Method of making an arbitrary surface optical element

Abstract

An arbitrary surface optical element, such as a mirror for use in a rear projection television, includes a non-optical portion and an optical portion. The non-optical portion circumscribes the optical portion and has a thickness greater than the optical portion. Accordingly, the two portions cool at approximately the same rate, thereby minimizing warpage from differential cooling.

1 . A method of forming an optical element, comprising: 
 molding a resin into a part with a mold, the part having a non-optical portion and an optical portion, the non-optical portion having a thickness greater than the optical portion;    cooling the part; and    applying thin film onto the part.    
   
   
       2 . The method of  claim 1 , wherein the applying thin film includes applying one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter, via evaporation.  
   
   
       3 . The method of  claim 1 , wherein the applying thin film includes applying one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter via lamination.  
   
   
       4 . The method of  claim 3 , wherein the resin includes a thermoplastic material and wherein the lamination includes laminating a protective film to the part.  
   
   
       5 . The method of  claim 4 , further comprising using a pressure sensitive or thermo set adhesive that has a higher melt temperature than either the film or part to ensure adhesion during the lamination.  
   
   
       6 . The method of  claim 4 , wherein the lamination includes applying a protective coating to the reflective film.  
   
   
       7 . The method of  claim 1 , wherein the molding includes using a mold that becomes part of the optical element.  
   
   
       8 . The method of  claim 1 , wherein the molding includes applying vacuum from a first side of the mold and pressure from a second side of the mold.  
   
   
       9 . The method of  claim 1 , wherein the non-optical portion includes at least one rib.  
   
   
       10 . The method of  claim 1 , wherein the non-optical portion extends outward from the optical portion with a dimension that is at least about twice the thickness of the optical portion.