METHOD FOR GENERATING MICROSTRUCTURE IN A FILM FROM A ROLL

Abstract

METHOD FOR GENERATING MICROSTRUCTURE IN A FILM FROM ONE ROLL. The present disclosure relates to a method for designing a spherical microstructure mold module (604-614) to be incorporated into a calendering roll (600) to generate a microstructure (108) on a flat surface (104), comprising calculating a first curvature (204) on a flat cross-sectional surface (202) to a first microstructure point of the spherical microstructure mold module, calculating a second curvature (210) of a spherical surface (102) of the spherical microstructure mold module, measuring a radius (214) of the spherical surface (102), the radius (214) being from the center of the spherical surface (102) to the first microstructure point, and determining a microstructure location (108) on the flat surface (104), the location being derived from the first curvature (204), the second curvature (210), and the radius (214).

Description

1 / 19 “METHOD FOR GENERATING MICROSTRUCTURE IN A FILM FROM A ROLL” BACKGROUND FIELD OF DISSEMINATION

[0001] The present disclosure relates to a method for generating a microstructure in a film by incorporating a spherical microstructure mold module design in a calendering roll. DESCRIPTION OF THE RELATED TECHNIQUE

[0002] Large microstructure matrices have been designed for ophthalmic lens products. Ophthalmic lens products are typically made up of a lens and a film, and the film is typically laminated onto an optical surface of the lens. The optical surface of ophthalmic lenses is generally spherical. However, when transforming microstructure matrices on the optical surface into a film surface, the microstructure matrices deform, since the film is a flat surface before being applied to the lens.

[0003] The description of the Prior Background is intended to generally provide context for the disclosure. The inventors' work, as described in this background section, as well as aspects of the description that cannot be classified as prior art at the time of filing, are not expressly or implicitly admitted as prior art against the present disclosure. SUMMARY

[0004] The present disclosure relates to a method for designing a spherical microstructure mold module to be incorporated into a calendering roll to generate a microstructure in a film.

[0005] According to one embodiment, the present disclosure further relates to a method for designing a spherical microstructure mold module to be incorporated into a calendering roll to generate a microstructure on a flat surface, comprising calculating a first curvature on a flat cross-sectional surface for a first microstructure point of the spherical microstructure mold module, calculating a second curvature of a surface Petition 870220093947, dated 11 / 10 / 2022, page 10 / 41 2 / 19 spherical of the spherical microstructure mold module, measure a radius of the spherical surface, being the radius from the center of the spherical surface to the first microstructure point, and determine a microstructure location on the flat 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 flat cross-sectional surface, the first curvature being a longitude of the first microstructure point in 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 in the spherical microstructure mold module.

[0006] According to one embodiment, the present disclosure further relates to a method of calendering one or more microstructure dies onto a film, comprising extruding a thermoplastic film between a first roll and a second roll, and embossing one or more microstructure dies onto the thermoplastic film by the second roll, the second roll having one or more individual microstructure die modules, each microstructure die module corresponding to one or more microstructure dies, wherein the first roll and the second roll are controlled to achieve a predetermined temperature and a predetermined pressure, the first roll including a smooth cylinder, the second roll including a cylinder and one or more individual microstructure die modules being on the cylinder.

[0007] According to one embodiment, the present disclosure further relates to a roll structure, comprising a roll structure including a cylinder, at least one spherical microstructure mold module attached to the cylinder, and at least one microstructure mold die arranged on a spherical surface of a respective one of at least one spherical microstructure mold module, wherein the at least one microstructure die being applied to form microstructure dies in a thermoplastic film in contact with the roll structure, wherein the spherical microstructure mold module includes one or more molds Petition 870220093947, dated 11 / 10 / 2022, page 11 / 41 3 / 19 of microstructure, and the microstructure matrices are designed to be arranged on a spherical ophthalmic lens surface.

[0008] According to one embodiment, the present disclosure further relates to a film for disposing of microstructures on an optical film of an ophthalmic lens, comprising one or more microstructure matrices on the optical film, the one or more microstructure matrices on the optical film being formed by a roll, wherein the roll includes one or more individual microstructure mold modules, each of the one or more individual microstructure mold modules corresponding to a respective one or more microstructure matrices on the optical film, and wherein the location of each microstructure on the one or more microstructure matrices is determined based on the curvatures and a radius of the optical film of the ophthalmic lens.

[0009] The preceding paragraphs have been provided as a general introduction and are not intended to limit the scope of the following claims. The embodiments described, along with other advantages, will be better understood by reference to the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A fuller appreciation of the disclosure and many of its associated advantages will be easily obtained as it becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which:

[0011] FIG. 1 is an illustration of a method for transforming the microstructure matrix from a spherical surface to a planar surface, according to an exemplary embodiment of the present disclosure;

[0012] FIG. 2 is an illustration of the calculation of a microstructure matrix location on a planar surface corresponding to a microstructure matrix location on a spherical surface, according to an exemplary embodiment of the present disclosure;

[0013] FIG. 3 is a design flow diagram of a mold module. Petition 870220093947, dated 11 / 10 / 2022, page 12 / 41 4 / 19 spherical microstructure to be incorporated into a calendering roll to generate a microstructure, according to an exemplary embodiment of the present disclosure;

[0014] FIG. 4A is an illustration of a top view of an individual microstructure mold module with a microstructure matrix on a spherical surface, according to an exemplary embodiment of the present disclosure;

[0015] FIG. 4B is an illustration of a cross-sectional view of an individual microstructure mold module with a microstructure matrix on a spherical surface, according to an exemplary embodiment of the present disclosure;

[0016] FIG. 5 is an illustration of one or more individual microstructure mold modules with different microstructure designs, according to an exemplary embodiment of the present disclosure;

[0017] FIG. 6 is an illustration of different microstructure designs in a calendering roll, according to an exemplary embodiment of the present disclosure;

[0018] FIG. 7 is an illustration of a film extrusion and microstructure embossing system using rollers, according to an exemplary embodiment of the present disclosure;

[0019] FIG. 8 is an illustration of a film with microstructure matrices after embossing by the system of FIG. 7, according to an exemplary embodiment of the present disclosure;

[0020] FIG. 9 is a flow diagram of a method for creating microstructure matrices on a roll-by-roll film, according to an exemplary embodiment of the present development. DETAILED DESCRIPTION

[0021] The terms “one” or “an,” as used in this document, are defined as one or more than one. The term plurality, as used in this document, is defined as two or more than two. The term “another,” as used in this document, is defined as at least one 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 “a modality,” “certain modalities,” “a modality,” “an implementation,” “an example,” or Petition 870220093947, dated 11 / 10 / 2022, p. 13 / 41 5 / 19 Similar terms mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of this disclosure. Thus, the appearance of such phrases in multiple places throughout this descriptive report does not necessarily refer to the same embodiment. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments, without limitation.

[0022] The terms about and approximately are defined as being close to, as understood by someone skilled in the art.

[0023] The present disclosure process may comprise, consist essentially of, or consist of ingredients, components, particular compositions, etc., disclosed throughout the descriptive report.

[0024] According to one embodiment, the present disclosure describes a method for transforming a microstructure matrix designed for a spherical surface, for example, an ophthalmic surface, with different optical designs, into a flat surface, for example, a calendering roll surface. For example, this method can be used to transform the microstructure matrix design of the ophthalmic surface into the calendering roll surface. Consequently, the time and cost associated with designing microstructure matrices specifically for the spherical surface or the flat surface can be reduced.

[0025] According to one embodiment, the present disclosure describes a method for designing a spherical microstructure mold module to be incorporated into a calendering roll to generate a microstructure on a flat surface. For example, the method of designing a spherical microstructure mold module can be used for efficient embossing of microstructures on films with spherical surfaces by calendering rolls.

[0026] According to one embodiment, the present disclosure describes a method for calendering one or more microstructure matrices onto a film. For example, the method for calendering one or more microstructure matrices onto Petition 870220093947, dated 11 / 10 / 2022, page 14 / 41 6 / 19 a film can be used for calendering microstructure matrices onto an optical film of an ophthalmic lens with different optics and dimensions, for example, spherical and cylindrical powers, for example, monofocal or progressive vision, aspherical or spherical, or other lens diameters.

[0027] According to one embodiment, the present disclosure describes a method for designing a calendering roll sleeve which is made of individual interchangeable modules with one or more microstructure designs. Each individual module can be assembled or removed without affecting other modules. Consequently, the time and cost associated with producing ophthalmic lenses with different microstructures, different optics, and different dimensions can be reduced.

[0028] Returning now to the figures, a schematic illustration of the transformation of microstructure matrices from a spherical surface, for example, an ophthalmic surface in an ophthalmic lens with different optical designs, to a flat surface, for example, a calendering roll surface, will now be described with reference to FIG. 1. The ophthalmic lens material may be polycarbonate (PC), polymethyl methacrylate (PMMA), polystyrene, maleic anhydride polystyrene, polyamide, thermoplastic urethane, thermosetting 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 surface material of the calendering roll can be thermoplastic, glass, metal, or combinations thereof.The surface material of the calendering roll may have a softening temperature and / or glass transition temperature between 60 °C and 240 °C.

[0029] According to one embodiment, schematic illustration 100 represents the transformation of the design of a microstructure matrix 106 on a spherical surface 102 into a microstructure matrix 108 on a planar surface 104. The microstructure matrix 106 is represented by all open circles on the spherical surface 102. The microstructure matrix 106 can be a matrix design Petition 870220093947, dated 11 / 10 / 2022, page 15 / 41 7 / 19 of specific microstructure for a spherical surface 102 that will later be transformed into microstructure matrix 108 on the flat surface 104. The microstructure matrix 108 is represented by all the dashed circles on the flat surface 104.

[0030] According to one embodiment, the microstructure matrix may include optical microstructures such as microgrooves, microprisms, microlenses, Fresnel microstructure matrix, diffractive structures, microlens matrix, moth-eye microstructure matrix, and the like. The microstructure matrix may have different shapes, for example, squares, circles, ellipses, triangles, or a combination thereof. The microstructure matrix may have one or more variables, for example, length, width, pitch, duty cycle, etc. The microstructures may be arranged on film surfaces and are typically on the order of one hundredth of a millimeter in diameter to about 2 millimeters in diameter (0.01 mm to 2 mm), and about 1 micron in height, but may be between 0.01 µm and 100 µm in height.

[0031] In one embodiment, the spherical surface 102 may be a surface of an ophthalmic lens. The ophthalmic lens may contain film structures on the surface, for example, a single-layer film structure, a multi-layer film structure, a laminate, or a combination thereof. Consequently, specific microstructure arrays may be designed only onto specific film structures on the ophthalmic lens and may or may not be interchangeable.

[0032] According to one embodiment, the film structure may be a single-layer film structure comprising a photochromic dye, a blue light-blocking dye, a UV-cutting dye, an IR-blocking dye, or any other functional constituent.

[0033] According to one embodiment, the film structure may be a multilayer film structure including at least one layer comprising a photochromic dye, a blue light-blocking dye, a UV-blocking dye, an IR-blocking dye, or any other Petition 870220093947, dated 11 / 10 / 2022, page 16 / 41 8 / 19 functional constituent.

[0034] In one embodiment, the microstructures in the microstructure matrix 106 can be transformed from the spherical surface 102 to the planar surface 104 based on one or more parameters, for example, radius, curvatures, locations, etc. The transformation will be described in more detail with reference to FIG. 2.

[0035] In one embodiment, and with reference to FIG. 2, transforming microstructures into a microstructure matrix from a spherical surface 102 to a planar surface 202 in FIG. 2 can be achieved as illustrated in schematic illustration 200. For example, a microstructure point location of the microstructure matrix 106 on the spherical surface 102, which corresponds to a microstructure point location of the microstructure matrix 108 on the planar surface 104, can be calculated using the various parameters in FIG. 2. The parameters are described in more detail in the following paragraphs.

[0036] According to one embodiment, with reference to FIG. 2, the spherical surface 102 and the planar surface 104 are illustrated in FIG. 2. A planar surface of cross-section 202 is also illustrated in FIG. 2. In one embodiment, the planar surface of cross-section 202 may be on the same surface as the microstructure point of the microstructure matrix 106. The planar surface of cross-section 202 may be parallel to the planar surface 104. The planar surface of cross-section 202 may be perpendicular to line 212, for example, line 3 in FIG. 2. Line 212 may be defined as zero-degree latitude, for example, 0 degrees, of the spherical surface 102.

[0037] According to one embodiment, a first curvature 204 in FIG. 2, for example, a first angle α, can be calculated between lines 206 and 208 on the planar cross-sectional surface 202. Line 206, for example, line 1 in FIG. 2, can be a projection line of a ray, for example, line 214, of the spherical surface 102 in FIG. 2. The projection line 206 can be on the planar cross-sectional surface 202. In one embodiment, the first curvature can be a longitude of the microstructure point of the microstructure matrix 106 on the spherical surface 102. Line 208, for example, line 2 in FIG. 2, can be extended from a Petition 870220093947, dated 11 / 10 / 2022, page 17 / 41 9 / 19 center of the flat surface of cross-section 202 to an edge of the flat surface of cross-section 202. In one embodiment, line 208 can be defined as zero degrees of longitude, for example, 0 degrees of longitude, on the spherical surface 102.

[0038] According to one embodiment, a second curvature 210 in FIG. 2, for example, a second angle β, can be calculated between lines 212 and 214. Line 212, for example, line 3 in FIG. 2, can be extended from a center of the spherical surface 102 to an edge of the spherical surface 102. The edge of the spherical surface on line 212 can also be on the flat surface 104. Line 212 can be in contact with the flat surface 104. Line 212 can be extended from a center of the spherical surface 102 to a bottom of the spherical surface 102, and the bottom of the spherical surface 102 can be on the flat surface 104. Line 212 can be perpendicular to the flat surface 104. In one embodiment, line 212 can be defined as zero degrees latitude, for example, 0 degrees latitude, of the spherical surface 102. The second curvature 210 can be calculated as a latitude of the microstructure point of the microstructure matrix 106 on the spherical surface 102.

[0039] According to one embodiment, line 214 can be a radius, for example, r in FIG. 2, of the spherical surface 102. Line 214, for example, line 4 in FIG. 2, can be extended from a center of the spherical surface 102 to the microstructure point of the microstructure matrix 106. In one embodiment, the radius r of the spherical surface 102 can be between 50 mm and 800 mm.

[0040] According to one embodiment, after calculating the microstructure point location of the microstructure matrix 106 on the spherical surface 102 corresponding to the location, for example, p in FIG. 2, of the microstructure point of the microstructure matrix 108 on the planar surface 104 by the parameters described above, for example, the first curvature 204, the second curvature 210 and the radius 214. In one embodiment, the microstructure point location of the microstructure matrix 108 can be described as (α, p). The microstructure point location of the microstructure matrix 108 on the planar surface 104 can be defined by the first curvature α and the length p, for example, 216, can be Petition 870220093947, dated 11 / 10 / 2022, page 18 / 41 10 / 19 calculated using equation 1 as shown below. p = 2πΓβ / 360 (Eq. 1)

[0041] where p is the length of the microstructure point of the microstructure matrix 108 on the planar surface 104, ré the radius 214 of the spherical surface 102 and β is the second curvature 210. In one embodiment, for example, the location of the microstructure point of the microstructure matrix 108 on the planar surface 104 may have a first curvature α of 90 degrees and a length p of 20 mm.

[0042] According to one embodiment, and with reference to FIG. 3, a method 300 is a method for designing a spherical microstructure mold module to be incorporated into a calendering roll to generate a microstructure. The method 300 can be achieved, first, in step 302, by calculating a first curvature on a flat cross-sectional surface. The first curvature 204 is described earlier in FIG. 2. The first curvature 204 may lie between lines 206 and 208 in FIG. 2 on the flat cross-sectional surface 202. The first curvature 204 may represent a microstructure point longitude of the microstructure matrix 106 on the spherical surface 102 in FIG. 2. In one embodiment, each microstructure of the microstructure matrix may correspond to each individual microstructure mold module in the microstructure mold module.

[0043] According to one embodiment, secondly, in step 304 of method 300, method 300 is achieved by calculating a second curvature on a spherical surface. In one embodiment, the second curvature 210 can be the angle between lines 212 and 214 in FIG. 2 on the spherical surface 102. The second curvature 210 can represent a latitude of the microstructure point of the microstructure matrix 106 on the spherical surface 102 in FIG. 2.

[0044] According to one embodiment, thirdly, in step 306 of method 300, method 300 is achieved by measuring a radius of a spherical surface. In one embodiment, the radius can be line 214, for example, line 4 in FIG. 2. The radius of the spherical surface 102 can be in the range of 50 mm to 800 mm.

[0045] According to one embodiment, and with reference to FIG. 3, fourth, in step 308 of method 300, method 300 is achieved by determining a location Petition 870220093947, dated 11 / 10 / 2022, page 19 / 41 11 / 19 of the microstructure on the flat surface. In one embodiment, the determination of the location is achieved using equation 1 and the parameters provided in steps 302, 304, and 306. The order of the calculations in steps 302, 304, and 306 may not need to be the same as in FIG. 3. For example, 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 second curvatures are calculated.

[0046] In one embodiment, and with reference to FIG. 4A, a top view of an individual microstructure mold module with a microstructure matrix on a spherical surface is illustrated. For example, the microstructure matrix in the individual microstructure mold module in FIG. 4A may be the microstructure matrix 106 on the spherical surface 102 in FIG. 1. In one embodiment, the microstructure matrix in the individual microstructure mold module in FIG. 4A may be one of the microstructure mold modules in the spherical microstructure mold modules.

[0047] According to one embodiment, the microstructure matrix 106 in the individual microstructure mold module may include optical microstructures such as microgrooves, microprisms, microlenses, Fresnel microstructure matrix, diffractive structures, microlens matrix, moth-eye microstructure matrix and the like. The microstructure matrix may have different shapes in the microstructure matrix, for example, squares, circles, ellipses, triangles or a combination thereof. The microstructure matrix may have one or more variables for the microstructure matrix, for example, length, width, pitch, microstructure matrix duty cycle, etc. The microstructures may be arranged on film surfaces and may be between 0.01 mm to 2 mm in diameter and 0.01 µm to 100 µm in height.

[0048] According to one embodiment, the spherical surface 102 in FIG. 4A may be an ophthalmic lens surface. The lens may contain a single-layer film structure, a multi-layer film structure, or a laminate, etc.

[0049] In one embodiment, and with reference to FIG. 4B, a cross-sectional view of the individual microstructure mold module with a design of is illustrated. Petition 870220093947, dated 11 / 10 / 2022, page 20 / 41 12 / 19 Microstructure matrix on the spherical surface. The microstructure matrix design in FIG. 4B can be embossed onto the spherical surface. The microstructure matrix design can include different microstructures, for example, a square, a triangle, a circle, or a combination thereof. In one embodiment, the microstructures in the microstructure matrix can be between 0.01 mm and 2 mm in diameter and 0.01 µm and 100 µm in height.

[0050] In one embodiment, and with reference to FIG. 5, one or more individual microstructure mold modules with different microstructure designs are illustrated. Each optical microstructure design can correspond to a specific individual microstructure mold module in one or more individual microstructure mold modules. The different optical designs, for example, sku1, sku2, sku3, sku4, sku5, sku6, skuN in the individual microstructure mold modules can be arranged in a 502 film structure to create microstructure mold module arrays. In one embodiment, the microstructure mold module array can be on a spherical surface or on a flat surface. In some embodiments, the 502 film structure can be a single-layer film structure comprising optically sensitive materials, rubber, plastics, or a combination thereof.In some embodiments, the film structure may be a multilayer film structure comprising one or more films, for example, thermoplastic films, optical films, polymer films, or a combination thereof.

[0051] In one embodiment, and with reference to FIG. 6, different optical microstructure designs, for example, individual microstructure mold modules, are illustrated on the calendering roll 600. The calendering roll 600 may include a cylinder 602 and different microstructure designs on the individual microstructure mold modules, for example, microstructure mold module 604 with optical design sku1, microstructure mold module 606 with optical design sku2, microstructure mold module 608 with optical design sku3, microstructure mold module 610 with optical design sku4, microstructure mold module 612 with optical design sku5, microstructure mold module 614 with optical design Petition 870220093947, dated 11 / 10 / 2022, page 21 / 41 13 / 19 sku6, etc.

[0052] According to one embodiment, each individual microstructure mold module of the individual microstructure mold modules, for example, individual microstructure mold modules 604, 606, 608, 610, 612 and 614, can be attached to cylinder 602 by one or more bonding methods. For example, the method may include bonding the individual microstructure mold modules to cylinder 602 by a physical bonding method, for example, using high pressure or high temperature. For another example, the method may include bonding the individual microstructure mold modules to cylinder 602 by a chemical bonding method, for example, using materials such as epoxy, glue, etc.

[0053] According to one embodiment, the microstructure matrix in the individual microstructure mold module can be designed to be arranged on a spherical surface. For example, the microstructure matrix can be arranged on an ophthalmic lens surface.

[0054] According to one embodiment, the 602 cylinder can have a diameter between 20 mm and 300 mm and a length between 80 mm and 2000 mm. The 602 cylinder can be made of plastic, metal, glass, or a combination thereof.

[0055] In one embodiment, and with reference to FIG. 7, a system 700 for film extrusion and microstructure embossing is illustrated. The system 700 includes a calendering roll 600 and a regular roll 704. The calendering roll 600 is described in detail in FIG. 6. In one embodiment, the calendering roll 600 includes one or more individual microstructure mold modules 604, 606, 608, 610, 612 and 614, which are arranged on the cylinder 602 in FIG. 6.

[0056] According to one embodiment, each microstructure mold module of one or more individual microstructure mold modules may correspond to a microstructure matrix of one or more microstructure matrices to be embossed onto film 706. Furthermore, the microstructure matrix design in each microstructure mold module is different as described earlier in FIG. 6, for example, sku1, sku2, sku3, sku4, sku5 and sku6.

[0057] In some applications, the 600 calendering roll can be replaced Petition 870220093947, dated 11 / 10 / 2022, page 22 / 41 14 / 19 by a stamp. The stamp can be used to create microstructures on a film.

[0058] In addition, the 600 calendering roll can be integrated into an injection molding machine to create microstructure dies on surfaces, for example, optical surface, plastic surface or metallic surface, etc.

[0059] According to one embodiment, the system 700 may include a film extrusion machine 702. The film extrusion machine 702 may be a plastic film extrusion machine or similar. In one embodiment, the film extrusion machine 702 may extrude a film 706 between the regular roll 704 and the calendering roll 600. The film 706 may be a thermoplastic film, optically sensitive film, or similar.

[0060] According to one embodiment, the microstructure matrices on the film 706 can be embossed by one or more individual microstructure mold modules 604, 606, 608, 610, 612, 614 using the calendering roll 600. In one embodiment, the calendering roll 600 can be applied at a temperature with a certain range, for example, 60°C and 240°C, before starting the embossing process of one or more microstructure matrices on the film 706. The regular roll 704 can be applied at a temperature with a certain range, for example, 60°C and 240°C, before starting the embossing process of microstructure matrices on the film 706.

[0061] According to one embodiment, the regular roll 704 can be a cylinder with or without any pattern. In one embodiment, the regular roller 704 can be a cylinder with a smooth surface. The cylinder of the regular roller 704 can be made of metal, plastic, or a combination thereof.

[0062] In one embodiment, and with reference to FIG. 8, a product 800 including microstructure matrices 804 in a film 706 is illustrated. The microstructure matrices 804 in the film 706 are embossed by one or more individual microstructure mold modules 604, 606, 608, 610, 612, 614 on the calendering roll 600. In one embodiment, the film 706 with microstructure matrices 804 with different optical designs can be used as an optical film 706 of an ophthalmic lens. Each microstructure matrix of one or more microstructure matrices 804 can correspond to a respective microstructure mold module of the one or more Petition 870220093947, dated 11 / 10 / 2022, page 23 / 41 15 / 19 individual microstructure mold modules 604, 606, 608, 610, 612, 614 on optical film 706.

[0063] According to one embodiment, the 800 product can also be integrated into an inkjet printing device, a stamping device, a laminating device or an injection molding device, on any type of surface, for example, metal device surfaces, plastic device surfaces, glass device surfaces, etc., where ink can be absorbed.

[0064] According to one embodiment, the location of each microstructure mold module of one or more individual microstructure mold modules 604, 606, 608, 610, 612, 614 can be determined based on the first curvature 204, the second curvature 210, and the radius r of the optical film surface of the ophthalmic lens. The determination is described in detail above in the paragraphs associated with FIG. 2.

[0065] In one embodiment, and with reference to FIG. 9, a method 900 for creating microstructure matrices in a film, for example, a thermoplastic film, can be achieved, first in step 902 of method 900, by extruding a thermoplastic film between a regular roll and a calendering roll. In one embodiment, the regular roll can be roll 704 in FIG. 7 and the calendering roll can be roll 600 in FIG. 6 and FIG. 7.

[0066] According to one embodiment, after a thermoplastic film is extruded between rolls 704 and 600, in step 904 of method 900, one or more microstructure matrices are embossed onto the thermoplastic film by calendering roll 600. In one embodiment, structure 700 in FIG. 7 can be used to emboss one or more microstructure matrices onto the thermoplastic film.

[0067] Obviously, numerous modifications and variations are possible in light of the above teachings. It should therefore be understood that within the scope of the appended claims, the invention may be practiced in a manner other than as specifically described in this document.

[0068] Modalities of the present disclosure may also be as follows Petition 870220093947, dated 11 / 10 / 2022, page 24 / 41 16 / 19 established in the parentheses below.

[0069] (1) A method for designing a spherical microstructure mold module to be incorporated into a calendering roll to generate a microstructure on a flat surface, comprising calculating a first curvature on a flat cross-sectional surface to 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, being the radius from the center of the spherical surface to the first microstructure point, and determining a microstructure location on the flat surface, the location being derived from the first curvature, the second curvature and the radius.

[0070] (2) The method according to (1), wherein the first curvature is between a first line and a second line on the flat cross-sectional surface, the first curvature being a length of the first microstructure point in the spherical microstructure mold module.

[0071] (3) The method according to (2), wherein the first line is a projection line of the radius of the spherical surface onto the plane cross-section surface and the second line is from a center of the plane cross-section surface to an edge of the plane cross-section surface.

[0072] (4) The method according to (1), wherein 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 in the spherical microstructure mold module.

[0073] (5) The method according to (4), wherein the third line is from a center of a spherical surface of the spherical microstructure mold module to a bottom of the spherical surface and the fourth line is from the center of the spherical surface to the first microstructure point, the bottom of the spherical surface being on the flat surface.

[0074] (6) The method according to (1), wherein the calendering roll includes one or more microstructure molds in the spherical microstructure mold module, each microstructure mold of one or more microstructure molds having a Petition 870220093947, dated 11 / 10 / 2022, page 25 / 41 17 / 19 different microstructure design.

[0075] (7) A method of calendering one or more microstructure matrices onto a film, comprising extruding a thermoplastic film between a first roll and a second roll and embossing one or more microstructure matrices onto the thermoplastic film by the second roll, the second roll having one or more individual microstructure mold modules, each microstructure mold module of one or more individual microstructure mold modules corresponding to a microstructure matrix of one or more microstructure matrices.

[0076] (8) The method according to (7), wherein the first roll and the second roll are controlled to reach a predetermined temperature, the first roll including a smooth cylinder, the second roll including a cylinder and one or more individual microstructure mold modules being in the cylinder.

[0077] (9) The method according to (7), wherein each microstructure mold module of one or more individual microstructure mold modules has a different microstructure design.

[0078] (10) The method according to (9), wherein each microstructure design corresponding to each microstructure mold module is determined based on curvatures and a radius of the microstructure matrix in the film.

[0079] (11) A roll structure comprising a roll structure including a cylinder, at least one spherical microstructure mold module attached to the cylinder, and at least one microstructure mold die disposed on a spherical surface of a respective at least one spherical microstructure mold module, wherein the at least one microstructure die is applied to form microstructure dies in a thermoplastic film in contact with the roll structure.

[0080] (12) The roll structure according to (11), wherein the spherical microstructure mold module includes one or more microstructure molds.

[0081] (13) The roll structure according to (11), wherein the microstructure arrays are designed to be arranged on a spherical ophthalmic lens surface. Petition 870220093947, dated 11 / 10 / 2022, page 26 / 41 18 / 19

[0082] (14) A film for disposing of microstructures on an optical film of an ophthalmic lens, comprising one or more microstructure matrices on the optical film, the one or more microstructure matrices on the optical film being formed by a roll, wherein the roll includes one or more individual microstructure mold modules, each of the one or more individual microstructure mold modules corresponding to a respective one or more microstructure matrices on the optical film.

[0083] (15) The film according to (14), wherein a location of each microstructure in one or more microstructure arrays is determined based on the curvatures and a radius of the optical film of the ophthalmic lens.

[0084] (16) A method of molding one or more microstructure matrices onto a film, comprising extruding a thermoplastic film into a first device, and embossing one or more microstructure matrices onto the thermoplastic film by a second device, the second device 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 matrix of the one or more microstructure matrices.

[0085] (17) The method according to (16), wherein the first device is a molding device and the second device is a roll, the molding device having a flat surface and the roll including a cylinder and the one or more individual microstructure mold modules being in the cylinder.

[0086] (18) The method according to (16), wherein the first device is a stamping device and the second device is a metal stamp, the surfaces of the stamping device and metal stamp being flat.

[0087] (19) The method according to (16), further comprising the use of the stamping device to arrange one or more microstructure matrices in an optical film of an ophthalmic lens.

[0088] By providing the development capabilities, it is possible to manufacture microstructures (e.g., microlenses) without creating expensive custom rolls with multiple designs. Petition 870220093947, dated 11 / 10 / 2022, page 27 / 41 19 / 19 fixed. The interchangeable mold modules, designed with the shape of the roll and the eventual shape of the lens in mind, can be easily replaced when a new lens design or shape is envisioned or implemented. This customizable nature of the mold modules improves the manufacturing process, allowing for faster roll upgrades, corrections, and repairs, as only one or a few of the mold modules on the roll need to be replaced, leaving most of the roll intact. This contrasts with previous systems, which required the entire roll to be replaced when even one of the molds needed modification or repair.

[0089] Thus, the preceding discussion discloses and describes merely illustrative embodiments of the present invention. As will be understood by those skilled in the art, the present invention may be carried out in other specific forms without departing from the spirit or essential characteristics thereof. Consequently, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, as well as the other claims. The disclosure, including any readily discernible variants of the teachings of this document, defines, in part, the scope of the terminology of the aforementioned claim, so that no inventive subject matter is devoted to the public. Petition 870220093947, dated 11 / 10 / 2022, pp. 28 / 41

Claims

1 / 3 CLAIMS 1. Method for designing a spherical microstructure mold module to be incorporated into a calendering roll to generate a microstructure on a flat surface (104), characterized in that it comprises: calculating a first curvature (204) on a flat surface of cross-section (202) to a first microstructure point of the spherical microstructure mold module; calculating a second curvature (210) of a spherical surface (102) of the spherical microstructure mold module; measuring a radius (214) of the spherical surface (102), the radius (214) being from the center of the spherical surface (102) to the first microstructure point; and determining a microstructure location on the flat surface, the location being derived from the first curvature (204), the second curvature (210) and the radius (214).

2. Method according to claim 1, characterized in that the first curvature (204) is between a first line (206) and a second line (208) on the flat cross-sectional surface (202), the first curvature (204) being a longitude of the first microstructure point in the spherical microstructure mold module.

3. Method according to claim 2, characterized in that the first line (206) is a projection line of the radius (214) of the spherical surface (102) onto the flat cross-sectional surface (202) and the second line (208) is from a center of the flat cross-sectional surface (202) to an edge of the flat cross-sectional surface (202).

4. Method according to claim 1, characterized in that the second curvature (210) is between a third line (212) and a fourth line (214) on the spherical surface (102), the second curvature (210) being a latitude of the first microstructure point in the spherical microstructure mold module.

5. Method according to claim 4, characterized in that Petition 870240104040, dated 06 / 12 / 2024, page 11 / 16 2 / 3 the third line (212) is from a center of a spherical surface (102) of the spherical microstructure mold module to a bottom of the spherical surface (102) and the fourth line (214) is from the center of the spherical surface (102) to the first microstructure point, the bottom of the spherical surface (102) being on the flat surface (104).

6. Method according to claim 1, characterized in that the calendering roll (600) includes one or more microstructure molds in the spherical microstructure mold module, each microstructure mold having one or more microstructure molds having a different microstructure design.

7. A method for calendering one or more microstructure matrices onto a film, characterized in that it comprises: extruding a thermoplastic film between a first roll and a second roll; and embossing one or more microstructure matrices onto the thermoplastic film by the second roll, the second roll having one or more spherical microstructure mold modules according to the method defined in any one of claims 1 to 6, each microstructure mold module of the one or more spherical microstructure mold modules corresponding to a microstructure matrix of the one or more microstructure matrices.

8. A method according to claim 7, characterized in that the first roller and the second roller are controlled to reach a predetermined temperature, the first roller including a smooth cylinder, the second roller including a cylinder, and one or more spherical microstructure mold modules being on the cylinder.

9. A method according to claim 7, characterized in that each microstructure mold module of one or more individual spherical microstructure mold modules has a different microstructure design.

10. Method, according to claim 9, characterized in that each spherical microstructure design corresponding to each microstructure mold module is determined based on curvatures and a radius of the microstructure matrix in the film.

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