Lens for displaying a virtual image
A lens for projecting a virtual image comprising first and second body sections coupled along first and second surfaces to form an internal interface within the lens, and a reflective coating on at least a portion of either the first surface or the second surface configured to redirect light projected into the second body section toward an eye of a wearer. Another lens comprising first and second body sections having different indices of refraction, and an interface configured to redirect light toward an eye of a wearer for display as a virtual image. A method for manufacturing a lens comprising providing a first body section, casting on a first surface of the first body section a material for forming a second body section, and curing the material to form the second body section and bond it to the first body section to form a unitary lens.
1. A method for manufacturing a lens blank, the method comprising:
providing a first body section having a first surface and an opposing surface, the opposing surface defining a front surface of the lens blank;
casting, on the first surface of the first body section, a material for forming a second body section; and
curing the material to form the second body section and bond it to the first body section to form the lens blank with a unitary body.
2. A method as set forth in claim 1 , wherein the first body section is formed of glass, acrylate, urethane, or polycarbonate.
3. A method as set forth in claim 1 , wherein the first surface is shaped to manipulate image light in a manner that produces a virtual image in a field of vision of the wearer of a lens formed from the lens blank.
4. A method as set forth in claim 1 , wherein the second body section is formed of glass, acrylate, urethane, or polycarbonate.
5. A method as set forth in claim 1 , wherein the second body section has substantially the same index of refraction as the first body section.
6. A method as set forth in claim 1 , wherein the second body section has a substantially different index of refraction as the first body section.
7. A method as set forth in claim 1 , wherein the step of casting includes positioning a mold opposite the first surface of the first body section and introducing, into a cavity between the mold and the first surface of the first body section, a material from which the second body section is formed.
8. A method as set forth in claim 1 , wherein the step of curing includes at least one of exposing the material to heat and exposing the material to ultraviolet or other wavelengths of light.
9. A method as set forth in claim 1 , further including the step of applying a coupling material on the first surface of the first body section.
10. A method as set forth in claim 9 , wherein the coupling material facilitates bonding of the second body section to the first body section.
11. A method as set forth in claim 1 , further including the step of coating at least a portion of the first surface with a reflective material.
12. A method as set forth in claim 11 , wherein the reflective material includes one of silver, nickel, aluminum, chromium, titanium, various dielectric stack materials including metal oxides, glass or other suitable materials to create a surface which reflect a significant amount of light.
13. A method as set forth in claim 11 , wherein the coating of reflective material is transparent or translucent.
14. A method as set forth in claim 11 , wherein the step of coating includes coating less than the entirety of the first surface with the reflective material.
15. A method as set forth in claim 11 , wherein the reflective surface is shaped to manipulate the image light in a manner that produces a virtual image in a field of vision of the wearer of a lens formed from the lens blank.
16. A method as set forth in claim 11 , further including the step of applying a protective material over the reflective material.
17. A method as set forth in claim 16 , wherein the protective material protects the reflective coating from reacting with reagents in the material from which the second body section is formed.
18. A method as set forth in claim 11 , further including applying a prism thinning technique to one or both of the first and second body sections to reduce a thickness of the lens blank without disturbing the reflective material or interface formed by the coupling of the first and second surfaces.