Wire grid polarizer and method of manufacture
View Patent ↗A polarizing optical article formed by selectively applying a conductive coating to a portion of a structured surface formed of a series of linear peaks and valleys.
1. A method for forming a polarizer comprising:
imparting a linear structure of peaks and valleys on a surface of a first portion of a polymeric optical article during molding of the polymeric optical article;
imparting a linear structure of peaks and valleys on a surface of a second portion of the polymeric optical article during molding of the polymeric optical article that is different from the linear structure of peaks and valleys on the surface of the first portion of the polymeric optical article; and
forming substantially distinct individual wires on the surface of the polymeric optical article by applying a conductive coating directly on to less than an entirety of the peaks of the linear structure of peaks and valleys of the first portion of the polymeric optical article and the second portion of the polymeric optical article;
providing the first portion of the polymeric optical article and the second portion of the polymeric optical article with different polarizing efficiencies relative to one another through said forming substantially distinct individual wires.
2. The method of claim 1 wherein imparting the linear structure of peaks and valleys on the surface of the first portion of the polymeric optical article comprises forming the linear structure on a front surface of the polymeric optical article.
3. The method of claim 1 wherein imparting the linear structure of peaks and valleys on the surface of the first portion of the polymeric optical article comprises imparting the linear structure during cast molding of the optical article.
4. The method of claim 1 wherein imparting the linear structure of peaks and valleys on the surface of the first portion of the polymeric optical article comprises forming a finished single vision optical lens.
5. The method of claim 1 wherein imparting the linear structure of peaks and valleys on the surface of the first portion of the polymeric optical article comprises molding the polymeric optical article with a film insert upon which the linear structure is formed.
6. The method of claim 1 wherein imparting the linear structure of peaks and valleys on the surface of the first portion of the polymeric optical article comprises imparting the linear structure during injection molding of the optical article.
7. The method of claim 1 wherein imparting the linear structure of peaks and valleys on the surface of the first portion of the polymeric optical article comprises imparting a series of peaks and valleys having a pitch in a range of 150 to 300 nanometers on the optical article.
8. The method of claim 1 wherein forming substantially distinct individual wires on the surface of the polymeric optical article comprises applying the conductive coating directly on to only a portion of a side of the peaks of the linear structure.
9. The method of claim 1 wherein forming substantially distinct individual wires on the surface of the polymeric optical article comprises applying the conductive coating from an angle relative to a best fit line through the surface of the optical article that is greater than zero and less than 90 degrees.
10. The method of claim 1 wherein forming substantially distinct individual wires on the surface of the polymeric optical article comprises applying a reflective conductive coating.
11. The method of claim 1 wherein forming substantially distinct individual wires on the surface of the polymeric optical article comprises applying a non-reflective conductive coating.
12. The method of claim 1 wherein forming substantially distinct individual wires on the surface of the polymeric optical article comprises applying a transparent conductive coating.
13. A method for forming a polarized ophthalmic article comprising:
forming a linear pattern of peaks and valleys on a surface of a first portion of a thin film;
forming a linear pattern of peaks and valleys on a surface of a second portion of the thin film;
applying a conductive coating directly on to a portion of the peaks of the linear pattern of peaks and valleys of the first portion and the second portion of the thin film;
forming a plurality of conductive wires across at least a portion of the peaks of the linear pattern of peaks and valleys of the first portion and the second portion of the thin film through said applying such that a polarizing efficiency of the first portion is different from a polarizing efficiency of the second portion; and
incorporating the thin film into an ophthalmic article during molding of the ophthalmic article.
14. The method of claim 13 wherein incorporating the thin film into an ophthalmic article during molding of the ophthalmic article comprises incorporating the thin film into an ophthalmic article during injection molding of the ophthalmic article.
15. The method of claim 13 wherein incorporating the thin film into an ophthalmic article during molding of the ophthalmic article comprises incorporating the thin film into an ophthalmic article during cast molding of the ophthalmic article.
16. A molded polarized ophthalmic lens comprising:
a polymeric lens having a convex optical surface, a concave optical surface, a first portion, and a second portion through which a lens user looks;
a substantially uniform linear series of peaks and valleys formed within the first portion of the polymeric lens;
a substantially uniform linear series of peaks and valleys formed within the second portion of the polymeric lens; and
a conductive coating applied directly on to less than an entirety of the peaks of the series of peaks and valleys of the first portion of the polymeric lens and the second portion of the polymeric lens so as to form conductive wires;
a polarizing efficiency of the first portion of the polymeric lens different from a polarizing efficiency of the second portion of the polymeric lens.
17. The lens of claim 16 wherein the substantially uniform linear series of peaks and valleys of the first portion of the polymeric lens and the second portion of the polymeric lens are formed on a surface of a thin film that is molded to the lens.
18. The lens of claim 16 wherein the conductive coating is applied to only a portion of a side of a peak of the substantially uniform linear series of peaks and valleys of the first portion of the polymeric lens and the second portion of the polymeric lens.