Cut Pattern For Film

Abstract

A cut pattern for a film or film laminate used in the fabrication of optical articles such as lenses.

What is claimed is: 
     
         1 . A cut pattern for the formation of film wafers for making optical articles comprising:
 a plurality of individual wafer templates each having six sides of equal length; and   a series of rows and columns in which the plurality of individual wafer templates are arranged such that each of the six sides of an individual wafer template of said plurality of individual wafer templates is adjacent and parallel to a side of a different wafer template of said plurality of individual wafer templates.   
     
     
         2 . The cut pattern of  claim 1  wherein each of the six sides of the individual wafer template of said plurality of individual wafer templates is shared with the side of the different wafer template of said plurality of individual wafer templates. 
     
     
         3 . The cut pattern of  claim 1  wherein each of the six sides of the individual wafer template of said plurality of individual wafer templates is spaced apart from the side of the different wafer template of said plurality of individual wafer templates. 
     
     
         4 . The cut pattern of  claim 1  wherein two of the six sides of the individual wafer template of said plurality of individual wafer templates are differentially spaced apart from the side of the different wafer template of said plurality of individual wafer templates. 
     
     
         5 . The cut pattern of  claim 1  wherein an intersection of a pair of sides of said six sides is curved. 
     
     
         6 . The cut pattern of  claim 5  wherein said curve has a same radius as a radius of a circular optical article in which a film wafer made from said plurality of individual wafer templates will be employed. 
     
     
         7 . A wafer for use in the formation of a circular optical article comprising:
 six sides of equal length; and   a maximum dimension that is approximately equal to a maximum dimension of the circular optical article in which the wafer will be employed.   
     
     
         8 . The wafer of  claim 7  wherein an intersection of a pair of sides of said six sides with one another is curved. 
     
     
         9 . The wafer of  claim 7  wherein intersection of a pair of said six sides with one another has a curved shape having a same radius as a radius of the optical article in which the wafer will be employed. 
     
     
         10 . A method for forming film wafers for use in the formation of optical articles comprising:
 forming a single wafer template having six straight sides of equal length, an intersection of each pair of adjacent sides of said six straight sides forming a curve;   duplicating the wafer template in a series of rows and columns;   arranging the rows and columns of the duplicated wafer templates such that each side of a first wafer template is adjacent and parallel to a side of a different wafer template; and   using said arrangement of rows and columns of the duplicated wafer templates to cut a plurality of individual wafers from a sheet of film.   
     
     
         11 . The method of  claim 10  wherein the step of forming a single wafer template having six straight sides of equal length, an intersection of each pair of adjacent sides of said six straight sides forming a curve comprises forming said curve with a same radius as a radius of a circular optical article in which one of said plurality of individual wafers will be employed. 
     
     
         12 . The method of  claim 10  wherein the step of arranging the rows and columns of the duplicated wafer templates such that each side of a first wafer template is adjacent and parallel to a side of a different wafer template comprises arranging the rows and columns of the duplicated wafer template such that each side of the first wafer template is shared with a side of a different wafer template. 
     
     
         13 . The method of  claim 10  wherein the step of arranging the rows and columns of the duplicated wafer templates such that each side of a first wafer template is adjacent and parallel to a side of a different wafer template comprises arranging the rows and columns of the duplicated wafer template such that each side of the first wafer template is spaced apart from a side of a different wafer template. 
     
     
         14 . The method of  claim 10  wherein the step of arranging the rows and columns of the duplicated wafer templates such that each side of a first wafer template is adjacent and parallel to a side of a different wafer template comprises arranging the rows and columns of the duplicated wafer templates such that a spacing between rows of the duplicated wafer templates is less than a spacing between columns of the duplicated wafer templates. 
     
     
         15 . The method of  claim 10  wherein the step of using said arrangement of rows and columns of the duplicated wafer templates to cut individual wafers from a sheet or film comprises cutting individual wafers from a sheet of film laminate. 
     
     
         16 . A method for forming an injection molded lens comprising:
 placing a hexagonal-shaped film wafer within a mold forming a portion of a lens mold cavity;   closing the mold cavity;   injecting a molten resin in the closed mold cavity; and   removing the lens from the mold cavity.   
     
     
         17 . The method of  claim 16  wherein the step of placing a hexagonal-shaped film wafer within a mold forming a portion of a lens mold cavity comprises placing a hexagonal-shaped wafer having curved corners within said mold. 
     
     
         18 . The method of  claim 16  wherein the step of placing a hexagonal-shaped film wafer within a mold forming a portion of a lens mold cavity comprises placing a hexagonal-shaped wafer having curved corners having a radius equal to the radius of an interior shape of said mold.