U.S. patent application number 13/024293 was filed with the patent office on 2011-08-11 for method and appartus for making retarder in stereoscopic glasses.
Invention is credited to Roger Wen-Yi Hsu.
Application Number | 20110193248 13/024293 |
Document ID | / |
Family ID | 44353065 |
Filed Date | 2011-08-11 |
United States Patent
Application |
20110193248 |
Kind Code |
A1 |
Hsu; Roger Wen-Yi |
August 11, 2011 |
Method and Appartus for Making Retarder in Stereoscopic Glasses
Abstract
A 3-D stereoscopic viewing lens which the retarder film is made
of a PVA film. A 3-D stereoscopic viewing lens having a linear
polarized film, one or more lens substrate layers, and an epoxy
layer. A process of making retarder film including mounting a PVA
film to an assembly line; wetting, cleaning, and washing the PVA
film through said assembly line; softening, expanding and
stretching the PVA film's x-axis through said assembly line; adding
gap filling agent to the PVA film; stretching the PVA film's y-axis
through a width frame holder and as a result transforming the PVA
film into a retarder film.
Inventors: |
Hsu; Roger Wen-Yi; (Rancho
Cucamonga, CA) |
Family ID: |
44353065 |
Appl. No.: |
13/024293 |
Filed: |
February 9, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61302553 |
Feb 9, 2010 |
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61313598 |
Mar 12, 2010 |
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61334856 |
May 14, 2010 |
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Current U.S.
Class: |
264/2.7 ;
359/463 |
Current CPC
Class: |
G02B 30/25 20200101;
B29D 11/00634 20130101; G02B 5/3083 20130101 |
Class at
Publication: |
264/2.7 ;
359/463 |
International
Class: |
B29D 11/00 20060101
B29D011/00; G02B 27/22 20060101 G02B027/22 |
Claims
1. A curved retarder for a 3-D stereoscopic viewing lens wherein
said retarder film is comprised of a PVA film wherein said retarder
film is made comprising the following steps: a. mounting a PVA film
to an assembly line; b. wetting, cleaning, and washing said PVA
film through said assembly line; c. softening, expanding and
stretching said PVA film's x-axis through said assembly line; d.
adding gap filling agent to said PVA film; e. stretching said PVA
film's y-axis through a width frame holder having an upper frame
and a lower frame wherein said upper frame closes onto said lower
frame whereby securing said PVA film wherein said width frame
holder extends along y-axis of said PVA film whereby transforming
said PVA film into a retarder film; f. mounting said retarder film
onto a multiple holding frame wherein said multiple holding frame
is comprised of an upper frame and a lower frame wherein said upper
frame closes onto said lower frame whereby securing said PVA film
from shrinking; g. pressing a convex mold onto said retarder film
to force said retarder film into a desired curved shape through one
or more openings of said multiple holding frame; h. heating said
retarder film to reduce said retarder film's moisture content; i.
drying said retarder film.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional
application Ser. No. 61/302,553 filed on Feb. 9, 2010, U.S.
provisional application Ser. No. 61/313,598 filed on Mar. 12, 2010,
U.S. provisional application Ser. No. 61/313,598 filed on Apr. 23,
2010, U.S. provisional application Ser. No. 61/334,856 filed on May
14, 2010, the disclosures of which are incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention entails a novel process of forming a
curved lens for improved 3-D perception of stereoscopic motion
pictures, whereby the curved lens shape is formed involving a
continuous stretch process of making the retarder film to prevent
distortion and defects due to forming the retarder in curved form.
The novel method allows for thinner stretching of PVA (organic
polyvinyl alcohol) and polymer to perfect the curve shape for
better matching between the lens and the user's eyes. Other
improvements include the ability for retarder optical device to be
laminated to the linear or circular polarizer without need for an
extra polymer sheet, thereby improving light transmission for 3-D
stereoscopic viewing, and for production of various specific
thicknesses of the retarder film to enhance viewing contrast.
BACKGROUND OF THE INVENTION
[0003] Stereoscopy, or three dimensional imaging, relates to any
technique that records three dimensional visual information and
creates an illusion of enhanced depth in a user's perceived image.
Traditional two dimensional images utilize human visual cues of
occlusion of one object by another, convergence of parallel edges,
change in size of textured patterns, haze, desaturation, shift to
bluishness, and subtended visual angle. Stereoscopy enhances the
illusion of depth in motion pictures, photographs, and other two
dimensional images by presenting slightly different images to each
eye, and thereby adding the human visual cue of stereopsis.
[0004] Glasses for viewing three dimensional images exist in two
categories: active and passive. Among active 3-D glasses are liquid
crystal shutter glasses and display glasses. Liquid crystal shutter
glasses contain liquid crystal that blocks or passes light through
synchronization with images on a computer display, using alternate
frame sequencing. Stereoscopic head-mounted displays include one
display per eye, which display a different perspective near each
eye, and are not used in conjunction with an external screen to be
viewed at distance. Examples of active 3-D glasses include Active
shutter glasses lens controlled by infrared (IR), radio frequency
(RF), DLP-LINK.RTM., BLUE-TOOTH.RTM. TRANSMITTER which use
electronic component to receive signal from emitter connected to
display to activate a light shutter with the frequency of 120 Hertz
or 240 Hertz or more.
[0005] Passive 3-D glasses include linearly-polarized glasses,
circularly-polarized glasses, infitec glasses, complementary color
analyphs, chromadepth method glasses, anachrome compatible color
analyph glasses, and red-eye shutter glasses where the most
prevalent would be linearly-polarized glasses and
circularly-polarized glasses. Linearly polarized glasses are used
when a stereoscopic motion picture is projected and superimposed on
the same screen through orthogonal polarizing filters. The viewer
wears glasses containing orthogonal polarizing filters, which only
pass through similarly polarized light and block orthogonally
polarized light, allowing the viewer to only see one of the images
in each eye to achieve a 3-D effect. Viewers must keep their heads
level in order to prevent bleeding of images from the left and
right channels into the opposite channel.
[0006] Circularly polarized glasses are used in circumstances where
two images are projected superimposed onto a screen through
circular polarizing filters of opposite handedness. The user wears
eyeglasses which contain a pair of circular polarizing filters
mounted in reverse, whereby light that is left-circularly polarized
is extinguished by the right-handed analyzer and light that is
right-circularly polarized is extinguished by the left-handed
analyzer. This allows the user to tilt his head while viewing
stereoscopic images and still maintain left and right
separation.
[0007] Passive linear lenses exploit the wavelength difference
between blue and red color lenses to create a 3-D effect. However,
this method results in a perceived image that deviates from the
actual color of the object.
[0008] Circularly polarized glasses have the advantage over linear
polarized glasses because viewers with circularly polarized glasses
may tilt their heads and look about without a disturbing loss of
3-D perception, whereas viewers using linear polarized glasses must
keep their heads aligned within a narrow range of tilt for
effective 3-D perception, or risk seeing double or darkened
images.
[0009] Passive circularly polarized lenses in the market currently
use flat lenses, which do not match the user's eyeball curvature
and cause eye fatigue and discomfort. In addition, 3D effects is
distorted if the viewers tilts their head beyond a certain angle
from direct viewing of the screen. Despite the apparent short falls
of the flat lens design, current market continues to utilize flat
lens approach because distortion would result from curving the flat
lens after molding and cutting the lens to suit the eye curvature.
Specifically, this is caused primarily due to the fact that such
method would rearrange the molecules in the film and degrade visual
clarity.
[0010] As for active 3-D technology, the active shutter glass lens
needs to be in a dark room in order to realize better resolution
and full stereoscopic sensation. Some people like this but some
will feel uncomfortable as well as their eyes and brain will get
tired in a longer period time over than 2 hours. Moreover, although
active shutter glass lens has high resolution, the flat shape of
frame and heavier than usual weight cause increased eye strain, eye
pressure, and induce nausea and headache when wore over long
periods of time. Further, due to the flat lens shape, such lenses
do not match the natural curvature of the eye. Due to the flashing
of stereoscopic images at 120 Hertz or more, it tends to cause
greater eye discomfort without a lens curvature. Thus, this
invention also aims to create curvature lens for active 3D
glasses.
[0011] Taken as a whole, current construction of flat lens, both
active and passive, limits the frame shape and design. Even when we
try to use flat sheet laminated to cut shape and with heating to
bend; it reduces the resolution of viewing, and lead to discomfort
in eyes and brain. Thus, the present invention solves the problem
by continuously stretching the polarized lens and forming the lens
into curved shape.
[0012] Further, a retarder is an optical device that alters the
polarization state of a light wave traveling through it. The new
method of processing the retarder with new laminate technology
improves the 3-D stereoscopic image. The linear polarized film or
partially circular polarized film is glued to the retarder inside
the retarder include gap filling agent. The epoxy liquid is
laminated outside the retarder then cured with air or UV light to
create a "3-D circular polarized function card". The new function
card will have a better birefrigent effect without extra polymer
sheets, thus improving transmission. Currently state of the art
allows for 60-85% transmission. Also current market uses polymer
sheets to support the linear polarizer. The use of polymer sheet
requires moist glue, which interferes with transmission. This
support must be assembled using half-dry glue on the lens, which
negatively affects lens clarity. Dry glue cannot be used in this
assembly due to the limiting nature of the thick polymer retarder
and linear polarizer.
[0013] In our invention, the thinness of the retarder and PVA film
(polarizer) allows the application of almost crystallized
lamination possible. Specifically, the present invention solves
this problem through a process by which a thin retarder and PVA or
circular polarizer may be produced and assembled with dry glue.
This process allows the wearer to view stereoscopic images for a
longer time period without discomfort. The process entails
application of organic polyvinyl alcohol (PVA) or any selection
among polymer polyurethane (PU), polyvinyl chloride (PVC),
polypropylene (PP), polycarbonate (PC), or polyester (PE) as the
ingredient to create retarder film with linear or partially
circular polarization on different surfaces, such as flat and
curved sheets, as a substantial improvement to current flat 3-D
lenses and to end user viewing comfort. Other advantages of these
methods versus previous methods include making distortion-free,
thinner, flexible, functional, comparable, durable,
optimal-performance circular polarized 3D lens. This innovative
method allows for conformation of the lens shape onto a flat and
curved surface when the lens is still malleable and moist rather
than cutting the lens from a flat sheet of polymer.
OBJECT OF THE INVENTION
[0014] The purpose of present invention is to apply high quality
retarder film to create full color, and virtually high resolution
passive circular polarized 3D lens for aesthetical and comfortable
eyewear to view stereoscopic images. Other advantages of these
method versus previous methods include making distortion-free,
thinner, flexible, functional, comparable, durable,
optimal-performance circular polarized 3D lens. This innovative
method allows production of forming lens shape into a flat and
curved surface when the lens is still malleable and moist rather
than cutting the lens from a flat sheet of polymer.
[0015] Objective of the present invention include production of
high quality retarder film and application of said film to passive
circularly polarized 3-D lenses in order to create aesthetically
pleasing and highly comfortable eyewear to view stereoscopic images
in accurate and brilliant color and full resolution.
[0016] Another objective of this invention is to produce
distortion-free, thinner, more flexible and durable, and
visually-optimized circularly-polarized 3-D lenses through the
novel process of forming curved lens surfaces during the malleable
or moist lens production phase, as opposed to cutting the lens from
a flat polymer sheet, which causes optical distortion and end user
discomfort.
SUMMARY OF THE INVENTION
[0017] One aspect of the invention includes a 3-D stereoscopic
viewing lens comprising a retarder film wherein the retarder film
is comprised of a PVA film. In one embodiment, the 3-D stereoscopic
viewing lens further comprising a linear polarized film, one or
more lens substrate layers, an epoxy layer. In another embodiment,
the 3-D stereoscopic viewing lens is has a shape of a curvature. In
another embodiment, the 3-D stereoscopic viewing lens further
comprising a linear polarized film, a LCD layer, an ITO layer, a
glass layer and a lens substrate layer In another embodiment, the
retarder film is made comprising the following steps: mounting a
PVA film to an assembly line; wetting, cleaning, and washing the
PVA film through the assembly line; softening, expanding and
stretching the PVA film's x-axis through the assembly line; adding
gap filling agent to the PVA film; stretching the PVA film's y-axis
through a width frame holder whereby transforming the PVA film into
a retarder film. In another embodiment, the retarder film is made
further comprising the following steps: mounting the retarder film
onto a multiple holding frame; pressing a convex mold onto the
retarder film to force the retarder film into a desired curved
shape through one or more openings of the multiple holding frame;
heating the retarder film to reduce the retarder film's moisture
content; drying the retarder film.
[0018] In yet another embodiment, water is used in the process of
wetting, cleaning and washing. In another embodiment, the
processing of wetting, cleaning and washing is continued until the
PVA film reaches approximately 70%-85% water saturation. In another
embodiment, the processing of softening, expanding and stretching
is carried out by one or more rollers mounted in the assembly line.
In another embodiment, the gap filling agent is comprised on of
potassium iodide, sodium iodide, copper (I) iodide, boric acid, and
sodium tetra borate decahedra. In another embodiment, the gap
filling agent is added during the processing of softening,
expanding and stretching the PVA film. In another embodiment, the
gap filling agent is added during the processing of softening,
expanding and stretching the PVA film.
[0019] In another embodiment, the retarder film is stretched to
about 3 to 6 times its original size along its x-axis. In another
embodiment, the retarder film's width is reduced to about one half
of its original width. In another embodiment, the retarder film's
thickness is reduced to 0.02-0.12 mm thick.
[0020] In yet another embodiment, the retarder film is heated to
about 60.degree. C. to 80.degree. C. wherein the process of heating
is continued until the retarder film's moisture content is reduced
to about 50%; In another embodiment, the process of drying takes
place in a environment at approximately 25.degree. C. and at 40-50%
humidity until the retarder film's moisture content is reduced to
about 40%.
[0021] In another aspect of the invention, method of making a 3-D
stereoscopic viewing lens comprising the following steps: mounting
a PVA film to an assembly line; wetting, cleaning, and washing the
PVA film through the assembly line; softening, expanding and
stretching the PVA film's x-axis through the assembly line; adding
gap filling agent to the PVA film; stretching the PVA film's y-axis
through a width frame holder whereby transforming the PVA film into
a retarder film; mounting the retarder film onto a multiple holding
frame; pressing a convex mold onto the retarder film to force the
retarder film into a desired curved shape through one or more
openings of the multiple holding frame; heating the retarder film
to reduce the retarder film's moisture content; drying the retarder
film. In another embodiment, the method further includes preparing
a concave mold and a convex mold; adding epoxy onto the concave
mold; affixing the retarder film onto the convex mold; positioning
the retarder film with convex mold wherein the retarder film with
convex mold is pressed down onto the epoxy with concave mold;
compressing the convex mold with the concave mold; applying UV
treatment to the convex mold and the concave mold; opening the
convex mold and the concave mold; affixing a linear polarized film
to the convex mold; adding UV glue to the retarder film; pressing
the convex mold having the linear polarized film to the concave
mold having the retarder film with UV glue; applying UV dry
treatment to the concave mold and the convex mold whereby the
retarder film laminates with the linear polarized film to form
circular polarized film; removing the convex mold from the concave
mold; applying UV glue to the circular polarized film; affixing
lens substrate to the convex mold; compress the convex mold having
the lens substrate with the concave mold having the circular
polarized film to form a 3-D stereoscopic viewing lens; applying UV
treatment to the convex mold and the concave mold; remove the 3-D
stereoscopic viewing lens from the convex mold and the concave
mold. In another embodiment, the lens substrate is selected from a
group consisting of AC, CR, PU, TAC, and GLASS.
[0022] In another aspect of the invention, a retarder for a 3-D
stereoscopic viewing lens wherein the retarder film is comprised of
a PVA film is disclosed. In another embodiment, the retarder film
is made comprising the following steps: mounting a PVA film to an
assembly line; wetting, cleaning, and washing the PVA film through
the assembly line; softening, expanding and stretching the PVA
film's x-axis through the assembly line; adding gap filling agent
to the PVA film; stretching the PVA film's y-axis through a width
frame holder whereby transforming the PVA film into a retarder
film; mounting the retarder film onto a multiple holding frame;
pressing a convex mold onto the retarder film to force the retarder
film into a desired curved shape through one or more openings of
the multiple holding frame; heating the retarder film to reduce the
retarder film's moisture content; drying the retarder film.
[0023] In another aspect of the invention, a 3-D stereoscopic
viewing lens comprising a retarder film wherein the retarder film
is comprised of a polymer film selected from a group consisting of
PU, PVC, PP, PC, NYLON, PE, CAB, CP, DAC and TAC film is disclosed.
In another embodiment, the retarder film is made comprising the
following steps: keeping a polymer film in a proper temperature at
over 90.degree. C.-120.degree. C. until the polymer is malleable;
mounting the polymer film to an assembly line; softening, expanding
and stretching the polymer film's x-axis through the assembly line;
stretching the polymer film's y-axis through a width frame holder
whereby transforming the polymer film into a retarder film.
[0024] In yet another aspect of the invention, a 3-D stereoscopic
viewing lens comprising the following steps is disclosed: providing
polymer film selected from a group consisting of PU, PVC, PP, PC,
NYLON, PE, CAB, CP, DAC and TAC film; keeping the polymer film in a
proper temperature at over 90.degree. C.-120.degree. C. until the
polymer is malleable; mounting the polymer film to an assembly
line; softening, expanding and stretching the polymer film's x-axis
through the assembly line; stretching the polymer film's y-axis
through a width frame holder whereby transforming the polymer film
into a retarder film; mount the retarder film onto a multiple
holding frame; pressing a convex mold onto the polymer film to
force the retarder film into a desired curved shape through one or
more openings of the multiple holding frame; preparing a concave
mold and a convex mold; adding epoxy onto the concave mold;
affixing the retarder film onto the convex mold; positioning the
retarder film with convex mold wherein the retarder film with
convex mold is pressed down onto the epoxy with concave mold;
compressing the convex mold with the concave mold; applying UV
treatment to the convex mold and the concave mold; opening the
convex mold and the concave mold; affixing a linear polarized film
to the convex mold; adding UV glue to the retarder film; pressing
the convex mold having the linear polarized film to the concave
mold having the polymer film with UV glue; applying UV dry
treatment to the concave mold and the convex mold whereby the
retarder film laminates with the linear polarized film to form a
circular polarized film; removing the convex mold from the concave
mold; applying UV glue to the circular polarized film; affixing
lens substrate to the convex mold; compress the convex mold having
the lens substrate with the concave mold having the circular
polarized film to form a 3-D stereoscopic viewing lens; applying UV
treatment to the convex mold and the concave mold; removing the 3-D
stereoscopic viewing lens from the convex mold and the concave
mold.
[0025] In yet another aspect of the invention, the making of a 3-D
stereoscopic view lens further includes the following steps:
preparing a concave mold and a convex mold; adding liquid glass
onto the concave mold to form a glass substrate layer; apply glue
to the glass substrate layer; affixing the retarder film onto the
convex mold; positioning the retarder film with convex mold wherein
the retarder film with convex mold is pressed down onto the glass
substrate layer with concave mold; compressing the convex mold with
the concave mold; applying UV treatment to the convex mold and the
concave mold; opening the convex mold and the concave mold;
affixing a linear polarized film to the convex mold; adding UV glue
to the retarder film; pressing the convex mold having the linear
polarized film to the concave mold having the retarder film with UV
glue; applying UV dry treatment to the concave mold and the convex
mold whereby the retarder film laminates with the linear polarized
film to form circular polarized film; removing the convex mold from
the concave mold; applying UV glue to the circular polarized film;
affixing lens substrate to the convex mold; compress the convex
mold having the lens substrate with the concave mold having the
circular polarized film to form a 3-D stereoscopic viewing lens;
applying UV treatment to the convex mold and the concave mold;
remove the 3-D stereoscopic viewing lens from the convex mold and
the concave mold.
[0026] In yet another aspect of the invention, the making of a 3-D
stereoscopic view lens further includes the following steps: adding
a glass substrate layer to a concave mold; vacuum coating the glass
substrate layer with an ITO layer; adding a LCD layer to the ITO
layer; affixing s lens substrate layer to a convex mold; adjoin the
lens substrate layer with the retarder film; compressing the convex
mold with the concave mold whereby the retarder film adjoins with
the LCD layer to form a 3-D stereoscopic viewing lens; applying UV
treatment; removing the convex mold from the concave mold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 depicts an embodiment of stretching of the retarder
film;
[0028] FIG. 2 depicts an embodiment of the adjustable width holding
frame;
[0029] FIG. 3 depicts an embodiment of an adjustable holding
frame;
[0030] FIG. 4A depicts an embodiment of the multiple frame
holder;
[0031] FIG. 4B depicts an embodiment of the multiple frame
holder;
[0032] FIG. 5A depicts an embodiment of a 3-D lens;
[0033] FIG. 5B depicts an embodiment of a 3-D lens;
[0034] FIG. 6 depicts an embodiment of how a retarder film is
aligned against a linear polarized film;
[0035] FIG. 7A depicts an embodiment of a 3-D lens;
[0036] FIG. 7B depicts an embodiment of a 3-D lens;
[0037] FIG. 8 depicts variations of how a retarder film is aligned
against a linear polarized film;
[0038] FIG. 9A depicts an embodiment of a 3-D lens;
[0039] FIG. 9B depicts an embodiment of a 3-D lens;
[0040] FIG. 10 depicts an embodiment of a 3-D lens;
[0041] FIG. 11 depicts another embodiment of stretching of the
retarder film;
[0042] FIG. 12 depicts an embodiment of the adjustable width
holding frame;
[0043] FIG. 13 depicts an embodiment of an adjustable holding
frame;
[0044] FIG. 14A depicts an embodiment of the multiple frame
holder;
[0045] FIG. 14B depicts an embodiment of the multiple frame
holder;
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0046] The present invention discloses the making of the retarder
film using the continuous stretching process to conform to the lens
shape. It can reduce the distortion and defect of forming the
retarder film. Specifically, the present invention provides method
where it can stretch PVA (using a wetting process), and form it
into curve shape and to become a retarder. The thinness of the
film, using a wetting process, and proper temperature of polymer
makes the polymer fit the shape of mold in perfect match. That is
excellent for retarder to form most shape and curve. The new
invention can apply to 3-D glasses, advertisement panel, tail
light, lamp, especially curved shape.
[0047] In addition, gap filling agent was added to the water tank
in the assembly line process to fill almost all the gaps of
molecule in PVA film to create a birefrigent film, flat or any
shape of retarder film. While the curved lens has better 3D effect
than flat lens, the new invention further provides method for
improving the effect of flat lens because the molecules of PVA or
polymer (PU, PVC, PP, PC, NYLON, PE, CAB, CP, DAC and TAC film) are
arranged in order.
[0048] New method to process retarder with new laminate technology
improves the 3D stereoscopic image. The linear polarized film is
glued to the retarder film wherein inside the retarder film has
inclusion of gap filling agent. The epoxy liquid was laminated to
the outside of the retarder film then cured with air or UV light to
create an effective "3-D CIRCULAR POLARIZED FUNCTION CARD". The new
function card will have better birefrigent effect without extra
polymer sheet, thus improve the transmission. Other invention
includes wherein the past, the use of multiple polymer sheets to
support linear polarizer requires the use of moist glue for the
polymer sheet to be glued to the linear polarizer. The moisture of
the glue often interferes with transmission of light. In the
present invention, because the thinness of the PVA film, it makes
the application of lamination of PVA film with linear polarizer
possible for crystallized lamination.
[0049] Present invention can reduce the use of either the retarder,
linear polarized film materials to half of what the market is
currently commanding, primarily due to the use of the application
of epoxy to form support.
[0050] The following description is not to be taken in a limiting
sense, but is made merely for the purpose of describing the general
principles of the invention. The steps described herein for
performing methods form one embodiment of the invention, and,
unless otherwise indicated, not all of the steps must necessarily
be performed to practice the invention, nor must the steps
necessarily be performed in the order listed. The present invention
is a retarder film and a method of making retarder. The major steps
in producing the retarder and a 3-D stereoscopic viewing lens are
described in the following sections.
Example One
I. Preparation of PVA Film for Use to Form Retarder Film
[0051] FIG. 1 depicts one embodiment of an assembly line to prepare
a retarder film. Specifically, FIG. 1 depicts the process of
continuous stretch of the PVA film along its X-axis. Starting with
an untreated roll of PVA film, without directional molecular
arrangement. Using rollers to stretch and transport PVA film from
one or more stages as follows: [0052] a. mount an untreated roll of
PVA film 101 at the beginning of assembly line 105; [0053] b. use
water to in processing tank 104 to wet, clean, and wash the film
101 until it has approximately 70%-85% water saturation; [0054] c.
softening, expanding and stretching the film as the film 101
continues to be stretched through roller 102, roller 103 and roller
106.
[0055] In the stretching process gap filling agent (mixture of
potassium iodide, sodium iodide, copper (I) iodide, boric acid, and
sodium tetra borate decahedra) was added to the processing tank 104
to form an improved PVA film. The addition of the gap filling agent
is used to fill the pores of the molecules to have birefringent
effect. PVA film is stretched to about 3 to 6 times its original
size along the x-axis, combining stretch, its width is reduced to
about one half of its original widths, and its thickness is reduced
to 0.12-0.02 mm thick. The molecules of the PVA film will become
more evenly aligned.
II. Forming the Retarder Film of Example One and Forming it into
the Desired Curved Shape Using a Convex Mold
[0056] FIG. 2 and FIG. 3 depict one embodiment of a manual and
semi-automatic or automatic adjustable clamping frame used for the
next step of transforming the PVA film into a retarder film.
Specifically, after steps performed in FIG. 1, FIG. 2 depicts one
embodiment of a width-adjustable holding frame 208 to hold the PVA
film along the Y-axis 209 using a top and bottom clamping frames
together with hinges 207; FIG. 3 depicts one embodiment of an
adjustable holding frame 308 stretched along the Y-axis 209 to a
preset lockable position 311 wherein the extension rod 310 locks it
in place. Specifically, the PVA film is stretched here along the Y
axis until the PVA film is 0.05 mm-0.01 mm in thickness. The PVA
film, once stretched in its X-axis and its Y-axis, it becomes a
functional retarder film. The retarder film, remaining in proper
temperature and moisture during the processing phase, is stabilized
between lower frame plate and upper frame, which are held together
with frame hinges 207. Additional clips can be used to help prevent
retarder film from shrinking during shaping.
[0057] FIG. 4A depicts one embodiment of the retarder film 401
being formed into a multiple holding frame 408 to form into a
curved or flat or any desired shape comprising the steps of: [0058]
a. stabilize and place retarder film 401 onto the multiple holding
frames 408 using multiple holding frame hinges 412; [0059] b. next
press a convex mold 424 (FIG. 4B) onto retarder film 415 (FIG. 4B)
to force the retarder film 412 (FIG. 4B) into the desired curved
shape through the oval openings 413 (FIG. 4A) of multiple frame
holder 414 (FIG. 4B); [0060] c. heat the retarder film at
60.degree. C. to 80.degree. C. until its moisture content is about
50%; [0061] d. inspect and mark the molecule direction of the
retarder film 415 (FIG. 4B); and [0062] e. dry the retarder film
415 (FIG. 4B) at approximately 25.degree. C. and 40-50% humidity
until its moisture content is about 40%.
[0063] Next, (referring back to FIG. 4A) retarder film is cut and
removed from the multiple holding frame 408. As described earlier,
multiple holding frame 408 has an opening 413 in the center, which
allows convex mold to be pushed through multiple holding frame 408
and against the retarder film 401. One side of convex mold is used
to shape the retarder film 401. The convex surface of convex mold
is pushed into the flat piece of soft retarder film to bend it into
the desired shape, curve or arc.
[0064] Since retarder film is soft and wet, it will conform to its
shape to the mold. In one embodiment, convex mold is made of glass,
such as glass in common practice for forming thermosetting resin
ophthalmic lenses, or another material that is relatively
transparent or semi-transparent polymer, so that the epoxy can be
cured by UV light which passes through the mold. In other
embodiments, convex mold is made of a material which conducts heat,
so that heat can pass through the mold. Once arc is formed,
retarder film is next heated at about 80.degree. C. or less to
remove the moisture in the retarder film without melting it. This
should take about 10 minutes. Retarder film is relatively soft
because it was "wet" due to its moisture content made, and once it
becomes "dry" due to the reduction in moisture content, it will fix
or lock in its shape. It is noted that temperatures above
80.degree. C. may melt or liquefy the retarder film.
[0065] Next, retarder film is inspected in a quality control stage
after the initial drying for air bubbles, dirt, color evenness,
tears, etc. The dioptre and other optical properties of the
retarder film can be measured. If all is approved, the lens is
marked with a molecule direction. After marking, the retarder film
can then be removed to a clean room at room temperature and low
humidity levels for further cooling. This produces a curved, dry
retarder film that adheres better to epoxy, which eventually
becomes part of the 3-D stereoscopic viewing lens.
Example Two
III. Preparation of Polymer Film for Use to Form Retarder Film
[0066] FIG. 11 depicts one embodiment of an assembly line to
prepare a retarder film. Polymer film can be polymer Polyurethane
(PU), Polyvinyl chloride (PVC),Polypropylene (PP), Polycarbonate
(PC), Polyester (PE), (CAB) Cellulose Acetate Butyrate, (CP)
Cellulose Acetate Propionate, (DAC) Cellulose Diacetate and (TAC)
Triacetate Cellulose film. Specifically, FIG. 11 depicts the
process of continuous stretch of the polymer film along the X-axis.
Starting with an untreated roll of polymer film, without
directional molecular arrangement. Using rollers to stretch and
transport polymer film from one or more stages as follows: [0067]
d. mount an untreated roll of polymer film 1101 at the beginning of
assembly line 1105; [0068] e. heat the polymer film to temperature
over 90.degree. C.-120.degree. C. wherein said film becomes
malleable; [0069] f. stretching the film as the film 1101 continues
to be stretched through roller 1102, roller 1103 and roller
1106.
[0070] Polymer film is stretched to about 3 to 6 times its original
size along the x-axis, combining stretch, its width is reduced to
about one half of its original widths, and its thickness is reduced
to 0.12-0.02 mm thick. The molecules of the polymer film will
become more evenly aligned.
IV. Forming the Retarder Film of Example Two and Forming it into
the Desired Curved Shape Using a Convex Mold
[0071] FIG. 12 and FIG. 13 depict one embodiment of a manual and
semi-automatic or automatic adjustable clamping frame used for the
next step of transforming the polymer film into a retarder film.
Specifically, after steps performed in FIG. 11, FIG. 12 depicts one
embodiment of a width-adjustable holding frame 1208 to hold the
polymer film along the Y-axis 1209 using a top and bottom clamping
frames together with hinges 1207; FIG. 3 depicts one embodiment of
an adjustable holding frame 1308 stretched along the Y-axis 1209 to
a preset lockable position 1311 wherein the extension rod 1310
locks it in place. Specifically, the polymer film is stretched here
along the Y axis until the PVA film is 0.05 mm-0.01 mm in
thickness. The polymer film, once stretched in its X-axis and its
Y-axis, it becomes a functional retarder film. After stretching is
done, use the spectrum measure machine and reflection index data to
adjust the stretch machine to what is desired.
[0072] The retarder film, remaining in proper temperature during
the processing phase, is stabilized between lower frame plate and
upper frame, which are held together with frame hinges 1207.
Additional clips can be used to help prevent retarder film from
shrinking during shaping.
[0073] FIG. 14A depicts one embodiment of the retarder film 1401
being formed into a multiple holding frame 1408 to form into a
curved or flat or any desired shape comprising the steps of: [0074]
f. stabilize and place retarder film 1401 onto the multiple holding
frames 1408 using multiple holding frame hinges 1412; [0075] g.
next press a convex mold 1424 (FIG. 14B) onto retarder film 1415
(FIG. 14B) to force the retarder film 1415 (FIG. 14B) into the
desired curved shape through the oval openings 1413 (FIG. 14A) of
multiple frame holder 1414 (FIG. 14B); [0076] h. inspect and mark
the molecule direction of the retarder film 1415 (FIG. 14B);
and
[0077] Next, (referring back to FIG. 14A) retarder film is cut and
removed from the multiple holding frame 1408. As described earlier,
multiple holding frame 1408 has an opening 1413 in the center,
which allows convex mold to be pushed through multiple holding
frame 1408 and against the retarder film 1401. One side of convex
mold is used to shape the retarder film 1401. The convex surface of
convex mold is pushed into the flat piece of soft retarder film to
bend it into the desired shape, curve or arc.
V. Addition of Hard Epoxy to the Outer, Convex Side of the Retarder
Film of Example One and Example Two
[0078] FIG. 5A depicts one embodiment of an overview of a 3-D
stereoscopic viewing lens comprising a convex mold 521, a concave
mold 518 holding epoxy layer 517, retarder film 516, linear
polarized film 515 and lens substrate 514. Depicted in FIG. 5B
(from the left column down and up and through the right column),
the steps are as follows: [0079] a. polish and clean the surface of
concave mold 518; [0080] b. add about 5 cc of hard epoxy 517 in
liquid form onto concave mold 518; and [0081] c. position concave
mold 518 and convex mold 521 together so that the outer surface of
retarder film 516 is pressed down onto epoxy liquid 517; [0082] d.
compress molds together; [0083] e. apply UV treatment 520; [0084]
f. apply linear polarized film 515 on the convex mold 518; [0085]
g. add UV glue 519 on the top of the retarder film 516; [0086] h.
press convex mold 521 having linear polarized film 515 on to the UV
glue 519 [0087] i. adding UV dry treatment 520; [0088] j. here a
"3-D circular polarized function card" is formed; [0089] k. add UV
glue 519 on top of polarized function card; [0090] l. affixing lens
substrate comprised of AC, CR, PU, TAC, or GLASS materials 514 on
to convex mold; [0091] m. compress molds together; when laminating
the retarder 516 and linear polarized 519, paying careful attention
that the angle is correct at +45 degrees and -45 degrees as
disclosed in FIG. 6 where the retarder 622 is positioned against
linear polarized film 623 at a -45 degree and at a -45 degree;
differences within 5 degrees still can be acceptable. [0092] n.
determine direction of polarization; and [0093] o. apply UV
treatment 520
[0094] The lens' convex and concave mold can be made of transparent
glass. About 5 cc of hard epoxy 517 is used, which should spread
out to form a layer about 0.1 mm-0.5 mm thick, preferably 0.2
mm-0.3 mm for good surface tension. This eventually becomes layer
of hard epoxy in lens. Epoxy liquid should be heated to about
80.degree. C. to 90.degree. C. so that they will be liquid or
semi-liquid, to help eliminate bubbles. The liquid epoxy is soft
enough to flow, but it is not so viscous that it will flow away
without adhering. The liquid epoxy 517 can be dripped onto the
concave mold 518, smoothly expanding from the center in a circular
motion to evenly spread the epoxy 517 to help remove air bubbles.
This process can be performed in an environment at approximately
room temperature.
[0095] In one embodiment, holding frame holding retarder film 516
in contact with convex mold 521, and the convex mold
521-plus-retarder film 516 combination is inverted and placed on
top of concave mold 518 and attached together. Because the final
layer of hard epoxy 517 is less than 0.5 mm, no gasket is needed.
During UV treatment 520, the liquid epoxy 517 is cured and made
hard using ultraviolet light, heat, radiation, pressure, passage of
time, or other methods for treatment epoxy.
[0096] FIG. 7A depicts one embodiment of an overview of 3D
Stereoscopic view lens comprising a convex mold 721, a concave mold
726, lens substrate layer 724 and glass lens 725, retarder film
716, linear polarized film 715. Depicted in FIG. 7B (from the left
column down and up and through the right column), the steps are as
follows: [0097] a. polish and clean the surface of concave mold
726; [0098] b. add about 5 cc of glass substrate 725 onto concave
mold 726, which creates the convex side of the lens; and [0099] c.
position concave mold 726 and convex mold 721 together so that the
outer surface of retarder film 716 can be pressed down onto glass
layer 725; [0100] d. affix retarder 716 to convex mold 721; [0101]
e. apply glue 719 to the glass substrate layer 725 [0102] f.
compress molds together; [0103] g. determine direction of the
retarder 716; and [0104] h. dried with air or UV light 720; [0105]
i. affix linear polarized film 715 on the convex mold 721; [0106]
j. add UV glue 719 on the concave side of the retarder 716; [0107]
k. compress molds together; when laminating the retarder 716 and
linear polarized film 715, paying careful attention that the angle
is correct at +45 degrees and -45 degrees, but not limited to any
other combination of desired degree. [0108] l. determine direction
of polarization; and [0109] m. dried with air or UV light 720
[0110] n. remove convex mold 721 from concave mold 726 [0111] o.
add lens substrate (AC, CR, PU, TAC, or GLASS) 724 to convex mold
721 and compress molds together to form a 3-D stereoscopic viewing
lens.
[0112] The retarder-plus-glass collection is then sent to an
assembly line with UV treatment equipment to be hardened for about
three minutes. Fine shaping can also be performed manually at this
stage by cutting away excess retarder. This produces a retarder
film with a hard layer of glass on its outer, convex surface. In
another embodiment, this produces a polarized wafer coated with
glass on both sides. The uncoated concave side, the glass-lined
convex side, or both sides could then be combined with a base
material, through casting in a gasket mold, injection molding, or
other methods for combining lens components.
[0113] Lens substrate can be GLASS, acrylic (AC), polyurethane
(PU), triacetate (TAC), casting resin (CR), cellulose acetate
(CAB), cellulose propionate (CP), or NYLON; substrate can have one
side or two sides' coatings. Linear polarized film also includes
partially circular polarized film.
[0114] FIG. 8 depicts the combinations of lens inserts to right
side and left side depending on the direction of TV and projector.
Although the present invention has been described by way of example
with references to the drawings, it is to be noted herein that
various changes and modifications, including performing steps in
different orders, will be apparent to those skilled in the art.
Therefore, unless such changes and modifications depart from the
scope of the present invention, they should be construed as being
included therein.
Example Three
I. Utilizing PVA Film and Linear Polarized Film for LCD Use
[0115] FIG. 9A depicts one embodiment of an overview of utilizing
PVA film as retarder film, using the methods depicted above, for
LCD use comprising a convex mold 921, a concave mold 926, lens
substrate layer 924 and glass lens 925, ITO layer 928, LCD layer
927, retarder film 915. Depicted in FIG. 9B, the steps are as
follows: [0116] a. add lens substrate 925 onto the exposed, concave
926 (top flat) side of the mold; [0117] b. vacuum coated with ITO
(electrode conductor) 928 to form the direction in LCD; [0118] c.
add liquid crystal display layer (LCD) 927 to concave mold 926;
[0119] d. place convex mold 921 on top; having a lens substrate
layer 916 adjoined with UV glue 919 to retarder film 924 so that
the concave 926 having LCD 927 surface presses against retarder
film 924; by paying careful attention that the angle is correct at
+45 degrees and -45 degrees; [0120] e. Applying UV treatment.
[0121] The same method can be applied on flat surface as depicts in
FIG. 10 [0122] a. add lens substrate 1025 onto the exposed, bottom
flat 1026 side of the mold; [0123] b. vacuum coated with ITO
(electrode conductor) 1028 to form the direction in LCD 1027;
[0124] c. add liquid crystal display (LCD) 1027 to bottom flat mold
1026; [0125] d. affixing retarder 1016 with substrate 1024 with
glue 1019 to top flat 1024; [0126] e. place top flat 1021 on top;
having a lens substrate layer 1024 adjoined with UV glue 1019 to
retarder film 1016 so that the bottom flat 1026 having LCD 1027
surface presses against retarder film 1016; by paying careful
attention that the angle is correct at +45 degrees and -45 degrees;
[0127] f. apply UV treatment.
* * * * *