IP Library › Patent Application 11682891
Patent Application
App. No. 11/682,891

METHOD OF MAKING AN ARBITRARY SURFACE OPTICAL ELEMENT

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Quick Facts
Patent No.
US None
App. No.
11/682,891
Abstract

An arbitrary surface optical element, such as a mirror for use in a rear projection television, includes a non-optical portion and an optical portion. The non-optical portion circumscribes the optical portion and has a thickness greater than the optical portion. Accordingly, the two portions cool at approximately the same rate, thereby minimizing warpage from differential cooling.

Claims (13)

1 . A method of forming an optical element, comprising:

molding a resin into a part with a mold, the part having a non-optical portion and an optical portion, the non-optical portion having a thickness greater than the optical portion;

cooling the part; and

applying thin film onto the part.

2 . The method of claim 1 , wherein the applying thin film includes applying one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter, via evaporation.

3 . The method of claim 1 , wherein the applying thin film includes applying one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter via lamination.

4 . The method of claim 3 , wherein the resin includes a thermoplastic material and wherein the lamination includes laminating a protective film to the part.

5 . The method of claim 4 , further comprising using a pressure sensitive or thermo set adhesive that has a higher melt temperature than either the film or part to ensure adhesion during the lamination.

6 . The method of claim 4 , wherein the lamination includes applying a protective coating to the reflective film.

7 . The method of claim 1 , wherein the molding includes using a mold that becomes part of the optical element.

8 . The method of claim 1 , wherein the molding includes applying vacuum from a first side of the mold and pressure from a second side of the mold.

9 . The method of claim 1 , wherein the non-optical portion includes at least one rib.

10 . The method of claim 1 , wherein the non-optical portion extends outward from the optical portion with a dimension that is at least about twice the thickness of the optical portion.