Method for producing microstructures on films by means of rollers

Abstract

The present disclosure relates to a method for designing a spherical microstructure mold (604-614) module to be incorporated into a calendering roll (600) to produce a microstructure (108) on a planar surface (104), the method comprising: calculating a first curvature (204) on a cross-sectional planar surface (202) of a first microstructure point of the spherical microstructure mold module; calculating a second curvature (210) of the spherical surface (102) of the spherical microstructure mold module; measuring a radius (214) of the spherical surface (102), the radius (214) being from a center of the spherical surface (102) to the first microstructure point; and determining a location of the microstructure (108) on the planar surface (104), the location being derived from the first curvature (204), the second curvature (210), and the radius (214).

Description

Background Art Technical Field

[0001] The present disclosure relates to a method for producing microstructures on films by incorporating a spherical microstructured mold module design into a calendering roll.

[0002] Related technical notes

[0003] Larger microstructure arrays have been designed for use in ophthalmic lens products. Ophthalmic lens products typically consist of a lens and a film, with the film typically laminated onto the optical surface of the lens. The optical surface of an ophthalmic lens is typically spherical. However, because the film is a planar surface before application to the lens, the microstructure array on the optical surface is distorted when transferred to the film surface.

[0004] The foregoing "background technology" description is intended to generally introduce the context of the present disclosure. The work of the inventors described in this background section, as well as aspects of this description that may not be identified as prior art at the time of filing, are neither explicitly nor implicitly admitted to be prior art against the present disclosure. Summary of the Invention

[0005] The present disclosure relates to a method of designing a spherical microstructured mold module to be incorporated into a calendar roll to produce microstructures on a film.

[0006] According to an embodiment, the present disclosure relates to a method for designing a spherical microstructure mold module to be incorporated into a calendering roller to produce a microstructure on a planar surface, the method comprising: calculating a first curvature on a cross-sectional plane surface of a first microstructure point of the spherical microstructure mold module; calculating a second curvature of the spherical surface of the spherical microstructure mold module; measuring a radius of the spherical surface, the radius from the center of the spherical surface to the first microstructure point; and determining a positioning of the microstructure on the planar surface, the positioning 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 cross-sectional plane surface, the first curvature is the longitude of the first microstructure point on the spherical microstructure mold module, and the second curvature is between a third line and a fourth line on the spherical surface, the second curvature is the latitude of the first microstructure point on the spherical microstructure mold module.

[0007] According to an embodiment, the present disclosure further relates to a method for calendering one or more microstructure arrays on a film, the method comprising: extruding a thermoplastic film between a first roller and a second roller; and embossing one or more microstructure arrays on the thermoplastic film through the second roller, the second roller having one or more separate microstructure mold modules, each of the one or more separate microstructure mold modules corresponding to a microstructure array in the one or more microstructure arrays, wherein the first roller and the second roller are controlled to reach a predetermined temperature and a predetermined pressure, the first roller comprises a smooth cylinder, the second roller comprises a cylinder and the one or more separate microstructure mold modules, and the one or more separate microstructure mold modules are on the cylinder.

[0008] According to an embodiment, the present disclosure further relates to a roller structure comprising: a roller structure comprising a cylinder; at least one spherical microstructure mold module, the at least one spherical microstructure mold module being attached to the cylinder; and at least one microstructure mold array, the at least one microstructure mold array being arranged on a spherical surface of a corresponding spherical microstructure mold module in the at least one spherical microstructure mold module, wherein the at least one microstructure array is applied to form a microstructure array on a thermoplastic film contacting the roller structure, wherein the spherical microstructure mold module comprises one or more microstructure molds, and the microstructure array is designed to be arranged on the surface of a spherical ophthalmic lens.

[0009] According to an embodiment, the present disclosure further relates to a film for setting microstructures on an optical film of an ophthalmic lens, the film including one or more microstructure arrays on the optical film, the one or more microstructure arrays on the optical film being formed by a roller, wherein the roller includes one or more separate microstructure mold modules, each of the one or more separate microstructure mold modules corresponds to a corresponding microstructure array in the one or more microstructure arrays on the optical film, and wherein the positioning of each microstructure in the one or more microstructure arrays is determined based on the curvature and radius of the optical film of the ophthalmic lens.

[0010] The foregoing paragraphs are provided as a general introduction and are not intended to limit the scope of the appended claims.The described embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A more complete appreciation thereof will be readily obtained as the present disclosure and many of its attendant advantages become better understood by reference to the following detailed description considered in conjunction with the accompanying drawings, in which:

[0012] Figure 1is an illustration of a method for converting a microstructure array from a spherical surface to a planar surface according to an exemplary embodiment of the present disclosure;

[0013] Figure 2 is a graphical representation of calculating positioning of a microstructure array on a planar surface corresponding to positioning of a microstructure array on a spherical surface according to an exemplary embodiment of the present disclosure;

[0014] Figure 3 is a flow chart of designing a spherical microstructure mold module to be incorporated into a calendaring roll to produce microstructures according to an exemplary embodiment of the present disclosure;

[0015] Figure 4A is an illustration of a top view of an individual microstructure mold module having an array of microstructures on a spherical surface according to an exemplary embodiment of the present disclosure;

[0016] Figure 4B is an illustration of a cross-sectional view of an individual microstructure mold module having an array of microstructures on a spherical surface according to an exemplary embodiment of the present disclosure;

[0017] Figure 5 is an illustration of one or more separate microstructure mold modules having different microstructure designs according to an exemplary embodiment of the present disclosure;

[0018] Figure 6 is an illustration of different microstructure designs on a calendering roll according to an exemplary embodiment of the present disclosure;

[0019] Figure 7 is a diagram of a system for film extrusion and microstructure imprinting by rollers according to an exemplary embodiment of the present disclosure;

[0020] Figure 8 The film according to the exemplary embodiment of the present disclosure is Figure 7 Illustration of the system with a microstructure array after imprinting;

[0021] Figure 9 is a flow chart of a method for creating a microstructure array on a film by a roller according to an exemplary embodiment of the disclosure. DETAILED DESCRIPTION

[0022] As used herein, the terms "one" or "an" are defined as one or more than one. As used herein, the terms "plurality" are defined as two or more than two. As used herein, the term "another" is defined as at least a second or more. As used herein, the terms "comprising" and / or "having" are defined as including (i.e., open language). References to "one embodiment," "certain embodiments," "embodiments," "implementations," "examples," or similar terms throughout this document mean that the specific features, structures, or characteristics described in conjunction with the embodiment are included in at least one embodiment of the present disclosure. Therefore, the appearance of such phrases throughout this specification or their appearance in various places do not necessarily refer to the same embodiment. In addition, specific features, structures, or characteristics may be combined in any appropriate manner in one or more embodiments without restriction.

[0023] The terms "about" and "approximately" are defined as approximately what one skilled in the art understands.

[0024] The disclosed methods may "comprise," "consist essentially of," or "consist of" the specific ingredients, components, compositions, etc. disclosed throughout this specification.

[0025] According to embodiments, the present disclosure describes a method for transferring a microstructure array designed for a spherical surface (e.g., an ophthalmic surface) with a different optical design to a planar surface (e.g., a calendar roll surface). For example, this method can be used to transfer a microstructure array design from an ophthalmic surface to a calendar roll surface. Accordingly, the time and cost associated with designing a microstructure array specifically for a spherical surface or a planar surface can be reduced.

[0026] According to an embodiment, the present disclosure describes a method for designing a spherical microstructure mold module to be incorporated into a calendar roll to produce microstructures on a planar surface. For example, the method for designing a spherical microstructure mold module can be used to efficiently emboss microstructures on a film using a spherical surface through a calendar roll.

[0027] According to embodiments, the present disclosure describes a method for calendering one or more microstructure arrays on a film. For example, the method for calendering one or more microstructure arrays on a film can be used to calender microstructure arrays on an optical film for ophthalmic lenses having different optical properties and sizes (e.g., spherical and cylindrical powers, single vision or progressive vision, aspherical lens diameters, spherical lens diameters, or other lens diameters).

[0028] According to one embodiment, this disclosure describes a method for designing a calendaring roll sleeve made of individually interchangeable modules with one or more microstructure designs. Each individual module can be assembled or removed without affecting the others. Consequently, the time and cost associated with producing ophthalmic lenses with varying microstructures, optical properties, and sizes can be reduced.

[0029] Turning now to the drawings, reference will now be made to Figure 1 A schematic diagram depicting the conversion of a microstructure array from a spherical surface (e.g., an ophthalmic surface on an ophthalmic lens having different optical designs) to a planar surface (e.g., a calendering roller surface). The material of the ophthalmic lens can be polycarbonate (PC), polymethyl methacrylate (PMMA), polystyrene, polystyrene maleic anhydride, polyamide, thermoplastic polyurethane, thermoset polyurethane, polyester, copolyester, polysulfone, cyclic olefin copolymer (OCO), polydioxyphenylene, allyl diglycol carbonate, polythiourethane, episulfide polymer, epoxy resin, poly(meth)acrylate, polythiomethacrylate, or a combination thereof. The material of the calendering roller surface can be a thermoplastic material, glass, metal, or a combination thereof. The material of the calendering roller surface can have a softening temperature and / or a glass transition temperature between 60° C. and 240° C.

[0030] Schematic diagram 100 depicts the conversion of a design of a microstructure array 106 on a spherical surface 102 into a microstructure array 108 on a planar surface 104, according to an embodiment. Microstructure array 106 is represented by all hollow circles on spherical surface 102. Microstructure array 106 may be a specific microstructure array design for spherical surface 102 that will later be converted into microstructure array 108 on planar surface 104. Microstructure array 108 is represented by all dotted circles on planar surface 104.

[0031] According to an embodiment, the microstructure array may include optical microstructures such as microgrooves, microprisms, microlenses, Fresnel microstructure arrays, diffraction structures, microlens arrays, moth-eye microstructure arrays, etc. The microstructure array may have different shapes in the microstructure array, such as square, circular, elliptical, triangular, or a combination thereof. The microstructure array may have one or more variables for the microstructure array, such as the length, width, spacing, duty cycle, etc. of the microstructure array. The microstructures may be provided on the surface of a film, the diameter of which is typically about one hundredth of a millimeter to about 2 millimeters (0.01 mm to 2 mm) and the height is typically about 1 micron, but the height may be between 0.01 μm and 100 μm.

[0032] In an embodiment, the spherical surface 102 may be the surface of an ophthalmic lens. The ophthalmic lens may include a film structure on the surface, such as a single-layer film structure, a multi-layer film structure, a laminate, or a combination thereof. Accordingly, a specific microstructure array may be designed only on a specific film structure on the ophthalmic lens and may or may not be interchangeable.

[0033] According to an embodiment, the film structure may be a single-layer film structure including a photochromic dye, a blue-cut dye, a UV-cut dye, an IR-cut dye, or any other functional component.

[0034] According to an embodiment, the film structure may be a multi-layer film structure including at least one layer including a photochromic dye, a blue light cut-off dye, a UV cut-off dye, an IR cut-off dye, or any other functional component.

[0035] In an embodiment, the microstructures on the microstructure array 106 can be transformed from a spherical surface 102 to a planar surface 104 based on one or more parameters (eg, radius, curvature, positioning, etc.). Figure 2 This conversion is described in more detail.

[0036] In the examples, and with reference to Figure 2 , converting the microstructures in the microstructure array from the spherical surface 102 to Figure 2 The planar surface 202 in the diagram can be implemented as shown in the schematic diagram 200. For example, Figure 2 Various parameters in φ calculate the positioning of the microstructure points of the microstructure array 106 on the spherical surface 102 corresponding to the positioning of the microstructure points of the microstructure array 108 on the planar surface 104. These parameters are described in more detail in the following paragraphs.

[0037] According to the embodiment, reference Figure 2 , Figure 2 A spherical surface 102 and a planar surface 104 are shown. Figure 2 Also shown is a cross-sectional planar surface 202. In an embodiment, the cross-sectional planar surface 202 may be on the same surface as the microstructure points of the microstructure array 106. The cross-sectional planar surface 202 may be parallel to the planar surface 104. The cross-sectional planar surface 202 may be perpendicular to the line 212 (e.g., Figure 2 3). Line 212 may be defined as the zero latitude (eg, 0 degrees) of spherical surface 102.

[0038] According to an embodiment, the line 206 and the line 208 on the cross-sectional plane surface 202 may be calculated. Figure 2 The first curvature 204 (eg, first angle α) of the line 206 (eg, Figure 2 Line 1) in can be Figure 2The projection line 206 may be on the cross-sectional plane surface 202. In an embodiment, the first curvature may be the longitude of the microstructure points of the microstructure array 106 on the spherical surface 102. The line 208 (e.g., Figure 2 The line 208 may extend from the center of the cross-sectional plane surface 202 to the edge of the cross-sectional plane surface 202. In an embodiment, the line 208 may be defined as zero degrees longitude (eg, 0 degrees longitude) on the spherical surface 102.

[0039] According to an embodiment, the value of the scalar value may be calculated between line 212 and line 214. Figure 2 The second curvature 210 (eg, the second angle β) in the line 212 (eg, Figure 2 3) can extend from the center of the spherical surface 102 to the edge of the spherical surface 102. The edge of the spherical surface on the line 212 can also be on the planar surface 104. The line 212 can contact the planar surface 104. The line 212 can extend from the center of the spherical surface 102 to the bottom of the spherical surface 102, and the bottom of the spherical surface 102 can be on the planar surface 104. The line 212 can be perpendicular to the planar surface 104. In an embodiment, the line 212 can be defined as the zero degree latitude (e.g., 0 degree latitude) of the spherical surface 102. The second curvature 210 can be calculated as the latitude of the microstructure points of the microstructure array 106 on the spherical surface 102.

[0040] According to an embodiment, line 214 may be a radius of spherical surface 102 (eg, Figure 2 r in ). Line 214 (e.g., Figure 2 The line 4) in FIG. 4 may extend from the center of the spherical surface 102 to a microstructure point of the microstructure array 106. In an embodiment, the radius r of the spherical surface 102 may be between 50 mm and 800 mm.

[0041] According to an embodiment, the positioning of the microstructure points of the microstructure array 108 on the planar surface 104 (eg, first curvature 204, second curvature 210 and radius 214) is calculated by the parameters described above. Figure 2 After the microstructure points of the microstructure array 106 corresponding to the first curvature α and the length ρ (e.g., 216) are positioned on the spherical surface 102. In an embodiment, the positioning of the microstructure points of the microstructure array 108 can be described as (α, ρ). The positioning of the microstructure points of the microstructure array 108 on the planar surface 104 can be defined by the first curvature α and the length ρ (e.g., 216). The length ρ can be calculated by the following equation 1.

[0042] ρ = 2πrβ / 360 (Equation 1)

[0043] Where p is the length of the microstructure points of the microstructure array 108 on the planar surface 104, r is the radius 214 of the spherical surface 102, and β is the second curvature 210. In an embodiment, for example, the positioning of the microstructure points of the microstructure array 108 on the planar surface 104 may have a first curvature α of 90 degrees and a length p of 20 mm.

[0044] According to the embodiment, and reference Figure 3 , method 300 is a method of designing a spherical microstructure mold module to be incorporated into a calendaring roll to produce a microstructure. Method 300 may be implemented by first calculating a first curvature on a cross-sectional plane surface at step 302. Figure 2 The first curvature 204 is described in Figure 2 In FIG, the first curvature 204 may be between line 206 and line 208 on the cross-sectional plane surface 202. Figure 2 , the first curvature 204 may represent the longitude of a microstructure point of the microstructure array 106 on the spherical surface 102. In an embodiment, each microstructure of the microstructure array may correspond to each individual microstructure mold module in the microstructure mold module.

[0045] According to an embodiment, secondly, at step 304 of method 300, method 300 is implemented by calculating a second curvature on the spherical surface. Figure 2 In , the second curvature 210 may be the angle between the line 212 and the line 214 on the spherical surface 102. Figure 2 , the second curvature 210 may represent the latitude of a microstructure point of the microstructure array 106 on the spherical surface 102 .

[0046] According to an embodiment, again, at step 306 of method 300, method 300 is implemented by measuring the radius of the spherical surface. In an embodiment, the radius can be line 214 (e.g., Figure 2 The radius of the spherical surface 102 may range from 50 mm to 800 mm.

[0047] According to the embodiment, and reference Figure 3 Finally, at step 308 of method 300, method 300 is implemented by determining the location of the microstructure on the planar surface. In an embodiment, the location is determined by using equation 1 and the parameters provided in steps 302, 304, and 306. The order of the calculations in steps 302, 304, and 306 does not have to be the same. Figure 3 For example, the second curvature may be calculated before the first curvature is calculated, or the radius of the spherical surface may be measured before the first curvature and the second curvature are calculated.

[0048] In the examples, and with reference to Figure 4A , shows a top view of a separate microstructured mold module having a microstructure array on a spherical surface. For example, Figure 4A The microstructure array in the individual microstructure mold modules can be Figure 1 In an embodiment, the microstructure array 106 is formed on the spherical surface 102. Figure 4A The microstructure array in the separate microstructure mold module can be one of the microstructure mold modules in the spherical microstructure mold module.

[0049] According to an embodiment, the microstructure array 106 in the separate microstructure mold module may include optical microstructures such as microgrooves, microprisms, microlenses, Fresnel microstructure arrays, diffraction structures, microlens arrays, moth-eye microstructure arrays, etc. The microstructure array may have different shapes in the microstructure array, such as square, circular, elliptical, triangular, or a combination thereof. The microstructure array may have one or more variables for the microstructure array, such as the length, width, spacing, duty cycle, etc. of the microstructure array. The microstructure may be provided on the film surface and may have a diameter between 0.01 mm and 2 mm and a height between 0.01 μm and 100 μm.

[0050] According to an embodiment, Figure 4A The spherical surface 102 in the embodiment can be the surface of an ophthalmic lens. The lens can include a single-layer film structure, a multi-layer film structure, or a laminate, etc.

[0051] In the examples, and with reference to Figure 4B , showing a cross-sectional view of an individual microstructured mold module having a microstructure array design on a spherical surface. Figure 4B The microstructure array design in the embodiment can be embossed on a spherical surface. The microstructure array design can include different microstructures, such as square, triangular, circular, or a combination thereof. In an embodiment, the microstructures in the microstructure array can have a diameter between 0.01 mm and 2 mm and a height between 0.01 μm and 100 μm.

[0052] In the examples, and with reference to Figure 5, showing one or more separate microstructure mold modules with different microstructure designs. Each optical microstructure design can correspond to a specific separate microstructure mold module in one or more separate microstructure mold modules. The different optical designs (e.g., sku1, sku2, sku3, sku4, sku5, sku6, skuN) in the separate microstructure mold modules can be set on the membrane structure 502 to produce an array of microstructure mold modules. In an embodiment, the microstructure mold module can be on a spherical surface or on a planar surface. In some embodiments, the membrane structure 502 can be a single-layer membrane structure comprising an optically sensitive material, rubber, plastic, or a combination thereof. In some embodiments, the membrane structure can be a multilayer membrane structure comprising one or more films (e.g., thermoplastic film, optical film, polymer film, or a combination thereof).

[0053] In the examples, and with reference to Figure 6 , showing different microstructure optical designs (e.g., separate microstructure mold modules) on a calendering roller 600. The calendering roller 600 may include a cylinder 602 and different microstructure designs in separate microstructure mold modules, such as a microstructure mold module 604 with an optical design sku1, a microstructure mold module 606 with an optical design sku2, a microstructure mold module 608 with an optical design sku3, a microstructure mold module 610 with an optical design sku4, a microstructure mold module 612 with an optical design sku5, and a microstructure mold module 614 with an optical design sku6.

[0054] According to an embodiment, each of the individual microstructure mold modules (e.g., individual microstructure mold modules 604, 606, 608, 610, 612, and 614) can be attached to the cylinder 602 by one or more bonding methods. For example, the method can include bonding the individual microstructure mold modules to the cylinder 602 by a physical bonding method (e.g., using high pressure or high temperature). For another example, the method can include bonding the individual microstructure mold modules to the cylinder 602 by a chemical bonding method (e.g., using a material such as epoxy resin, glue, etc.).

[0055] According to an embodiment, the microstructure array in a separate microstructure mold module can be designed to be disposed on a spherical surface. For example, the microstructure array can be disposed on the surface of an ophthalmic lens.

[0056] According to an embodiment, the diameter of the cylinder 602 may be between 20 mm and 300 mm and the length may be between 80 mm and 2000 mm. The cylinder 602 may be made of plastic, metal, glass, or a combination thereof.

[0057] In the examples, and with reference to Figure 7, a system 700 for film extrusion and microstructure embossing is shown. The system 700 includes a calender roll 600 and a conventional roll 704. Figure 6 In an embodiment, the calendering roller 600 includes one or more separate microstructure mold modules 604, 606, 608, 610, 612 and 614, which are arranged at the bottom of the calendering roller 600. Figure 6 On the cylinder 602 in the middle.

[0058] According to an embodiment, each microstructure mold module of the one or more separate microstructure mold modules may correspond to a microstructure array in the one or more microstructure arrays to be imprinted on the film 706. In addition, the microstructure array design in each microstructure mold module is the same as previously described. Figure 6 The microstructure array designs described in (e.g., sku1, sku2, sku3, sku4, sku5, and sku6) are different.

[0059] In some embodiments, the calendar roll 600 may be replaced by a stamp. A stamp can be used to create microstructures on the film.

[0060] Additionally, the calendar roll 600 can be integrated with an injection molding machine to produce an array of microstructures on a surface (eg, an optical surface, a plastic surface, a metal surface, etc.).

[0061] According to an embodiment, the system 700 may include a film extruder 702. The film extruder 702 may be a plastic film extruder, etc. In an embodiment, the film extruder 702 may extrude a film 706 between a conventional roller 704 and a calendar roller 600. The film 706 may be a thermoplastic film, an optically sensitive film, etc.

[0062] According to an embodiment, a calendering roller 600 may be used to emboss a microstructure array onto a film 706 using one or more individual microstructure mold modules 604, 606, 608, 610, 612, 614. In an embodiment, a temperature within a range (e.g., 60° C. to 240° C.) may be applied to the calendering roller 600 prior to commencing the process of embossing one or more microstructure arrays onto the film 706. In an embodiment, a temperature within a range (e.g., 60° C. to 240° C.) may be applied to the conventional roller 704 prior to commencing the process of embossing the microstructure array onto the film 706.

[0063] According to the embodiment, the conventional roller 704 can be a cylinder with or without any pattern. In the embodiment, the conventional roller 704 can be a cylinder with a smooth surface. The cylinder of the conventional roller 704 can be made of metal, plastic, or a combination thereof.

[0064] In the examples, and with reference to Figure 8, a product 800 is shown that includes a microstructure array 804 on a film 706. The microstructure array 804 on the film 706 is embossed by one or more individual microstructure mold modules 604, 606, 608, 610, 612, 614 on a calendar roll 600. In an embodiment, a film 706 having different optical designs of microstructure arrays 804 can be used as an optical film 706 for an ophthalmic lens. Each microstructure array of the one or more microstructure arrays 804 can correspond to a corresponding microstructure mold module in the one or more individual microstructure mold modules 604, 606, 608, 610, 612, 614 on the optical film 706.

[0065] According to an embodiment, the product 800 can be further integrated with an inkjet printing device, a stamping device, a laminating device, or an injection molding device on any type of surface (e.g., a metal device surface, a plastic device surface, a glass device surface, etc., where the ink can be absorbed).

[0066] According to an embodiment, the positioning of each of the 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 surface of the optical film of the ophthalmic lens. Figure 2 This determination is described in detail in the associated paragraphs.

[0067] In the examples, and with reference to Figure 9 The method 900 for producing an array of microstructures on a film (e.g., a thermoplastic film) can be implemented by first extruding the thermoplastic film between a conventional roller and a calendaring roller at step 902 of the method 900. In an embodiment, the conventional roller can be Figure 7 The roller 704 in the calendering roller can be Figure 6 and Figure 7 Roller 600 in.

[0068] According to an embodiment, after the thermoplastic film is extruded between roller 704 and roller 600, at step 904 of method 900, one or more microstructure arrays are embossed on the thermoplastic film by calendering roller 600. In an embodiment, the thermoplastic film may be formed using Figure 7 The structure 700 in FIG. 1 is an array of one or more microstructures embossed into a thermoplastic film.

[0069] Obviously, many modifications and variations are possible in light of the above teachings.It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.

[0070] Embodiments of the present disclosure may also be described as follows in brackets.

[0071] (1) A method for designing a spherical microstructure mold module to be incorporated into a calendering roller to produce a microstructure on a planar surface, the method comprising: calculating a first curvature on a cross-sectional planar surface of a first microstructure point of the spherical microstructure mold module; calculating a second curvature of the spherical surface of the spherical microstructure mold module; measuring a radius of the spherical surface, the radius being from a center of the spherical surface to the first microstructure point; and determining a position of the microstructure on the planar surface, the position being derived from the first curvature, the second curvature, and the radius.

[0072] (2) The method according to (1), wherein the first curvature is between the first line and the second line on the cross-sectional plane surface, and the first curvature is the longitude of the first microstructure point on the spherical microstructure mold module.

[0073] (3) The method according to (2), wherein the first line is a projection line of the radius of the spherical surface on the cross-sectional plane surface, and the second line is from the center of the cross-sectional plane surface to the edge of the cross-sectional plane surface.

[0074] (4) The method according to (1), wherein the second curvature is between a third line and a fourth line on the spherical surface, and the second curvature is the latitude of the first microstructure point on the spherical microstructure mold module.

[0075] (5) The method according to (4), wherein the third line is from the center of the spherical surface of the spherical microstructure mold module to the bottom of the spherical surface, and the fourth line is from the center of the spherical surface to the first microstructure point, and the bottom of the spherical surface is on the plane surface.

[0076] (6) The method according to (1), wherein the calendering roller includes one or more microstructure molds on the spherical microstructure mold module, and each of the one or more microstructure molds has a different microstructure design.

[0077] (7) A method for calendering one or more microstructure arrays on a film, the method comprising: extruding a thermoplastic film between a first roller and a second roller; and embossing one or more microstructure arrays on the thermoplastic film by the second roller, the second roller having one or more separate microstructure mold modules, each microstructure mold module in the one or more separate microstructure mold modules corresponding to a microstructure array in the one or more microstructure arrays.

[0078] (8) The method according to (7), wherein the first roller and the second roller are controlled to reach a predetermined temperature, the first roller comprises a smooth cylinder, the second roller comprises a cylinder and the one or more individual microstructure mold modules, and the one or more individual microstructure mold modules are on the cylinder.

[0079] (9) The method according to (7), wherein each of the one or more separate microstructure mold modules has a different microstructure design.

[0080] (10) The method according to (9), wherein each microstructure design corresponding to each microstructure mold module is determined based on the curvature and radius of the microstructure array on the film.

[0081] (11) A roller structure comprising: a roller structure comprising a cylinder; at least one spherical microstructure mold module, the at least one spherical microstructure mold module being attached to the cylinder; and at least one microstructure mold array, the at least one microstructure mold array being arranged on a spherical surface of a corresponding spherical microstructure mold module in the at least one spherical microstructure mold module, wherein the at least one microstructure array is applied to form a microstructure array on a thermoplastic film contacting the roller structure.

[0082] (12) The roller structure according to (11), wherein the spherical microstructure mold module includes one or more microstructure molds.

[0083] (13) The roller structure according to (11), wherein the microstructure array is designed to be provided on a surface of a spherical ophthalmic lens.

[0084] (14) A film for setting microstructures on an optical film of an ophthalmic lens, the film including one or more microstructure arrays on the optical film, the one or more microstructure arrays on the optical film being formed by a roller, wherein the roller includes one or more separate microstructure mold modules, each microstructure mold module in the one or more separate microstructure mold modules corresponds to a corresponding microstructure array in the one or more microstructure arrays on the optical film.

[0085] (15) The film of (14), wherein the positioning of each microstructure in the one or more microstructure arrays is determined based on the curvature and radius of the optical film of the ophthalmic lens.

[0086] (16) A method for molding one or more microstructure arrays on a film, the method comprising: extruding a thermoplastic film into a first device; and embossing one or more microstructure arrays on the thermoplastic film through a second device, the second device having one or more separate microstructure mold modules, each microstructure mold module in the one or more separate microstructure mold modules corresponding to a microstructure array in the one or more microstructure arrays.

[0087] (17) The method of (16), wherein the first device is a molding device and the second device is a roller, the molding device has a planar surface, the roller comprises a cylinder, and the one or more individual microstructure mold modules are on the cylinder.

[0088] (18) The method according to (16), wherein the first device is a stamping device and the second device is a metal die, and the surfaces of the stamping device and the metal die are planar.

[0089] (19) The method according to (16) further includes using the stamping device to set the one or more microstructure arrays on the optical film of the ophthalmic lens.

[0090] By providing the features of the present disclosure, microstructures (e.g., microlenses) can be manufactured without the need to produce expensive custom rollers with many fixed designs. Replaceable mold modules, designed with the shape of the roller and the final shape of the lens in mind, can be easily replaced as new designs or lens shapes are conceived or implemented. The customizable nature of these mold modules improves the manufacturing process because only one or a few mold modules on the roller need to be replaced, leaving the majority of the roller intact, allowing for faster updating, calibration, and repair of the roller. This is in contrast to previous systems that required replacement of the entire roller when even one of the molds needed modification or repair.

[0091] Therefore, the foregoing discussion discloses and describes only exemplary embodiments of the present invention. As will be appreciated by those skilled in the art, the present invention may be embodied in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the disclosure of the present invention is intended to be illustrative, rather than limiting, the scope of the present invention and the scope of the other claims. This disclosure (including any readily discernible variations of the teachings herein) partially defines the scope of the aforementioned claim terms so that no creative subject matter is dedicated to the public.

Claims

1. A method of designing a spherical microstructured mold module to be incorporated into a calendar roll to produce microstructures on a planar surface (104), the method comprising: Calculating a first curvature (204) on a cross-sectional plane surface (202) of a first microstructure point of the spherical microstructure mold module; Calculating a second curvature (210) of the spherical surface (102) of the spherical microstructure mold module; measuring a radius (214) of the spherical surface (102), the radius (214) being from a center of the spherical surface (102) to the first microstructure point; as well as A position of the microstructure on the planar surface is determined, the position being derived from the first curvature (204), the second curvature (210), and the radius (214).

2. The method according to claim 1, wherein The first curvature (204) is between a first line (206) and a second line (208) on the cross-sectional plane surface (202), and the first curvature (204) is the longitude of the first microstructure point on the spherical microstructure mold module.

3. The method according to claim 2, wherein: The first line (206) is a projection line of a radius (214) of the spherical surface (102) onto the cross-sectional plane surface (202), and the second line (208) runs from a center of the cross-sectional plane surface (202) to an edge of the cross-sectional plane surface (202).

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

5. The method according to claim 4, wherein The third line (212) runs from the center of the spherical surface (102) of the spherical microstructure mold module to the bottom of the spherical surface (102), and the fourth line (214) runs from the center of the spherical surface (102) to the first microstructure point, the bottom of the spherical surface (102) being on the planar surface (104).

6. The method according to claim 1, wherein The calendering roller (600) comprises one or more microstructured molds on the spherical microstructured mold module, and each of the one or more microstructured molds has a different microstructure design.

7. A method for calendaring one or more microstructure arrays on a film, the method comprising: extruding a thermoplastic film between a first roller and a second roller; as well as One or more microstructure arrays are embossed on the thermoplastic film by the second roller, and the second roller has one or more spherical microstructure mold modules according to any one of claims 1 to 6, and each microstructure mold module in the one or more spherical microstructure mold modules corresponds to a microstructure array in the one or more microstructure arrays.

8. The method according to claim 7, wherein: The first roller and the second roller are controlled to reach a predetermined temperature. The first roller comprises a smooth cylinder. The second roller comprises a cylinder and the one or more separate microstructure mold modules. The one or more spherical microstructure mold modules are on the cylinder.

9. The method according to claim 7, wherein: Each of the one or more spherical microstructure mold modules has a different microstructure design.

10. The method according to claim 9, wherein: Each microstructure design corresponding to each spherical microstructure mold module is determined based on the curvature and radius of the microstructure array on the film.

Images