Wire Grid Polarizer And Method Of Manufacture

Abstract

A polarizing optical article formed by selectively applying a conductive coating to a portion of a structured surface formed of a series of linear peaks and valleys.

What is claimed is: 
     
         1 . A method for forming a polarized ophthalmic article comprising:
 forming a linear structured surface on a film or film laminate;   coating at least a portion of the linear structured surface with a conductive coating so as to form wires on said film or film laminate in a manner that a majority of a linear dimension of said formed wires are independent of one another;   applying a liquid form of a lens substrate to said film or film laminate;   allowing said liquid form to harden so as to form a laminate polarized ophthalmic article.   
     
     
         2 . The method of  claim 1  wherein the step of applying said liquid form of said lens substrate to said film or film laminate comprises an injection molding process. 
     
     
         3 . The method of  claim 1  wherein the step of applying said liquid form of said lens substrate to said film or film laminate comprises a casting process. 
     
     
         4 . The method of  claim 1  wherein said forming a linear structured surface and said coating at least a portion of said linear structured surface comprises forming a graded polarizer across at least a portion of said film or film laminate. 
     
     
         5 . The method of  claim 4  wherein an upper portion of said film or film laminate has a higher polarizing efficiency than a lower portion of said film or film laminate. 
     
     
         6 . The method of  claim 1  wherein said forming a linear structured surface comprises forming a pattern of concentric circles. 
     
     
         7 . The method of  claim 1  wherein the step of forming a linear structured surface on said film or film laminate comprises the process of imprinting by replication from a mold. 
     
     
         8 . The method of  claim 1  wherein the step of forming a linear structured surface on said film or film laminate comprises forming a series of peaks and valleys having a pitch in a range of 150 to 300 nanometers. 
     
     
         9 . The method of  claim 1  wherein the step of coating at least a portion of the linear structured surface comprises coating only a portion of a tip of a plurality of peaks of the linear structured surface. 
     
     
         10 . The method of  claim 1  wherein the step of coating at least a portion of the linear structured surface comprises coating from an angle relative to a best fit line that is greater than zero and less than 90 degrees. 
     
     
         11 . The method of  claim 1  wherein the step of coating at least a portion of the linear structured surface comprises coating a reflective conductive coating. 
     
     
         12 . The method of  claim 1  wherein the step of coating at least a portion of the linear structured surface comprises coating a non-reflective conductive coating. 
     
     
         13 . The method of  claim 1  wherein the step of coating at least a portion of the linear structured surface comprises coating a transparent conductive coating. 
     
     
         14 . The method of  claim 1 , wherein said film laminate is a photochromic film laminate. 
     
     
         15 . The method of  claim 1 , wherein said polarized ophthalmic article is a multifocal polarized ophthalmic article. 
     
     
         16 . A method for forming a polarized ophthalmic article comprising:
 forming a linear pattern of peaks and valleys on a surface of a film or film laminate;   coating at least a portion of the surface of the film or film laminate with a conductive coating from an angle relative to a best fit line that is greater than zero and less than 90 degrees;   forming a plurality of conductive wires through said coating;   applying a liquid form of a lens substrate to said film or film laminate;   allowing said liquid form to harden so as to form a polarized ophthalmic article.   
     
     
         17 . The method of  claim 16  wherein the step of applying said liquid form of a lens substrate to said film or film laminate comprises the process of injection molding. 
     
     
         18 . The method of  claim 16  wherein the step of applying said liquid form of a lens substrate to said film or film laminate comprises the process of casting. 
     
     
         19 . The method of  claim 16  wherein said forming a linear pattern of peaks and valleys and said coating at least a portion of the surface of film or film laminate comprises forming a graded polarizer across at least a portion of said film or film laminate. 
     
     
         20 . The method of  claim 19  wherein an upper portion of said film or film laminate has a higher polarizing efficiency than a lower portion of said film or film laminate. 
     
     
         21 . The method of  claim 16  wherein said forming a linear pattern of peaks and valleys comprises forming a pattern of concentric circles. 
     
     
         22 . A laminate polarized ophthalmic lens comprising:
 a film or film laminate having a linear structured surface on said film or film laminate;   a conductive coating applied to said linear structured surface so as to form substantially distinct conductive wires on said surface of said film or film laminate;   said film or film laminate fused to a lens substrate through hardening of a liquid state of said substrate to a solid state of said substrate.   
     
     
         23 . The lens of  claim 22  wherein said hardening comprises the solidifying of an injection molded lens substrate. 
     
     
         24 . The lens of  claim 22  wherein said hardening comprises the solidifying of a cast lens substrate.