Lens sheet having lens array formed in preselected areas and articles formed therefrom

Abstract

A lens sheet having one or more lens arrays positioned in selected discrete areas. Each lens array includes a plurality of lenses, each having a width, a height, and a lens peak. The lens array is set below the planar surface of the lens sheet, such that lens array does not extend above the lens sheet. Furthermore, the lens array is completely bordered by or contained within planar portions of the lens sheet. One or more dimensional images are printed below each of the lens arrays, and/or one or more static images can be printed on the planar portions of the lens sheet.

What is claimed is: 
     
         1 . A lens sheet presenting a first surface and a planar second surface, the lens sheet comprising:
 at least one lens array formed in the first surface, the at least one lens array including a plurality of lenses;   at least one planar portion defined on the first surface, wherein a peak of each lens of the at least one lens array does not extend beyond the at least one planar portion of the first surface, wherein the at least one lens array is entirely bordered by at least one planar portion; and   an image layer applied to the second surface, wherein the image layer is viewable through the first surface.   
     
     
         2 . The lens sheet of  claim 1 , wherein the image layer is printed directly on the second surface. 
     
     
         3 . The lens sheet of  claim 1 , wherein the image layer is printed on a separate substrate bonded to the second surface of the lens sheet. 
     
     
         4 . The lens sheet of  claim 1 , wherein the image layer is applied below a lens array of the at least one lens array such that the image layer is viewable through the lens array. 
     
     
         5 . The lens sheet of  claim 1 , further comprising a second image layer, wherein the second image layer is applied to the second surface below the at least one planar portion of the first surface such that the second image layer is viewable through the at least one planar portion. 
     
     
         6 . The lens sheet of  claim 1 , further comprising an image layer applied to the at least one planar portion of the first surface. 
     
     
         7 . The lens sheet of  claim 1 , wherein the lens sheet comprises a first lens array and a second lens array, wherein lenses of the first lens array present a first lens height and a first lens density, and wherein the lenses of the second lens array present a second lens height and a second lens density. 
     
     
         8 . A card comprising:
 a polymeric sheet having a first planar side, and a second side including at least one lens array and at least one planar portion defined thereon, the at least one lens array comprising a plurality of lenses, wherein a peak of each lens array does not extend beyond the at least one planar portion, and wherein the at least one lens array is entirely bordered by at least one planar portion; and   an image layer applied to the first planar side of the polymeric sheet, wherein at least a portion of the image layer is positioned below a lens array of the at least one lens array such that an image is viewable through the lens array to the second side.   
     
     
         9 . The card of  claim 8 , wherein an opaque layer is applied over at least a portion of the first side. 
     
     
         10 . The card of  claim 9 , wherein the opaque layer extends over at least a portion of the image layer. 
     
     
         11 . The card of  claim 8 , wherein an ink layer is applied to one or more of the at least one planar portions on the second side. 
     
     
         12 . A method of forming a lens sheet, the method comprising:
 providing a polymeric sheet presenting a first surface and a second surface;   forming one or more lens arrays in an area of the first surface of the polymeric sheet, wherein remaining portions of the first surface comprise one or more planar portions, wherein each lens array comprises a plurality of lenses, wherein a peak of each lens does not extend above the one or more planar portions, and wherein the at least one lens array is entirely bordered by at least one planar portion; and   applying at least one image layer to the second surface, wherein the image layer is viewable through the first surface.   
     
     
         13 . The method of  claim 12 , wherein providing a polymeric sheet comprises extruding or casting a polymeric material onto an engraved cylinder or plate patterned with a relief of the one or more lens arrays, and wherein forming the one or more lens arrays comprises embossing the polymeric sheet with one or more lens arrays via the engraved cylinder or plate. 
     
     
         14 . A method of forming an imaged lens sheet, the method comprising:
 providing a lens sheet presenting a first surface and a planar second surface, the lens sheet including at least one lens array formed in the first surface, the at least one lens array including a plurality of lenses, and at least one planar portion defined on the first surface, wherein a peak of each lens of the at least one lens array does not extend beyond the at least one planar portion of the first surface, and wherein the at least one lens array is entirely bordered by at least one planar portion; and   applying an image layer to the second surface of the polymeric sheet, the image layer being viewable through the first surface.   
     
     
         15 . The method of  claim 14 , wherein at least a portion of the image layer is positioned below at least one lens array of the one or more lens arrays such that an image is viewable through the lens array to the first surface. 
     
     
         16 . The lens sheet of  claim 14 , wherein the image layer is applied to the second surface below the at least one planar portion of the first surface such that the image layer is viewable through the at least one planar portion. 
     
     
         17 . The lens sheet of  claim 14 , wherein the image layer is printed directly onto the second surface lens sheet. 
     
     
         18 . The lens sheet of  claim 14 , wherein the image layer is printed on a separate substrate and bonded to the second surface of the lens sheet. 
     
     
         19 . The method of  claim 14 , further comprising:
 printing one or more ink layers on one or more of the planar portions of the first surface of the lens sheet.   
     
     
         20 . The method of  claim 14 , further comprising:
 cutting the imaged lens sheet into a plurality of cards.