutting the wafer may include cutting the laminate to define an outer edge of the wafer. 
     In some such implementations of the present methods, cutting the wafer may occurs subsequent to displacing the liquefied portion of the thermoplastic layer. Additionally, or alternatively, displacing the liquefied portion of the thermoplastic layer may include compressing the portion of the thermoplastic layer of the laminate. In some implementations, compressing the portion of the thermoplastic layer of the laminate may displace the liquefied portion in a direction outward from a center of the wafer. 
     In some such implementations of the present methods, the method further includes sealing a sidewall of the wafer. Additionally, or alternatively, cutting the wafer from the laminate may occur prior to liquefying the at least the portion of a thermoplastic layer of the laminate. In some implementations, the method may also include thermoforming the wafer, and placing the thermoformed wafer into a mold cavity to form an optical article. 
     In some of the foregoing implementations of the present apparatuses (e.g., wafers of an optical article), a wafer includes a laminate. The laminate includes a first layer and a second layer. The first layer includes a first matrix material having a lower surface and an upper surface opposite the lower surface. The second layer includes a second matrix material and the second layer is coupled to the first layer and covers at least a portion of the lower surface or the upper surface. A first thickness at a central portion of the first layer that is greater than a second thickness at an edge portion of the first layer. In some such implementations, a glass transition temperature of the first matrix material may be lower than a glass transition temperature of the second matrix material. Additionally, or alternatively, the first matrix material may include a thermoplastic polyurethane (TPU) resin material. 
     In some such implementations of the present apparatuses, the second layer covers at least a portion of the lower surface. Additionally, or alternatively, the laminate may further include a third layer having a third matrix material. For example, the third layer may be coupled to the first layer and cover at least a portion of the upper surface. In some implementations, the second matrix material, the third matrix material, or both the second and third matric materials include polycarbonate. 
     In some of the foregoing implementations of the present systems (e.g. for forming an optical wafer), a system includes an imprinting apparatus configured to imprint an outline of a wafer on a laminate sheet. The imprinting apparatus includes a sealing band configured to heat and compress an edge portion of a wafer. The system further includes a cutting apparatus configured to cut the wafer from the laminate sheet. In some such implementations, the sealing band may define an angled surface that is configured to direct a portion of a thermoplastic layer of the wafer from the edge portion of the wafer. 
     In some such implementations of the present systems, the sealing band is configured to define an annular imprint in the laminate sheet. The annular imprint may have a first diameter. Additionally, or alternatively, the cutting apparatus may include a die cutter configured to cut through the laminate sheet at the annular imprint to define an edge surface of the wafer. 
     In some of the foregoing implementations of the present apparatuses (e.g., tools for sealing a wafer with a thermoplastic layer for use in an optical article), a tool includes a first insert and a second insert. The first insert includes a first inner surface configured to contact a first surface of a wafer. The first inner surface defines a first opening of a first cavity configured to receive a first portion of a wafer. The second inner surface is configured to contact a second surface of the wafer. The second inner surface defines a second opening of a second cavity configured to receive a second portion of a wafer. During a sealing operation, the first insert and the second insert are configured to: apply heat, pressure, or both to the wafer; and reduce a thickness of a layer of the wafer positioned between the first inner surface of the first insert and the second inner surface of the second insert. 
     In some such implementations of the present apparatuses, the first inner surface defines: a first sidewall having a first diameter; a second sidewall having a second diameter that is greater than the first diameter; and a ledge extends between the first sidewall and the second sidewall. Additionally, or alternatively, the second inner surface may define a third sidewall having a third diameter that is substantially equal to the first diameter. In some such implementations, the second insert may further include an outer surface that has a fourth diameter that is substantially equal to the second diameter. In some implementations, during the sealing operation: the first surface of the wafer is in contact with the ledge; and the first and second insert are configured to compress an outer edge portion of the wafer to reduce the thickness of the layer of the wafer at the outer edge portion. 
     As used herein, various terminology is for the purpose of describing particular implementations only and is not intended to be limiting of implementations. For example, as used herein, an ordinal term (e.g., “first,” “second,” “third,” etc.) used to modify an element, such as a structure, a component, an operation, etc., does not by itself indicate any priority or order of the element with respect to another element, but rather merely distinguishes the element from another element having a same name (but for use of the ordinal term). The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The term “substantially” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed implementations, the term “substantially” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent. 
     The term “about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range and includes the exact stated value or range. The term “substantially” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed implementation, the term “substantially” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, or 5 percent; and the term “approximately” may be substituted with “within 10 percent of” what is specified. The statement “substantially X to Y” has the same meaning as “substantially X to substantially Y,” unless indicated otherwise. Likewise, the statement “substantially X, Y, or substantially Z” has the same meaning as “substantially X, substantially Y, or substantially Z,” unless indicated otherwise. The phrase “and/or” means and or or. To illustrate, A, B, and/or C includes: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. In other words, “and/or” operates as an inclusive or. Additionally, the phrase “A, B, C, or a combination thereof” or “A, B, C, or any combination thereof” includes: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. 
     Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), and “include” (and any form of include, such as “includes” and “including”) are open-ended linking verbs. As a result, an apparatus that “comprises,” “has,” or “includes” one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, a method that “comprises,” “has,” or “includes” one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps. 
     Any implementation of any of the systems, methods, and article of manufacture can consist of or consist essentially of—rather than comprise/have/include—any of the described steps, elements, and/or features. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb. Additionally, the term “wherein” may be used interchangeably with “where”. Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described. The feature or features of one implementation may be applied to other implementations, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the implementations. 
     Some details associated with the implementations are described above, and others are described below. Other implementations, advantages, and features of the present disclosure will become apparent after review of the entire application, including the following sections: Brief Description of the Drawings, Detailed Description, and the Claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale (unless otherwise noted), meaning the sizes of the depicted elements are accurate relative to each other for at least the configuration depicted in the figures. 
         FIG. 1  is a diagram that illustrates an example of stages of a process of an optical system for manufacturing an optical article. 
         FIG. 2A  is another diagram that illustrates an example of a first process for producing a wafer used manufacturing an optical article. 
         FIG. 2B  an illustrative view of an example of a first tool that includes a cutting apparatus and an imprinting apparatus of the optical system. 
         FIG. 2C  an illustrative view of an example of a second tool that includes a cutting apparatus and an imprinting apparatus of the optical system. 
         FIG. 3A  is a cross-sectional view of various examples of an imprinting apparatus of the optical system. 
         FIG. 3B  is a cross-sectional view of various examples of a cutting apparatus of the optical system. 
         FIG. 4A  is another diagram that illustrates an example of a second process for producing a wafer used manufacturing an optical article. 
         FIG. 4B  is a perspective view of an example of a sealing apparatus of the optical system. 
         FIG. 4C  is a side cross-sectional view of the sealing apparatus of  FIG. 4B . 
         FIG. 5  is a flowchart illustrating an example of a method of forming a wafer of the optical system. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a diagram of illustrative stages of a system for manufacturing an optical article, such as an optical lens (e.g., a semi-finished (SF) lens product), is shown and generally designated  100 . System  100  may be configured to produce a non-contaminating optical wafer for use in manufacture of the optical article. 
     At a first stage  110 , a laminate  112  having one or more layers may be provided or formed. Each layer of laminate  112  may include a thermoplastic material consolidated (e.g., by pressure and/or temperature) to form a stack. As shown in  FIG. 1 , laminate  112  includes an inner layer  114  and one or more outer layers  116  that each cover at least a portion of the inner layer. For example, a first outer layer (e.g.,  116 ) may be disposed on a top surface of inner layer  114  and a second outer layer (e.g.,  118 ) may be disposed on a bottom surface of the inner layer. Inner layer  114  and outer layers  116 ,  118  may be coupled together in any suitable manner such as, for example, via an adhesive layer (e.g., through adhesive lamination, adhesive coating lamination, or the like), without an adhesive layer (e.g., extrusion lamination), or any other known process. 
     Inner layer  114  may include a first matrix material  115 . In some implementations, first matrix material  115  includes an optically functional thermoplastic elastomeric film such as, for example, a thermoplastic polyurethane (“TPU”) (e.g., amorphous TPU, Tecoflex EG85A, Tecoflex EG80A, Estane ALR E77A-V, Estane AG 8451, Estane VSN F5000, or the like), a semi-crystalline Polyether-block-polyamides (PEBA) (e.g., Pebax 5533, Pebax 4533, Pebax 4033, Pellethane 80A or the like), a soft adhesive layer, or any other thermoplastic elastomeric material. In some implementations, one or more additives may be included within matrix material  115 . For example, an optical additive and/or a process additive (e.g., photochromic dye, tint dye, dye absorbers of selective wavelengths, electrochromic dyes, stabilizers, flow modifiers, and/or the like) can be blended with matrix material  115  to produce an optically functional film (e.g., inner layer  114 ). 
     Outer layers  116 ,  118  may include a second matrix material  117 . In some implementations, second matrix material  117  includes a transparent polycarbonate film (e.g., Lexan PC, and/or the like). Second matrix material  117  may have a higher glass transition temperature (or melt temperature) than first matrix material  115 . In some implementations, a thickness of outer layers  116  may be greater than thickness of inner layer  114  to prevent defects from forming during wafer formation; however, in other implementations, inner layer  114  and outer layers  116 ,  118  may be sized and shaped in any suitable manner. Although outer layers  116 ,  118  are described a both having the second matrix material  117 , in other implementations, one of the outer layers  116 ,  118  includes second matrix material and the other of the outer layers  116 ,  118  includes a third matrix material that is different from the second matrix material. 
     Laminate  112  from first stage  110  is provided to a second stage  120  indicated by arrow  119 . At second stage  120 , laminate  112  is positioned relative to a tool  122 . Tool  122  may be configured to remove (e.g., cut) and/or seal a portion of laminate  112 . For example, tool  122  may be configured to cut a circular or oval shaped disk from laminate  112  that forms a wafer  130 . 
     Tool  122  includes a cutting apparatus  124  and an imprinting apparatus  126 . In some implementations, tool  122  may include a uniform body that includes cutting apparatus  124  and imprinting apparatus  126  coupled thereto, while in other implementations, the tool may include multiple district components that include or correspond to cutting apparatus  124  and imprinting apparatus  126 . For example, tool  122  may include roller (e.g., a cylindrical roller), a planar die, a belt, or other suitable arrangement known in the art. 
     Cutting apparatus  124  may use heat, chemicals, force (e.g., cutting edge), or any suitable means to remove wafer  130  from laminate  112 . For example, cutting apparatus  124  may include a cutting die (e.g., knife die, blanking die,) that cuts an outline pattern (e.g., die pattern) of wafer  130 . For example, cutting apparatus  124  may include a plurality of circular die cutters having a sharp edge configured to cut a plurality of wafers (e.g.,  130 ) from laminate  112 . 
     Imprinting apparatus  126  is configured to seal (e.g., via heat and pressure) a portion of laminate  112  and/or wafer  130 . To illustrate, imprinting apparatus  126  may apply heat and pressure to one or more circular or ring portions of laminate  112  such that at least a portion of one of the layer (e.g., inner layer  114 ) is displaced. For example, imprinting apparatus  126  (e.g., heated blunt die) may apply pressure to heated laminate  112  and imprint a shallow annular impression in the laminate sheet to displace a portion of inner layer  114 . Imprinting apparatus  126  may generate heat at a temperature greater than a glass transition temperature (e.g., melt point) of inner layer  114  and apply pressure to laminate  112  to displace a portion of the inner layer. In this way, wafer  130  may include a reduced thickness of a center TPU layer (e.g.,  114 ) around an outer edge of the wafer. In some such some implementation, imprinting apparatus  126  may generate heat at a temperature less than a glass transition temperature (e.g., melt point) of outer layers  116  such that only a portion of inner layer  114  is displaced by the imprinting apparatus. For example, imprinting apparatus  126  may include a plurality of circular hot bands having a dull edge configured to compress a circular portion of wafers (e.g.,  130 ) or laminate  112 . In some implementations, imprinting apparatus  126  (e.g., dull edge) may be shaped to direct the portion of inner layer  114  in a desired direction (as described further with reference to  FIG. 3C ). 
     In some implementations of system  100 , imprinting apparatus  126  and cutting apparatus  124  cooperate to form wafer  130 . To illustrate, imprinting apparatus  126  may apply heat and pressure to one or more circular portions of laminate  112  and cutting apparatus  124  may then cut the circular portion(s) to produce a wafer (e.g.,  130 ), as described further herein at least with reference to  FIG. 2A . Alternatively, cutting apparatus  124  may cut one or more circular portions of laminate  112  to produce wafer  130  and imprinting apparatus  126  may then apply heat and pressure to an outer edge of each wafer  130  to seal an elastomeric layer (e.g., inner layer  114 ), as described further herein at least with reference to  FIG. 4A . 
     In some implementations, system  100  includes a control device  128 , such as a processor and a memory (e.g., a storage device). For example, control device  128  may be coupled to or included in tool  122 . Control device  128  (e.g., memory) may be configured to store model data, such as two or three dimensional model data of wafer  130  or optical article  102 . For example, model data may include outline data that corresponds to an outline of a wafer  130  that is to be cut from laminate  112 . In this way, tool  122  may be configured receive model data corresponding to a desired shape of wafer  130  and interact with laminate  112  to form the wafer, or a plurality of wafers, according to the model data. 
     Laminate  112  from second stage  120  may be formed into one or more wafers  130  provided to a third stage  140  as indicated by an arrow  139 . At third stage  140 , an illustrative example of wafer  130  is shown. 
     Wafer  130  may include a top surface  132  (e.g., a first surface), a bottom surface  134  (e.g., a second surface) and an outer wall  136 . Outer wall  136  may extend between top surface  132  and bottom surface  134  of wafer  130 . In some implementations, outer wall  136  may intersect with top and bottom surfaces to define a periphery of wafer  130 . In some implementations, top surface  132  and bottom surface  134  include or correspond to the top surface and the bottom surface of laminate  112 , respectively. For example, wafer  130  may include the same layup (e.g., inner layer  114  and one or more outer layers  116 ) as described above with reference to laminate  112 . To illustrate, inner layer  114  may include a lower surface  137  and an upper surface  138  opposite the lower surface. In such implementations, a first outer layer (e.g.,  116 ) is coupled to lower surface  137  of inner layer  114  and a second outer layer (e.g.,  118 ) is coupled to upper surface  138  of the inner layer. Wafer  130  may be a flat circular disc, however wafer  130  may be sized/shaped in any suitable manner (e.g., elliptical, oval, or otherwise rounded disc) for manufacture of a suitable optical article. 
     In some implementations, wafer  130  includes a central portion  142  and an outer edge portion  144 . Outer edge portion  144  may correspond to a portion of laminate  112  that is contacted by imprinting apparatus  126 , at second stage  120 . For example, wafer  130  includes an imprint  146  (e.g., a recessed portion) at outer edge portion  144 . In some implementations, outer edge portion  144  includes outer wall  136  that defines a periphery of wafer  130 . Outer edge portion  144  may surround and cooperate with central portion  142  to define wafer  130 . For example, outer edge portion  144  and central portion  142  may be concentric portions of wafer  130  with outer edge portion surrounding the central portion. In some implementations, each layer (e.g.,  114 ,  116 ,  118 ) may include a central portion (e.g.,  142 ) and an outer edge portion (e.g.,  144 ) that correspond to the central portion and outer edge portion, respectively, of wafer  130 . 
     In the depicted implementation, central portion  142  includes a first thickness D1 measured from top surface  132  to bottom surface  134  along a straight line that is substantially orthogonal to top and bottom surfaces. Additionally, outer edge portion  144  includes a second thickness D2 measured from top surface  132  to bottom surface  134  along a straight line that is substantially orthogonal to top and bottom surfaces. In some implementations, first thickness D1 of central portion  142  of wafer  130  is greater than second thickness D2 of edge portion  144  of the wafer. For example, first thickness D1 is greater than second thickness D2 by a distance that is greater than or equal to any of, or between any two of, the following: 0.01, 0.02, 0.03, 0.04, and 0.05, 0.06 or more millimeters (mm). 
     In some implementations, a thickness of at least one of the layers (e.g.,  114 ,  116 ,  118 ) of wafer  130  at outer edge portion  144  is less than a thickness of the least one layer at the central portion. For example, as imprinting apparatus  126  may heat wafer  130 , matrix material  115  of inner layer  114  may be changed into a viscous state and, upon application of pressure, the matrix material subjected to the pressure is displaced, reducing the thickness of a portion (e.g., imprint  146 ) of inner layer  114 . To illustrate, inner layer  114  may include a third thickness D3 measured from a top surface (e.g.,  138 ) to a bottom surface (e.g.,  137 ) of inner layer  114  along a straight line (e.g., orthogonal to surface  132 ) at central portion  142  and a fourth thickness D4 measured from the top surface to the bottom surface of the inner layer along a straight line at outer edge portion  144 . At third stage  140 , fourth thickness D4 may correspond to a height of wafer  130  at imprint  146 . In this manner, a thickness of inner layer  114  at outer wall  136  (e.g., D4) may be less than or equal to such that edge bleed (e.g., oozing) of wafer  130  may be reduced or eliminated during formation of the optical article, as described further herein with reference to stage  160 . In some implementations, the outer layers of wafer  130  may be, but need not be, pressed together such that at least a portion a first outer layer (e.g.,  116 ) may contact a portion of a second outer layer (e.g.,  118 ). 
     Wafer  130  from third stage  140  is provided to a fourth stage  150  as indicated by an arrow  149 . At fourth stage  150 , wafer  130  may be provided to thermoform equipment  151  (e.g., a thermoform chamber) and thermoformed to from a concave wafer  152  that is configured to fit within a mold insert (e.g.,  154 ,  156 ). For example, wafer  130  may be thermoformed (e.g., via heat and pressure) to a semi-spherical dome shape suitable for use in making optical lenses. In some implementations, wafer  130  may be thermoformed to generate a thermoformed wafer  152  having a concave side and convex side similar to that of optical article  102 . To illustrate, thermoformed wafer  152  may be shaped to include or correspond to a desired lens diameter (e.g., between 60 mm and 100 mm), a desired base curve of the lens or base curve of the mold insert  154  (e.g., between 0.25 and 8.50). Wafer  152  includes the same layup as wafer  130 . For example, inner layer (e.g.,  114 ) of wafer  152  may have a thickness at outer wall  136  that is less than or equal to a thickness of inner layer at a center of wafer  152 . In this way, edge defects (e.g., buckling, crease formation, out-of-plane deformation, or the like) at outer wall  136  may be prevented as wafer  130  is heated and shaped to form wafer  152 . 
     Wafer  130  (e.g., thermoformed wafer  152 ) from fourth stage  150  is provided to a fifth stage  160  as indicated by an arrow  159 . At fifth stage  160 , wafer  152  may be disposed within a mold device  161 . Mold device may include a mold inserts  154 ,  156  and a mold block  164 . To further illustrate, wafer  152  may be disposed within mold inserts  154 ,  156  and the mold inserts are subsequently coupled to mold block  164 . For example, mold inserts  154 ,  156  are disposed within a space defined by a sidewall  166  of mold block  164 . Mold inserts  154 ,  156  may be sized and shaped such that when they are coupled together, the inserts cooperate to define a cavity  162  that corresponds to a desired shape of optical article  102 . In some implementations, sidewall  166  of mold block  164  may cooperate with mold inserts  154 ,  156  to define a portion of cavity  162 . For example, mold insert  156  may include a convex, concave, or plano surface and mold insert  154  may include a convex, concave, or plano surface having a same, similar, larger or smaller, base curve (e.g., radius of curvature) that define opposing surfaces of a cavity  162 . 
     As shown, moldable material  158  is injected onto the wafer  152  while wafer  152  is positioned within cavity  162 . Moldable material  148  may include a transparent or semi-transparent thermoplastic material, such as polycarbonate, thermoplastic urethane, polyacrylate, polyester, copolyester, polymethacrylate, poly(methyl methacrylate), polystyrene, polyamide, polysulfone, polyphenylsulfone, polyetherimide, polypentene, polyolefin, ionomer, ethylene methacrylic acid, cyclic olefin copolymer, acrylonitrile, styrene maleic anhydride, a copolymer thereof, or a derivative or mixture thereof. Moldable material  158  (e.g., matrix material) may be heated, into a liquid form, and injected onto wafer  152 . For example, moldable material  158  is injected at a high temperature (up to 300 C) and high pressure (500-30,000 psi) so that the moldable material takes the form of cavity  162  and can then be cooled to solidify. During cooling, moldable material  158  fuses to wafer  152  to form a semi-finished optical article (e.g.,  102 ). Injection of moldable material  158  onto wafer  152  may cause one of the layers (e.g.,  114 ,  116 ) of the wafer to transform into a low viscous (e.g., liquid) state. For example, moldable material  158  may be injected at a temperature that is much greater than a glass transition temperature of at least one layer (e.g., thermoplastic elastomeric layer) of wafer  152 . Specifically, the molten material (e.g.,  158 ) injected into cavity  162  may be injected at a temperature that is greater than the glass transition of matrix material  115  of inner layer  114  such that the inner layer becomes fluid (e.g., a low viscous liquid) and is capable of flowing out under pressure (i.e., oozing out) from wafer  152  onto a surface that defines cavity  162  or between an outer side surface of inserts (e.g.,  154 ,  156 ) and the walls of the mold block. 
     In the implementations shown, the reduced thickness of inner layer  114  at outer wall  136  (e.g., D4) prevents matrix material  115  from bleeding out from the outer wall of wafer  152 . For example, the thickness D4 of inner layer  114  at outer edge portion  144  limits and/or prevents movement of inner layer  114  at outer wall  136 . In this manner, matrix material  115  may be prevented from oozing from wafer  152  or may be slowed such that moldable material  158  is able to contact outer wall  136  before matrix material oozes from the wafer. As a result, moldable material  158  may reach outer wall  136  and encapsulate any liquefied material that oozes out from inner layer  114  of wafer  152  to prevent the liquefied material from contaminating the mold inserts  154 ,  156  the mold block  164 , and/or the space between outer side surfaces of the inserts and sidewall  166 . Accordingly, wafer  152  may reduce or eliminate contamination of one or more components (e.g., mold insert  154 , mold receiver  156 ) of system  100 , thus allowing easy removal of inserts from the mold block and otherwise decreasing manufacturing time of optical article. 
     Wafer  152  and moldable material  158  are provided to a sixth stage  170  as indicated by an arrow  169 . At sixth stage  170 , wafer  152  and moldable material  158  are removed from cavity  162  after solidifying. In some implementations, one or more finishing processes may, but need not be, performed on to wafer  152  and moldable material  158  to form optical article  102 . For example, in some implementations, optical article  102  may be subjected to a finishing process, such as, for example, coating, stamping, printing, grinding, polishing, buffing, etching, edging, machining, or another process may occur to produce a finished optical article. As shown, wafer  142  and moldable material  156  are post processed (e.g., edged) to form a shaped lens, however, in other implementations, article  102  will contain a similar shape as cavity  154  (e.g., rounded). As wafer  152  did not contaminate mold inserts  154 ,  156  or mold block  164 , the inserts may be easily removed from the mold block and a second wafer (e.g.,  152 ) may be placed within cavity  162  and a second optical article (e.g.,  102 ) may be formed without cleaning. 
     In some implementations, control device  128  includes a processor  127  and memory  129 . Memory  129  may include read only memory (ROM) devices (e.g., programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), optical storage, or the like), random-access memory (RAM) devices (e.g., synchronous RAM (SRAM), dynamic RAM (DRAM), synchronous dynamic RAM (SDRAM), or the like), one or more HDDs, flash memory devices, SSDs, other devices configured to store data in a persistent or non-persistent state, or a combination of different memory devices. Memory  129  may store instructions that, when executed by processor  127 , cause processor  127  to perform, initiate, and/or control the operations described herein. Although described as including processor  127 , in other implementations, control device  128  can include application specific integrated circuits (ASIC), field-programmable gate arrays (FPGA), very large scale integrated (VLSI) circuits, or other circuitry. Additionally, control device  128  may include an interface, such as a wired interface or a wireless interface, to enable communication with one or more components of system  100 . Control device  128  may also include a user interface to enable a user to control operations of system  100 . 
     Control device  128  may be configured to control operations of one or more components of system  100 . For example, control device  128  may control one or more of cutting apparatus  124  and/or imprinting apparatus  126 , such as by setting temperatures or pressures applied by cutting apparatus  124  and/or imprinting apparatus  126 . As another example, control device  128  may control operation of one or more actuators (not shown) to cause movement (e.g., translation, rotation, and/or the like) of laminate  112 , cutting apparatus  124 , and/or imprinting apparatus  126 . In this way, tool  122 , or components thereof, may be operated to engage with laminate  112  to produce wafer  130 . 
     Although described as a single control device (e.g., a single processor), in other implementations, control device  128  may include multiple devices or processors (e.g., a processor system) that perform the control operations. For example, control device  128  may be a distributed system with multiple processors that each perform some of the control operations described herein. To further illustrate, a first device or processor may control operation of cutting apparatus  124  and a second device or processor may control operation of imprinting apparatus  126 . 
     In some implementations, system  100  may include wafer  130 ,  152  for producing optical article  102 . In some implementations, wafer  130 ,  152  includes laminate  112  having first layer  114  and second layer  116 . In such implementations, first layer  114  includes first matrix material  115  having a first surface (e.g., lower surface  137 ) and a second surface (e.g., an upper surface  138 ) opposite the first surface. First matrix material (e.g.,  115 ) may include a thermoplastic polyurethane (TPU) resin material. In some such implementations, second layer  116  includes second matrix material  117 , and the second layer is coupled to the first layer and covers at least a portion of the first surface or the second surface. A first thickness (D3) at a central portion  142  of first layer  114  is greater than a second thickness (D4) at edge portion  144  of first layer  114 . 
     In some implementations, a glass transition temperature of first matrix material  115  is lower than a glass transition temperature of second matrix material  117 . In some such implementations, laminate  112  may include third layer  118  which includes a third matrix material. The second matrix material and the third matric material may include the same material or may include different materials. Second layer  116  may cover at least a portion of the first surface (e.g.,  137 ) of first layer  114 . Additionally, third layer  118  may be coupled to first layer  114  and cover at least a portion of the second surface (e.g.,  138 ). 
     In some of the foregoing implementations, system  100  may be operable for forming optical wafer  102 . For example, system  100  may include imprinting apparatus  126  configured to imprint an outline of wafer  130  on laminate sheet  112  and cutting apparatus  124  configured to cut a wafer from laminate sheet  112 . In some such implementations, imprinting apparatus  126  includes a sealing band configured to heat and compress edge portion  144  of wafer  130 . For example, the sealing band may define an angled surface configured to direct a portion of thermoplastic layer  114  of wafer  130  from edge portion  144  of wafer  130 . In some implementations, the sealing band is configured to define annular imprint  146  in laminate sheet  112 , and cutting apparatus  124  includes a die cutter configured to cut through laminate sheet  112  at annular imprint  146  to define edge surface  136  of wafer  130 . 
     As another example, in some implementations, system  100  may be configured such that cutting apparatus  124  is configured to cut the wafer from the laminate sheet  112 . In such implementations, imprinting apparatus  126  (or another tool) is configured to imprint an outline of wafer  130  to form a recessed portion of the wafer. 
     Some of the foregoing implementations include a tool  122  for sealing a wafer with a thermoplastic layer for use in an optical article. In some implementations, tool  122  includes imprinting apparatus  126  having a first insert and second insert operable during a sealing operation to apply heat, pressure, or both to wafer  130  and reduce a thickness (D4) of layer  114  of the wafer positioned between the first insert and the second insert. 
     Thus, system  100  may include tool  122  that engages laminate  112  to form a wafer (e.g.,  130 ) to reduce or eliminate edge bleed. Tool  122  may include a cutting apparatus  124  and/or imprinting apparatus  126  to reduce a thickness of at least one thermoplastic layer of laminate at an outer edge portion (e.g.,  144 ) to prevent contamination during the manufacture of an optical article. Tool  122  may enable mass production of wafers with minimized edge bleed to enable a scalable system for prevention of edge bleeding from thermoplastic based optically functional laminate wafers and subsequent contamination of the mold cavity without sacrificing the cosmetic appearance of the lenses. 
     Referring now to  FIG. 2A-2D , aspects for producing an optical wafer—for use in manufacture of an optical article—by a first process are shown. For example,  FIG. 2A  shows a illustrative diagram of a system  200  for producing a wafer  230  used manufacturing an optical article,  FIG. 2B  shows an illustrative view of a tool that includes a cutting apparatus  224  and an imprinting apparatus  226 , FIG. C are cross-sectional views of various examples of imprinting apparatus  226 , and  FIG. 2D  are cross-sectional views of various examples of cutting apparatus  224 . System  200  may include or correspond to system  100 . Additionally, wafer  230  may include or correspond to wafer  130 . 
     As shown in  FIG. 2A , at a first stage  210 , laminate  212  is positioned relative to imprinting apparatus  226 . Laminate may include an inner layer  214  having a first matrix material  215  that is disposed between two outer layers  216 ,  218  having a second matrix material  217 . Laminate  212 , inner layer  214 , and outer layers  216 ,  218  may include or correspond to laminate  112 , inner layer  114 , and outer layers  116 ,  118 , respectively. For example, inner layer  214  may include a lower surface  237  and an upper surface  238 . Although outer layers  216 ,  218  are described a both having the second matrix material  217 , in other implementations, one of the outer layers  216 ,  218  includes second matrix material and the other of the outer layers  216 ,  218  includes a third matrix material that is different from the second matrix material. 
     As depicted at first stage  210 , laminate  212  may be disposed between opposing components of imprinting apparatus  226 . However, in in other implementations, imprinting apparatus may be positioned either above or below laminate  212  to produce the annular imprints. Imprinting apparatus  226  may include one or more protrusions  260  configured to interact (e.g., via heat and pressure) with laminate  212  to reduce a thickness of a portion (e.g.,  244 ) inner layer  214 . Each protrusion  260  may be shaped based on the desired characteristics of wafer  230 . For example, each protrusion  260  may include a surface having a dull edge  262  that is configured to contact laminate  212 . Protrusions  260  may be heated and left in contact with laminate  212  for a sufficient time and/or temperature to reduce the viscosity of the center TPU layer (e.g.,  214 ) so that it will flow when compressed. To illustrate, imprinting apparatus  226  may, but need not, include a plurality of annular hot bands (e.g.,  260 ) configured to apply heat and pressure to laminate  212  to create a plurality of annular imprints (e.g.,  246 ) within the laminate. In this way, each protrusion  260  may liquefy a layer (e.g., inner layer  214 ) of laminate  112  and disperse a portion of the liquefied layer to create a seal within laminate  112 . As used herein, annular is not necessarily limited to a circle, but may include another geometry or shape. In some implementations, each protrusion  260  may be sized and shaped in any suitable manner such that imprint  246  corresponds to a diameter of a desired wafer (e.g.,  230 ). For example, the protrusions  260  may be any suitable shape, such as polygonal (e.g., square, rectangular, hexagonal, octagonal, and/or the like), circular, elliptical, an irregular shape, a combination thereof, and/or the like. 
     Laminate  212  (having imprints) from first stage  110  is provided to a second stage  220  as indicated by arrow  219 . At second stage  220 , laminate  212  is positioned relative to cutting apparatus  224  configured to remove (e.g., cut) one or more wafers  230  from laminate  212 . Wafer  230  may include or correspond to wafer  130 , and may include a top surface  232 , a bottom surface  234 , an outer wall  236 , a central portion  242  and an outer edge portion  244  that include or correspond to top surface  132 , bottom surface  134 , outer wall  136 , central portion  142  and outer edge portion  144 , respectively. In some implementations, laminate  212  from first stage  110  may be moved from imprinting apparatus toward cutting apparatus  224  at second stage  220  or, alternatively, laminate  212  may remain stationary after interacting with the imprinting apparatus and cutting apparatus may be moved relative to the laminate at second stage  220 . 
     Cutting apparatus  224  may include one or more protrusions  270  configured to interact with laminate  212  to remove a portion (e.g., wafer  230 ) of the laminate. In some implementations, protrusions  270  may include a surface (e.g., annular surface) having a sharp edge  272 . In some implementations, each protrusions  270  may include a diameter that is substantially equal to the diameter of the protrusion (e.g.,  260 ) of imprinting apparatus. For example, a width of protrusions  260  may be greater than or equal to a width of protrusions  270  to create imprints  246  with sufficient width to allow sharp edge  272  to cut through this region and leave outer wall  236  of wafer  230  with little-to-no TPU film. The shape of protrusions  260  and protrusions  270  may include any geometry (e.g., circular, oval, square, rectangular, triangular) and may, but need not, include a pattern along the inside or outside of its circumference to form one or more structural features of wafer  230  such as, for example, a tab, a spur, a notch, combination thereof, or the like. 
     In some implementations, cutting apparatus  224  may include a plurality of annular die cutters configured to apply force to laminate  212  to remove (e.g., cut) wafer  230  from laminate  212 . Accordingly, laminate  212  may be aligned with cutting apparatus  224  such that sharp edge  272  of each protrusion  270  cuts the laminate at imprint  246 . In this way, wafer  230  is formed having a thickness (D2) at outer edge portion  244  that is less than a thickness (D1) at central portion  242 . As a result, edge bleed (e.g., oozing) of wafer  230  may be reduced or eliminated during a thermoforming or injection molding process to form the optical article. In some implementations, one or more other process may be used to seal outer wall  236  of wafer  230  to further prevent edge bleed. For example, system  200  may include heating outer edge portion  244  to a temperature that is greater than or equal to the temperature of imprinting apparatus  226 , ultrasonic welding may be used to seal the top and bottom polycarbonate films (e.g.,  116 ) at outer wall of wafer  230 , or the like. 
     Referring now to  FIGS. 2B and 2C , illustrative examples of a tool  222   a - b  that includes cutting apparatus  224  and imprinting apparatus  226  is shown. To illustrate,  FIG. 2A  shows a first example of a tool  222   a  that is a flat tool (e.g., a planar/stamp tool) and  FIG. 2B  shows a second example of a tool  222   b  that is a roller. Tool  222   a - b  may be used in a continuous roll-to-roll web or roll-to-plate process to form wafer  230 . Tool  222   a - b  may include or correspond to tool  122 . 
     As shown in  FIG. 2B , tool  222   a  includes a plate  225  that is coupled to, or includes, cutting apparatus  224  and imprinting apparatus  226 . In some implementations, plate  225  may include a planar surface that can be any suitable geometry (e.g., circular, oval, square, rectangular, triangular). For example, plate  225  may include a first row of a plurality of heated blunt dies (e.g.,  260 ) positioned along a length of the plate and a second row of a plurality of die cutters (e.g.,  270 ) positioned along the length of the plate. A length and/or width of plate  225  may be substantially equal to a length or width of laminate  212  and can be pressed into laminate  212  to create a plurality of imprints using heated blunt dies (e.g.,  260 ) and then further pressed to cut laminate  212  at the plurality of imprints using die cutters (e.g.,  270 ). Laminate  212  or plate  225  may be moved each time plate  225  is pressed into laminate  212  to enable a portion of laminate  212  previously imprinted by the first row of heated blunt dies (e.g.,  260 ) to be aligned with the second row of die cutters (e.g.,  270 ). In this way, plate  225  allows imprinting apparatus  226  and cutting apparatus  224  to contact the same portion of laminate  212  during wafer formation. Although plate  225  is shown having a single row for imprinting and a single row for cutting, plate  225  may include a plurality of respective imprinting and cutting rows to increase the manufacturing time of wafer  230 . Additionally, or alternatively, although cutting apparatus  224  and imprinting apparatus  226  are disposed on a single plate (e.g.,  225 ), in other implementations, tool  222   a  may include multiple plates (e.g.,  225 ) each having a cutting apparatus (e.g.,  224 ) and/or an imprinting apparatus (e.g.,  226 ). In the foregoing implementations, wafers formed using plate  225  may include a thickness (e.g., D4 of inner layer  114 ) at outer edge portion  244  that is less than a thickness (e.g., D3 of inner layer  114 ) at central portion  242  to reduce or eliminate edge bleed. 
     As shown in  FIG. 2C , tool  222   b  includes a cylindrical roller  223  that is coupled to, or includes, cutting apparatus  224  and imprinting apparatus  226 . For example, roller  223  may include a first row of a plurality of heated blunt dies (e.g.,  260 ) positioned along a length of the roller and a second row of a plurality of die cutters (e.g.,  270 ) positioned along the length of the roller. Roller  223  may be sized to span a width or a length of laminate  212  and can be rolled along the laminate to create a plurality of imprints using heated blunt dies (e.g.,  260 ) and then further rolled along the laminate to cut the laminate at the plurality of imprints using die cutters (e.g.,  270 ). As shown, cutting apparatus  224  and imprinting apparatus  226  are disposed on a single roller (e.g.,  223 ). In such implementations, the diameter of roller  223 , the spacing between first row and second row, size of heated blunt dies (e.g.,  260 ) and die cutters (e.g.,  270 ), the number of wafers to be formed, or other factors may be optimized to allow imprinting apparatus  226  and cutting apparatus  224  may contact the same portion of laminate  212 . In other implementations, tool  222   b  may include multiple cylindrical rollers (e.g.,  223 ). In this way, a first roller may include or correspond to cutting apparatus  224  and a second roller may include or correspond to imprinting apparatus  226  and first and second roller may be rolled independently across laminate  212  to form wafers (e.g.,  230 ). In the foregoing implementations, wafers formed using roller tool  222   b  may include a thickness (e.g., D4 of inner layer  114 ) at outer edge portion  244  that is less than a thickness (e.g., D3 of inner layer  114 ) at central portion  242  to reduce or eliminate edge bleed. With either tool  222   a - b , imprinting apparatus  126  is in contact with laminate  212  for a sufficient time at a sufficient temperature for the heat to reduce the viscosity of the center TPU layer (e.g.,  114 ) so that it will flow when compressed. 
     In some implementations, system  200  may include wafer  230  for producing an optical article (e.g.,  102 ). In some implementations, wafer  230  includes laminate  212  having first layer  214  and second layer  216 . In such implementations, first layer  214  includes first matrix material  215  having lower surface  237  and upper surface  238  opposite lower surface  237 . In some such implementations, second layer  216  includes second matrix material  217 , and second layer  216  is coupled to first layer  214  and covers at least a portion of lower surface  237  or upper surface  238 . In some of the foregoing implementations, a first thickness (e.g., D3) at a central portion  242  of first layer  214  (of wafer  230 ) is greater than a second thickness (e.g., D4) at an edge portion  244  of first layer  214 . In some implementations, a glass transition temperature of first matrix material  215  is lower than a glass transition temperature of second matrix material  217 . In some such implementations, first matrix material  215  includes a thermoplastic polyurethane (TPU) resin material. Laminate  212  includes a third layer  218  having a third matrix material which may be the same as or different from second matrix material  217 . In such implementations, second layer  216  covers at least a portion of lower surface  237  of first layer  214 , and third layer  218  is coupled to first layer  214  and covers at least a portion of upper surface  238 . 
     In some of the foregoing implementations, system  200  may be operable for forming an optical wafer. In such implementations, system  200  includes imprinting apparatus  226  configured to imprint an outline of a wafer (e.g.,  230 ) on laminate sheet  212  and cutting apparatus  224  configured to cut wafer  230  from laminate sheet  212 . In some such implementations, imprinting apparatus  226  includes a sealing band (e.g.,  260 ) configured to heat and compress an edge portion (e.g.,  244 ) of the wafer. The sealing band  260  may define an angled surface configured to direct a portion of a thermoplastic layer (e.g.,  214 ) of the wafer from the edge portion (e.g.,  144 ) of the wafer. In some implementations, the sealing band  260  is configured to define annular imprint  246  in laminate sheet  212 , and cutting apparatus  224  includes a die cutter  270  configured to cut through laminate sheet  212  at annular imprint  246  to define edge surface  236  of wafer  230 . 
     Referring now to  FIGS. 3A and 3B , cross-sectional views of one or more components of an imprinting apparatus and a cutting apparatus are shown. For example,  FIG. 3A  shows a sectional views of protrusions  360   a - d  of the imprinting apparatus having different dull edges  362   a - d  (e.g., pressing edges), and  FIG. 3B  shows a sectional view of protrusions  370   a - c  of the cutting apparatus having different sharp edges  372   a - c  (e.g., cutting edges). Imprinting apparatus and cutting apparatus may include or correspond to imprinting apparatus  226 ,  126  and cutting apparatus  224 ,  124 , respectively. 
     Imprinting apparatus is configured to engage a portion of a laminate to apply heat and/or pressure to reduce a thickness (e.g., D2) of the portion of the laminate. For example, imprinting apparatus may contact the laminate (e.g.,  112 ,  212 ) for a sufficient time and at a sufficient pressure and/or temperature to reduce the viscosity of a center TPU layer (e.g.,  114 ) and displace a portion of the center TPU layer where the imprinting apparatus contacts the laminate. In some implementations, imprinting apparatus may include one or more protrusions  360   a - d  configured to contact the laminate. Each protrusion  360   a - d  may include an annular body  364  that includes a corresponding dull edge  362   a - d  that is configured to contact a layer of the laminate without piercing the layer. In some implementations, dull edges  362   a - d  may include or correspond to a bottom surface of a corresponding annular body  364   a - d . While depicted in conjunction with annular body  364   a - d , each of dull edge  362   a - d  may be coupled to any other suitable component of imprinting apparatus with similar functionality. 
     As shown in  FIG. 3A , protrusion  360   a  includes a dull edge  362   a  that corresponds to a planar bottom surface of annular body  364   a . In other implementations, a dull edge may extend from a bottom surface of an annular body to guide a molten layer inside the laminate when contacted by the protrusion. To illustrate, protrusion  360   b  includes an annular body  364   b  that has a dull edge  362   b  that is rounded and extends from a bottom surface of the annular body. In this way, dull edge (e.g.,  362   b ) may apply force to the laminate without piercing an outer layer of the laminate. As shown, dull edge  362   a ,  362   b  is symmetrical to evenly distribute a viscous layer of the laminate. However, in other implementations, dull edge (e.g.,  362   c ,  362   d ) is asymmetrical to direct a molten layer in a certain direction. For example, protrusion  360   c  includes an annular body  364   c  having a dull edge  362   c  that is angled toward an outer surface of annular body  364   c  to guide a molten layer away from a center of protrusion  360   c . Dull edge  362   c  includes a straight portion that is angled away from protrusion  360   c , while in other implementations, a protrusion  360   d  includes an annular body  364   d  having a dull edge  362   d  that is curved toward an outer surface of annular body  364   d . In this way, the shape of dull edge (e.g.,  362   c - d ) can be designed such that a TPU layer flows away from a center of a wafer and the excess TPU ends up in a residual (e.g., scrap) portion of the laminate. 
     Referring now to  FIG. 3B , a sectional view of protrusions  370   a - c  of the cutting apparatus having different sharp edges  372   a - c  are shown. Each protrusion  370   a - c  may include a corresponding annular body  374   a - c  and a corresponding sharp edge  372   a - c  that is configured to cut through at least a portion of a laminate. Each sharp edge  372   a - c  may be sized such that a contact point of the sharp edge provides sufficient pressure to pierce the laminate. For example, protrusion  370   a  may include an annular body  374   a  having a sharp edge  372   a  that extends from a bottom surface of annular body  374   a . Sharp edge  372   a  is symmetrical to cut a portion of the laminate. However, in other implementations, sharp edge  372   b ,  372   c  may be asymmetrical to achieve a particular purpose such as, for example, creating angled wafers, cutting through specific multi-layer laminate constructions (e.g., sort, hard, or combination), or other suitable purpose known in the art. For example, protrusion  370   b  includes an annular body  374   b  having a sharp edge  372   b  that is angled relative to the bottom surface of annular body  374   b , and protrusion  370   c  includes an annular body  374   c  having a sharp edge  372   c  that is angled toward an outer surface of annular body  374   c . While depicted in conjunction with annular body  374   a - c , sharp edges  372   a - c  may be coupled to any other suitable component of cutting apparatus with similar functionality. 
     Referring now to  FIG. 4A-4C , aspects of producing an optical wafer—for use in manufacture of an optical article—by a second process is shown. For example,  FIG. 4A  shows an illustrative diagram of a system  400  for producing a wafer  430  used in manufacturing an optical article (e.g.,  102 ),  FIG. 2B  shows a perspective view of an example of an imprinting apparatus  426  used in system  400 , and  FIG. 4C  shows a cross-sectional view of imprinting apparatus  426  in use with a wafer  430 . 
     As shown in  FIG. 4A , at a first stage  410 , laminate  412  is positioned relative to a cutting apparatus  424  of tool (e.g.,  120 ). Laminate may include an inner layer  414  having a first matrix material  415  that is disposed between two outer layers  416 ,  418  having a second matrix material  417 . Although outer layers  416 ,  418  are described a both having the second matrix material  417 , in other implementations, one of the outer layers  416 ,  418  includes second matrix material and the other of the outer layers  416 ,  418  includes a third matrix material that is different from the second matrix material  417 . Laminate  412 , inner layer  414 , and outer layers  416  may include or correspond to laminate  112 ,  212 , inner layer  114 ,  214 , and outer layers  116 ,  118 , respectively. Inner layer  414  may include a lower surface  437  and an upper surface  438 . 
     As depicted at first stage  410 , laminate  412  may be disposed between opposing components of cutting apparatus  424 . However, in in other implementations, cutting apparatus  424  may be positioned either above or below laminate  412 . Cutting apparatus  424  may include one or more protrusions  470  configured to interact with laminate  412  to remove a portion (e.g., wafer  430 ) of the laminate. In some implementations, protrusions  470  may include a surface (e.g., annular surface) having a sharp edge  472  configured to pierce laminate  412  to remove one or more wafers  430  from the laminate. For example, protrusions  470  may include or correspond to cutting apparatus  124  and/or protrusion  370   a - c.    
     Wafer  430  may include or correspond to wafer  130 , and may include a top surface  432 , a bottom surface  434 , an outer wall  436 , a central portion  442  and an outer edge portion  444  that include or correspond to top surface  132 , bottom surface  134 , outer wall  136 , central portion  142  and outer edge portion  144 , respectively. As shown at first stage  410 , wafers  430  produced by cutting apparatus  424  are circular, but may be any suitable geometry, such as polygonal (e.g., square, rectangular, hexagonal, octagonal, and/or the like), circular, elliptical, an irregular shape, a combination thereof, and/or the like. 
     Wafers  430  from first stage  410  are provided to a second stage  420  indicated by arrow  419 . At second stage  420 , laminate  112  is positioned relative to an imprinting apparatus  426  that is configured to interact (e.g., via heat and pressure) with wafer  230  to reduce a thickness of a portion (e.g., outer edge portion  444 ) of the wafer. In some implementations, wafers  430  from first stage  410  may be moved from cutting apparatus  424  toward imprinting apparatus  426  at second stage  420  or, alternatively, wafers  430  may remain stationary after interacting with the cutting apparatus  424  and imprinting apparatus  426  may be moved relative to the wafers at second stage  420 . 
     Imprinting apparatus  426  may be positioned above laminate  412 , below the laminate, or both to produce imprints  446  on wafer  430 . Imprinting apparatus  426  may be heated and left in contact with wafer  430  for a sufficient time, pressure, and/or temperature to reduce the viscosity of a center TPU layer (e.g.,  114 ) so that it will flow when compressed. For example, imprinting apparatus  426  may include one or more protrusions  460  having a dull edge  462  that is configured to contact laminate  412  to reduce a thickness of a portion (e.g.,  244 ) inner layer  214 . Protrusions  460  may include or correspond to imprinting apparatus  426  and/or protrusions  360   a - d . Each protrusion  260  may be shaped based on the desired characteristics of wafer  230 . In this way, imprinting apparatus  426  may apply pressure to outer edge portion  444  of wafer  430  to decrease a thickness of the center TPU layer (e.g.,  114 ) to create a seal at outer wall  436  of the wafer. As a result, edge bleed (e.g., oozing) of wafer  230  may be reduced or eliminated during a subsequent thermoforming or injection molding process. In some implementations, one or more other process may be used to seal outer wall  436  of wafer  430  to further prevent edge bleed. For example, system  400  may include heating outer edge portion  444  to a temperature that is greater than or equal to the temperature of imprinting apparatus  426 , ultrasonic welding may be used to seal the top and bottom polycarbonate films (e.g.,  416 ) at outer wall of wafer  430 , or the like. 
     Referring now to  FIGS. 4B and 4C , views of an example of imprinting apparatus  426  are shown. To illustrate,  FIG. 4B  shows a perspective view of imprinting apparatus  426  and  FIG. 4C  shows a cross-sectional view of imprinting apparatus  426 . As shown, imprinting apparatus  426  is configured to engage a single wafer (e.g.,  430 ), however, it should be understood that imprinting apparatus  426  may be configured to seal a plurality of wafers (e.g.,  430 ) to facilitate efficient manufacture of the wafers. 
     Imprinting apparatus  426  may include a first insert  480  and a second insert  490  configured to cooperate to seal wafer  430 . First insert  480  may be configured to receive a first portion of wafer  430  (e.g., from cutting apparatus  424 ) and second insert  490  may be configured to receive a second portion of the wafer. In this way, first and second inserts  480 ,  490  may engage wafer  430  to decrease a thickness of at least one layer (e.g.,  414 ) of wafer  430  to prevent edge bleed during subsequent manufacturing processes. 
     First insert  480  includes a first inner surface  481  that defines a cavity  482  configured to receive a portion of wafer  430 . As shown, first inner surface  481  includes a base  483 , a first sidewall  484 , a second sidewall  486 , and a ledge  485  (e.g., a surface) that extends between the first sidewall and the second sidewall. First sidewall  484  corresponds to a first diameter D5 and extends from base  483  to define a first portion of cavity  482 . Second sidewall  486  corresponds to a second diameter D6 that is greater than first diameter D5 to form ledge  485  that extends laterally between first and second sidewalls  484 ,  486 . In some implementations, second sidewall  486  defines a second portion of cavity  482  that defines an opening of the cavity  482 . In some implementations, first diameter D5 is less than a diameter of wafer  430  so that an outer surface (e.g.,  132 ,  134 ) of the wafer contacts ledge  485  while the wafer is disposed within cavity  482 . Accordingly, ledge  485  (in conjunction with surface  499  of second insert  490 ) may apply pressure to wafer  430  at outer edge portion  444  of bottom surface  134  to reduce a thickness of at least one layer of the wafer at the outer edge portion  444 . 
     Second insert  490  includes a second inner surface  491  and an outer surface  495 . Second inner surface  491  includes a base  493  and a third sidewall  494  that cooperate to define a second cavity  492  configured to receive a second portion of wafer  430 . Third sidewall  494  may extends away from base  493  and define an opening of cavity  492 . In some implementations, third sidewall  494  corresponds to a third diameter D7 that may be, but need not be, equal to or substantially equal to first diameter D5. Outer surface  495  corresponds to a fourth diameter D8 that is greater than first diameter D5 and third diameter D7, and is less than second diameter D6. Accordingly, second insert  490  is able to be disposed within the portion of cavity  482  defined by second sidewall  486  and may apply pressure to wafer  430  at outer edge portion  444  of top surface  132  to reduce a thickness of at least one layer of the wafer at the outer edge portion  444 . In this manner, first insert  480  and second insert  490  may be positionable to seal a central TPU layer (e.g.,  114 ) and prevent edge bleed during subsequent manufacturing processes. 
     In some implementations, system  400  may include a wafer (e.g.,  130 ,  430 ) for producing an optical article ( 102 ). In some implementations, the wafer (e.g.,  430 ) includes a laminate  412  having a first layer (e.g.,  414 ) and a second layer (e.g.,  416 ). In such implementations, first layer includes first matrix material  415  having lower surface  437  and upper surface  438  opposite the lower surface  437 . In some such implementations, second layer (e.g.,  416 ) includes second matrix material  417 , and the second layer is coupled to the first layer and covers at least a portion of lower surface  437  or upper surface  438 . In some of the foregoing implementations, a first thickness (e.g., D3) at a central portion (e.g.,  442 ) of the first layer (e.g.,  414 ) that is greater than a second thickness (e.g., D4) at an edge portion (e.g.,  444 ) of the first layer. In some implementations, a glass transition temperature of first matrix material  415  is lower than a glass transition temperature of second matrix material  417 . In some such implementations, first matrix material  415  includes a thermoplastic polyurethane (TPU) resin material. Laminate  412  includes a third layer (e.g.,  418 ) having a third matrix material. In such implementations, second layer (e.g.,  416 ) covers at least a portion of lower surface  437  of first layer (e.g.,  414 ) and third layer (e.g.,  418 ) is coupled to the first layer (e.g.,  414 ) and covers at least a portion of upper surface  438 . 
     In some of the foregoing implementations, system  400  may be operable for forming an optical wafer (e.g.,  102 ). In such implementations, system  400  includes cutting apparatus  424  configured to cut a wafer (e.g.,  430 ) from laminate  412 , such as a laminate sheet, and imprinting apparatus  426  configured to imprint the wafer. In some such implementations, imprinting apparatus  426  includes a sealing band (e.g.,  260 ,  362   a - d ,  460 ) configured to heat and compress an edge portion (e.g.,  444 ) of the wafer. The sealing band may define an angled surface configured to direct a portion of a thermoplastic layer (e.g.,  414 ) of the wafer from the edge portion (e.g.,  144 ) of the wafer. 
     In some implementations, system  400  includes a tool (e.g.  426 ) configured to seal a wafer with a thermoplastic layer for use in an optical article (e.g.,  102 ). Tool (e.g.,  426 ) includes first insert  480  including first inner surface  481  configured to contact a first surface (e.g.,  432 ) of a wafer (e.g.,  430 ). First inner surface defines a first opening of a first cavity (e.g.,  482 ) configured to receive a first portion of a wafer. Tool (e.g.,  426 ) includes second insert  490  having second inner surface  491  configured to contact a second surface (e.g.,  434 ) of the wafer (e.g.,  430 ). Second inner surface  491  defines a second opening of a second cavity (e.g.,  492 ) configured to receive a second portion of a wafer. In some such implementations, during a sealing operation, first insert  480  and second insert  490  are configured to apply heat, pressure, or both to the wafer and reduce a thickness of a layer (e.g.,  114 ) of the wafer (e.g.,  430 ) positioned between first inner surface  481  of first insert  480  and second inner surface  491  of second insert  490 . In some of the foregoing implementations, first inner surface  481  defines or includes first sidewall  484  corresponding to a first diameter (e.g., D5) and second sidewall  486  corresponding to second diameter (e.g., D6) that is greater than the first diameter. In some implementations, ledge  485  (e.g., a surface) extends between first sidewall  484  and second sidewall  486 . In some implementations, second inner surface  491  defines or includes third sidewall  494  corresponding to a third diameter (e.g., D7) that is substantially equal to the first diameter (e.g., D5). Second insert  490  further includes outer surface  495  that corresponds to a fourth diameter (e.g., D8) that is substantially equal to the second diameter (e.g., D7). In some implementations, during the sealing operation, first surface  432  of the wafer is in contact with ledge  485  and the first and second inserts  480 ,  490  are configured to compress an outer edge portion (e.g.,  444 ) of the wafer (e.g.,  430 ) to reduce the thickness of the layer of the wafer at the outer edge portion. 
     Referring to  FIG. 5 , an example of a method of forming one or more wafers is shown. Method  500  may be performed by one or more components as described with reference to  FIG. 1, 2A-2C, 3A, 3B , or  4 A- 4 C. For example, method  500  may be performed by one or more components of systems  100 ,  200 ,  400 . 
     Method  500  includes liquefying at least a portion of a thermoplastic layer of a laminate, at  502 . Laminate may include or correspond to laminate  112 ,  212 ,  412 . For example, the liquefied portion of the thermoplastic layer may include or correspond to inner layer  114 ,  214 ,  414 . In some implementations, an imprinting apparatus ( 126 ,  226 ,  426 ) may be utilized to liquefy the portion of the thermoplastic layer. In some implementations, liquefying the at least the portion of the thermoplastic layer of the laminate includes heating the at least the portion of a thermoplastic layer of the laminate. Additionally, or alternatively, liquefying the at least the portion of the thermoplastic layer of the laminate includes applying pressure to the at least the portion of a thermoplastic layer of the laminate. 
     Method  500  further includes displacing the liquefied portion of the thermoplastic layer, at  504 . For example, an imprinting apparatus may apply pressure to an annular portion of the laminate to displace the liquefied portion of inner layer ( 114 ,  214 ,  414 ) to reduce a thickness of the laminate at the annular portion. 
     Method  500  also includes cutting a wafer from the laminate, at  506 . Wafer may include or correspond to wafer  130 ,  230 ,  430 . In some implementations, a cutting apparatus ( 124 ,  224 ,  424 ) may be utilized to cut a wafer from the laminate. To illustrate, cutting apparatus ( 124 ,  224 ,  424 ) may apply a force to an annular portion of the laminate to produce the wafer from the laminate. In some implementations, cutting the wafer from the laminae may be performed subsequent to or prior to liquefying and/or displacing. To illustrate, some implementations, cutting the wafer includes cutting the laminate to define an outer edge of the wafer. 
     In some of the foregoing implementations, displacing the liquefied portion of the thermoplastic layer includes compressing the portion of the thermoplastic layer of the laminate. In some such implementations, compressing the portion of the thermoplastic layer of the laminate displaces the liquefied portion in a direction outward from a center of the wafer. 
     In some implementations of method  500 , cutting the wafer occurs subsequent to displacing the liquefied portion of the thermoplastic layer. However, in other implementations of method  500 , displacing the liquefied portion of the thermoplastic layer occurs subsequent to cutting the wafer. Some of the foregoing methods include a step of sealing a sidewall of the wafer. Some methods may include thermoforming the wafer and, in some such methods, placing the thermoformed wafer into a mold cavity to form an optical article. 
     Thus, method  500  may produce a wafer that may reduce or eliminate edge bleed. Method  500  may liquefy a portion of a thermoplastic layer of a laminate and displace the liquefied portion of the thermoplastic layer to form a wafer having a reduced thickness of the thermoplastic layer of laminate at an outer edge portion to prevent contamination during the manufacture of an optical article. Method  500  may enable mass production of wafers with minimized edge bleed to enable a scalable system for prevention of edge bleeding from thermoplastic based optically functional laminate wafers and subsequent contamination of the mold cavity without sacrificing the cosmetic appearance of the lenses. 
     The above specification and examples provide a complete description of the structure and use of illustrative configurations. Although certain configurations have been described above with a certain degree of particularity, or with reference to one or more individual configurations, those skilled in the art could make numerous alterations to the disclosed configurations without departing from the scope of this disclosure. As such, the various illustrative configurations of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and configurations other than the one shown may include some or all of the features of the depicted configurations. For example, elements may be omitted or combined as a unitary structure, connections may be substituted, or both. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one configuration or may relate to several configurations. Accordingly, no single implementation described herein should be construed as limiting and implementations of the disclosure may be suitably combined without departing from the teachings of the disclosure. 
     The previous description of the disclosed implementations is provided to enable a person skilled in the art to make or use the disclosed implementations. Various modifications to these implementations will be readily apparent to those skilled in the art, and the principles defined herein may be applied to other implementations without departing from the scope of the disclosure. Thus, the present disclosure is not intended to be limited to the implementations shown herein but is to be accorded the widest scope possible consistent with the principles and novel features as defined by the following claims. The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.