Catadioptric lens assembly having two or more lens components

Abstract

The optical lens assembly includes an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each lens having an effective lens area defined as a maximum lens area configured to transmit an image emitted by the display. A first at least partially optically transmissive film is disposed on the curved first major surface of the ophthalmic lens and substantially conforms to the first major surface of the ophthalmic lens. A second at least partially optically transmissive film is disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the intermediate lens and substantially conforms to each of the curved second major surface of the ophthalmic lens and the curved first major surface of the intermediate lens. A first retarder layer is disposed between the second major surface of the intermediate lens and the first major surface of the display lens and substantially conforms to each of the second major surface of the intermediate lens and the first major surface of the display lens. A third at least partially optically transmissive film is disposed on the curved second major surface of the display lens and substantially conforms to the second major surface of the display lens.

Description

Summary of the Invention

[0001] In some aspects of the present disclosure, an optical lens assembly for displaying an image emitted by a display to a viewer is provided, the optical lens assembly including an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens. Each lens has an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display. Over the corresponding effective lens areas, the ophthalmic lenses have curved first and second major surfaces opposite each other, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than two times tmax1. The intermediate lens has a curved first major surface, an opposing second major surface, and a maximum thickness tmax2 that is at least 1.5 times greater than tmax1. The display lens has a first major surface and an opposing curved second major surface. A first at least partially optically transmissive film is disposed proximate to the curved first major surface of the ophthalmic lens and substantially conforms to the first major surface of the ophthalmic lens. a second at least partially optically transmissive film disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the mid lens and substantially conforms to each of the curved second major surface of the ophthalmic lens and the curved first major surface of the mid lens; a first retarder layer disposed between the second major surface of the mid lens and the first major surface of the display lens and substantially conforms to each of the second major surface of the mid lens and the first major surface of the display lens; and a third at least partially optically transmissive film disposed on the curved second major surface of the display lens and substantially conforms to the second major surface of the display lens. For substantially normally incident light and at least one wavelength within the visible wavelength range extending from about 450 nm to about 650 nm (i.e., visible to humans), the first through third at least partially optically transmissive layers each transmit at least 30% of the normally incident light having a first polarization state, and the second and third at least partially optically transmissive layers each block at least 30% of the normally incident light having an orthogonal second polarization state.

[0002] In some aspects herein, an optical lens assembly is provided for displaying an image emitted by a display to a viewer, the optical lens assembly including an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each lens having an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display. the ophthalmic lenses have, at least over corresponding active lens areas, curved first and second major surfaces opposite each other, the major surfaces of the ophthalmic lenses each having an actual surface profile that deviates from the prescribed surface profile by a first maximum peak-to-valley, the first maximum peak-to-valley deviation being less than about 10 micrometers; the ophthalmic lenses have a maximum thickness tmax1 and a minimum thickness tmin1 that is less than about 30% less than tmax1; the mid lens has a curved first major surface bonded to the second major surface of the ophthalmic lens and an opposite second major surface, at least one of the first and second major surfaces of the mid lens having an actual surface profile that deviates from the prescribed surface profile by a second maximum peak-to-valley, the second maximum peak-to-valley deviation being greater than about 15 micrometers; the mid lens has a maximum thickness tmax2 that is at least two times greater than tmax1; and the display lens has a first major surface bonded to the second major surface of the mid lens and an opposite curved second major surface. A reflective polarizer is disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the mid-lens and substantially conforms to each of the curved second major surface of the ophthalmic lens and the curved first major surface of the mid-lens. For substantially normally incident light and at least one wavelength within the visible wavelength range spanning from about 450 nm to about 650 nm, the reflective polarizer transmits at least 50% of the normally incident light having a first polarization state and reflects at least 50% of the substantially normally incident light having an orthogonal second polarization state.

[0003] In some aspects herein, there is provided an optical lens assembly for displaying an image emitted by a display to a viewer, the optical lens assembly including an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each lens having an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display. Over at least the corresponding effective lens areas, the ophthalmic lenses have opposite curved first and second major surfaces, a maximum thickness tmax1 at a first location of the ophthalmic lens, and a minimum thickness tmin1 at a second location of the ophthalmic lens spaced a distance d1 from the first location, such that tmin1 is less than about 30% than tmax1 and (tmax1-tmin1) / d1 is less than about 0.1. The intermediate lens has a curved first major surface bonded to the second major surface of the ophthalmic lens, an opposite second major surface, a maximum thickness tmax2, and a minimum thickness tmin2 that is more than about 30% less than tmax2, such that tmax2 is at least 30% greater than tmax1. The intermediate lens has a maximum birefringence less than about 15 nm for at least one wavelength in the visible wavelength range spanning from about 450 nm to about 650 nm. The display lens has a first major surface bonded to the second major surface of the intermediate lens, and an opposite curved second major surface. A reflective polarizer is disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the intermediate lens, and substantially conforms to each of the curved second major surface of the ophthalmic lens and the curved first major surface of the intermediate lens. For substantially normally incident light and at least one wavelength within the visible wavelength range, the reflective polarizer transmits at least 50% of the normally incident light having a first polarization state and reflects at least 50% of the normally incident light having an orthogonal second polarization state.

[0004] In some aspects herein, there is provided an optical lens assembly for displaying an image emitted by a display to a viewer along an optical axis, the optical lens assembly including an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens. Each lens has an effective lens area defined as a maximum lens area configured to transmit an image emitted by the display along the optical axis. At least over the corresponding effective lens areas, the ophthalmic lens has curved first and second major surfaces opposite each other, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than about 30% than tmax1. The intermediate lens has a curved first major surface bonded to the second major surface of the ophthalmic lens, an opposite second major surface, a maximum thickness tmax2, and a minimum thickness tmin2 that is more than about 30% less than tmax2, such that tmax2 is at least 30% greater than tmax1. The display lens has a first major surface facing the second major surface of the intermediate lens and an opposite curved second major surface. The active lens area of ​​the mid lens and the display lens defines a space between a second major surface of the mid lens and a first major surface of the display lens. One or more optical elements fill the space and bond the mid lens and the display lens together. In the space, a minimum gap between the second major surface of the mid lens and the first major surface of the display lens is Gmin, and a maximum gap between the second major surface of the mid lens and the first major surface of the display lens is Gmax, whereby Gmax - Gmin is about 20 micrometers or greater.

[0005] In some aspects herein, there is provided an optical lens assembly for displaying an image emitted by a display to a viewer along an optical axis, the optical lens assembly including an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens. Each lens has an effective lens area defined as a maximum lens area configured to transmit an image emitted by the display along the optical axis. At least over the corresponding effective lens areas, the ophthalmic lens has curved first and second major surfaces opposite each other, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than about 30% than tmax1. The intermediate lens has a curved first major surface bonded to the second major surface of the ophthalmic lens, an opposite second major surface, a maximum thickness tmax2, and a minimum thickness tmin2 that is more than about 30% less than tmax2, such that tmax2 is at least 30% greater than tmax1. The display lens has a first major surface facing the second major surface of the intermediate lens and an opposite curved second major surface. The intermediate lens and the active lens area of ​​the ophthalmic lens define a space between a first major surface of the intermediate lens and a second major surface of the ophthalmic lens. One or more optical elements fill the space and bond the intermediate lens and the ophthalmic lens together. In the space, a minimum gap between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens is Hmin, and a maximum gap between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens is Hmax, whereby Hmax-Hmin is about 20 micrometers or greater.

[0006] In some aspects of the present specification, there is provided an optical lens assembly including: an intermediate lens disposed adjacent to a display lens and bonded to the display lens, the intermediate lens having a curved first major surface, an opposite second major surface, a maximum thickness tmax, and a minimum thickness tmin that is more than about 30% less than tmax, the display lens having the first major surface facing the second major surface of the intermediate lens and the opposite curved second major surface; and an optical film disposed between the second major surface of the intermediate lens and the first major surface of the display lens and bonded to at least one of the second major surface of the intermediate lens and the first major surface of the display lens. The second major surface of the intermediate lens and the first major surface of the display lens define a space between the second major surface of the intermediate lens and the first major surface of the display lens, wherein in the space, a minimum gap between the second major surface of the intermediate lens and the first major surface of the display lens is Gmin and a maximum gap between the second major surface of the intermediate lens and the first major surface of the display lens is Gmax, and Gmax-Gmin≧20 micrometers. [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a cutaway side view of a typical two-lens optical lens assembly of the prior art. [Figure 2] 1 is a cutaway side view of an optical lens assembly according to an embodiment herein. [Figure 3A] 3 provides a side view of the optical lens assembly of FIG. 2, showing further details, according to an embodiment herein. [Figure 3B] 3 provides a side view of the optical lens assembly of FIG. 2, showing further details, according to an embodiment herein. [Figure 4] 1 illustrates details of a lens interface of an optical lens assembly according to certain embodiments herein. [Figure 5] 1 illustrates details of a lens interface of a portion of an optical lens assembly according to certain embodiments herein. [Figure 6A]10 defines normal incident light for various layers of an optical lens assembly according to certain embodiments herein. [Figure 6B] 10 defines normal incident light for various layers of an optical lens assembly according to certain embodiments herein. [Figure 6C] 10 defines normal incident light for various layers of an optical lens assembly according to certain embodiments herein. DETAILED DESCRIPTION OF THE INVENTION

[0008] In the following description, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various embodiments. The drawings are not necessarily to scale. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. Accordingly, the following detailed description is not to be taken in a limiting sense.

[0009] Polarized catadioptric (i.e., involving both reflection and refraction of light) lens systems require lenses that simultaneously possess both high shape accuracy and low birefringence. High shape accuracy is required because, in a typical catadioptric lens system, two surfaces are reflective, and the reflecting surface deflects the beam at twice the angle of incidence. Due to the large beam deviation upon reflection, shape errors (creating local tilt errors) result in large wavefront errors upon reflection. Low birefringence is required because polarized catadioptric lenses use polarization transformation to "fold" the optical path. Birefringence present within a lens alters the polarization state from its ideal state, resulting in reduced contrast and efficiency of the lens assembly and reduced brightness of the primary image.

[0010] When designing compact, wide-field polarized catadioptric lens systems, extreme lens geometries with large thickness variations may be required. It is well known in the art that large thickness variations in molded plastic lenses result in both significant shape errors and significant birefringence. Both shape errors and birefringence are due to thermal contraction during the cooling stage of the injection molding process, which causes shape changes and increases internal stresses. The inherent tensile, compressive, and shear stresses change the local refractive index of the lens, resulting in birefringence.

[0011] According to some aspects of the present specification, an optical lens assembly is provided in which at least one of the component lenses (i.e., two or more lenses that can be assembled to make the optical lens assembly) does not have strong refractive power, allowing it to have loose shape accuracy, and another of the component lenses is shaped to allow easier injection molding and significantly reduced shape errors. For example, the component lens located on the eye side of the optical lens assembly (the eye-side lens, or simply the "ophthalmic lens") may be configured with a nearly constant thickness across the lens. Configuring the ophthalmic lens to have a substantially constant thickness allows for injection molding of the ophthalmic lens with very small shape errors.

[0012] According to some aspects herein, an optical lens assembly for displaying an image emitted by a display to a viewer includes an intermediate lens disposed between an ophthalmic lens (i.e., the lens closest to the viewer's eye) and a display lens (i.e., the lens closest to the display or picture generating unit that generates the image displayed to the viewer) and bonded to the ophthalmic lens and the display lens. Each of the lenses (component lenses) has an effective lens area defined as the largest lens area configured to transmit the image emitted by the display.

[0013] In some embodiments, the following may be true over the corresponding active lens area: The Ophthalmic Lens may have opposed curved first and second major surfaces, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than about 2 times, less than about 1.9 times, less than about 1.7 times, less than about 1.5 times, less than about 1.3 times, or less than about 1.1 times less than tmax1; the intermediate lens may have a curved first major surface, an opposite second major surface, and a maximum thickness tmax2 that is at least 1.5 times, at least 2.0 times, at least 2.5 times, at least 3.0 times, at least 4.0 times, or at least 5.0 times greater than tmax1; The display lens may have a first major surface and an opposite curved second major surface.

[0014] In some embodiments, the ophthalmic lens may have a substantially constant thickness. In some embodiments, the curved first major surface of the mid-lens may be curved in two mutually orthogonal directions. In some embodiments, the second major surface of the mid-lens may be substantially planar. In some embodiments, the second major surface of the mid-lens may be curved in at least one direction. In some embodiments, the second major surface of the mid-lens may be substantially cylindrical. In some embodiments, at least one of the curved first and second major surfaces of the ophthalmic lens may be curved in two mutually orthogonal directions.

[0015] In some embodiments, the first at least partially optically transmissive film is disposed proximate to the curved first major surface of the ophthalmic lens and substantially conforms to the first major surface of the ophthalmic lens. In some embodiments, the first at least partially optically transmissive film may be disposed on the first major surface of the ophthalmic lens and substantially conform to the first major surface of the ophthalmic lens. In some embodiments, the first at least partially optically transmissive film may be bonded to the first major surface of the ophthalmic lens by a bonding layer (e.g., an optical adhesive layer). In some embodiments, the first at least partially optically transmissive film may be an absorbing polarizer. In some embodiments, the first at least partially optically transmissive film may be an optically clear layer.

[0016] In some embodiments, a second at least partially light-transmitting film (e.g., a reflective polarizer) is disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the mid lens and substantially conforms to each of the curved second major surface of the ophthalmic lens and the curved first major surface of the mid lens. A first retarder layer (e.g., a quarter-wave plate) is disposed between the second major surface of the mid lens and the first major surface of the display lens and substantially conforms to each of the second major surface of the mid lens and the first major surface of the display lens.

[0017] In some embodiments, a third at least partially optically transmissive film (e.g., a 50:50 beam splitter film) is disposed on the curved second major surface of the display lens and substantially conforms to the second major surface of the display lens. In some embodiments, the third at least partially optically transmissive film may be disposed on the curved second major surface of the display lens by one or more of lamination, electroplating, electroless plating, vacuum deposition, plasma-enhanced chemical vapor deposition, and printing.

[0018] For purposes of this specification, the term "film" may mean a coating, a thin film, a thick film, a monolayer film, a multilayer film, a polymer film (e.g., polyethylene terephthalate or PET), or any other suitable layer that can be distinguished from the lens or component to which it is adjacent and / or bonded.

[0019] In some embodiments, for substantially normally incident light and at least one wavelength within the visible wavelength range spanning from about 450 nm to about 650 nm (i.e., visible to humans), each of the at least partially optically transmissive first through third layers may transmit at least 30%, at least 40%, or at least 50% of normally incident light having a first polarization state (e.g., light polarized about the reference x-axis of the layer), and each of the at least partially optically transmissive second and third layers may block at least 30%, at least 40%, or at least 50% of normally incident light having an orthogonal second polarization state (e.g., light polarized about the reference y-axis of the film, orthogonal to the x-axis). In some embodiments, for substantially normally incident light and at least one wavelength within the visible wavelength range, the partially optically transmissive first layer (e.g., an optically clear layer) may transmit at least 80% of normally incident light for each of the first and second polarization states. In some embodiments, for substantially normally incident light and at least one wavelength in the visible wavelength range, the at least partially optically transmissive first layer (e.g., an absorbing polarizer) may transmit at least 50% of the normally incident light having a first polarization state and may absorb at least 30% of the normally incident light having a second polarization state.

[0020] According to some aspects of the present specification, an optical lens assembly for displaying an image emitted by a display to an observer includes an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each lens having an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display.

[0021] In some embodiments, the following may be true over the corresponding active lens area: an Ophthalmic Lens (i.e., the lens component closest to the viewer's eye during operation) may have curved first and second major surfaces that are opposite one another, each of the major surfaces of the Ophthalmic Lens having an actual surface profile that deviates from a prescribed surface profile by a first maximum peak-to-valley, the first maximum peak-to-valley deviation being less than about 10 micrometers, the Ophthalmic Lens having a maximum thickness tmax1 and a minimum thickness tmin1 that is less than about 30% less than tmax1; the intermediate lens (i.e., the lens component disposed between the Ophthalmic Lens and the Display Lens) may have a curved first major surface bonded to the second major surface of the Ophthalmic Lens and an opposite second major surface, wherein at least one of the first and second major surfaces of the intermediate lens has an actual surface profile that deviates from the prescribed surface profile by a second maximum peak-to-valley, the second maximum peak-to-valley deviation being greater than about 15 micrometers, and the intermediate lens has a maximum thickness tmax2 that is at least about two times greater than tmax1; The display lens (i.e., the lens component closest to the display and farthest from the viewer) may have a first major surface bonded to the second major surface of the intermediate lens and an opposite curved second major surface.

[0022] In some embodiments, a reflective polarizer may be disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the intermediate lens, and may substantially conform to each of the second major surface of the ophthalmic lens and the first major surface of the intermediate lens. In some embodiments, for substantially normally incident light and at least one wavelength in the visible wavelength range spanning from about 450 nm to about 650 nm, the reflective polarizer may transmit at least 50%, at least 55%, at least 60%, or at least 70% of normally incident light having a first polarization state (e.g., x-axis) and may reflect at least 50%, at least 55%, at least 60%, or at least 70% of normally incident light having an orthogonal second polarization state (e.g., y-axis).

[0023] According to some aspects of the present specification, an optical lens assembly for displaying an image emitted by a display to an observer includes an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each lens having an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display.

[0024] In some embodiments, the following may be true over the corresponding active lens area: The Ophthalmic Lens may have opposing curved first and second major surfaces, a maximum thickness tmax1 at a first location of the Ophthalmic Lens, and a minimum thickness tmin1 at a second location of the Ophthalmic Lens spaced a distance d1 from the first location, whereby tmin1 is less than about 30% less than tmax1 and (tmax1-tmin1) / d1 is less than about 0.1; the intermediate lens may have a curved first major surface bonded to the second major surface of the ophthalmic lens, an opposite second major surface, a maximum thickness tmax2 and a minimum thickness tmin2 that is more than about 30% less than tmax2, such that tmax2 is at least 30% greater than tmax1; and the intermediate lens may have a maximum birefringence less than about 15 nm for at least one wavelength in the visible wavelength range spanning from about 450 nm to about 650 nm; The display lens may have a first major surface bonded to the second major surface of the intermediate lens and an opposite curved second major surface.

[0025] In some embodiments, a reflective polarizer may be disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the mid lens and substantially conform to each of the second major surface of the ophthalmic lens and the first major surface of the mid lens. In some embodiments, for substantially normally incident light and at least one wavelength in the visible wavelength range, the reflective polarizer may transmit at least 50%, at least 55%, at least 60%, or at least 70% of the normally incident light having a first polarization state and reflect at least 50%, at least 55%, at least 60%, or at least 70% of the normally incident light having an orthogonal second polarization state.

[0026] According to some aspects herein, an optical lens assembly for displaying an image emitted by a display to a viewer along an optical axis includes an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each having an effective lens area defined as a maximum lens area configured to transmit an image emitted by the display along the optical axis.

[0027] In some embodiments, the following may be true over the corresponding active lens area: The Ophthalmic Lens may have opposed curved first and second major surfaces, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than about 30% less than tmax1; the intermediate lens may have a curved first major surface bonded to the second major surface of the ophthalmic lens, an opposite second major surface, a maximum thickness tmax2, and a minimum thickness tmin2 that is more than about 30% less than tmax2, such that tmax2 is at least 30% greater than tmax1; The display lens may have a first major surface facing the second major surface of the intermediate lens and an opposite curved second major surface.

[0028] In some embodiments, the active lens area of ​​the intermediate lens and the display lens may define a space between the second major surface of the intermediate lens and the first major surface of the display lens. In some embodiments, one or more optical elements may fill the space and bond the intermediate lens and the display lens to each other. In some embodiments, the one or more optical elements filling the space may include one or more adhesive layers. In some embodiments, the one or more optical elements filling the space may include a retarder layer (e.g., a quarter-wave plate). In some embodiments, the gap in the space between the second major surface of the intermediate lens and the first major surface of the display lens varies irregularly across the space. That is, the space defined between the second major surface of the intermediate lens and the first major surface of the display lens may vary along one or more directions in the space when not filled with one or more optical elements (i.e., optical elements are omitted).

[0029] In some embodiments, the minimum gap defined in the space between the second major surface of the intermediate lens and the first major surface of the display lens is Gmin, and the maximum gap between the second major surface of the intermediate lens and the first major surface of the display lens is Gmax, such that Gmax - Gmin is about 20 micrometers or more, about 25 micrometers or more, or about 30 micrometers or more.

[0030] According to some aspects herein, an optical lens assembly for displaying an image emitted by a display to a viewer along an optical axis includes an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each having an effective lens area defined as a maximum lens area configured to transmit an image emitted by the display along the optical axis.

[0031] In some embodiments, the following may be true over the corresponding active lens area: The Ophthalmic Lens may have opposed curved first and second major surfaces, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than about 30% less than tmax1; the intermediate lens may have a curved first major surface bonded to the second major surface of the ophthalmic lens, an opposite second major surface, a maximum thickness tmax2, and a minimum thickness tmin2 that is more than about 30% less than tmax2, such that tmax2 is at least 30% greater than tmax1; The display lens may have a first major surface facing the second major surface of the intermediate lens and an opposite curved second major surface.

[0032] In some embodiments, the active lens area of ​​the intermediate lens and the ophthalmic lens may define a space between a first major surface of the intermediate lens and a second major surface of the ophthalmic lens. In some embodiments, one or more optical elements may fill the space and bond the intermediate lens and the ophthalmic lens to each other. In some embodiments, the one or more optical elements filling the space may include one or more adhesive layers. In some embodiments, the one or more optical elements filling the space may include a reflective polarizer. In some embodiments, the gap in the space between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens may vary irregularly across the space. That is, the space defined between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens may vary along one or more directions in the space when not filled with one or more optical elements (i.e., optical elements are omitted).

[0033] In some embodiments, the minimum gap defined in the space between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens is Hmin, and the maximum gap between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens is Hmax, such that Hmax-Hmin is about 20 micrometers or more, about 25 micrometers or more, or about 30 micrometers or more.

[0034] According to some aspects of the present disclosure, an optical lens assembly may include: an intermediate lens disposed adjacent to a display lens and bonded to the display lens, the intermediate lens having a curved first major surface, an opposite second major surface, a maximum thickness tmax, and a minimum thickness tmin that is more than about 30% less than tmax, the display lens having a first major surface facing the second major surface of the intermediate lens and an opposite curved second major surface; and an optical film disposed between the second major surface of the intermediate lens and the first major surface of the display lens and bonded to at least one of the second major surface of the intermediate lens and the first major surface of the display lens. In some embodiments, the optical film may be insert molded with one of the second major surface of the intermediate lens and the first major surface of the display lens, or embedded in one of the second major surface of the intermediate lens and the first major surface of the display lens (i.e., the optical film may be integral with either the intermediate lens or the display lens, and positioned so as to be embedded between the intermediate lens and the display lens). In some embodiments, the optical film may be a retarder, a reflective polarizer, an absorbing polarizer, or a polymer film (eg, a polyethylene terephthalate (PET) film).

[0035] In some embodiments, the second major surface of the intermediate lens and the first major surface of the display lens may define a space between the second major surface of the intermediate lens and the first major surface of the display lens, wherein the minimum gap in the space between the second major surface of the intermediate lens and the first major surface of the display lens is Gmin and the maximum gap between the second major surface of the intermediate lens and the first major surface of the display lens is Gmax, and Gmax - Gmin is about 20 micrometers or more, about 25 micrometers or more, or about 30 micrometers or more.

[0036] Referring now to the drawings, FIG. 1 is a cutaway side view of a typical two-lens optical lens assembly of the prior art. Prior art lenses 150 in two-component (or "two-lens") optical lens assemblies feature a display-side lens or display lens 50 disposed on and cemented to an observer-side lens or observer lens 15. The display lens 50 is disposed adjacent to a display 10 ("picture generating unit" or PGU), which generates an image 11 transmitted through the lens assembly 150 that is viewed by the eyes of an observer 20 as a perceived image 12. The observer lens 15 has a curved first major surface 14 and a substantially planar second major surface 16. In this cutaway side view, the first major surface 14 and the second major surface 16 define a cross section of varying thickness across the observer lens 15. The first major surface 14 of the observer lens 15, closest to the observer 20, typically has a reflective polarizer (not shown) disposed thereon. Due to the significant thickness variation across the observer lens 15, the lens is expected to have high residual molding stresses, which can result in high birefringence. The observer lens 15 also has large shape errors due to differential thermal shrinkage across the part.

[0037] In addition, when the observer lens 15 is manufactured by insert molding or an "in-mold decoration" process (i.e., a reflective polarizer is placed on the first major surface 14 during an insert molding process while the lens is cooled), the lens may have large shape errors due to highly anisotropic thermo-mechanical properties such as the elastic modulus and coefficient of thermal expansion (CTE).

[0038] FIG. 2 is a cutaway side view of one embodiment of an optical lens assembly according to the present disclosure, and FIGS. 3A and 3B provide side views of the optical lens assembly of FIG. 2 , showing additional details and layers. Looking first to FIG. 2 , which shows the optical lens assembly at a high level, the optical lens assembly 200 includes an intermediate lens 30 positioned between and cemented to a display lens 50 and an eye-side lens or ophthalmic lens 40. That is, what was implemented as a single-component observer lens 15 in FIG. 1 is split into two lens components in the embodiment of FIG. 2: the intermediate lens 30 and the ophthalmic lens 40. By implementing the lens assembly as three lens components, the ophthalmic lens 40 can be configured as a thin lens with a substantially constant thickness, significantly reducing the shape error across the varying thickness of the single-component observer lens 15 seen in the prior art embodiment of FIG. 1 . Compared to prior art lens components such as the observer lens 15 of FIG. 1 , the ophthalmic lens 40 may have lower birefringence, reduced warp, reduced shape error, reduced astigmatism, and increased reliability. For example, the ophthalmic lens 40 may have an improved ability to withstand extreme temperature ranges and humidity fluctuations without significant changes in shape or form. Additionally, the mid lens 30 is easier to mold because it does not need to have tight shape tolerances and can be optimized for low birefringence without excessive effort to maintain tight shape tolerances. In some embodiments, the mating surfaces of the mid lens 30 (i.e., the surfaces that are bonded to the ophthalmic lens 40 and the display lens 50) are not highly refractive or reflective surfaces and can be bonded to the ophthalmic lens 40 and the display lens 50 using, for example, an optically clear adhesive, such as optical cement, with a refractive index similar to that of the lens components being bonded.

[0039] 3A and 3B provide further details regarding the optical lens assembly 200 of FIG. 2 and should be reviewed together for the following discussion. The optical lens assembly 200 includes a mid lens 30 disposed between and bonded to an ophthalmic lens 40 and a display lens 50. In some embodiments, the mid lens 30 has a curved first major surface 32 and an opposite second major surface 33. In some embodiments, the display lens 50 has a first major surface 52 and an opposite curved second major surface 53. In some embodiments, the ophthalmic lens 40 has opposite curved first major surface 42 and curved second major surface 43.

[0040] In some embodiments, the major surfaces 42, 43 of the ophthalmic lens may each have an actual surface profile that deviates from the prescribed surface profile by a first maximum peak-to-valley value, and the first maximum peak-to-valley deviation may be less than about 10 micrometers. In some embodiments, at least one of the first and second major surfaces 32, 33 of the mid lens 30 may have an actual surface profile that deviates from the prescribed surface profile by a second maximum peak-to-valley value, and the second maximum peak-to-valley deviation is greater than about 15 micrometers, about 20 micrometers, or about 25 micrometers.

[0041] 3B , in some embodiments, the ophthalmic lens may have a maximum thickness tmax1 and a minimum thickness tmin1 that is less than about 30%, less than about 25%, less than about 20%, or less than about 15% less than tmax1. In some embodiments, tmax1 is located at a first location on the ophthalmic lens 40, and tmin1 is located at a second location on the ophthalmic lens 40, the second location being a distance d1 from the first location. In some embodiments, the value of (tmax1-tmin1) / d1 may be less than about 0.1. In some embodiments, the mid lens 30 may have a minimum thickness tmin2 and a maximum thickness tmax2, where tmax2 is at least two times, at least three times, or at least four times greater than tmax1.

[0042] In some embodiments, a first at least partially optically transmissive film 60 is disposed on and substantially conforms to the curved first major surface 42 of the ophthalmic lens 40. In some embodiments, the first at least partially optically transmissive film 60 may be an absorbing polarizer. In some embodiments, the first at least partially optically transmissive film 60 may be an optically clear film. In some embodiments, the first at least partially optically transmissive film 60 may be bonded to the curved first major surface 42 of the ophthalmic lens 40 by a bonding layer 110.

[0043] In some embodiments, the second at least partially light-transmitting film 70 is disposed between the curved second major surface 43 of the ophthalmic lens 40 and the curved first major surface 32 of the mid lens 30 and substantially conforms to the curved second major surface 43 of the ophthalmic lens 40 and the curved first major surface 32 of the mid lens 30, respectively. In some embodiments, the second at least partially light-transmitting film 70 may be a reflective polarizer. In some embodiments, the second at least partially light-transmitting film 70 may be bonded to the curved second major surface 43 of the ophthalmic lens 40 and the curved first major surface 32 of the mid lens 30 by one or more adhesive layers 83.

[0044] In some embodiments, the Ophthalmic Lens 40 may have a substantially constant thickness. In some embodiments, the Ophthalmic Lens 40 may be fabricated using an injection molding or insert molding process. In some embodiments, the Ophthalmic Lens 40 may be molded with a first at least partially optically transparent film 60 and a second at least partially optically transparent film 70 on either side of the Ophthalmic Lens 40. This creates a "sandwich" structure with an inner core and an outer "skin" disposed on opposing curved first and second major surfaces 42, 43.

[0045] In some embodiments, the first retarder layer 80 may be disposed between and substantially conform to the second major surface 33 of the mid lens 30 and the first major surface 52 of the display lens 50. In some embodiments, the first retarder layer 80 may be bonded to the second major surface 33 of the mid lens 30 and the first major surface 52 of the display lens 50 by one or more adhesive layers 81, 83. In some embodiments, the first retarder layer 80 may be insert molded (i.e., integrated) with either the mid lens 30 or the display lens 50. In such embodiments, the first retarder layer 80 may be embedded between the mid lens 30 and the display lens 50. In some embodiments, the first retarder layer 80 may be a quarter wave plate.

[0046] In some embodiments, a third at least partially light-transmitting film 90 may be disposed on and substantially conform to the curved second major surface 53 of the display lens 50. In some embodiments, the third at least partially light-transmitting film 90 may be a 50:50 beam splitter film.

[0047] Each of these lens components (i.e., intermediate lens 30, ophthalmic lens 40, and display lens 50) has an effective lens area, which is defined as the largest lens area configured to transmit the image 11 emitted by the display 10 through the optical lens assembly 200, to be viewed as a perceived image 12 by the eye of the observer 20. These effective lens areas include the effective lens area 51 of the display lens 50, the effective lens area 41 of the ophthalmic lens 40, and the effective lens area 31 of the intermediate lens 30.

[0048] In an exemplary embodiment, the image 11 is transmitted by the display 10 as image light rays 95. The image light rays 95 are transmitted from the display 10 toward the optical lens assembly 200, first incident on the 50:50 beam splitter film 90 and transmitted through the display lens 50. The image light rays 95 may then pass through the quarter wave plate 80, be reflected by the reflective polarizer 70, pass back through the quarter wave plate 80, be reflected by the beam splitter film 90, and finally pass back through the quarter wave plate 80, through the reflective polarizer 70 (now in the proper polarization state for passage), and exit through the ophthalmic lens 40 to create the image 12 perceived by the eye of the observer 20 along the optical axis 120. The paths of the image light rays 95 through the various lens components define the effective lens areas 51, 31, and 41, respectively. Note that only the outermost image rays 95 are shown as an example in FIG. 3A to better illustrate the boundaries of the effective lens areas 51, 31 and 41.

[0049] In some embodiments, for substantially normally incident light 101 (incident light 101, see FIG. 6B ) and at least one wavelength within the visible wavelength range (e.g., light visible to humans in the range spanning from about 450 nm to about 650 nm), the reflective polarizer may transmit at least 50%, at least 55%, at least 60%, or at least 65% of the normally incident light having a first polarization state (e.g., aligned with the x-axis of the film) and reflect at least 50%, at least 55%, at least 60%, or at least 65% of the normally incident light having an orthogonal second polarization state (e.g., aligned with the y-axis of the film).

[0050] In some embodiments, for substantially normally incident light and at least one wavelength in the visible wavelength range spanning from about 450 nm to about 650 nm, the first through third at least partially optically transmissive layers each transmit at least 30%, at least 35%, at least 40%, or at least 45% of the normally incident light having a first polarization state (x-axis), and the second and third at least partially optically transmissive layers each block at least 30%, at least 35%, at least 40%, or at least 45% of the normally incident light having an orthogonal second polarization state (y-axis). See FIG. 6A for a definition of normally incident light 102 on the third at least partially optically transmissive film 90. See FIG. 6B for a definition of normally incident light 101 on the second at least partially optically transmissive film 70. See FIG. 6C for a definition of normally incident light 100 on the first at least partially optically transmissive film 60.

[0051] Figure 4 shows an alternative view of the optical lens assembly 200 showing further details regarding the interface between the display lens 50 and the mid lens 30, and Figure 5 shows further details regarding the interface between the ophthalmic lens 40 and the mid lens 30. Many of the components in Figures 4 and 5 are repeated from Figure 3, and like-numbered components are assumed to have similar functions as already described elsewhere herein, unless explicitly stated otherwise.

[0052] 4, an optical lens assembly 200 includes a mid lens 30 disposed between and bonded to an ophthalmic lens 40 and a display lens 50. The interface between the display lens 50 and the mid lens 30 is shown with exaggerated detail to illustrate that surface 52 (of the display lens 50) and surface 33 (of the mid lens 30) may have significant surface profile errors. That is, the mid lens 30 and the display lens 50 do not have strong optical power, allowing them to have loose shape accuracy, and the active lens areas 51 and 31 of the display lens 50 and the mid lens 30, respectively, define a space 130 between these lens components that may be filled with one or more optical elements (e.g., adhesive filler and / or retarder layers). In this space 130, the minimum gap between the second major surface 33 of the intermediate lens 30 and the first major surface 52 of the display lens 50 is Gmin, and the maximum gap between the second major surface 33 of the intermediate lens 30 and the first major surface 52 of the display lens 50 is Gmax, such that the value of Gmax-Gmin is about 20 micrometers or more, about 25 micrometers or more, or about 30 micrometers or more. In some embodiments, the gap 131 between the intermediate lens 30 and the display lens 50 in the space 130 may vary irregularly across the space 130.

[0053] 5 shows similar details regarding the interface between the ophthalmic lens 40 and the mid lens 30. Note that for clarity, only a portion of the optical lens assembly 200A is shown, focusing on the interface between the ophthalmic lens 40 and the mid lens 30. The interface between the ophthalmic lens 40 and the mid lens 30 is shown with exaggerated detail, and the surface 43 (of the ophthalmic lens 40) and the surface 32 (of the mid lens 30) may have significant surface profile errors. That is, at least the surfaces 43 of the mid lens 30 and the ophthalmic lens 40 may have loose shape accuracy. The active lens areas 41 and 31 of the ophthalmic lens 40 and the mid lens 30, respectively, define a space 135 between these lens components, which may be filled with one or more optical elements (e.g., an adhesive filler and / or a reflective polarizer). In this space 135, the minimum gap between the first major surface 32 of the intermediate lens 30 and the second major surface 43 of the ophthalmic lens 40 is Hmin, and the maximum gap between the first major surface 32 of the intermediate lens 30 and the second major surface 43 of the ophthalmic lens 40 is Hmax, such that the value of Hmax-Hmin is about 20 micrometers or more, about 25 micrometers or more, or about 30 micrometers or more. In some embodiments, the gap 136 between the intermediate lens 30 and the ophthalmic lens 40 in the space 135 may vary irregularly across the space 135.

[0054] Terms such as "about" will be understood by those of ordinary skill in the art in the context in which they are used and described herein. Unless otherwise clear to those of ordinary skill in the art in the context in which they are used and described herein, the use of "about" as applied to quantities expressing feature sizes, amounts, and physical characteristics will be understood to mean within 10 percent of a particular value. A quantity given as about or approximately a particular value may be the exact particular value. For example, unless otherwise clear to those of ordinary skill in the art in the context in which they are used and described herein, an amount having a value of about 1 means that the amount has a value between 0.9 and 1.1, and may even be 1.

[0055] Terms such as "substantially" will be understood by those of ordinary skill in the art in the context in which they are used and described herein. If the use of "substantially equal" is not clear to those of ordinary skill in the art in the context in which they are used and described herein, "substantially equal" means approximately equal, with "about" being as defined above. If the use of "substantially parallel" is not clear to those of ordinary skill in the art in the context in which they are used and described herein, "substantially parallel" means within 30 degrees of parallel. Directions or surfaces described as substantially parallel to one another may, in some embodiments, be within 20 degrees, or within 10 degrees, of parallel, or may be parallel or nominally parallel. If the use of "substantially aligned" is not clear to those of ordinary skill in the art in the context in which they are used and described herein, "substantially aligned" means aligned within 20% of the width of the objects being aligned. Objects described as substantially aligned may, in some embodiments, be aligned within 10% or within 5% of the width of the objects being aligned.

[0056] All references, patents, or patent applications referenced above are hereby incorporated by reference in their entirety. In the event of any inconsistency or contradiction between any portion of the incorporated reference and this application, the information in the foregoing statement shall prevail.

[0057] Descriptions of elements in the figures should be understood to apply equally to corresponding elements in other figures unless otherwise indicated. While specific embodiments have been illustrated and described herein, those skilled in the art will recognize that the specific embodiments illustrated and described may be replaced by various alternative and / or equivalent embodiments without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Accordingly, the present disclosure is intended to be limited only by the claims and equivalents thereof. In the following, exemplary embodiments are presented. [Item 1] an optical lens assembly for displaying to a viewer an image emitted by a display, the optical lens assembly comprising: an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each of the lenses having an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display, whereby, at least over the corresponding effective lens area: the ophthalmic lens having opposed curved first and second major surfaces, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than two times tmax1; the intermediate lens has a curved first major surface, an opposite second major surface, and a maximum thickness tmax2 that is at least 1.5 times greater than tmax1; the display lens having a first major surface and an opposite curved second major surface; and a first at least partially optically transparent film disposed proximate to and substantially conforming to the curved first major surface of the ophthalmic lens; a second at least partially optically transparent film disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the mid lens, the second at least partially optically transparent film substantially conforming to each of the curved second major surface of the ophthalmic lens and the curved first major surface of the mid lens; a first retarder layer disposed between the second major surface of the intermediate lens and the first major surface of the display lens, the first retarder layer substantially conforming to each of the second major surface of the intermediate lens and the first major surface of the display lens; a third at least partially light-transmitting film disposed on the curved second major surface of the display lens and adapted to substantially conform to the curved second major surface of the display lens; 1. An optical lens assembly, wherein, for substantially normally incident light and at least one wavelength in a visible wavelength range spanning from about 450 nm to about 650 nm, each of the at least partially optically transmissive first, second, and third layers transmits at least 30% of the substantially normally incident light having a first polarization state, and each of the at least partially optically transmissive second and third layers blocks at least 30% of the substantially normally incident light having an orthogonal second polarization state. [Item 2] Item 10. The optical lens assembly of item 1, wherein the third at least partially light-transmitting film is disposed on the curved second major surface of the display lens by at least one of lamination, electroplating, electroless plating, vacuum deposition, physical vapor deposition, plasma-enhanced chemical vapor deposition, and printing. [Item 3] Item 1, an optical lens assembly according to item 1, wherein at least one of the curved first and second major surfaces of the ophthalmic lens is curved in two directions that are perpendicular to each other. [Item 4] Item 2. The optical lens assembly of item 1, wherein the curved first major surface of the intermediate lens is curved in two directions that are perpendicular to each other. [Item 5] Item 10. The optical lens assembly of item 1, wherein the second major surface of the intermediate lens is substantially planar. [Item 6] Item 1, the optical lens assembly, wherein the second major surface of the intermediate lens is curved in at least one direction. [Item 7] Item 10. The optical lens assembly of item 1, wherein the second major surface of the intermediate lens is substantially cylindrical. [Item 8] Item 1. The optical lens assembly of item 1, wherein the first at least partially light-transmitting film is disposed on the first major surface of the ophthalmic lens and substantially conforms to the first major surface of the ophthalmic lens. [Item 9] Item 9. The optical lens assembly of item 8, wherein the first at least partially optically transmissive film is bonded to the curved first major surface of the ophthalmic lens by a bonding layer. [Item 10] 3. The optical lens assembly of claim 2, wherein for the substantially normally incident light and the at least one wavelength within the visible wavelength range, the first at least partially light transmissive film transmits at least 80% of the substantially normally incident light for each of the first and second polarization states. [Item 11] Item 10. The optical lens assembly of item 1, wherein for the substantially normally incident light and at least one wavelength within the visible wavelength range, the first at least partially light transmissive film transmits at least 50% of the substantially normally incident light having the first polarization state and absorbs at least 30% of the substantially normally incident light having the second polarization state. [Item 12] an optical lens assembly for displaying to a viewer an image emitted by a display, the optical lens assembly comprising: an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each of the lenses having an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display, whereby, at least over the corresponding effective lens area: the ophthalmic lens has first and second curved opposed major surfaces, each of the major surfaces of the ophthalmic lens having an actual surface profile that deviates from a first prescribed surface profile by a first maximum peak-to-valley, the first maximum peak-to-valley deviation being less than about 10 micrometers; the ophthalmic lens has a maximum thickness tmax1 and a minimum thickness tmin1 that is less than about 30% less than tmax1; the intermediate lens having a curved first major surface bonded to the second major surface of the ophthalmic lens and an opposite second major surface, at least one of the first and second major surfaces of the intermediate lens having an actual surface profile that deviates from a second prescribed surface profile by a second maximum peak-to-valley, the second maximum peak-to-valley deviation being greater than about 15 micrometers, and the intermediate lens having a maximum thickness tmax2 that is at least two times greater than tmax1; an intermediate lens, such that the display lens has a first major surface bonded to the second major surface of the intermediate lens and an opposite curved second major surface; and a reflective polarizer disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the intermediate lens, the reflective polarizer substantially matching each of the curved second major surface of the ophthalmic lens and the curved first major surface of the intermediate lens, the reflective polarizer transmitting at least 50% of the substantially normally incident light having a first polarization state and reflecting at least 50% of the substantially normally incident light having an orthogonal second polarization state for substantially normally incident light and for at least one wavelength within a visible wavelength range spanning from about 450 nm to about 650 nm. [Item 13] an optical lens assembly for displaying to a viewer an image emitted by a display, the optical lens assembly comprising: an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each of the lenses having an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display, whereby, at least over the corresponding effective lens area: the ophthalmic lens having first and second curved opposed major surfaces, a maximum thickness tmax1 at a first location of the ophthalmic lens, and a minimum thickness tmin1 at a second location of the ophthalmic lens spaced a distance d1 from the first location, wherein tmin1 is less than about 30% of tmax1, and (tmax1-tmin1) / d1 is less than about 0.1; the intermediate lens has a curved first major surface bonded to the second major surface of the ophthalmic lens, an opposite second major surface, a maximum thickness tmax2 and a minimum thickness tmin2 that is more than about 30% less than tmax2, wherein tmax2 is at least 30% greater than tmax1, and the intermediate lens has a maximum birefringence of less than about 15 nm for at least one wavelength in a visible wavelength range spanning from about 450 nm to about 650 nm; an intermediate lens, such that the display lens has a first major surface bonded to the second major surface of the intermediate lens and an opposite curved second major surface; an optical lens assembly comprising: a reflective polarizer disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the intermediate lens, the reflective polarizer substantially matching each of the curved second major surface of the ophthalmic lens and the curved first major surface of the intermediate lens, the reflective polarizer transmitting at least 50% of the substantially normally incident light having a first polarization state and reflecting at least 50% of the substantially normally incident light having an orthogonal second polarization state for substantially normally incident light and for the at least one wavelength within the visible wavelength range. [Item 14] an optical lens assembly for displaying an image emitted by a display to a viewer along an optical axis, the optical lens assembly comprising: an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each of the lenses having an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display along the optical axis, whereby, at least over a corresponding effective lens area: the ophthalmic lens having opposed curved first and second major surfaces, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than about 30% less than tmax1; the intermediate lens having a curved first major surface bonded to the second major surface of the ophthalmic lens, an opposite second major surface, a maximum thickness tmax2 and a minimum thickness tmin2 that is more than about 30% less than tmax2, wherein tmax2 is at least 30% greater than tmax1; the display lens comprises an intermediate lens having a first major surface facing the second major surface of the intermediate lens and an opposite curved second major surface; an optical lens assembly, wherein the intermediate lens and the active lens area of ​​the display lens define a space between the second major surface of the intermediate lens and the first major surface of the display lens, one or more optical elements fill the space and bond the intermediate lens and the display lens to each other, wherein a minimum gap between the second major surface of the intermediate lens and the first major surface of the display lens in the space is Gmin and a maximum gap between the second major surface of the intermediate lens and the first major surface of the display lens is Gmax, and wherein Gmax-Gmin≧20 micrometers. [Item 15] Item 15. The optical lens assembly of item 14, wherein the one or more optical elements filling the space comprise one or more adhesive layers. [Item 16] Item 15. The optical lens assembly of item 14, wherein the one or more optical elements filling the space comprise a retarder layer. [Item 17] Item 15. The optical lens assembly of item 14, wherein the gap of the space between the second major surface of the intermediate lens and the first major surface of the display lens varies irregularly across the space. [Item 18] an optical lens assembly for displaying an image emitted by a display to a viewer along an optical axis, the optical lens assembly comprising: an intermediate lens disposed between an ophthalmic lens and a display lens and bonded to the ophthalmic lens and the display lens, each of the lenses having an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display along the optical axis, whereby, at least over a corresponding effective lens area: the ophthalmic lens having opposed curved first and second major surfaces, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than about 30% less than tmax1; the intermediate lens having a curved first major surface bonded to the second major surface of the ophthalmic lens, an opposite second major surface, a maximum thickness tmax2 and a minimum thickness tmin2 that is more than about 30% less than tmax2, wherein tmax2 is at least 30% greater than tmax1; the display lens comprises an intermediate lens having a first major surface facing the second major surface of the intermediate lens and an opposite curved second major surface; An optical lens assembly, wherein the intermediate lens and the effective lens area of ​​the ophthalmic lens define a space between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens, one or more optical elements fill the space and cement the intermediate lens and the ophthalmic lens together, wherein in the space, a minimum gap between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens is Hmin and a maximum gap between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens is Hmax, and Hmax-Hmin≧20 micrometers. [Item 19] Item 19. The optical lens assembly of item 18, wherein the one or more optical elements filling the space comprise one or more adhesive layers. [Item 20] Item 19. The optical lens assembly of item 18, wherein the one or more optical elements filling the space comprise a reflective polarizer. [Item 21] Item 19. The optical lens assembly of item 18, wherein a gap (136) of the space between the first major surface of the intermediate lens and the second major surface of the ophthalmic lens varies irregularly across the space. [Item 22] 1. An optical lens assembly comprising: an intermediate lens disposed adjacent to and bonded to the display lens, the intermediate lens having a curved first major surface, an opposite second major surface, a maximum thickness tmax, and a minimum thickness tmin that is more than about 30% less than tmax, the display lens having its first major surface facing the second major surface of the intermediate lens and its opposite curved second major surface; an optical film disposed between the second main surface of the intermediate lens and the first main surface of the display lens and bonded to at least one of the second main surface of the intermediate lens and the first main surface of the display lens; an optical lens assembly, wherein the second major surface of the intermediate lens and the first major surface of the display lens define a space between the second major surface of the intermediate lens and the first major surface of the display lens, wherein in the space, a minimum gap between the second major surface of the intermediate lens and the first major surface of the display lens is Gmin and a maximum gap between the second major surface of the intermediate lens and the first major surface of the display lens is Gmax, and wherein Gmax-Gmin≧20 micrometers. [Item 23] Item 23. The optical lens assembly of item 22, wherein the optical film is embedded in the optical assembly and insert molded with one of the second major surface of the intermediate lens and the first major surface of the display lens. [Item 24] Item 23. The optical lens assembly of item 22, wherein the optical film is a retarder, a reflective polarizer, an absorbing polarizer, or a polyethylene terephthalate (PET) film.

Claims

1. an optical lens assembly for displaying to a viewer an image emitted by a display, the optical lens assembly comprising: Ophthalmic lenses, A display lens; an intermediate lens disposed between the ophthalmic lens and the display lens and bonded to the ophthalmic lens and the display lens, wherein the intermediate lens, the ophthalmic lens, and the display lens each have an effective lens area defined as a maximum lens area configured to transmit the image emitted by the display, whereby, at least over the corresponding effective lens area: the ophthalmic lens having first and second curved opposed major surfaces, a maximum thickness tmax1, and a minimum thickness tmin1 that is less than two times tmax1; the display lens having a first major surface and an opposite curved second major surface; the intermediate lens having a curved first major surface, an opposite second major surface, and a maximum thickness tmax2 that is at least 1.5 times greater than tmax1; An intermediate lens, a first at least partially light-transmitting film including an absorbing polarizer disposed proximate to and substantially conforming to the curved first major surface of the ophthalmic lens; a second at least partially light-transmitting film including a reflective polarizer disposed between the curved second major surface of the ophthalmic lens and the curved first major surface of the mid-lens, the second at least partially light-transmitting film substantially conforming to each of the curved second major surface of the ophthalmic lens and the curved first major surface of the mid-lens; a first retarder layer disposed between the second major surface of the intermediate lens and the first major surface of the display lens, the first retarder layer substantially conforming to each of the second major surface of the intermediate lens and the first major surface of the display lens, the first retarder layer being insert molded with one of the intermediate lens and the display lens and thereby embedded therein; a third at least partially light-transmitting film disposed on the curved second major surface of the display lens and adapted to substantially conform to the curved second major surface of the display lens; the ophthalmic lens is molded with the first at least partially optically transparent film and the second at least partially optically transparent film on opposite major surfaces of the ophthalmic lens to form a sandwich structure having an inner core defined by the ophthalmic lens and outer skins defined by the first at least partially optically transparent film and the second at least partially optically transparent film; 1. An optical lens assembly, wherein, for substantially normally incident light and at least one wavelength in a visible wavelength range spanning from about 450 nm to about 650 nm, the at least partially optically transmissive first, second, third layers each transmit at least 30% of the substantially normally incident light having a first polarization state, and the at least partially optically transmissive second and third layers each block at least 30% of the substantially normally incident light having an orthogonal second polarization state.

2. 10. The optical lens assembly of claim 1, wherein the third at least partially light-transmitting film is disposed on the curved second major surface of the display lens by at least one of lamination, electroplating, electroless plating, vacuum deposition, physical vapor deposition, plasma-enhanced chemical vapor deposition, and printing.

3. The optical lens assembly of claim 1 , wherein at least one of the curved first and second major surfaces of the ophthalmic lens is curved in two mutually perpendicular directions.

4. The optical lens assembly of claim 1 , wherein the curved first major surface of the mid lens is curved in two mutually perpendicular directions.

5. The optical lens assembly of claim 1 , wherein the second major surface of the mid lens is substantially planar.

6. The optical lens assembly of claim 1 , wherein the second major surface of the mid lens is curved in at least one direction.

7. The optical lens assembly of claim 1 , wherein the second major surface of the mid lens is substantially cylindrical.

8. The optical lens assembly of claim 1 , wherein the first at least partially light-transmitting film is disposed on and substantially conforms to the first major surface of the ophthalmic lens.

9. 2. The optical lens assembly of claim 1, wherein for the substantially normally incident light and at least one wavelength in the visible wavelength range, the first at least partially light transmissive film transmits at least 50% of the substantially normally incident light having the first polarization state and absorbs at least 30% of the substantially normally incident light having the second polarization state.

Images