Film GLUE lens system

Abstract

A film glue lens system for securely affixing a functional film to a base lens using an adhesive may include a lens holder for holding the base lens and a clamp for holding the functional film. The lens holder and the clamp may each be movable to axially or concentrically align the base lens with the functional film, and the lens holder may be movable to cause the base lens to contact and apply pressure to the functional film. The film glue lens system may further include a radiative heater or an ultraviolet lamp movable with respect to the lens holder and the clamp, which may cure the adhesive deposited between the functional film and the base lens. The film glue lens system may also include an infrared pyrometer and / or a camera positioned to monitor the adhesive curing process.

Description

FILM GLUE LENS SYSTEMRELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application Serial No.: 63 / 598,268, filed November 13, 2023, entitled Film Glue Lens System, and which is hereby incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTION

[0002] Optical articles such as ophthalmic spectacle lenses may incorporate additional functionalities, such as photochromic, electrochromic, mirrored, and / or polarized functionalities. Current practices utilized in the manufacture of such functional lenses have proven to be both costly and to require a significant amount of stock inventory materials and production machinery.

[0003] As a first example, polycarbonate functional lenses are often manufactured by molding specified functional wafers to the front surface of a base lens by injecting molten polycarbonate onto the back of a polycarbonate-based film laminate.

[0004] As a second example, Casted photochromic and polarized lenses are often manufactured by embedding a film wafer into a cast lens by utilizing either a tape or gasket process for the film placement or by spin coating a photochromic layer on the outside surface of the lens.

[0005] The use of these processes may contribute to increases in both the cost and the time required to develop or manufacture new types of lenses including new functional films and / or combinations with different base lenses. For example, the optimization and subsequent use of a molding or spin coating process across differing functional wafers may be time consuming and relatively labor intensive, such as by requiring molding members or molding gaskets to be modified to accommodate various types, size, or styles of functional films and / or base lenses.

[0006] Moreover, processes may necessitate the retention of a significant number of stock keeping units (“SKUs”); each representing a differently configured base lens or wafer, in order to produce or help develop a variety of different lenses.

[0007] Still further, many new or existing functional films may be impossible to apply using, or may have to be extensively modified to survive, traditional cast or injection molding processes and / or spin coating processes.

[0008] In view of the above, there is a clear need for a system, method, and / or device which can secure functional wafers, films, or film laminates, such as, but not limited to, polycarbonate based photochromic, polarized, electrochromic, or mirrored wafers, films, or film laminates, to a cast or molded base lens, such as, but not limited to, those made from 1.50 index Trivex, or 1.60, 1.67, or 1.74 index polycarbonate, without utilizing traditional molding or spin coating techniques.SUMMARY OF THE INVENTION

[0009] Disclosed herein are systems, devices, and / or methods for securely affixing a functional film to a lens blank by an adhesive.

[0010] In some examples, the techniques described herein relate to a film glue lens system, including: a lens holder for securing a base lens; a clamp for securing a functional film; an actuator for driving the lens holder towards the clamp such that the base lens contacts and applies pressure to the functional film; an adhesive for securing the functional film to the base lens; and a heater for curing the adhesive.

[0011] In some examples, the techniques described herein relate to a film glue lens system, wherein the lens holder is adjustable between a first lateral position for loading the base lens onto the lens holder and a second lateral position in axial alignment with the clamp.

[0012] In some examples, the techniques described herein relate to a film glue lens system, wherein the clamp is adjustable between a first lateral position for loading the functional film into the clamp and a second lateral position in axial alignment with the lens holder when the lens holder is in the second lateral position.

[0013] In some examples, the techniques described herein relate to a film glue lens system, wherein the actuator includes a vertical actuator such that the lens holder may be raised or lowered between a first vertical position and a second vertical position for causing the base lens to contact the functional film.

[0014] In some examples, the techniques described herein relate to a film glue lens system, further including a pyrometer for monitoring a curing process of the adhesive.

[0015] In some examples, the techniques described herein relate to a film glue lens system, further including a vacuum generator for applying a vacuum to the functional film and the base lens during curing of the adhesive.

[0016] In some examples, the techniques described herein relate to a film glue lens system, further including a camera for monitoring a curing process of the adhesive.

[0017] In some examples, the techniques described herein relate to a film glue lens system, wherein the heater includes an irradiative heater that is pivotable between a first position and a second position for curing the adhesive.

[0018] In some examples, the techniques described herein relate to a film glue lens system, further including a frame, wherein the clamp is movably positioned on a track located an upper surface of the frame.

[0019] In some examples, the techniques described herein relate to a film glue lens system, wherein the functional film includes a polarized film, a photochromic film, an electrochromic film, and / or a nanopatterned film.

[0020] In some examples, the techniques described herein relate to a method of affixing a functional film to a lens, including the steps of: positioning a lens blank on or in a lens holder; securing a functional film to a clamp; moving the clamp and the lens holder into vertical alignment; applying an adhesive to the functional film or the lens blank; moving the lens holder or the clamp such that the lens blank contacts the functional film; and heating the functional film to cure the adhesive.

[0021] In some examples, the techniques described herein relate to a method, wherein moving the lens holder or the clamp such that the lens blank contacts the functional film includes translating the lens holder axially along a vertical axis.

[0022] In some examples, the techniques described herein relate to a method, wherein moving the clamp and / or the lens holder into vertical alignment includes moving the clamp from a first lateral position to a second lateral position and moving the lens holder from a first lateral position to a second lateral position.

[0023] In some examples, the techniques described herein relate to a method, wherein moving the clamp from the first lateral position to the second lateral position includes translating the clamp axially along a second lateral axis and moving the lens holder from the first lateral position to the second lateral position includes translating the lens holder along a second lateral axis.

[0024] In some examples, the techniques described herein relate to a method, wherein heating the functional film so as to cure the adhesive is accomplished by irradiative heating.

[0025] In some examples, the techniques described herein relate to a method, wherein heating the functional film so as to cure the adhesive includes pivoting an irradiative heater from a first position extending parallel to the vertical axis to a second position extending orthogonally to the vertical axis.

[0026] In some examples, the techniques described herein relate to a method, wherein securing the functional film to the clamp first includes selecting the functional film from the group consisting of a polarized film, a photochromic film, an electrochromic film, and a nanopatterned film.

[0027] In some examples, the techniques described herein relate to a method, wherein securing the functional film to the clamp includes clamping the functional film between an upper clamp portion and a lower clamp portion of the clamp.

[0028] In some examples, the techniques described herein relate to a method, wherein heating the functional film to cure the adhesive includes concurrently applying a vacuum to the lens blank and the functional film.

[0029] In some examples, the techniques described herein relate to a method, wherein securing the functional film to the clamp includes positioning the functional film at least partially over a circular opening extending through the clamp.

[0030] In some examples, the techniques described herein relate to a method, wherein translating the lens holder along the vertical axis so that an entire surface area of the lens blank applies pressure to the functional film includes translating the lens blank at least partially into a circular opening of an upper surface of a frame supporting the clamp.

[0031] In some examples, the techniques described herein relate to a method, wherein curing the functional film includes pivoting a heater from a first position to a second position and monitoring the functional film and the lens blank with a camera and / or pyrometer.BRIEF DESCRIPTION OF THE DRAWINGS

[0032] These and other aspects, features and advantages of which embodiments of the invention are capable of will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which:

[0033] Fig. 1 is a frontal view of a film glue lens system, in accordance with at least one example.

[0034] Fig. 2 is a diagram illustrating a film glue lens system, in accordance with at least one example.

[0035] Fig. 3 is a flowchart illustrating a method of applying a functional film to a base lens, in accordance with at least one example.

[0036] Fig. 4 is a cross-section of a functional film, in accordance with at least one example.

[0037] Fig. 5 is a perspective view of a base lens, in accordance with at least one example.

[0038] Fig. 6 is a cross-section of a functional lens, in accordance with at least one example.

[0039] Fig. 7 is a perspective view of a film glue lens system with a clamp in a first position and a lens holder in a first position, in accordance with at least one example.

[0040] Fig. 8 is a perspective view of a lower portion of a clamp, in accordance with at least one example.

[0041] Fig. 9 is a perspective view of a film glue lens system with a clamp in a second position and a lens holder in a first position, in accordance with at least one example.

[0042] Fig. 10 is a perspective view of a film glue lens system with a clamp in a second position, in accordance with at least one example.

[0043] Fig. 11 is a top perspective view of a film glue lens system with a lens holder in a first position, in accordance with at least one example.

[0044] Fig. 12 is a perspective view of a lens holder in a first position with a base lens positioned thereon, in accordance with at least one example.

[0045] Fig. 13 is a top perspective view of a film glue lens system with a clamp in a second position and a lens holder in a first vertical position, in accordance with at least one example.

[0046] Fig. 13 is a perspective view of a film glue lens system, in accordance with at least one example.

[0047] Fig. 14 is a perspective view of a film glue lens system with a clamp in a second position and a lens holder in a second vertical position, in accordance with at least one example.

[0048] Fig. 15 is a perspective view of a lens holder in a first position with a base lens positioned thereon, in accordance with at least one example.

[0049] Fig. 16 is a perspective view of a film glue lens system with an overhead assembly with a shield in a first position, in accordance with at least one example.

[0050] Fig. 17 is a perspective view of an overhead assembly with a shield in a second position, in accordance with at least one example.

[0051] Fig. 18 is a perspective view of a film glue lens system including an overhead vertical actuator, in accordance with at least one example.

[0052] Fig. 19 illustrates a system diagram of a film glue lens system, in accordance with at least one example.

[0053] Fig. 20 is a flowchart illustrating a method of applying a functional film to a base lens, in accordance with at least one example.DETAILED DESCRIPTION

[0054] Specific examples of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the examples illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.

[0055] For the purposes of this specification, use of the terms “about”, “around”, or “approximately” when referring to a value may be understood to mean within 10% of the stated value (either greater or lesser), inclusive.

[0056] Disclosed herein are systems, methods, and devices for securing a functional film, a film wafer, or a thin film laminate to a base lens to form a functional lens (e.g., a lens blank or clear stock lens having a functional film attached thereto). The functional film, film wafer, or film laminate (hereinafter “the functional film” for brevity) may be adapted to provide numerous different functions, such as but not limited to, photochromic, polarized, electrochromic, micropatterned, nanopatterned, wire grid, or mirrored properties. The systems, methods, and devices disclosed herein may be adapted to secure or attach the functional film to a base lens through the application of adhesives, including glue, along with pressure and / or heat.

[0057] The base lens may be fabricated using various methods, such as, but not limited to, traditional casting or injection molding processes. In some examples, the functional film may be comprised of a pre-cut functional film, such as sized and shaped to correspond to the dimensional extents of the base lens. In other examples, the functional film may be cut to size after being secured to the base lens. In some examples, the functional film may be pre-coated or pretreated with an adhesive immediately before being attached to the base lens. In some examples, the functional film and / or the base lens may be pretreated or pre-coated with an adhesive any time prior to the functional film being applied to the base lens.

[0058] In some examples, the functional film may be secured within a clamp or other holding mechanism with a side of the functional film on which adhesive is deposited facing or otherwise oriented toward a lens holder. A base lens may then be loaded onto the lens holder, such as a pedestal that is adjustably positioned with respect to the clamp holding the functional film. Next, the lens holder may be driven towards the clamp holding the functional film, such as in an upward, lateral, or downwards direction. For example, a first actuator may be operated to cause the lens holder, with the base lens thereon, to move toward the clamp until the base lens contacts the functional film. The lens holder may remain in place for an amount of time sufficient to allow the adhesive to cure, thereby bonding the functional film to the base lens to form a functional lens. The lens holder may then be retracted to its original position, and the functional lens may subsequently be removed from the lens holder. In some examples, the functional lens may then undergo various additionalpostproduction processing and / or finishing operations known in the art, such as lens coating and / or further shaping and sizing.

[0059] The use of the systems, methods, and devices shown and / or described herein may thereby provide many benefits over existing systems and methods for affixing a functional film to a base lens, such as injection molding, casting, or spin coating. For example, the systems, methods, and devices shown and / or described herein may enable functional lenses to be produced without requiring an inventory of different pre-cut or otherwise pre-prepared (for molding or casting) functional films or base lenses, molding gaskets, molding members, or other associated materials to be kept in inventory. Furthermore, relative to existing processes, the systems, methods, and devices shown and / or described herein can more simply and more efficiently attach a functional film to a base lens, which may greatly reduce the cost and time required to develop new functional lens types, by eliminating the need to utilize, and / or optimize a cast or injection molding process, or spin coating process, to incorporate differing functional films. In this way, the systems, methods, and devices shown and / or described herein may provide a universal solution to attach a wide variety of functional films to a wide variety of base lenses or lens blanks.

[0060] Finally, the systems, methods, and devices shown and / or described herein may also provide the capability to explore new types of base lenses or functional film technologies that are not compatible with traditional casting, molding, or spin coating processes. As such, the systems, methods, and devices shown and / or described herein may help to provide a faster and more economical path for testing new laminate technologies, such as, among others, holographic laminates, thinner laminates, or smart laminates.

[0061] Specific examples are described below. However, it should be appreciated that any of the features from any of the examples can be mixed and matched with each other in any combination. Hence, the present invention should not be restricted to only these examples, but any broader combination(s) thereof.

[0062] Fig. 1 illustrates an example of a film glue lens system 100, in accordance with at least example. The film glue lens system 100 may be adapted for use in securely attaching a functional film 102 to a base lens 104.

[0063] The functional film 102 may comprise a wide variety of different optical films, film laminates, or wafers including one or more individual films or substrate layers available in the art, such as, but not limited to, adapted to provide polarizing, photochromic, electrochromic, holographic, piezoelectric (“PZ”), or mirrored functionality. In further examples, the functional film 102 may comprise a wire grid layer, one or more smart film layers, or any other type of film, or film laminate, or technology wafer for filtering wavelengths of light or otherwise providing an optical function. In still further examples, the functional film 102 may comprise one or more material layers adapted to help improve shock or shatter resistance of the base lens 104.

[0064] The base lens 104 may be comprised of a clear (e.g., uncolored) cast or molded optical lens (e.g., a lens blank or stock lens). The base lens 104 may, in some examples, be composed of a material having a refractive index of, but not limited to, between about 1.5 and about 1.8. In some examples, the base lens 104 may be composed of polycarbonate, Trivex, CR-39 (Columbia Resin #39), glass, acrylic, or high-index plastic having a refractive index of, but not limited to, about 1.5, 1.67, or 1.74.

[0065] The base lens 104 may also generally possess a thickness that is common to ophthalmic lenses, such as by measuring between, but not limited to, about 10 millimeters and about 20 millimeters in overall thickness. In one specific example, the base lens 104 may measure about 12 millimeters in thickness. However, it should be appreciated that the methods, systems, and devices shown and / or described herein may be utilized with a base lens 104 having various thicknesses outside of the aforementioned example range.

[0066] The base lens 104 may further possess any base curve shape known or used in the art, such as, but not limited to, a 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , or 12 base curve shape. In some specific examples, the base lens 104 may possess a 4 basecurve or a 6 base curve shape. In various examples, the base lens 104 may include any functional shaping characteristic or corrective power known in the art such as, among others, diameter (“DIA”) or diameter and / or radius of curvature, power (“PWR”), which refers to a positive or a negative number indicating the degree of correction for improving near vision and / or distance vision, cylinder (“CYL”), which refers to a positive or negative number for addressing astigmatism, axis (“AX”), addition (“ADD”), single vision near (“SVN”), single vision distance (“SVD”), or sagitta (“SAG”). In still further examples, the base lens 104 may include microlenses, lenslets, and / or other segmented or progressive Fresnel features.

[0067] In some examples, the base lens 104 may be pre-treated with an adhesive that may respond (e.g., cure) to pressure, light or radiation, and / or temperature. In some examples, the base lens 104 may also be fabricated using a corona, chemical, or other treatment which may help enhance the surface adhesion of an upper surface 105 of the base lens 104 such as shown in Fig. 5.

[0068] The base lens 104 may then be positioned on or in a lens holder 108. The lens holder 108 may be configured to hold, support, or otherwise retain the base lens 104. The base lens 104 may be secured in place on or in the lens holder 108 using various methods or securing mechanisms, such as, but not limited to, one or more clamps, or by virtue of being positioned within an appropriately sized and shaped recess or opening of the lens holder 108. In some examples, the base lens 104 may be placed on top of the lens holder 108 without any specific structure securing the base lens 104 thereto. The lens holder 108 may include, or may be coupled to, a pedestal 110, such as, but not limited to, a cylindrical or rectangular pedestal. The pedestal 110 and / or the lens holder 108 may be mounted on a first actuator 112.

[0069] In some examples, the pedestal 110 may be driven by the first actuator 112 so that the lens holder 108, and base lens 104 thereon, move towards a clamp 106 holding the functional film 102. The first actuator 112 may be comprised of any type of linear actuator, such as, but not limited to, an electric, pneumatic, electromechanical, or electrohydraulic actuator.

[0070] The direction in which the lens holder 108 and / or the pedestal 110 may be driven towards the clamp 106 may vary in different examples, and thus should not be construed as being limited to the vertical movement as shown in the figures. For example, as shown in Fig. 1 , the lens holder 108 and the pedestal 110 may be driven vertically upwardly in the direction indicated by arrow 115. In other examples, the lens holder 108 may be driven in a lateral or transverse direction (e.g., orthogonally to the direction indicated by the arrow 115), in a vertically downward direction (e.g., 180 degrees to the direction indicated by the arrow 115), or in various other directions.

[0071] The clamp 106 may be adapted to maintain the functional film 102 in a position or location that is axially aligned with the lens holder 108, the pedestal 110, and / or the first actuator 112. The clamp 106 may be comprised of a wide variety of different types of clamping devices or securing mechanisms adapted to secure the functional film 102 therein before, during, and, in some examples, after an adhesive curing process. In one example, the clamp 106 may be comprised of a C-clamp. In such an example, two flat, or alternatively, two correspondingly curved members, may first be placed on either side of the functional film 102, and subsequently, the two members may be clamped together by one or more C-clamps to thereby sandwich the functional film 102 therebetween.

[0072] In another example, the clamp 106 may comprise a screw clamp. In such an example, two flat or correspondingly curved members may be placed on either side of the functional film 102 and then threadedly engaged with one another to sandwich the functional film 102 therebetween.

[0073] In yet another example, the clamp 106 may comprise a hydraulic or a pneumatic toggle clamp or may otherwise be configured to perform hydraulic and / or pneumatic functions, such as described with respect to Figs. 7-12 below.

[0074] In any such examples, the clamp 106 may be adjustable, or may include adjustable elements, so as to accommodate a range of functional films having different dimensions, such as, but not limited to, differing surface areas, thicknesses, or other dimensional extents. In this manner, the clamp 106 may enable the film glue lens system 100 to accommodate a wide range of different functional films. As may beappreciated, the functional film 102 may be secured within the clamp 106 until the functional film 102 is attached to the base lens 104 in order to form a functional lens 114 such as shown in Fig. 6.

[0075] In some examples, before the first actuator 112 is used to drive the base lens 104 toward the clamp 106 that contains the functional film 102, an adhesive may be deposited on the functional film and / or the base lens 104. The adhesive may be any adhesive suitable for securing a functional film, functional wafer, or film laminate material to the base lens 104, such as, but not limited to, pressure and / or heat sensitive adhesives, moisture cured adhesives, or adhesives cured by ultraviolet light or electron-beams. In various examples, the adhesive may be comprised of one of the coatings disclosed in U.S. Pat. Application Serial No. 18 / 628,487, filed April 04, 2024, the entire contents of which are hereby incorporated by reference in its entirety.

[0076] In some examples, the adhesive may comprise a polyurethane adhesive. In one example, the adhesive may comprise 3M 8213 OCA adhesive curable at about eighty degrees Fahrenheit. In another example, the adhesive may comprise 3M 8146- 2 OCA and 3M CEF 3104AS OCA, which may be cured by the application of pressure. In another example, the adhesive may comprise 3M 3099 UV adhesive. In a still further example, the adhesive may comprise Dymax 3099 adhesive.

[0077] Subsequently, the first actuator 112 may move the base lens 104 toward the clamp 106 until the base lens 104 contacts, and applies pressure to, the functional film 102. In this respect, the first actuator 112 may stop, such as via a manual user input to the first actuator 112 or automatically at the direction of a controller, such as the central controller 180 of Fig. 19, at a predetermined position in which the base lens 104 may apply a desired amount of pressure to the functional film 102. As may be appreciated, such as position may be selected such that an entire surface area of the base lens 104 is in contact with the functional film 102. Finally, a curing mechanism such as a heater 140, or an infrared or ultraviolet light, may be utilized to cure the adhesive and thereby bond the functional film 102 to the base lens 104.

[0078] Fig. 2 is a diagram illustrating an example film glue lens system 100, in accordance with at least one example. In the example of Fig. 2, the heater 140 maycomprise an infrared heater that may be positioned directed above the functional film 102 when secured within the clamp 106. Alternatively, the heater 140 may comprise a radiative heater, which may include various heating materials such as ceramics, quartz, and the like. In some examples, the heater 140 may be omitted and replaced by, or included but augmented by, another curing mechanism, such as but not limited to mechanisms capable of curing pressure and / or heat sensitive adhesives, moisture cured adhesives, or adhesives cured by ultraviolet light or electron-beams.

[0079] In some examples, such as shown in Fig. 2, the film glue lens system 100 may comprise a camera 150 and / or an infrared pyrometer 160. In one such example, both a camera 150 and the infrared pyrometer 160 may be positioned directly above the functional film 102 secured within the clamp 106 in order to aid in monitoring the curing process of the adhesive.

[0080] For example, the camera 150 and / or the pyrometer 160 may be configured to provide infrared sensing monitor and infrared measuring, respectively, of the temperature of the functional film 102 during the adhesive curing process. In some examples, a central controller, such as, but not limited to, a Proportional-integral- derivative (hereinafter “PID”) controller, may be utilized to completely or partially control the adhesive curing process. For example, a PID feedback loop may be formed with the heater 140, a PID controller, the camera 150, and / or the infrared pyrometer 160 to automatically maintain the temperature of the functional film 102, the base lens 104, and / or the adhesive at a set point or specific temperature, or otherwise within a certain temperature range, during the adhesive curing process.

[0081] In some examples, the camera 150 may comprise a thermal camera or an infrared camera that is configured to allow a user to view live images of the functional film 102 and / or the base lens 104 in the infrared range and / or in the visible light range. The camera 150 may also be operable to measure temperature in various points of interest, such as on or over a surface area of the functional film 102. In this respect, the camera 150 may provide a visual representation of uniformity and / or hot spots to help monitor the curing process and correct for any deficiencies or concerns. The camera 150 may be configured to collect (e.g., store in memory or output) real-timedata on the temperature of the functional film 102. In a more specific example, the camera 150 may comprise a Fluke Thermoview TV40 Camera.

[0082] Fig. 3 is a flowchart illustrating an example method of applying a film to a base lens. Fig. 3 is discussed with concurrent reference to Figs. 4-6, which illustrate, respectively, examples of the functional film 102, the base lens 104, and a functional lens 114 formed by bonding the functional film 102 to the base lens 104. In such examples, the functional lens 114 may conform to, or be shaped by, a curvature of the base lens 104. In other examples, the functional film 102 may comprise a pre-shaped functional wafter or functional laminate that corresponds to a curvature the base lens 104.

[0083] As illustrated in Fig. 3, the method may begin with selecting the functional film 102 at stage 190 and selecting the base lens 104 at stage 192. Next, during stage 190, the functional film 102 may be secured in a position within the clamp 106. In some such examples, the functional film 102 may be comprised of a pre-cut or sized film, such as a pre-cut film or technology wafer, and as such, securing the functional film 102 within the clamp 106 may not include resizing, cutting, or other shaping of the functional film 102. In other examples, the functional film 102 may be, for example, comprised of a film stock sheet, and as such, securing the functional film 102 within the clamp 106 may include cutting or shaping of the functional film 102 to a size that is receivable within the clamp 106. In some examples, a surface of the functional film 102, such as a lower surface 103 thereof as shown in Fig. 4, may first be pre-treated with an adhesive before the functional film 102 is secured within the clamp 106. In some examples, the functional film 102 may also be pre-treated to help improve surface adhesion, such as, but not limited to, via a corona, chemical, or any other treatment of the lower surface 103 adapted for improving adhesion.

[0084] Before, or after, the functional film 102 is secured within the clamp 106, the base lens 104 may be placed into or onto the lens holder 108 at stage 192. In some examples, as noted above, the base lens 104 may also be pre-treated to help improve surface adhesion before being placed into the lens holder 108.

[0085] An adhesive may be applied to the upper surface 105 of the base lens 104. The adhesive may, in some examples, be applied to cover at least a portion of a surface area of the upper surface 105. In some examples, the adhesive may also be applied to the lower surface 103 of the functional film 102.

[0086] At stage 194, the film glue lens system 100 may be operated to affix the functional film 102 to the adhesive containing surface of the base lens 104, resulting in the creation of the functional lens 114 such as shown in Fig. 6. For example, the actuator 112 may drive the upper surface 105 of the base lens 104 into contact with the lower surface 103 of the functional film 102 and maintain the base lens 104 in position until the adhesive has cured. Subsequently, at stage 196, the functional lens 114 may be removed from the lens holder 108 for processing into ophthalmic spectacle lenses or the like. In some examples, such processing may include any of various operations known in the art, such as, but not limited to, lens shaping, polishing, lens coating, or over-molding steps. In one such example, at stage 198, the lens coating of the functional lens 114 may comprise index matched hard coating to accommodate any refractive index difference between the functional film 102 and the base lens 104. As may be appreciated, such an operation may reduce the amount of light that reflects off the functional film 102 and / or the base lens 104, thereby allowing additional light to pass through the functional lens 114 to improve optical performance.

[0087] Figs. 7-18 illustrate a film glue lens system 100, in accordance with at least one example. Figs. 7-18 are discussed below concurrently. In various examples, the clamp 106, the lens holder 108, the pedestal 110, the first actuator 112, and / or the camera 150 shown in any of Figs. 7-18 may be similar, or different, to the clamp 106, the lens holder 108, the pedestal 110, the first actuator 112, and / or the camera 150 shown in any of Figs. 1-6. As shown in Figs. 7-18, the film glue lens system 100 may include a frame 118. The frame 118 may be configured to support any of various components of the film glue lens system 100 with respect to one another.

[0088] More particularly, the frame 118 may be adapted to help adjustably support both the clamp 106 which may retain the functional film 102 and the lens holder 108 which retains the base lens 104. The frame 118 may be comprised of various shapesand sizes in different examples. In some examples, the frame 118 may form a generally cuboidal or rectangular shape that extends over, and at least partially around, the pedestal 110 and / or the lens holder 108 when the lens holder 108 is axially aligned with the clamp 106. In other examples, the frame 118 may form other generally arched shapes that extend over, and at least partially around, the pedestal 110 and / or the lens holder 108. In some examples, all of the components of the film glue lens system 100, including the frame 1 18, may be positioned completely or partially within an enclosure configured to help reduce the risk of injury to an operator, such as due to the potential danger presented by various moving or heated parts of the film glue lens system 100.

[0089] In some examples, the film glue lens system 100 may include an upper track 120 and a lower track 122. The upper track 120 may be adapted to movably support the clamp 106 on an upper surface 124 of the frame 118. In some examples, the upper track 120 may be comprised of a single-track component. In other examples, the upper track 120 may be comprised of a first upper track 120A and a second upper track 120B which may be spaced laterally apart from each other, such as to help improve the stability of the clamp 106 during movement.

[0090] The upper track 120 may allow the clamp 106 to be translated toward a user, or translated away from a user, along a first lateral axis A1 extending parallel to upper track 120 such as shown in Fig. 9. In this respect, the clamp 106 may also include any of wheels, bearings, bushings, clamps, guides, or any other securing and / or friction reducing features necessary to enable the clamp 106 to slide securely along the upper track 120. In some examples, the clamp 106 may be translated or driven along the upper track 120 manually by a user.

[0091] In other examples, the clamp 106 may be translated or driven along the upper track 120 by a second actuator 125. The second actuator 125 may be similar to the first actuator 112, at least in that the second actuator 125 may be comprised of, but not limited to, an electric, pneumatic, electromechanical, or electrohydraulic linear actuator. In such examples, the second actuator 125 may be directly activated by a user, or alternatively, may be in communication with a central controller, such as thecentral controller 180 as shown in Fig. 19 in order to receive control commands or instructions therefrom.

[0092] The upper track 120 may be enable the clamp 106 to be moved between a first lateral position, such as shown in Figs. 7-8, and a second lateral position, such as shown in Figs. 9-10. The first lateral position of the clamp 106 may be adapted for loading the functional film 102 onto and securing the functional film 102 with the clamp 106, such by a user or via automated robotic means.

[0093] For example, the first lateral position of the clamp 106 may generally comprise a position along the upper track 120 that is nearest, or is most proximal to, a user. The second lateral position of the clamp 106 may be adapted to align the clamp 106, and the functional film 102 contained therein, with the lens holder 108 and / or the pedestal 110. For example, the second lateral position of the clamp 106 may comprise a position along the upper track 120 that is farthest from, or is most distal to, a user. The use of the first lateral position and the second lateral position of the clamp 106 may help to prevent or reduce the risk of injury to an operator due to moving or heated parts, such as by keeping the operator away from the functional film 102 when the base lens 104 is pressed against the functional film 102 by a press 141 and the first actuator 112.

[0094] As previously mentioned, the clamp 106 may be comprised of a wide variety of different devices or securing mechanisms operable to secure the functional film 102 in position therewithin. In some examples, the clamp 106 may be comprised of an upper portion 126 and a lower portion 128. In such an example, the upper portion 126 may be separable from the lower portion 128. For example, Fig. 8 illustrates the lower portion 128 with the upper portion 126 removed. In some such examples, the lower portion 128 may be comprised of a sled or platform that is slidably connected to the upper track 120. In this respect, the lower portion 128 may also include any of the wheels, bearings, bushings, clamps, guides, or any other securing and / or friction reducing features that may enable the clamp 106 to slide securely along the upper track 120. In some such examples, the upper portion 126 may be positionable within a plurality of stops 130 sized and shaped to maintain the upper portion 126 in aparticular position on the lower portion 128. In such an example, the plurality of stops 130 may each be adjustable, such as between at least two different positions on the lower portion 128, in order to accommodate a variety of shapes and sizes of functional film 102 and / or differently sized upper portions 126.

[0095] In other examples, the upper portion 126 and the lower portion 128 may be pivotable, slidable, hinged, or otherwise movable with respect to one another to enable the functional film 102 to be positioned therebetween. In some examples, the upper portion 126 may be moved away from the lower portion 128 to enable a user, or automated robotic mechanism(s), to position the functional film 102 on the lower portion 128. In some examples, the lower portion 128 may define a recess 129 that may be sized and shaped to receive the functional film 102 to prevent the functional film 102 from moving laterally along the lower portion 128 and or vertically through the lower portion 128.

[0096] Subsequently, the upper portion 126 may be moved back into place on the lower portion 128 to capture the functional film 102 between the upper portion 126 and the lower portion 128. The clamp 106 may also define an opening 132. The opening 132 may be sized and shaped to at least partially receive the base lens 104 and / or the lens holder 108 therein or therethrough. For example, when the functional film 102 is secured within the clamp 106, the opening 132 may enable the base lens 104 to contact, and apply pressure to, the exposed portion the lower surface 103 of the functional film 102 spanning the opening 132.

[0097] The opening 132 may thereby allow the functional film 102 to be stretched over, and / or uniformly bonded to, the entire upper surface 105 of the base lens 104, and in some examples, cause the functional film 102 to conform to the curvature of the upper surface 105 of the base lens 104. In one example, such as shown in Fig. 7, the opening 132 may be realized in the form a first circular opening 133 defined by the upper portion 126, and a second circular opening 134 defined by the lower portion 128. In such an example, when the upper portion 126 is placed on the lower portion 128 between the plurality of stops 130, the first circular opening 133 may be concentrically aligned with the second circular opening 134.

[0098] The lower track 122 may be adapted to movably support the lens holder 108 and / or the pedestal 110. In some examples, the lower track 122 may be comprised of a single-track component. In other examples, the lower track 122 may include a first lower track 122A and a second lower track 122B that may be spaced laterally apart from each other, such as to help improve the stability of the clamp 106 during movement. The lower track 122 may allow the lens holder 108 and / or the pedestal 110 to be translated toward a user, or away from a user, along a second lateral axis A2, such as shown in Fig. 11 , which may extend parallel to, but laterally or vertically offset from, the first lateral axis A1 such as shown in Fig. 10. In some examples, such as shown in Figs. 11 and 13, the pedestal 110 may be mounted on a platform 144. The platform 144, may include any of wheels, bearings, bushings, clamps, guides, or other securing and / or friction reducing features necessary to enable allow the platform 144 to slide securely on the lower track 122.

[0099] In some examples, the platform 144, to which the lens holder 108 and / or the pedestal 110 may be mounted, may be translated or driven along the lower track 122 manually by a user. In other examples, the platform 144, to which the lens holder 108 and / or the pedestal 110 may be mounted, may be translated or driven along the lower track 122 by a third actuator 136. The third actuator 136 may be similar to the first actuator 112 and the second actuator 125, at least in that the third actuator 136 may be comprised of an electric, pneumatic, electromechanical, or electrohydraulic linear actuator. In some such examples, the third actuator 136 may be directly activated by a user, or alternatively, may be in communication with a central controller, such as the central controller 180 as shown in Fig. 19, in order to receive control commands or instructions therefrom.

[0100] As previously mentioned, the lens holder 108 may be comprised of a variety of different devices configured to secure the base lens 104 in position thereon or therein. In some examples, such as shown in Figs. 11 -12, the lens holder 108 may be comprised of a generally circular tray or container including include a recess or groove 127 that may be sized and shaped to support the base lens 104, and limit radial or lateral movement between the lens holder 108. In some examples, the lens holder 108 may further include one or more clamps, or other securing mechanisms known inart, operable engage the base lens 104 and secure it in place on the lens holder 108. In still further examples, such as shown in Figs. 7-9 and 11 , the lens holder 108 may define a vacuum channel 113 connected to a vacuum generator 170, such as shown in Fig. 19.

[0101] The lower track 122 may be configured to enable the lens holder 108 and the pedestal 110 to be moved between a first lateral position, such as shown in Figs. 7-8 and 10, and a second lateral position, such as shown in Fig. 11. The first lateral position of the lens holder 108 may be adapted for loading the base lens 104 onto the lens holder 108. For example, the first lateral position of the lens holder 108 may be a position along the lower track 122 that is nearest, or most proximal to, a user. The second lateral position of the lens holder 108 may be adapted to align the lens holder 108 with the clamp 106, such as axially along a first vertical axis A3 such as shown in Fig. 10. The second lateral position of the lens holder 108 may further be configured to align an aperture 138 such as shown in Figs. 10 and 13, defined in the upper surface 124 of the frame 118, with the lens holder 108. The second lateral position may thereby enable the base lens 104 to be concentrically aligned with, or otherwise central positioned relative to, the portion of the functional film 102 which spans the opening 132 in the clamp 106.

[0102] Further, when the lens holder 108 is in the second lateral position, the lens holder 108 and / or the pedestal 110 may be inboard of, or otherwise within, the dimensional extents of the frame 118. As may be appreciated, the use of the first lateral position and the second lateral position of the lens holder 108 may help to prevent or reduce the risk of injury to an operator due to moving or heated parts, such as by keeping the operator away from the functional film 102 when the base lens 104 is pressed against the functional film 102 and / or the press 141 .

[0103] The lens holder 108 and / or the pedestal 110 may further be movable between a first vertical position, such as shown in Fig. 13, and a second vertical position, such as shown in Fig. 14. The first vertical position may generally be comprised of any location along the lower track 122. In other words, in the first vertical position, the lens holder 108 may be in a lowermost position, or otherwise most distalposition, relative to the upper surface 124 of the frame 118. In this respect, the first vertical position and the second lateral position of the lens holder 108 may, in some examples, be comprised of the same location along both the second lateral axis A2 and the vertical axis A3. In the second vertical position, the lens holder 108 may be in an uppermost position relative to the frame 118, in which the recess or groove 127 may be located above the upper surface 124 of the frame 118 to enable the base lens 104 to be positioned within the opening 132. As may be appreciated, as the lens holder 108 translates from the first vertical position to the second vertical position, the lens holder 108 may pass through the aperture 138 in the upper surface 124.

[0104] In view of the above, when the lens holder 108 is in the second vertical position, the base lens 104 positioned thereon may be in contact with the portion of the functional film 102 exposed by the opening 132 in the clamp 106 so that an adhesive on the base lens 104 and / or the functional film 102 may be cured to securely affix the functional film 102 to the base lens 104 and form the functional lens 114. As also previously mentioned above, the functional film 102 and / or the base lens 104 may be pre-loaded with the adhesive, or the adhesive may be applied to the functional film 102 or the base lens 104 during any of the aforementioned steps or operations.

[0105] In some examples, the lens holder 108 and the pedestal 110 may be moved between the first vertical position and the second vertical position by the first actuator 112. In some such examples, the first actuator 112 may be directly activated by a user, or alternatively, may be in communication with a central controller, such as the central controller 180, in order to receive control commands or instructions therefrom. In some examples, such as shown in Figs. 9, 12, and 15, the pedestal 110 may further include a cushioning spring 111.

[0106] In such an example, the pedestal 110 may be collapsible or telescopic along the vertical axis A3 to enable the pedestal 110 to decrease in height or length in response to vertical pressure. Such a feature may help enable the base lens 104 to apply a limited, or otherwise more easily controllable, amount of pressure to the functional film 102 by allowing the cushioning spring 111 and the pedestal 110 to compress, as shown in Fig. 15, when the base lens 104 contacts the functional film102. As may be appreciated, this may help to limit or prevent damage to the functional film 102.

[0107] In some examples, such a feature may also help enable a top surface 109 of the lens holder 108 to effectively seal against a bottom surface 123 of the lower portion 128 of the clamp 106, such as in an example where a vacuum may be applied through a vacuum channel 113 in the lens holder 108 as described in more detail below. In such examples, it is to be appreciated that the top surface 109 of the lens holder 108 and the bottom surface 123 of the lens holder 108 may also include annular protrusions or projections, O-rings, elastomeric materials, or other features or materials configured to help establish an air-tight seal between the interface of the bottom surface 123 of the clamp 106 and the top surface 109 of the lens holder 108.

[0108] In some examples, the press 141 may be positioned above or over the clamp 106. In the example shown in Figs. 7-18, the press 141 may include a contacting element 142 that is sized and shaped to conform to the upper surface 105 of the base lens 104. In some examples, press 141 may optionally include a heater adapted to heat the contacting element 142 to aid in adhesive curing. The press 141 may further include an adjustment mechanism 146. The adjustment mechanism 146 may be generally comprised of a pivot, arm, hinge, or other feature adapted to enable the contacting element 142 to movably attached to the frame 118 to allow the contacting element 142 to be adjustable between at least two positions. For example, the contacting element 142 may be pivoted between a first or passive position, such as shown in Figs. 9-10, and a second or active position, such as shown in Figs. 13- 14, in which the contacting element 142 may be positioned either directly above, or in direct contact with, the portion of the functional film 102 exposed within the opening 132 of the clamp 106. In some examples, the contacting element 142 may extend parallel to the vertical axis A3 when in the first or passive position and may extend perpendicularly or orthogonally to the vertical axis A3 when in the second or active position.

[0109] In the second or active position, the contacting element 142 may evenly pressure and / or heat the functional film 102, such as by being in continuous contactwith an entire surface area of the functional film 102 within the opening 132 of the clamp 106. This may help to avoid damage to the functional film 102 caused by hot spots, as well as to uniformly bond the functional film 102 across the curvature of the base lens 104. In some examples, the contacting element 142 may be moved from the first position to the second position by a user, such as via a manual input to the adjustment mechanism 146. In other examples, the contacting element 142 may be driven between the first position and the second position via an actuator, a motor, or any other electric, pneumatic, or hydraulic, or electrohydraulic device included within, or connected to, the adjustment mechanism 146. In some such examples, the actuator or motor of the adjustment mechanism 146 may be driven automatically, such as at the direction of a central controller, such as the central controller 180 shown in Fig. 19.

[0110] The film glue lens system 100 may also include the camera 150. The camera 150 may be similar to the camera 150 described above with respect to Figs 1 - 3. In the film glue lens system 100 shown in Figs. 7-12, the camera 150 may be positioned to monitor the temperature of the functional film 102 and / or the contacting element 142 during the adhesive curing process. In one example, the camera 150 may be secured or fastened to a camera mount 152 extending upwardly from the upper surface 124 of the frame 118. In some examples, the camera 150 may also include a pyrometer, such as an infrared pyrometer similar to as discussed with reference to Figs. 1 -3 above. It is appreciated that the infrared pyrometer and the camera 150 may be positioned anywhere on or about the frame 118.

[0111] The camera 150 and / or the infrared pyrometer, may as previously described above, monitor the curing process of the adhesive located between the functional film 102 and the base lens 104, such as by monitoring for uniformity of temperature and / or hotspots along the surface area of the functional film 102. In some examples, as also noted above, the camera 150 and / or the infrared pyrometer may be in communication with a PID controller, and / or a central controller 180, in order to form an automated feedback loop capable of automatically maintaining a temperature of the functional film 102, activating or deactivating an infrared lamp 156 (or alternatively an ultraviolet lamp), and / or maintaining a temperature of the contacting element 142 with aprogrammable range or preset temperature for an amount of time selected for curing the adhesive.

[0112] In some examples, the film glue lens system 100 may include a pair of arms 162A and 162B. The pair of arms 162A and 162B may be configured to help prevent relative movement between the upper portion 126 of the clamp 106 and the lower portion 128 of the clamp 106, as well as to apply an amount of compressive pressure to the functional film 102. In some examples, the pair of arms 162A and 162B may include adjustment mechanisms 164A and 164B. The adjustment mechanisms 164A and 164B may be generally comprised of a pivot, arm, hinge or other device adapted to enable the pair of arms 162A and 162B be movable between at least two positions. For example, the pair of arms 162A and 162B may be moved between a first position, such as shown in Fig. 10, and a second position, such as shown in Figs. 13-14. In some examples, the pair of arms 162A and 162B may extend parallel to the vertical axis A3 when in the first position. In the second position, the pair of arms 162A and 162B may be in contact with the upper portion 126 of the clamp 106 and may also extend perpendicularly or orthogonally to the vertical axis A3.

[0113] In some examples, the pair or arms 162A and 162B may be moved from their respective first positions to their respective second positions directly by a user, such as via a manual user input to the adjustment mechanisms 164A and 164B. In other examples, the pair of arms 162A and 164B may be moved or driven between their respective first positions and their second respective positions via an actuator, a motor, or any other electric, pneumatic, hydraulic, or electrohydraulic device of the adjustment mechanisms 164A and 164B. In some such examples, the adjustment mechanisms 164 and 164B may be driven automatically, such as the direction of the central controller 180 shown in Fig. 19, between the first position and the second position.

[0114] Finally, in some examples such as shown in Figs. 16-18, the film glue lens system 100 may include an overhead assembly 154. In some examples, the overhead assembly 154 may include an overhead track 155, an infrared lamp 156, a shield 157, a fourth actuator 158, and a fifth actuator 159. The overhead track 155 may extendlaterally or transversely over the upper surface 124 of the frame 118 on which the clamp 106 is adjustably supported. In some examples, the overhead track 155 may extend orthogonally to the first lateral axis A1 , the second lateral axis A2, and the vertical axis A3. The fourth actuator 158 and the fifth actuator 159 may be comprised of, but not limited to, an electric, pneumatic, electromechanical, hydraulic, or electrohydraulic actuator. The fourth actuator 158, the fifth actuator 159, and the infrared lamp 156 may be directly activated by a user via one or more user inputs thereto, or alternatively, may be in communication with a central controller, such as the central controller 180 shown in Fig 19, to receive automated commands therefrom.

[0115] The infrared lamp 156 may be used in an example method where the adhesive deposited on the functional film 102 and / or the base lens 104 may be infrared curable, such as adhesives designed to be cured with infrared light and / or electronbeams. In some example methods, the fourth actuator 158 may enable the shield 157 to be moved from a first lateral position that is laterally adjacent or offset from the opening 132 of the clamp 106, such as shown in Fig. 16, to a second position located over the opening 132 of the clamp 106, such as shown in Fig. 17. This may enable the infrared lamp 156 to remain continuously activated (e.g., in use), and the shield 157 may be actuated between the first lateral position and the second lateral position to enable or prevent, respectively, infrared light from reaching the adhesive.

[0116] In some examples methods, the fifth actuator 159 may enable the infrared lamp 156 and the shield 157 to be moved from a first vertical position located a significant distance apart from the clamp 106, such as shown in Figs 16-17, to a second vertical position adjacent or relatively close to the opening 132 of the clamp 106, such as shown in Fig. 18. As may be appreciated, this may enable the light emitted by the infrared lamp 156 to be selectively increased in intensity by increasing or decreasing the vertical distance between the functional film 102 and the base lens 104. In the above example methods, it is also appreciated that the contacting element 142 may be in its first position to ensure that the functional film 102 and the base lens 104 are not obstructed or prevented from receiving the infrared light emitted by the infrared lamp 156. However, while not shown in Figs. 16-18, the pair of arms 162A and 162B may still be in their respective second positions (e.g., in contact with theupper portion 126 of the clamp 106) without blocking the light output of the infrared lamp 156.

[0117] Fig. 19 illustrates a system diagram of the film glue lens system 100, in accordance with at least one example. As illustrated in Fig. 19, the film glue lens system 100 may include a central controller 180. The central controller 180 may be configured to perform any of the methods or techniques discussed in the present disclosure. For example, the central controller 180 may be in communication with one or more of the first actuator 112, the second actuator 125, the third actuator 136, the press 141 (which may include the adjustment mechanism 146), the pair of arms 162A and 162B (which may include the adjustment mechanisms 164A and 164B), the overhead assembly 154 (which may include the infrared lamp, the fourth actuator 158, and the fifth actuator 159), and the vacuum generator 170 in fluid communication with the vacuum channel 113 of the lens holder 108.

[0118] The central controller 180 may operate as an independent device or may be networked to other systems or devices. In a networked configuration, the central controller 180 may operate as a server machine, a client machine, or both, such as in server-client network environments. In one example, the central controller 180 may act as a peer machine in a peer-to-peer (P2P), or any distributed network environment. The central controller 180 may be realized in the form of a personal computer (“PC”), an electronic tablet, a personal digital assistant (PDA), a set-top box (STB), a network router, a web appliance, a switch or bridge, or any other device or system capable of executing instructions that cause or specify actions to be taken by that device or system. Further, while only a single box representing the central controller 180 is illustrated, the term “central controller” or “central computer” is to be taken as including any collection of devices that may individually, or jointly, execute one or more sets of instructions to perform any of the methods or techniques of the present disclosure, such as cloud computing, software as a service (“SaaS”), other computer cluster configurations.

[0119] The central controller 180 may include, among others, a processor 182, a memory 184, an input / output system (“I / O”) 186, and a communication module 188.The processor 182 may be comprised of a central processing unit (“CPU”), a graphics processing unit (“GPU”), a hardware processor core, or a combination thereof. The memory 184 may be comprised of a main memory and a static memory, some or all of which can communicate with each other via an interlink (e.g., bus). The memory 184 may further be comprised of a storage device (e.g., a drive unit) of the central controller 180 including a machine-readable medium on which system control software (e.g., one or more sets of data structures or instructions embodying or utilized by any one or more of the method, techniques, or functions of the present disclosure) is stored.

[0120] The I / O system 186 may include, among others, a display unit (e.g., a screen), an alphanumeric input device (e.g., a keyboard), and a user interface (Ul) navigation device (e.g., a mouse). In some examples, the display unit, the alphanumeric input device, and the Ul navigation device can be a touch screen display. In some examples, the display unit, the alphanumeric input device, and the Ul navigation device can include one or more buttons, switches, or other input features. The instructions (e.g., system control software) of the present disclosure may be transmitted or received, over a network using a transmission medium provided by the communication module 188. The communication module 188 may, in some examples, be comprised of a network interface device utilizing any of a number of transfer or communication protocols, such as, but not limited to, frame relay, internet protocol (“IP”), transmission control protocol (TCP), user datagram protocol (UDP), or hypertext transfer protocol (“HTTP). The term “transmission medium” as used in the present document is to encompass any intangible medium that may store, encode or carry instructions for execution by an electronic device or system, and includes digital or analog communications signals or other intangible medium to facilitate communication of software.

[0121] Example communication networks represented by a network over which the communication module 188 may receive or transmit instructions may include, for example, but not limited to, a packet data network (e.g., the Internet) a wide area network (WAN), a local area network (LAN), a mobile telephone network (e.g., cellular network), or a wireless data network, for example, but not limited to, the Institute ofElectrical and Electronics Engineers (“IEEE”) 802.11 family of standards, also known as Wi-Fi®, the IEEE 802.16 family of standards, also known as WiMax®, the IEEE 802.15.4 family of standards, Bluetooth (e.g., Bluetooth Low Energy (BLE), “LoRa”, or “LoRaWAN”, or peer-to-peer (P2P) networks. In further examples, the communication module 188 may include one or more physical jacks or one or more antennas to connect to the network. In some examples, the communication module 188 may also include a plurality of antennas to wirelessly communicate using at least one of singleinput multiple-output (SIMO), multiple-input multiple-output (MIMO), or multiple-input single-output (MISO) techniques.

[0122] Additionally, any of the first actuator 112, the second actuator 125, the third actuator 136, the press 141 (which may include the adjustment mechanism 146), the pair of arms 162A and 162B (which may include the adjustment mechanism 164A and 164B), the overhead assembly 154 (which may include at least the infrared lamp 156, the fourth actuator 158, and the fifth actuator 159), or the vacuum generator 170 may include a microprocessor, microcontroller, or any other satellite or ancillary control components necessary to enable the aforementioned components of the film glue lens system 100 to communicate with, and receive commands from, the central controller 180. In some such examples, the communication module 188 of the central controller 180 may include one or more physical jacks, or one or more dedicated antennas, to enable connection pathways to the microprocessors, microcontrollers, or any other satellite or ancillary control devices of various components of the film glue lens system 100.

[0123] Further, in some examples, the film glue lens system 100 may include one or more sensors, or sensing components, adapted to enable the central controller 180, or the microprocessors, microcontrollers, or satellite or ancillary devices of various components of the film glue lens system 100, to periodically or continuously monitor the position of any movable component of the film glue lens system 100, such as, but not limited to, the first actuator 112, the second actuator 125, the third actuator 136, the press 141 (which may include the adjustment mechanism 146), the pair of arms 162A and 162B (which may include the adjustment mechanism 164A and 164B), the fourth actuator 158, and the fifth actuator 159.

[0124] In view of all the above, in the operation of some examples of the film glue lens system 100, command signals issued by the central controller 180, or a control component (e.g., a microprocessor) of the first actuator 112, the second actuator 125, the third actuator 136, the press 141 (which may include the adjustment mechanism 146), the pair of arms 162A and 162B (which may include the adjustment mechanism 164A and 164B), the overhead assembly 154, or the vacuum generator 170 may result in the activation or deactivation of any component of the film glue lens system 100.

[0125] For example, an actuation command signal generated by the central controller 180 may cause a solenoid or solenoid driver component to open or close a hydraulic or pneumatic valve, such as in fluid communication with the first actuator 112, the second actuator 125, the third actuator 136, the adjustment mechanisms 164A and 164B, the adjustment mechanism 146, the fourth actuator 158, or the fifth actuator 159. In another example, an activation command signal generated by the central controller 180 may cause a heating element of the press 141 to begin heating, the infrared lamp 156 to activate, or may cause the first actuator 112, the second actuator 125, the third actuator 136, the adjustment mechanisms 164A and 164B, the adjustment mechanism 146, the fourth actuator 158, or the fifth actuator 159 to begin moving electrically, or the vacuum generator 170 to begin generating suction.

[0126] In some examples, the box represented by the press 141 and / or the camera 150 may include a PID controller, or alternatively, the central controller 180 may be configured to perform the functions of a PID controller, to thereby enable a PID feedback loop to be formed with a heater of the press 141 , the camera 150, the infrared lamp 156, and / or an infrared pyrometer thereof, to, in turn, to provide for automated and programmable control over the infrared lamp 156 and the temperature of the functional film 102, the base lens 104, and / or the contacting element 142 of the press 141 , during the adhesive curing process.

[0127] Fig. 20 is a flowchart illustrating a method 200 of applying the functional film 102 to the base lens 104 using the film glue lens system 100 shown in any of Figs. 7- 19, in accordance with at least one example. The steps or operations of method 200 are illustrated in a particular order for convenience and clarity; many of the discussedoperations can be performed by multiple different actors, devices, or systems or in a different order than set out in the example figure. It is understood that subsets of the operations discussed in method 200 can be attributable to a single actor, device, or system and can be considered a separate standalone process or method.

[0128] In some examples, the method 200 may begin at stage 210. At stage 210, a user, or automated robotic means, may position the base lens 104 on or in the lens holder 108. For example, the user, or the automated robotic means, may place the base lens 104 within the recess or groove 127 of the lens holder 108 to help prevent movement between the lens holder 108 and the base lens 104. As may be appreciated, the stage 210 may first include selecting the base lens 104 to be used for the method 200, such as from a plurality of different cast or molded lenses having differing characteristics, such as, but not limited to, corrective powers.

[0129] The method 200 may include stage 220. Stage 220 may be performed before, during, or after any of stages 210 above, or stages 230 or 240, described below. At stage 220, the user, or the automated robotic means, may apply an adhesive to the functional film 102 and / or the base lens 104. For example, the adhesive may be applied over an entire, or substantially an entire, surface area of the upper surface 105 of the base lens 104 and / or the lower surface of the functional film 102. In some examples, the method 200 may not include stage 210. In such an example, the lower surface 103 of the functional film 102 and / or the upper surface 105 of the base lens 104 may be pre-treated with an adhesive before the method 200 begins.

[0130] At stage 230, the user, or the automated robotic means, may secure the functional film 102 within the clamp 106. For example, the user, or the automated robotic means, may place the functional film 102, when the upper portion 126 is removed from the lower portion 128 of the clamp 106, on the lower portion 128 so that the functional film 102 spans the second circular opening 134. Next, the user, or the automated robotic means, may place the upper portion 126 over the functional film 102 on the lower portion 128 so that the first circular opening 133 is aligned with the second circular opening 134. Finally, the user, or the automated robotic means, mayclamp the functional film 102 between the upper portion 126 and the lower portion 128. For example, a user may directly activate, or the central controller 180 may activate, such as in response to one or more user inputs to the input / output system (“I / O”) 186, the adjustment mechanisms 164A and 164B to cause the pair of arms 162A and 164B to move from their respective first positions to their respective second positions to press the upper portion 126 against the functional film 102 and the lower portion 128.

[0131] At stage 240, the user, or the automated means, may move the clamp 106 and the lens holder 108 into vertical or axial alignment with each other. For example, a user may translate, or the central controller 180 may cause, such as in response to one or more user inputs to the input / output system (“I / O”) 186, the second actuator 125 to move the clamp 106 from its first lateral position to its second lateral position aligned with the vertical axis A3. Subsequently, or concurrently, the user, or the central controller 180 may cause the third actuator 136 to translate the lens holder 108 from its first lateral position to its second lateral position aligned with the vertical axis A3. After such operations, the portion of the functional film 102 that is exposed within the opening 132 of the clamp 106 may be aligned with the base lens 104 on the lens holder 108.

[0132] At stage 250, the user, or the automated means, may move the base lens 104 into contact with the functional film 102. For example, the central controller 180 may cause, in response to one or more user inputs to the input / output system (“I / O”) 186 of the central controller 180, the first actuator to translate the lens holder 108 and / or the pedestal 110 vertically, from its first vertical position along the lower track 122, through the aperture 138 in the upper surface 124 of the frame, and into its second vertical position at least partially within the opening 132 of the clamp 106. After such an operation, the upper surface 105 of the base lens 104 may be in continuous surface contact with the lower surface 103 of the functional film 102, and, in some examples, the upper surface 105 of the base lens 104 may also cause the functional film 102 form a curvature or a curved shape.

[0133] At stage 260, the functional film 102 may be bonded to the base lens 104.For example, with the functional film 102 in contact with the base lens 104, theadhesive may be cured to permanently secure the base lens 104 to the functional film 102 to form the functional lens 114. In one such example, if the adhesive used is a thermal and / or a pressure sensitive adhesive, the contacting element 142 of the press may be moved, such via a manual user input or via a command issued from the central controller 180, from its first position to its second position to cause the contacting element 142 to be in contact with the functional film 102 within the opening 132 of the clamp 106. Optionally, the contacting element 142 may begin heating to help cure the adhesive.

[0134] In another such example, if the adhesive used is an infrared curable adhesive, the infrared lamp 156 and the shield 157 may be moved, such via a manual user input or via a command issued from the central controller 180, from their first position to their second position to cause the infrared lamp 156 to be adjacent the functional film 102 within the opening 132 of the clamp 106. In some such examples, the shield 157 may, such via a manual user input or via a command issued from the central controller 180, first translate from its section position obstructing the infrared lamp 156 to its first position laterally offset from the infrared lamp 156 may begin heating to help cure the adhesive.

[0135] In either of the above examples, bonding the functional film 102 to the base lens 104 may optionally include the application of vacuum. For example, with the functional film 102 in contact with the base lens 104, the vacuum generator 170, such via a manual user input or via a command issued from the central controller 180, may begin applying a vacuum through the vacuum channel 113 defined in the lens holder 108. In response, a vacuum may be created between the lower surface 103 of the functional film 102 and the interface between the top surface 109 of the lens holder 108 and the bottom surface 123 of the clamp 106, which may help the functional film 102 uniformly conform to the curvature of the upper surface 105 of the base lens 104.

[0136] Moreover, stage 260 may also include monitoring and / or maintaining a temperature of the functional film 102 or the contacting element 142 via, among other components, the camera 150, an infrared pyrometer, a PID controller, and / or the central controller 180 for an amount of time sufficient to cure the adhesive. As maybe appreciated, such a period of time may vary depending on various factors, such as the adhesive used, or the material, and thickness, of the functional film 102 and the base lens 104. In some such examples, the amount of time may be, but not limited to, about 50 minutes and about 70 minutes. In other examples, such as if the adhesive used is a UV and / or electron beam curable adhesive, the infrared lamp 156 may be moved, such manually by a user, or via a command issued by the central controller 180 to the fourth actuator 158, from its first vertical position to its second vertical position and manually or automatically activated to begin exposing the adhesive to infrared, or in an alternative example, ultraviolet light.

[0137] In some examples, the method 200 may include stage 270. At stage 270, after an amount of time sufficient to cure the adhesive has passed, the user, or the automated robotic means, may remove the functional lens 114 from the lens holder 108. For example, the central controller 180 may automatically, or in response to one or more user inputs to the input / output system (“I / O”) 186, cause the first actuator 112 to move the lens holder 108 from its second vertical position back to its first vertical position along the lower track 122.

[0138] In some such examples, stage 270 may first include removing the upper portion 126 from the lower portion 128 to enable the functional lens 114 to be extracted from the clamp 106. In some such examples, a radially outermost portion of the functional film 102 may be present in the recess 129 of the lower portion 128, which may be sufficiently strong to support, and retain, the base lens 104 now bonded to the functional film 102. In some such examples, such a process may first include returning the pair or arms 162A and 162b from their respective second positions to their respective first positions to enable the upper portion 126 to be removed from the lower portion 128.

[0139] In other examples, upward the pressure exerted to the functional film 102 by the first actuator 112 and the base lens 104 may be sufficient to cause the functional film 102 to detach itself from the clamp 106 during the adhesive curing process. In such an example, the functional film 102 may be pressed against the contacting element 142 until the adhesive is cured, at which point the newly formed functional114 may remain in the lens holder 108 as the lens holder 108 returns to its first vertical position from its section vertical position.

[0140] In some examples, stage 270 may then include returning both the clamp 106 and the lens holder 108 to their respective first lateral positions. For example, a user may translate, or the central controller 180 may cause, such as in response to one or more user inputs to the input / output system (“I / O”) 186, the second actuator 125 to move the clamp 106 from its second lateral position to its first lateral position, and the third actuator 136 move the lens holder 108 from its second lateral position to its first lateral position.

[0141] In some examples, the functional lens 114 may then, by the user or the automated robotic means, be removed from the clamp 106 or the lens holder 108 for further processing via various post-processing stages or operations known in the art, such as, but not limited to, additional lens shaping, polishing, coating, or over-molding steps. In some examples, such post-processing may include, among others, hard- coating or scratch-resistant coating, anti-reflective coating, anti-fog coating, or ultraviolet treatment coating of the functional lens 114. Finally, in some examples, the method 200 may continue through the subsequent loading of another functional film 102 into the clamp 106, and the loading of another base lens 104 into the lens holder 108 for further use of the film glue lens system 100.

[0142] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.

Claims

What is claimed is:1 . A film glue lens system, comprising: a lens holder for securing a base lens; a clamp for securing a functional film; an actuator for driving the lens holder towards the clamp such that the base lens contacts and applies pressure to the functional film; an adhesive for securing the functional film to the base lens; and a curing mechanism for curing the adhesive.

2. The film glue lens system of claim 1 , wherein the lens holder is adjustable between a first lateral position for loading the base lens onto the lens holder and a second lateral position in axial alignment with the clamp.

3. The film glue lens system of claim 2, wherein the clamp is adjustable between a first lateral position for loading the functional film into the clamp and a second lateral position in axial alignment with the lens holder when the lens holder is in the second lateral position.

4. The film glue lens system of claim 1 , wherein the actuator is comprised of a vertical actuator such that the lens holder may be raised or lowered between a first vertical position and a second vertical position for causing the base lens to contact the functional film.

5. The film glue lens system of claim 1 , further comprising a vacuum generator for applying a vacuum to the functional film and the base lens during curing of the adhesive.

6. The film glue lens system of claim 1 , further comprising a camera for monitoring a curing process of the adhesive.

7. The film glue lens system of claim 1 , wherein the curing mechanism is comprised of an irradiative heater that is adjustable between a first position and a second position for curing the adhesive.

8. The film glue lens system of claim 1 , further comprising a frame, wherein the clamp is movably positioned on a track located an upper surface of the frame.

9. The film glue lens system of claim 1 , wherein the functional film is comprised of a polarized film, a photochromic film, an electrochromic film, and / or a nanopatterned film.

10. A method of affixing a functional film to a lens, comprising the steps of: positioning a lens blank on or in a lens holder; securing a functional film to a clamp; moving the clamp and the lens holder into vertical alignment; applying an adhesive to the functional film or the lens blank; moving the lens holder or the clamp such that the lens blank contacts the functional film; and curing the adhesive.11 . The method of claim 10, wherein moving the lens holder or the clamp such that the lens blank contacts the functional film includes translating the lens holder axially along a vertical axis.

12. The method of claim 11 , wherein moving the clamp and / or the lens holder into vertical alignment includes moving the clamp from a first lateral position to a second lateral position and moving the lens holder from a first lateral position to a second lateral position.

13. The method of claim 12, wherein moving the clamp from the first lateral position to the second lateral position includes translating the clamp axially along a secondlateral axis and moving the lens holder from the first lateral position to the second lateral position includes translating the lens holder along a second lateral axis.

14. The method of claim 13, wherein curing the adhesive is accomplished by irradiative heating.

15. The method of claim 14, wherein curing the adhesive includes pivoting an irradiative heater from a first position extending parallel to the vertical axis to a second position extending orthogonally to the vertical axis.

16. The method of claim 13, wherein securing the functional film to the clamp first includes selecting the functional film from the group consisting of a polarized film, a photochromic film, an electrochromic film, and a nanopatterned film.

17. The method of claim 16, wherein securing the functional film to the clamp includes clamping the functional film between an upper clamp portion and a lower clamp portion of the clamp.

18. The method of claim 16, wherein curing the adhesive includes concurrently applying a vacuum to the lens blank and the functional film.

19. The method of claim 18, wherein translating the lens holder along the vertical axis so that an entire surface area of the lens blank applies pressure to the functional film includes translating the lens blank at least partially into a circular opening of an upper surface of a frame supporting the clamp.

20. The method of claim 16, wherein curing the adhesive includes pivoting a heater from a first position to a second position and monitoring the functional film and the lens blank with a camera and / or pyrometer.

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