Patent Description:
Large microstructure arrays have been designed for ophthalmic lens products. Ophthalmic lens products are typically comprised of a lens and a film, and the film is typically laminated on an optical surface of the lens. The optical surface of the ophthalmic lenses is usually spherical. However, when transforming microstructure arrays on the optical surface to a film surface, the microstructure arrays deform since the film is a planar surface before being applied to the lens.

The foregoing "Background" description is for the purpose of generally presenting the context of the disclosure. Work of the inventors, to the extent it is described in this background section, as well as aspects of the description which may not otherwise qualify as prior art at the time of filing, are neither expressly or impliedly admitted as prior art against the present disclosure. Document <CIT> describes a bonding method of a resin mold and a roll-to-roll continuous mold composition.

The present disclosure relates to a method of designing a spherical microstructure mold module to be incorporated into a calendering roller for generating a microstructure on a film.

According to an embodiment, the present disclosure further relates to a method of designing a spherical microstructure mold module to be incorporated into a calendering roller for generating a microstructure on a planar surface, comprising calculating a first curvature on a cross-sectional planar surface for a first microstructure point of the spherical microstructure mold module, calculating a second curvature of a spherical surface of the spherical microstructure mold module, measuring a radius of the spherical surface, the radius being from the center of the spherical surface to the first microstructure point, and determining a location of the microstructure on the planar surface, the location being derived from the first curvature, the second curvature, and the radius, wherein the first curvature is between a first line and a second line on the cross-sectional planar surface, the first curvature being a longitude of the first microstructure point on the spherical microstructure mold module, the second curvature is between a third line and a fourth line on the spherical surface, the second curvature being a latitude of the first microstructure point on the spherical microstructure mold module.

According to an embodiment, the present disclosure further relates to a method of calendering one or more microstructure arrays on a film, comprising extruding a thermoplastic film between a first roller and a second roller, and embossing one or more microstructure arrays on the thermoplastic film by the second roller, the second roller having one or more individual microstructure mold modules, each microstructure mold module of the one or more individual microstructure mold modules corresponding to a microstructure array of the one or more microstructure arrays, wherein the first roller and the second roller are controlled to reach a predetermined temperature and a predetermined pressure, the first roller including a smooth cylinder, the second roller including a cylinder and the one or more individual microstructure mold modules being on the cylinder.

According to an embodiment that does not fall within the scope of the claims, the present disclosure further relates to a roller structure, comprising a roller structure including a cylinder, at least one spherical microstructure mold module attached to the cylinder, and at least one microstructure mold array disposed on a spherical surface of a respective one of the at least one spherical microstructure mold module, wherein the at least one microstructure array being applied to form microstructure arrays on a thermoplastic film contacting the roller structure, wherein the spherical microstructure mold module includes one or more microstructure molds, and the microstructure arrays are designed to be disposed on a spherical ophthalmic lens surface.

According to an embodiment that does not fall within the scope of the claims, the present disclosure further relates to a film for disposing microstructures on an optical film of an ophthalmic lens, comprising one or more microstructure arrays on the optical film, the one or more microstructure arrays on the optical film being formed by a roller, wherein the roller includes one or more individual microstructure mold modules, each of the one or more individual microstructure mold modules corresponding to a respective one of the one or more microstructure arrays on the optical film, and wherein a location of each microstructure in the one or more microstructure arrays is determined based on curvatures and a radius of the optical film of the ophthalmic lens.

The terms "a" or "an", as used herein, are defined as one or more than one. The term "plurality", as used herein, is defined as two or more than two. The term "another", as used herein, is defined as at least a second or more. The terms "including" and/or "having", as used herein, are defined as comprising (i.e., open language). Reference throughout this document to "one embodiment", "certain embodiments", "an embodiment", "an implementation", ''an example" or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.

The terms "about" and "approximately" are defined as being close to as understood by one of ordinary skill in the art.

The process of the present disclosure can "comprise," "consist essentially of," or "consist of' particular ingredients, components, compositions, etc., disclosed throughout the specification.

According to an embodiment, the present disclosure describes a method of transforming microstructure array designed for a spherical surface, e.g., an ophthalmic surface, with different optical designs, to a planar surface, e.g., a calendering roller surface. For instance, this method can be used to transform the microstructure array design from the ophthalmic surface to the calendering roller surface. Accordingly, the time and cost associated with designing microstructure arrays specifically for the spherical surface or the planar surface can be reduced.

According to an embodiment, the present disclosure describes a method of designing a spherical microstructure mold module to be incorporated into a calendering roller for generating a microstructure on a planar surface. For instance, the method of designing a spherical microstructure mold module can be used for efficiently embossing microstructures on films with spherical surfaces by calendering rollers.

According to an embodiment, the present disclosure describes a method of calendering one or more microstructure arrays on a film. For instance, the method of calendering the one or more microstructure arrays on a film can be used for calendering microstructure arrays on an optical film of an ophthalmic lens with different optics and dimension, e.g., spherical and cylinder powers, e.g., single vision or progressive vision, aspherical or spherical, or other lens diameters.

According to an embodiment, the present disclosure describes a method of designing a calendering roller sleeve which is made of individual interchangeable modules with one or more microstructure design. Each single module can be assembled or removed, without affecting other modules. Accordingly, the time and cost associated with producing ophthalmic lenses with different microstructures, different optics, different dimension, can be reduced.

Turning now to the figures, a schematic illustration of transforming microstructure arrays from a spherical surface, e.g., an ophthalmic surface on an ophthalmic lens with different optical designs, to a planar surface, e.g., a calendering roller surface, will now be described with reference to <FIG>. The material of the ophthalmic lens may be polycarbonate (PC), polymethyl methacrylate (PMMA), polystyrene, polystyrene maleic anhydride, polyamide, thermoplastic urethane, thermoset polyurethane, polyester, copolyesters, polysulfone, cyclic olefin copolymers (OCO), polyphenyl oxide, allyl diglycol carbonate, polythiourethane, episulfur polymers, epoxy, poly(meth)acrylates, polythiomethacrylates, or combinations thereof. The material of the calendering roller surface may be thermoplastic materials, glass, metal, or combinations thereof. The material of the calendering roller surface may have materials with softening temperature and/ or glass-transition temperature between <NUM> and <NUM>.

According to an embodiment, the schematic illustration <NUM> depicts transforming the design of a microstructure array <NUM> on a spherical surface <NUM> to microstructure array <NUM> on a planar surface <NUM>. The microstructure array <NUM> is represented by all of the open circles on the spherical surface <NUM>. The microstructure array <NUM> may be a specific microstructure array design for a spherical surface <NUM> which will later be transformed to microstructure array <NUM> on the planar surface <NUM>. The microstructure array <NUM> is represented by all of the dotted circles on the planar surface <NUM>.

According to an embodiment, the microstructure array may include optical microstructures such as microgrooves, microprisms, microlenses, Fresnel microstructures array, diffractive structures, micro lens array, moth eye microstructure array, and the like. The microstructure array may have different shapes in the microstructure array, e.g., squares, circles, ellipses, triangles, or a combination thereof. The microstructure array may have one or more variables for the microstructure array, e.g., length, width, pitch, duty cycle of the microstructure array, etc. The microstructures may be disposed on surfaces of films and which are typically on the order of a hundredth of a millimeter in diameter to about <NUM> millimeter in diameter (<NUM> to <NUM>), and about <NUM> micron in height but may be between <NUM> and <NUM> in height.

In an embodiment, the spherical surface <NUM> may be a surface of an ophthalmic lens. The ophthalmic lens may contain film structures on the surface, e.g., a single-layer film structure, a multi-layer film structure, laminate, or a combination thereof. Accordingly, specific microstructure arrays may be designed only on specific film structures on the ophthalmic lens and may or may not be interchangeable.

According to an embodiment, the film structure may be a single-layer film structure comprising a photochromic dye, a blue light cut dye, a UV cut dye, an IR cut dye, or any other functional constituent.

According to an embodiment, the film structure may be a multi-layer film structure including at least one layer comprising a photochromic dye, a blue light cut dye, a UV cut dye, an IR cut dye, or any other functional constituent.

In an embodiment, the microstructures on the microstructure array <NUM> may be transformed from the spherical surface <NUM> to the planar surface <NUM> based on one or more parameters, e.g., radius, curvatures, locations, etc. The transformation will be described in more detail with reference to <FIG>.

In an embodiment, and with reference to <FIG>, transforming microstructures in a microstructure array from a spherical surface <NUM> to a planar surface <NUM> in <FIG> may be achieved as is illustrated in the schematic illustration <NUM>. For instance, a location of a microstructure point of the microstructure array <NUM> on the spherical surface <NUM>, which corresponds to a location of the microstructure point of the microstructure array <NUM> on the planar surface <NUM>, may be calculated using the various parameters in <FIG>. The parameters are described in more detail in the following paragraphs.

According to an embodiment, with reference to <FIG>, the spherical surface <NUM> and the planar surface <NUM> are illustrated in <FIG>. A cross-sectional planar surface <NUM> is also illustrated in <FIG>. In an embodiment, the cross-sectional planar surface <NUM> may be on a same surface as the microstructure point of the microstructure array <NUM>. The cross-sectional planar surface <NUM> may be parallel to the planar surface <NUM>. The cross-sectional planar surface <NUM> may be perpendicular to the line <NUM>, e.g., line <NUM> in <FIG>. Line <NUM> may be defined as zero degree latitude, e.g., <NUM> degree, of the spherical surface <NUM>.

According to an embodiment, a first curvature <NUM> in <FIG>, e.g., a first angle α, may be calculated between lines <NUM> and <NUM> on the cross-sectional planar surface <NUM>. The line <NUM>, e.g., line <NUM> in <FIG>, may be a projection line of a radius, e.g., line <NUM>, of the spherical surface <NUM> in <FIG>. The projection line <NUM> may be on the cross-sectional planar surface <NUM>. In an embodiment, the first curvature may be a longitude of microstructure point of the microstructure array <NUM> on the spherical surface <NUM>. The line <NUM>, e.g., line <NUM> in <FIG>, may be extended from a center of the cross-sectional planar surface <NUM> to an edge of the cross-sectional planar surface <NUM>. In an embodiment, the line <NUM> may be defined as zero degree longitude, e.g., <NUM> degree longitude, on the spherical surface <NUM>.

According to an embodiment, a second curvature <NUM> in <FIG>, e.g., a second angle β, may be calculated between lines <NUM> and <NUM>. The line <NUM>, e.g., line <NUM> in <FIG>, may be extended from a center of the spherical surface <NUM> to an edge of the spherical surface <NUM>. The edge of the spherical surface on the line <NUM> may be also on the planar surface <NUM>. The line <NUM> may be in contact with the planar surface <NUM>. The line <NUM> may be extended from a center of the spherical surface <NUM> to a bottom of the spherical surface <NUM> and the bottom of the spherical surface <NUM> may be on the planar surface <NUM>. The line <NUM> may be perpendicular to the planar surface <NUM>. In an embodiment, the line <NUM> may be defined as zero degree latitude, e.g., <NUM> degree latitude, of the spherical surface <NUM>. The second curvature <NUM> may be calculated as a latitude of the microstructure point of the microstructure array <NUM> on the spherical surface <NUM>.

According to an embodiment, the line <NUM> may be a radius, e.g., r in <FIG>, of the spherical surface <NUM>. The line <NUM>, e.g., line <NUM> in <FIG>, may be extended from a center of the spherical surface <NUM> to the microstructure point of the microstructure array <NUM>. In an embodiment, the radius r of the spherical surface <NUM> may be between <NUM> to <NUM>.

According to an embodiment, after calculating the location of the microstructure point of the microstructure array <NUM> on the spherical surface <NUM> corresponding to the location, e.g., p in <FIG>, of the microstructure point of the microstructure array <NUM> on the planar surface <NUM> by the parameters described above, e.g., the first curvature <NUM>, the second curvature <NUM>, and the radius <NUM>. In an embodiment, the location of the microstructure point of the microstructure array <NUM> can be described as (α, ρ). The location of the microstructure point of the microstructure array <NUM> on the planar surface <NUM> can be defined by the first curvature α and length ρ, e.g., <NUM>, can be calculated by the equation <NUM> as below. <MAT>
where ρ is the length of the microstructure point of the microstructure array <NUM> on the planar surface <NUM>, r is the radius <NUM> of the spherical surface <NUM>, and β is the second curvature <NUM>. In an embodiment, for instance, the location of the microstructure point of the microstructure array <NUM> on the planar surface <NUM> may have a first curvature α of <NUM> degree and a length ρ of <NUM>.

According to an embodiment, and with reference to <FIG>, a method <NUM> is a method of designing a spherical microstructure mold module to be incorporated into a calendering roller for generating a microstructure. The method <NUM> may be achieved by, first, at step <NUM>, calculating a first curvature on a cross-sectional planar surface. The first curvature <NUM> is described previously in <FIG>. The first curvature <NUM> may be between lines <NUM> and <NUM> in <FIG> on the cross-sectional planar surface <NUM>. The first curvature <NUM> may represent a longitude of the microstructure point of the microstructure array <NUM> on the spherical surface <NUM> in <FIG>. In an embodiment, each microstructure of the microstructure array may correspond to each individual microstructure mold module in the microstructure mold module.

According to an embodiment, secondly, at step <NUM> of method <NUM>, the method <NUM> is achieved by calculating a second curvature on a spherical surface. In an embodiment, the second curvature <NUM> may be an angle between the lines <NUM> and <NUM> in <FIG> on the spherical surface <NUM>. The second curvature <NUM> may represent a latitude of the microstructure point of the microstructure array <NUM> on the spherical surface <NUM> in <FIG>.

According to an embodiment, thirdly, at step <NUM> of method <NUM>, the method <NUM> is achieved by measuring a radius of a spherical surface. In an embodiment, the radius may be the line <NUM>, e.g., line <NUM> in <FIG>. The radius of the spherical surface <NUM> may be in a range of <NUM> to <NUM>.

According to an embodiment, and with reference to <FIG>, fourth, at step <NUM> of method <NUM>, the method <NUM> is achieved by determining a location of the microstructure on the planar surface. In an embodiment, the determination of the location is achieved by using the equation <NUM>, and parameters provided in steps <NUM>, <NUM>, and <NUM>. The order of the calculations in the steps <NUM>, <NUM>, and <NUM> may not need to be the same as in <FIG>. For instance, a second curvature may be calculated before a first curvature is calculated, or a radius of a spherical surface may be measured before the first and the second curvatures are calculated.

In an embodiment, and with reference to <FIG>, a top view of an individual microstructure mold module with a microstructure array on a spherical surface is illustrated. For instance, the microstructure array in the individual microstructure mold module in <FIG> may be the microstructure array <NUM> on the spherical surface <NUM> in <FIG>. In an embodiment, the microstructure array in the individual microstructure mold module in <FIG> may be one of the microstructure mold module in the spherical microstructure mold modules.

According to an embodiment, the microstructure array <NUM> in the individual microstructure mold module may include optical microstructures such as microgrooves, microprisms, microlenses, Fresnel microstructures array, diffractive structures, micro lens array, moth eye microstructure array, and the like. The microstructure array may have different shapes in the microstructure array, e.g., squares, circles, ellipses, triangles, or a combination thereof. The microstructure array may have one or more variables for the microstructure array, e.g., length, width, pitch, duty cycle of the microstructure array, etc. The microstructures may be disposed on surfaces of films and may be between <NUM> to <NUM> in diameter and <NUM> and <NUM> in height.

According to an embodiment, the spherical surface <NUM> in <FIG> may be a surface of ophthalmic lens. The lens may contain a single layer film structure, a multi-layer film structure, or laminate, etc..

In an embodiment, and with reference to <FIG>, a cross-sectional view of the individual microstructure mold module with a microstructure array design on the spherical surface is illustrated. The microstructure array design in <FIG> may be embossed on the spherical surface. The microstructure array design may include different microstructures, e.g., a square, a triangle, a circle, or a combination thereof. In an embodiment, the microstructures in the microstructure array may be between <NUM> to <NUM> in diameter and <NUM> and <NUM> in height.

In an embodiment, and with reference to <FIG>, one or more individual microstructure mold modules with different microstructure designs are illustrated. Each optical microstructure design may correspond to a specific individual microstructure mold module in the one or more individual microstructure mold modules. The different optical designs, e.g. sku1, sku2, sku3, sku4, sku5, sku6, skuN in the individual microstructure mold modules may be disposed on a film structure <NUM> to create microstructure mold module arrays. In an embodiment, the microstructure mold module array may be on a spherical surface or a planar surface. In some embodiments, the film structure <NUM> may be a single-layer film structure comprising optical sensitive materials, rubber, plastics, or a combination thereof. In some embodiments, the film structure may be a multi-layer film structure comprising one or more films, e.g., thermolplastic films, optical films, polymer films, or a combination thereof.

In an embodiment, and with reference to <FIG>, different optical designs of microstructures, e.g., individual microstructure mold modules, are illustrated on the calendering roller <NUM>. The calendering roller <NUM> may include a cylinder <NUM>, and different microstructure designs in the individual microstructure mold modules, e.g., microstructure mold module <NUM> with optical design sku1, microstructure mold module <NUM> with optical design sku2, microstructure mold module <NUM> with optical design sku3, microstructure mold module <NUM> with optical design sku4, microstructure mold module <NUM> with optical design sku5, microstructure mold module <NUM> with optical design sku6, etc..

According to an embodiment, each individual microstructure mold module of the individual microstructure mold modules, e.g., individual microstructure mold modules <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, may be attached to the cylinder <NUM> by one or more bonding methods. For example, the method may include bonding the individual microstructure mold modules on the cylinder <NUM> by a physical bonding method, e.g., using high pressure or high temperature. For another example, the method may include bonding the individual microstructure mold modules on the cylinder <NUM> by a chemical bonding method, e.g., using materials such as epoxy, glue, etc..

According to an embodiment, the microstructure array in the individual microstructure mold module may be designed to be disposed on a spherical surface. For instance, the microstructure array may be disposed on an ophthalmic lens surface.

According to an embodiment, the cylinder <NUM> may have a diameter between <NUM> and <NUM> and a length of between <NUM> and <NUM>. The cylinder <NUM> may be made by plastic, metal, glass, or a combination thereof.

In an embodiment, and with reference to <FIG>, a system <NUM> for film extrusion and microstructure embossment is illustrated. The system <NUM> includes one calendering roller <NUM> and one regular roller <NUM>. The calendering roller <NUM> is described in details in <FIG>. In an embodiment, the calendering roller <NUM> includes one or more individual microstructure mold modules <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, which are disposed on the cylinder <NUM> in <FIG>.

Accordingly to an embodiment, each microstructure mold module of the one or more individual microstructure mold modules may correspond to a microstructure array of the one or more microstructure arrays to be embossed on the film <NUM>. In addition, the microstructure array design in each microstructure mold module is different as described previously in <FIG>, e.g., sku1, sku2, sku3, sku4, sku5, and sku6.

In some embodiments, the calendering roller <NUM> may be replaced by a stamp. The stamp may be used for creating microstructures on a film.

In addition, the calendering roller <NUM> may be integrated with an injection molding machine to create microstructure arrays on surfaces, e.g., optical surface, plastic surface, or metal surface, etc..

According to an embodiment, the system <NUM> may include a film extrusion machine <NUM>. The film extrusion machine <NUM> may be a plastic film extrusion machine, or the like. In an embodiment, the film extrusion machine <NUM> may extrude a film <NUM> between the regular roller <NUM> and the calendering roller <NUM>. The film <NUM> may be a thermoplastic film, optical sensitive film, or the like.

According to an embodiment, microstructure arrays on the film <NUM> may be embossed by the one or more individual microstructure mold modules <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> using the calendering roller <NUM>. In an embodiment, the calendering roller <NUM> may be applied with a temperature with a certain range, e.g., <NUM> and <NUM>, before starting the process of embossing the one or more microstructure arrays on the film <NUM>. The regular roller <NUM> may be applied with a temperature with a certain range, e.g., <NUM> and <NUM>, before starting the process of embossing microstructure arrays on the film <NUM>.

According to an embodiment, the regular roller <NUM> may be a cylinder with or without any pattern. In an embodiment, the regular roller <NUM> may be a cylinder with a smooth surface. The cylinder of the regular roller <NUM> may be made by metal, plastic, or a combination thereof.

In an embodiment, and with reference to <FIG>, a product <NUM> including microstructure arrays <NUM> on a film <NUM> is illustrated. The microstructure arrays <NUM> on the film <NUM> are embossed by one or more individual microstructure mold modules <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> on the calendering roller <NUM>. In an embodiment, the film <NUM> with microstructure arrays <NUM> with different optical designs may be used as an optical film <NUM> of an ophthalmic lens. Each microstructure array of the one or more microstructure arrays <NUM> may correspond to a respective microstructure mold module of the one or more individual microstructure mold modules <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> on the optical film <NUM>.

According to an embodiment, the product <NUM> may further be integrated with an ink jet printing device, a stamping device, a lamination device, or an injection molding device, on any types of surfaces, e.g., surfaces of metal devices, surfaces of plastic devices, surfaces of glass devices, etc., where the ink can be absorbed.

According to an embodiment, a location of each microstructure mold module of the one or more individual microstructure mold modules <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may be determined based on the first curvature <NUM>, the second curvature <NUM>, and the radius r of the surface of the optical film of the ophthalmic lens. The determination is previously described in details in the paragraphs associated with <FIG>.

In an embodiment, and with reference to <FIG>, a method <NUM> of creating microstructure arrays on a film, e.g., a thermoplastic film, may be achieved by, first at step <NUM> of method <NUM>, extruding a thermoplastic film between a regular roller and a calendering roller. In an embodiment, the regular roller may be the roller <NUM> in <FIG> and the calendering roller may be the roller <NUM> in <FIG> and <FIG>.

According to an embodiment, after a thermoplastic film being extruded between rollers <NUM> and <NUM>, at step <NUM> of the method <NUM>, embossing one or more microstructure arrays on the thermoplastic film by the calendering roller <NUM>. In an embodiment, the structure <NUM> in <FIG> may be used to emboss the one or more microstructure arrays on the thermoplastic film.

Obviously, numerous modifications and variations are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.

Claim 1:
A method of designing a spherical microstructure mold module to be incorporated into a calendering roller for generating a microstructure on a planar surface (<NUM>), comprising:
calculating a first curvature (<NUM>) on a cross-sectional planar surface (<NUM>) for a first microstructure point of the spherical microstructure mold module;
calculating a second curvature (<NUM>) of a spherical surface (<NUM>) of the spherical microstructure mold module;
measuring a radius (<NUM>) of the spherical surface (<NUM>), the radius (<NUM>) being from the center of the spherical surface (<NUM>) to the first microstructure point; and
determining a location of the microstructure on the planar surface, the location being derived from the first curvature (<NUM>), the second curvature (<NUM>), and the radius (<NUM>).