KR20060103924A - Variable optical arrays and variable manufacturing methods - Google Patents

Abstract

The invention divides the lens focusing process into two or more surfaces that incorporate multiple curved axial optic elements on each surface. The axial optics may be manufactured by molding, machining, or by suspended film (248). If suspended film is used, then both sides of an optic may have a suspended film that is transparent. Alternatively, one side of the suspend film optic may use a reflective film.

Description

Variable optical array and its manufacturing method {VARIABLE OPTICAL ARRAYS AND VARIABLE MANUFACTURING METHODS}

Reference in Related Applications:

This patent application claims the benefit of US Provisional Application No. 60/523076, "Easily Manufactured Optical Arrays Over a Wide Range of Sizes and Concentrations" (filed Nov. 18, 2003). The specification of this application is incorporated herein by reference in its entirety.

This application is related to US Provisional Application No. 60/523006, "Reflective Multiple Image Surfaces" (filed Nov. 18, 2003, Nov. 18, 2004). This application is related to US Provisional Application No. 60/53681, "Spatial Multiplexed Image Projector" (filed: 2204.01.16). This application is related to US Provisional Application, "Reflective Refraction Projection Screen" (filed May 25, 2004). This application is related to US Provisional Application No. 10/961834, "Projection-Receiving Surfaces Operating in a Strong Environment View" (filed 2004.10.07).

The present invention relates to a lens array, a method of manufacturing a lens array, and a configuration of various lens array systems.

Optical arrays using curved axis components have many uses. However, conventional efforts have been directly connected only to applications such as privacy glass (cylindrical glass aggregated in an array) of shower doors. Previously, there was no effort to apply such elements to the lenses of the optical elements. Even if it is, there is a lack of ability to manufacture very small lenses, the difficulty of producing a large amount of lens components in an array (array) and the problem that the characteristics of the lens can not be changed after the array fabrication tool is processed. Making such a tool is very expensive, difficult, and impossible to modify after it is made.

Summary of the Invention

The present invention overcomes the aforementioned disadvantages by taking a completely different approach. In particular, the present invention divides the lens focus process into two or more planes that combine multiple axial optic elements on each plane. “Axial optics” here includes the use of cylindrical lenses, for example. In the case of cylindrical lenses, if the lens is cut transversely to the cylindrical axis, it will have the same contour as obtained by cross cutting along the lens.

Although the present invention is by no means limited to cylindrical lenses, it will be conveniently and easily understood as an example of axial optics. Similarly, although the present invention relates to energy rather than light (eg acoustic or electromagnetic waves), the discussion below is limited to light because it can be easily associated with the optical system.

The layered optics can be produced through molding, machining or suspended film. If suspended film is used, there are several options. First, both of the optics can have a transparent suspended film. This leads to practical applications such as multi-imaging devices or rear projection screens described in detail below. Secondly, if one side of the optic is a reflective film, the multi-image of the kind described in the front projection screen or co-pending US patent application “reflective multi-image surface” (filed Nov. 18, 2004), detailed below. Reflective films leading to the device can be used.

The strong practical impact of the present invention is that a large amount of optical elements can be produced in narrow areas (approximately 90,000 lenses / square feet) and that the curvature of the lens varies without changing the tooling of the lens elements.

Further fields of use in the present invention will become more apparent from the following detailed description. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The detailed description and specific examples of the preferred embodiments of the present invention are merely illustrative and are not intended to limit the scope of the present invention.

The invention will be further understood through the following detailed description and the accompanying drawings which follow.

FIG. 1A is a view from above of the optical element of the first axis having a curved surface to receive light and a plane from which light exits, and the existing light is concentrated in the focal plane.

FIG. 1B is a view of the optical element of the second axis having a plane for receiving light and a curved surface from which light is emitted, and the existing light is concentrated in the focal plane.

FIG. 1C shows the physical obstructions of light, and FIG. 1D shows the partial physical obstructions of light.

FIG. 2A is a view from above, with the optical elements of the first and second axes perpendicular to each other with respect to the curved surface, with one focus indicating that light passes through both elements.

FIG. 2B is a top view of FIG. 2B, which is viewed from the upper side with the optical elements of the first and second axes perpendicular to each other with respect to the curved surface, and one focus also indicates that light passes through both elements.

FIG. 2C is a side view of FIG. 2A viewed from above with the optical elements of the first and second axes perpendicular to each other about a curved surface, with one focal point indicating that light passes through both elements.

FIG. 3A shows the optical elements of the first and second axes perpendicular to each other with respect to the plane and viewed from above, with one focal point indicating that light passes through both elements.

FIG. 3B is a top view of FIG. 3A seen from the top with the optical elements of the first and second axes perpendicular to each other about a plane, and one focal point shows that light passes through both elements.

FIG. 3C is a side view of FIG. 3A viewed from above with the optical elements of the first and second axes perpendicular to each other about a plane, with one focal point indicating that light passes through both elements.

4 is a view of the optical elements of the first and second axes around the curved surface through which the light intersects with two crossed lenses.

5 is a view from above of the array of axis lens elements.

FIG. 6A is a view from above with the first array of axial lens elements and the second array of axial optical elements perpendicular to each other with respect to the curved surface, with one focal point passing through the two optical elements.

6B is another side view of FIG. 6A showing an array of axial lens elements.

FIG. 6C is a top view of FIG. 6A viewed from the top with the first array of axial lens elements and the second array of axial optical elements perpendicular to each other with respect to the curved surface.

FIG. 7A is a top view of the first array of axis lens elements with a plane approaching the rounded face of the second array of axis lens elements, the first array being perpendicular to each other and the resulting projections as well have.

FIG. 7B is a side view of FIG. 7A.

FIG. 7C is a top view of FIG. 7A.

8A shows the overlapping portions of the first and second axis lens element arrays and is a hidden view of the projection view.

FIG. 8B is an upper side view of FIG. 8A showing the overlapping portions of the first and second axis lens element arrays, and a projection from above.

FIG. 8C shows the top view of the curved surfaces facing each other and tilting the first and second axial lens elements 45 degrees with the projection obscured.

FIG. 8D is a sectional view of FIG. 8C showing the curved surfaces facing each other and tilting the first and second axis lens elements by 45 degrees. The projection is from the top.

8E is a top view of the first and second axis lens element arrays centered on the registry, with the curved sides facing each other and with the projection obscured.

FIG. 8F is a view of the first and second axis lens element arrays viewed from the upper side with the bent surfaces facing each other as shown in FIG. 8E. The projection is from the top.

9A is a side view of the first curved surface of the array of optical elements.

9B is a side view of a second curved surface of the array of optical elements.

9C is a side view of a third curved surface and obstruction of the array of optical elements.

9D is a side view of a planar continuation forming a vertex in an array of optical elements.

9E is a continuous side view of a non-uniform curved surface in the array of optical elements.

10 is a view from above of a film suspended in a tool.

11 is a view of an external accessory mold.

FIG. 12 is an assembly view of FIG. 11 showing the outer accessory mold. FIG.

Figure 13 is a view of a rear projection screen utilizing the crossed optical arrays of the present invention.

14 shows a general concept of a practical class of uses of a spatial multiplex image decoder for a light source, a composite image, a lens array, and two different visual images within the viewing angle range, from a selected lens source group.

15A and 15B show a 9 * 9 array of a total of 81 pixels consisting of a composite image and a non-image of nine pixels.

Fig. 16 shows the general characteristics of a lens when the image is at its focal point, where the relationship of the pixel position to the composite image versus the visual image when the center ray emerges from each of the three pixels, and the specific lens source The arrangement of the pixels within the group, the position of the pixels according to the characteristics of the refractive optics that send energy in the same direction as the other pixels making up the source image directed towards the spectator.

FIG. 17 shows a profile of three lenses with each lens separating the image elements in different directions as shown in FIG. 16 and having the same focal length, size and position for the composite image element.

18 shows a one-dimensional lens array.

19 shows a two-dimensional lens array.

20 shows the base of the glass bead (glass beads) film.

21 shows crosstalk tissue associated with free beads.

FIG. 22 shows the projection light beam penetrating the cylindrical lens and reflecting back through the same lens backed off by the specular reflector.

Fig. 23 shows an example of arrangement of a bouillon film for producing a dense cylindrical lens array.

FIG. 24 shows a comprehensive plot of a clean film attached to a bulk clean refractive fill material in a cylindrical model and a reflective film attached to the other side of the bulk fill in a cylindrical model.

FIG. 25A shows a top view of a typical single tissue that can be fabricated with a matrix of projection screens, with many advantages including improved contrast and improved image contrast and the possibility of multiple images over conventional front projection screen technology. .

25B is a view from above of the tissue of FIG. 25A.

FIG. 25C is a top view of the tissue of FIG. 25A. FIG.

26 shows a thin, high elastic screen formed from small size beads.

Axial Optics

Prior to the details of the present invention, it is helpful to explain the concept of axial optics and how axial optics are obtained from the present invention. Axial optics can be obtained by machined or mold shown below.

First, the layering optics can be obtained by machining. In particular, during the milling operation, a piece of optically compatible material is placed in a milling bed and cut along a continuous axis (ball mill) to obtain a linear continuous cut when inspected from at least one observation point of view. Or other cut shapes). The mill can be offset to produce one cut which is also linear when observed in the same manner as mentioned above. These parallel cuts produce axial optics. By continuing the incidental parallel cuts an array of axial optics can be made.

Another mechanical operation for obtaining layered optics is extrusion. Axial optics can be made through extrusion, while spherical optics cannot be made through extrusion. The extrusion mold is processed longitudinally and then polished. A feature of the use of the layered optics of the present invention will be recognized through the example of one million spherical lenses on the square inch surface described above, together with the following description, which reduces manufacturing problems by thousands of times by using overlays of layered optics. Shows that

Generally speaking, many techniques are suitable for producing layered optical surfaces. This includes the machining of tools used to simulate pieces of objects on suitable surfaces. Quite a few techniques for making tools are milling, broaching, casting, compression, stamping, etching, vacuum forming, electroforming and extrusion. These tools attach materials to cavities (injection, casting, deposition, precipitation, photo-process, extrusion, etc.), or extraction (milling, broaching, etching, photoprocesses, etc.), or teeth. Used to process pieces through rings (rolling, plate compaction, stamping, melt molding, etc.).

I. CROSSED AXIAL OPTICS AND METHODS OF MANUFACTURE

The present invention uses two or more axial optical elements staggered together by using two or more sets of axes together so that two or more axial optical elements can be used in two or more axial standard optics (camera lenses, projector lenses, telescopes). The two axis focusing process initiated by a lens or the like) into two or more single axis steps. Fabrication of lens arrays using crossed axial optics is more practical and economical than fabrication of standard two-axis lens arrays.

1A and 1B, parallel rays are shown incident on two lenses from above vertically. (The impinging light beams that are parallel to each other or perpendicular to the lens surface are not a requirement of the present invention, but are intended to facilitate the description of the cited sphere.) Cylindrical lenses focus the beams on the lines. This focus has the effect of being aligned in one direction with the axis of the lens cylinder. Light rays converge at a certain distance from the lens depending on various characteristics such as the warping of the cylinder or the refractive index of the material from which the lens is made. After the rays have collected in the line, if there are no physical obstructions, the rays continue to diverge at the same divergence angle as the incoming angle (after being already in focus). The light beams converge on one side of the dense line from the other. On the other side, the rays diverge as they move.

However, the present invention includes the case where a total or partial physical blockage 15, 17 is used. Partial physical obstructions 15 and 17 are also included in the present invention. Physical obstacles 15 and 17 are shown in FIGS. 1C and 1D. The use of partial physical obstructions 15, 17 is to control the lens effective aperture, the interaction of incoming rays of the pixels of the image through the intermediate focal plane with transmission / reflective images, and spatial filtering. Including, but not limited to, encoding information. Examples of physical obstructions include, but are not limited to, photographic films, CCD video chips, and photosensitive materials. In addition, partial obstructions 15 and 17 may be required. An example of partial obstructions 15, 17 is an array of color filters. These filters are installed in the array focal plane to produce a composite image that is a composite of the pattern of incoming light and the pattern at the focal point of the array. The present invention is not limited to this example, and there are many other possibilities, such as using neutral color blockers instead of colored blockers. Further examples of selected (partial) obstructions of the array include the use of image information encoder / decoder, slide transparent film, and photographic film. This is because the partial obstruction and the overall obstruction 15, 17 may be referred to as the light obstruction or the physical location of the component, so that a rather transparent mediation of the component or a specific area of spatial filtering the overall light obstruction element or both It may be the result of mixing.

The first cylindrical lens 14a and the second cylindrical lens 14b of FIGS. 1A and 1B are aligned at right angles to each other and stacked vertically with each other, and generally referred to as “12” (FIGS. 2A, 2B, 2C, 3A, 3B, When the incident light as shown in 3C and 4 is aligned in the opposite direction to the incoming path, the first lens 14a focuses the incident light 12 on the outgoing light line 16 forming the line 18. The joint effect of the two lenses 14a and 14b focuses the light beam at point 22. The point 22 represents the point of intersection of the two outgoing light beams 16 each connected with the two lenses when considered approximately independent. Incident light 12 focused at point 22 impinges on an area that is roughly defined as the overlapping portion of the two cylindrical lenses. Thus, as shown in FIGS. 2A, 2B, 2C, 3A, 3B, 3C, crossed cylindrical lenses act together as a collector of light. Figures 2A, 2B and 2C show two lenses with their curvatures facing each other, while Figures 3A, 3B and 3C show flat surfaces facing each other.

It should be noted that the lens in the above example does not necessarily have curvature on one side and flat on the other. In fact, placing the crossed cylindrical arrays on opposite sides of the same piece of material is almost identical to the arrangement of Figures 3A, 3B and 3C. It should be noted that although the model usually used for the description of the present invention is a convex lens, it is not necessarily limited thereto. Furthermore, in the present invention, two or more axial optical surfaces can be stacked in succession.

4 shows that crossed lens arrays can be used to condense as easily as collecting light. In FIG. 4, light rays 28 coming from the light source 26 located at the combined focus of the two lenses 14a and 14b are adapted to emit toward the first lens 14a. The light rays 28 diverge out of the first lens 14b and are focused. The collected light rays 30 exit from the second lens 14a. Rays 30 that fall under the influence of the region where the two lenses overlap will be more concentrated than rays 28 initially emitted outward from the light source 26.

5 illustrates a surface of a piece of material in which one or more layering optics may be provided. Here, the axial lens array 32 consisting of five cylindrical lenses is represented by the junction of each other. (It is not a requirement in the present invention that all of the axial optics on the surface coincide in the same cross section as shown in Figures 9A-9E.)

In addition to the single cylindrical lens described above, a piece of material of the multi-cylindrical lens 32a can be intersected with another piece having the multi-cylindrical lens 32b to produce a two-dimensional lens array as shown in FIG. 6A. Here, the specific overlay area 20 associated with each cylindrical lens element is a condenser that makes its own focus 24 using the light beams striking the area 20. 6A, 6B and 6C have 25 single regions emerging from the five cylindrical lens surfaces of one array 32a transversely stacked on the five cylindrical lens surfaces in the second array 32b surface.

The present invention includes an arrangement in which each layered optic of a piece of material does not have to coincide with other layered optics of the same piece. In FIG. 6C the 25 overlapping regions are shown with dashed lines. However, not all overlapping portions of FIGS. 6A, 6B and 6C show the effect of the light rays.

7A, 7B, and 7C illustrate two-dimensional lens arrays 32a and 32b, which focus on the focal point 22 of the lenses 32a and 32b made by the overlapping regions 20 of the multiaxial optics 32a and 32b. The condenser emits from a plurality of light sources 26 positioned respectively. In practice, this state uses the arrays 32a and 32b shown in Figs. 6A, 6B and 6C in reverse.

The axes of the two sets of axial optics 32a and 32b need not be arranged perpendicular to each other. For example, following the cylindrical optical description, Figures 8E and 8F show that when the axes are aligned with each other, the results appear to focus on a series of parallel lines rather than on each array of points. As disclosed in FIGS. 8A-8D, when the set has a non-parallel tendency, focus starts to occur at the points. However, the points are not symmetric because the sets have a propensity to cross each other. Thus in Figures 8A, 8B, 8C, 8D, 8E, 8F, as the pieces rotate relative to each other, the resulting convergence of the projected rays moves in the order of a circle, an ellipse, and a straight line.

As mentioned above, the axial optics need not have a constant common model, nor do they have the same footprint size, the same purpose, except for continuous straight, circular, or other axial type fabrication that can be applied. The different common models do not have to be the same.

However, it is a common feature of the present invention to support creating an array of optical elements that is independent of the optical effects required. This is true whether it is about the axial optics of a set on the face of the same piece of material, or about the axial optics alone on the other side. This is an important difference from other optical systems, such as Fresnel lenses, in which the invention collectively produces a single displacement or focal point. Fresnel optical systems, for example, are designed to produce only one image in a scene when using one system. Unlike Freusnel, the present invention supports the creation of multiple images in one scene when using one system.

When an array of 1000 layered optics intersects with 1000 layered optical arrays, one million lenses are created.

Some cross-sectional areas of layering optics that may be applied to the present invention are shown in FIGS. 9A, 9B, 9C, 9D, 9E. Although the drawings in no way exhaustive all possible examples of the invention, they illustrate several important model concepts.

In addition, the shapes encompassed by the present invention, where the layering optics are inserted into pieces of material, such as linear cavities in plastic, glass or other suitable transparent material.

And liquids and gases of various refractive and transparent properties can flow within the system to change the focus, color and other characteristics of the lens array as appropriate.

A presently preferred embodiment of the present invention made and tested by the inventors is a design in which two axial optical pieces are made by casting a resin of the axial lens with a 1/16 '' spacing and a focal length of 1/8 ''. . To fabricate the arrays disclosed in FIGS. 6A, 6B, 6C, and 7A, 7B, 7C, two pieces using cylindrical axial optics are intersected as shown in FIGS. 2A, 2B, 2C, or 3A, 3B, 3C, respectively. . Although this particular embodiment is presently preferred, the present invention does not limit the shape, size, or fabrication techniques used in this embodiment.

A very useful feature of the present invention is that it is possible to fabricate a cost-effective two-dimensional lens array and, if possible, to facilitate the fabrication of an impractical spatial density lens array using conventional optical fabrication methods. In addition, in some embodiments of the present invention, the optical characteristics can be easily changed after processing.

The use of the array results is not limited to this, but is as the following optical example. Optical computing, communication, and coding; Rear and front projectors of theaters, homes, schools; Advertising signs and scoreboards; Combat vision devices for displaying different three-dimensional images as condensing selection pixels in each eye, glasses of a virtual reality system, and the like. As indicated above, the present invention is not limited to optical applications. The invention is also applicable to other electric field spectrum fields and to acoustic and mechanical energy.

II. Curved axial optics using suspended film

So far we have seen an optical array employing machined or molded optics. In the future, we will look at a completely different method of making optics—suspended films. Next, further practical uses using floating film optics are described.

In FIG. 10, the tool 134 is obtained by making a series of longitudinal cut sequences to make the thin wall 102 located at a distance D, which is preferably 1 mm. The tool 134 is shown as a v-shaped longitudinal cut, but square cuts are also possible. A hole (not shown) or groove may be placed along the bottom of the cut to provide communication at the differential pressure V. Transparent or reflective film 104 covers wall 102. Next, a differential pressure V is applied to the hole between the walls 102 to push the film 104, and a curved axial optic 110 is formed. It is very important here to understand that there is no further optical polishing required to obtain an optical quality surface. Then, in the first embodiment, the polymer 112 is poured behind the bent axial optics 110, resulting in permanently axial optics with optical focusing capabilities as shown in FIG. 2A. Preferred polymeric materials can be obtained from Applied Poleramics, Incorporated, of Benicia, California. Particularly preferred materials of Applied Poleramics are "EFM15" and "EFM18 phenolics or" 266 epoxy "and" AU16 polyurethane. " And may be coated with a thin acrylic or polyetalin, for example, to prevent other damages such as oxidation, abrasion, etc. Such coatings are available from Peabody Laboratories, Inc. located at 1901 S. 54th Street, Philadelphia PA 19143) and sold under the trade name “PERMALAC.” The differential pressure can be varied to vary the curvature of the layered optics.

In a second embodiment, the transparent tool 100 can be used with the film 104. Here, the bent axial optics continue to change their curvature in accordance with the degree of change in the differential pressure. When the projected image is focused through bent axial optics, the curvature of the optics can be varied by varying the degree of differential pressure V , resulting in varying focus of the image. When changing the focus is coordinated with changing the image or changing the position of the observer, this has a very useful purpose.

In another preferred embodiment, the film 104 is made of acetate, polyethlene, polypropylene, polycarbonate, or acrylic when the thickness is preferably between 0.25 mils and 1 mil. Can be used.

It is easy to see that when the two tools 100 intersect each other and are applied simultaneously, a crossed optical array is created. The space between the films 104 may then be filled with plastic (the term “plastic” is not limited to polymer but generally means being used in a broad sense). One of the preferred plastics, the aforementioned epoxy, is poured like water between the films because of its low viscosity, and cured after being heated. This approach is used with reference to FIGS. 11 and 12. In Figures 11 and 12 the mold is shown at 116 throughout. The mold 116 includes a leg support 118, a bottom support 120, a stabilizer plate 122, an upright support 124, and a space block 126 as a support structure. Hinge 128 allows easy access to the interior of the cavity by allowing swinging door 130 to swing and move later. This door 130 allows for a single access production with all possible elements taking into account the pre and post curing action that may include secondary trimming. As better seen in FIG. 12, the mold 116 includes a door 130, a radiator 131, a radiator gasket 132, a vacuum table 134, and a space gasket 136. The tools 100 are located on each side of the vacuum table 134. As can be seen in greater detail in FIG. 11, the temperature sensor array 140 includes an external heat source 142 (fixed to the door 130 using a high temperature adhesive), a high temperature fluid inlet hose 144, a vacuum hose 148. Likewise attached to the outside of the mold 116. In general, the film 104 is positioned on each of the two tools 100 on each side of the vacuum table 134. The door 130 is closed and locked by the assembly 150. The differential pressure is injected through the vacuum hose 140 to push the floating film 104 and solidify it into a bent axial optical shape. Both films are pushed away from each other. It is important that the pressure is injected through the vacuum hose 140, not the vacuum. Pour the desired epoxy and cure after plastic. Finally, an axial optical solids material is bent outward and has a common center, resulting in a result. The cover (pieces) may be flexible or rigid to varying degrees depending on the appropriate use. The cover can be combined with gravity, adhesives, solvents, vacuums, melts, pressures, mechanical devices, and other types of use. The edges of the stacked combinations can be left open or sealed. (Seal is for cleanliness and fluid containment; fluids of gas, liquid or a mixture of the two) The array assembly output is the same or different in shape, finish, material or application as the optical layer in which two or more axes are created. It is composed of layers with characteristics.

II.A. TRADITIONAL LENS-TYPE APPLICATIONS

Array assembly output can be written by itself or in combination with mechanical, electronic or other optical systems. Among other things, if both films 104 are transparent, the lens array output can be used with various axial optical widths in a crossed array arrangement for astigmatism correction, nanoscale light effects, and sizing of lenses per millimeter, Can focus at the pixel level.

II.B. Rear Projection Screen Purpose (REAR PROJECTION SCREEN APPLICATIONS)

And very high quality rear projection screens can be produced. As shown in FIG. 13, the array assembly output can be used to form the rear projection screen 151. In particular, the rear projection source 152 projects light rays through the rear projection screen 151, which is an intersected optical array, and produces an image 154 that can be viewed as a result.

II.C. SPATIALLY MULTIPLEXED IMAGE DECONVOLVER APPLICATIONS

Practical Uses of Array Assembly Results Using Transparent Films As a third class, spatial multiplexed image decoders (decoders) can be created. This represents a marked improvement over prismatic technology, which has shown more than one picture from the same side. The number of images can be similar to hundreds rather than two or three prisms. Also, while the prism is limited to one axis, the images can be selected by angular motion along one or more axes. The ability to achieve three-dimensional images without special glasses will also be greatly enhanced by the present invention. Applications include, but are not limited to, works of art, advertising, home decor, packaging, entertainment backdrops, amusement parks, and the like. When the present invention is applied to an image of a lens rather than a hologram image, the present invention has advantages over prior art systems.

Definitions of the terms are provided below to aid the understanding of the present invention.

A source image refers to a single image having elements that are entangled with elements into another source image to form a composite image. The observer sees the specific decoded source image within a certain angular range and the image conforms to the defined parameters of the present invention. The present invention is most prominent when integrating with several source images at different observable angles, but can work with only one source image.

As shown in FIG. 15, an element or pixel is a “fragment” of a source image located between lens source groups of a composite image.

Composite images, also called multiplexed images, are all source images entangled in such a way that the lens array of the present invention decodes each source image. That is, to align the pixels of each source image so that a coherent image is shown for the observer. The term can be made from a variety of materials and also applies to physical composite images located behind the lens array. In general, without the assistance of the decoding provided by the present invention, the composite image looks like a set of random dots that are incomprehensible.

A lens source group is a collection of pixels behind a single lens between lens arrays. Usually there are as many individual lenses in the lens array as the number of lens source groups. In a preferred embodiment the lens source group comprises at least one pixel from each source image.

Lens Array is an array of lenses located in front of a composite image. Each lens of the array has a lens source group below that contains corresponding pixels from the source image.

Viewable Image is the source image seen by the observer. This image is one of the source images and has been decoded from another source image inside the composite image by the action of a lens array.

Viewer Angular Region refers to the range of angles at which an observer can see the decrypted source image in the present invention. That is, it means the area where the viewable image is visible.

14 illustrates the general concept of this kind of practical use of the invention. Examples of each light source 152, composite image 150, lens array 156, the location of two viewable images 154 between two observer angular ranges 158 and examples of rays emitted from the selected group of lens sources Appear.

FIG. 15A is an array of 9 * 9 pixels, ie, a total of 81 pixels (1a-9a, 1b-9b, 1c-9c, 1d-9d, 1e-9e) constituting the composite image shown at 200 as a whole. , 1f-9f, 1g-9g, 1h-9h and 1i-9i). Also shown in the figure is a source image 220 consisting of nine pixels 1a-9i. Each pixel 1a-9i of the composite image is one pixel from nine different source images 1a-9i. The pixels 1a-9i from the source image are displayed in an arrangement specific to the composite image 200.

In this figure, the composite image 200 is made up of an array of nine lens source groups 210. Each pixel 1a-9i of each source image 220 is classified into numbers and lowercase letters. The numbers identify which pixels belong to the unique source image 220, and the letters indicate the location of each pixel within the source image 220. That is, pixels with the same lowercase letter belong to the same source group 210 and pixels with the same number belong to the same source image 220. For example, all pixels represented by the number "1" belong to the source image "1". All pixels indicated by the lowercase letter "a" belong to the lens source group "a".

Pixel 222 is placed in a particular lens source group 210 for consistency when source image 220 is decoded into viewable image 200. That is, it is not enough for all pixels to be emitted from the array in the same direction, but they must be arranged in place to create the proper structure of the image. 16 illustrates the relationship of pixel placement to image 220 as seen in composite image 200.

The arrangement of the lens source groups 210 in the composite image 220 is determined by the character display that the pixels include. The arrangement of lens source group 210 should correspond to the arrangement of pixels in source image 220. That is, the relative position of the lens source group 210 in the composite image 200 should correspond to the relative position of the pixels 1a-9i in the source image 220. If pixel 1a is located in the upper left corner of source image 220, lens source group 210 including pixel 1a should also be located in the upper left corner of composite image 200. For example, using the pixel of FIG. 16, since the pixel 1a is located at the upper left corner of the source image 1a, the lens source group 210 including the pixel 1a in the composite image 200 It must be located in the upper left corner of the composite image 200.

The arrangement of pixels within each lens source group 210 is very specific, and as shown in FIGS. 16 and 17, the positions of the pixels are similar to those of sending energy in the same direction as other pixels making up the source image directed towards the viewer. It is in harmony with the characteristics of the same refractive optical. It is recognized that there is always some level of bleeding during the movement of the location, but most viewing range will not have an overlap of the image in the space in which it is designed.

In this example, the use of the number "9" of the source image and the pixel number "9" of each lens source group coincident should never be interpreted as a requirement of the present invention. Determining the number of lens source groups is not the number of source images themselves, but the number of pixels between the source images with the highest resolution. For example, if the source image contains 1000 pixels, the present invention may have only one source image and 1000 source groups.

All source images do not have to have the same resolution. For example, a system with five source images may have a source image with 20 pixels, while the remaining four source images may have fewer numbers of various pixels. Therefore, the composite image has 20 lens source groups, but each source group does not necessarily include pixels of a source image having a low resolution. The number of pixels within each source group varies because it depends on each desired range of visible images. It is up to the designer to use the field.

In addition, the pixels in the lens source group do not necessarily have to be the same size. In order for the viewable image to have a larger observer angle range, the pixels can be made larger to match the other pixels (which will reduce the range of the total angle of the viewable image).

Composite image 200 may be opaque, transparent and neutral colored, colored, polarized or unpolarized, or any combination thereof. Applicable to the material of The composite image 200 may also be projected onto the rear projection screen.

The lens array is used to decode scattered pixels as distinguishable images are projected toward the viewer. FIG. 16 of the profile shows the general characteristics of lens 224 when the image is in focus. Lens 224 will be considered herein to be one of the lenses present in the lens array of the present invention. Three representative pixels of the lens source group associated with the lens are shown as "1a", "4a", and "7a", respectively. This indicates that the pixel originates from the source images "1", "4", "7" and the position between matching source images is "a" (in this case, the upper left corner of the composite image 200).

FIG. 16 shows an example of the central rays of light coming from each pixel "1a", "4a", and "7a". The light rays emitted from the lens are parallel to each other because the lens is located at the focal length from the pixel. The light rays from each pixel thus exit the lens in a different direction, depending on the characteristics of the lens and the position of the pixel. This creates three viewable images 222 representing three different locations in FIG. 16, as observers located in different directions correspondingly see different viewable images.

It is also important to note that the lens position at the focal point causes the light rays coming out of each pixel to “fill” the lens. This is shown with the light rays emitted from pixel 7a of FIG. Even if there is a space between the source image pixels in the composite image, the result of this "filling" is a consistently visible image.

FIG. 17 shows a profile of three lenses whose focal length, size and position coincide with elements of the composite image. As shown in Figure 16, each lens separates image elements in different directions. In the example provided in the figure, a 9 * 9 lens array covered with a 9 * 9 lens source group makes the spatial multiplexing element of FIG. 14 resolve to nine single source images.

The lens array is a lens array 32 bent in one dimension as shown by the bent layering array 32 depicted in FIG. 18, or a lens array bent in two dimensions, as in the example shown in FIG. 19, or a combination of the two. This can be The selection of the array is made suitable for optical features, in order to solve the composite image and project it towards the preselected viewer angular range.

It is not required for a lens between lens arrays to be the same or perfect as other lenses between the arrays. If the lens is warped, the image plane can be adjusted to eliminate it. In particular, pixels between particular groups of lens sources can be placed to reconcile defects or differences between the combining lenses. It is also not required that the lens position or focal length of the lens array be symmetrical or uniform.

Rays associated with observing an image can be provided through backlighting, front lighting or a combination of both. The light source can also come from the projector of the above embodiment, in which changes in the composite image are made in real time. The light rays may be neutral or colored, polarized or not polarized.

As described above, the observer will see multiple viewable images. However, each viewable image will only be visible in a limited observer angle range. The observer angular range of each viewable image is predetermined based on the design of the composite image and the characteristics of the lenses.

At large angles of the optical axis, lens performance and structure cannot provide adequate viewable images from the information located in the composite image. If the angle is large, the pixel element can be made by displaying a detailed image on the obstruction represented by the element of some embodiments of the present invention.

In embodiments involving obstructions, light that is not between the optical performance structures of the lens that does not refract the light rays of the pixels in the desired direction can be used to illuminate the “wall” located at the edge of the lens. These walls are similar to standard lens obstructions except that the obstructions of each lens have reflective properties that match the pattern drawn on the entire obstruction.

The presently preferred embodiment of the present invention is a basic model that can be easily modified. This basic model includes light sources (rear screen projectors or other light sources), composite images applied to materials or projected onto rear projection screens, lens arrays, and various source images. Multiple projectors can be used throughout the detailed description of the invention wherever a single projector is mentioned.

The invention can be seen not only by changing the configuration of the composite image, but also by moving the lens array and the composite image transverse to each other, and by changing the curvature of the bent axial optics and its orientation (angle and tilt). You can change the direction of each range of viewers in which an image is sent. In addition, the number and size of each range of observers in the viewable image can be finely tuned to the design of the composite image by changing the size of the pixels. This can be done in real time by using a computer to control the rear projection screen (including the TV screen) via the composite image.

The system can be designed by decoding only the pixels from the high resolution of the source image into an image that can be seen when the lens array is well focused. However, if the lens array is slightly out of focus, the high resolution source image pixels are averaged to form larger pixels of the low resolution source image. That is, the pixel group of each lens source group forms one pixel of the low resolution source image. The group of pixels is designed to average out to have the correct brightness and color of the low resolution source image.

The viewing position of the viewable image is based on the distance from the present invention as well as the angle of the composite image plane. This effect is obtained by lightly deviating pixels of the source image without the light rays emitted from a single lens of the lens array no longer flowing in the same direction as all the lenses are parallel. Instead of shooting the beam parallel to all lenses, the lens emits the beam at a reasonable distance from the composite image plane. Thus, it is possible to combine distance and angular properties to create visually dynamic symbols that change significantly as the viewer moves up, down, left, and near or far. This embodiment of the present invention requires careful design that involves the subtle exchange of optical parameters.

III. CURVED AXIAL OPTICS USING REFLECTIVE FILM

Various practical applications of the crossed axial optics presented above have been made in environments where axially curved optical arrays are evident. However, further practical uses may exist even when the axially curved optical array has one reflective face. The use of floating film 104 with one side that is reflective results in a completely new practical use. A particularly suitable, flexible and deformable film 104 with one reflective surface is an aluminum Kapton, 0.5 / 1000 to 1.0 / 1000 of Dunmore Corporation, 145 Wharton Road, Bristol, PA 19007-1620. Inch thickness) and aluminum polyester from Sigma Technology, Tucson, Arizona. 3M company also produces and sells non-metal reflective films.

III.A. REFLECTIVE MULTI-IMAGE SURFACE

If film 104 is used, a reflective multiple image surface is created. This surface is the subject of the co-pending US application "Reflective Multiple Image Surface (filed November 18, 2004)", which is hereby incorporated by reference in its entirety.

III.B. Front projection screen (FRONTt PROJECTION SCREEN)

In addition to the foregoing practical uses, which were the subject of a separate application, a front projection screen can also be created. Below is a detailed description of how the screen is made.

Contrast of the projected image relates to the intensity of the projected light beam observable with respect to the light intensity observable from the background source. As the increased intensity of the observable light from the background source of the viewing environment degrades the viewer's ability to see dark portions of the projected image, contrast constraints in a bright viewing environment are mostly the brighter parts of the image. This is caused by the loss of darkness in the image elements rather than the effect of the background lighting.

Ultimately, if there is no back light on the screen seen by the observer, there is at least enough light in the projection beyond the threshold that the human eye can detect, and the screen itself can be Assuming that the contrast is not degraded (crosstalk), the observer has the ability to see the inherent contrast of the projected image. One method of achievable background light removal is to remove non-transmissive light near the observer's eye (eg, using a darkroom). However, considering that the viewing environment of the observer, not the background lighting itself, is surrounded by the background lighting, the other choices become obvious. Thus, inherent contrast retention of the projected image can be created even under conditions with strong background lighting. This is possible by using a projection screen that switches the backlight from the viewer's field of view.

The contrast of the image projected on the screen can be improved by increasing the image brightness, reducing the background lighting effect, and a combination of both. Improving contrast with the first method (increase in brightness) is to limit the volume of projected light scattered by the screen, increasing the brightness of the image being viewed as a quantitative projection light. The second method (reduced background lighting) improves contrast by limiting the volume of light shining on the screen from the source, rather than being able to readjust the projector to the volume containing the audience. The approach of the present invention to improve this contrast offers another possibility. The use of the present invention as a contrast enhancement screen results in an angular screen-reflection where the light beam from the projector is focused towards the viewer and the projection beam is precisely shining when the viewer moves to a position outside the designed viewing volume. profile). Precise lightening of such intensity adds the possibility of displaying multiple, non-interfering images on the screen with each image observable within a particular viewing volume.

The present invention provides all three elements of the advantageous screen described above. Furthermore, the present invention can be manufactured more easily than the manufacturing method of screens having similar properties. These advantages are achieved through the simplicity of tool making and the appropriate price of materials (two advantages only).

Other techniques have been used to increase the contrast of the projected image. For example, using small glass beads 232 bonded to the surface of the reflective sheet 230 compared to simple diffused white reflective surfaces (eg, white paint and / or plastic diffuser sheet) in strength, It is advantageous. The small bead 232 acts like a small lens that focuses the ray 228 at a smaller viewing volume than the features of white paint coatings and plastic diffusers. The basic concept of such a glass bead screen is shown in FIG. 20.

Although some light intensity gains are made with glass bead screens, cross-talk is a significant drop observed in screens using plastic diffusers and / or glass beads. In the case of a plastic diffuser, the spread of the light rays 226 is somewhat isotropic, allowing light rays to expand laterally between the diffusers. Such lateral expansion results in a loss of contrast and color integrity of spatially suitable elements in the projected image. Spherical glass beads 232 also cause similar lateral extensions 226 between the beads 232. The reason for the cross-talk is that (1) the internal multi-bounce 226 moves geometrically across the refractive index interface of the ray, and (2) the curvature of the bead causes the projection ray to be the outer edge of the sphere. As you approach it, you will continue to make higher angles of incidence. According to the Fresnel relation, the reflection coefficient increases with the tangential angles. This makes the crosstalk problem stand out even before the light rays 228 enter the beads 232. 21 illustrates crosstalk results associated with glass beads 232.

Clearly most refractive spheres do not contribute to focusing the reflection of the projection beam at the correct viewing volume chosen. Only a small part of the phrase helps. The remaining causes not only crosstalk of adjacent spheres 232, but also diffusivity, which directs the projection beam to the region outside the desired viewing volume 226.

Even with the use of refractive elements, the present invention does not combine those parts of the refractive shape that do not help to discriminately reflect the ray at the desired viewing volume. Effectively, only selected portions of the refractive solids are used. Furthermore, bead spheres use dense cylindrical elements (one-dimensional refraction medium) instead of dense arrays and other bidirectional refractive solids. As described herein, only a suitable portion of the articulation cylinder is used, otherwise by facing the glass sphere the same type of crosstalk will result along the cross-axis of the cylinder. Are understood to be "cylinders" in the sense of the present invention and precise shapes are required to achieve the limitation of the projection light reflected at the desired viewing volume.)

The incoming projector beam 234 passes through the cylindrical lens 238, and the same lens 238 as shown in FIG. 22 when the lens 238 is bitten back by the specular refractive medium 240. Back). The effect of the lens array 238 has the effect of dispersing the reflected light 236 across the plane of the cylindrical axis without noticeable dispersion of other cross sections. When the appropriate parameter is selected, the reflected light 236 converges within a small and clear dispersion angle. If the arc of the lens 238 is adequate, a significant amount of incoming projection light shines on the lens surface at nearly a standard angle. This is represented by a high percentage of light rays 234 entering the lens (notably more light rays than the glass bead approach, as shown previously in FIG. 21).

The increase in efficiency of the incoming beam extends beyond the desire to subordinate more rays to the refractive effect of the cylindrical lens. Reduction of front reflections is important for maintaining a precise angular cutoff profile. As will be briefly described, the present invention seeks to preserve the reflection process for the projection light beam to the exposed reflective surface after the projection light beam passes through the cylindrical lens.

If an improvement in the proportion of light entering the refractive cylindrical material is desired, the cylindrical surface may be covered with an anti-reflective coating to reduce sudden refractive index changes. In the present invention, the antireflection layer can be easily added to the refractive surface by using a film having an ideal antireflection that is smaller than the refractive index of the cylindrical substrate and is the square root of the cylindrical substrate index.

Although no antireflective layer is required, material 248 can be used to obtain a very high lens surface finish. Indeed, in the fabrication embodiments of the present invention such materials have been used for the separation of surface finishes (refractive and reflective surfaces). This is possible by using a film 248 suspended between the narrow structural elements 252 of the refractive and reflective surface. FIG. 23 shows an example of a film-suspension arrangement for the manufacture of a dense cylindrical (bent axis) lens array 248.

In addition to the use of the cylindrical lens array 256, the present invention utilizes a non-planar specular reflector 258 behind the cylindrical lens array 256 to create a catadioptric system. An example of a refractive medium is an array of dense portions of a nominal cylindrical (bent layering elements) refracting medium 258. Such reflective array 256 is fabricated by floating films 254 and 258 in a manner similar to the generation of the refractive array of FIG. 10. The orientation of the cylindrical reflection axis is not the same as that of the refractive cylinder. In an unaligned condition, the cylindrical reflector 258 disperses the projection light along the axis as opposed to the dispersion by the refractive cylindrical elements 254. 24 is a clean film 254 attached to a bulky, bulky, clean refractive fill material 256 with a cylindrical model and attached to the opposite side of a bulk fill material 256 with a cylindrical model. The overall concept of reflective film 258 is illustrated (although the axes of refractive elements 254 and reflective elements 258 in the drawing are at right angles, this is not a requirement of all embodiments of the present invention). The effect of the arrangement of the present invention is that it is possible to fabricate a matrix of projection screen reflective cells with many advantages over conventional front projection screen techniques such as high gain enhanced contrast and multiple image points. A typical single tissue is shown in Figures 25A, 25B and 25C.

Some factors affect the selection of the thickness of the transparent bulk filling material 256 in the cell arrangement (the present invention anticipates gaps in gas, liquid or solid within the transparent bulk filling material). In most cases, cell-to-cell crosstalk avoidance is important. This can be done by keeping a small distance between the front and back sides. Refracting light-deflection appears at the surface, and the interior of the material has no major effect besides providing a focal space. In most designs, a reasonable distance between the refracting surface and the reflecting surface is required so that the light beam can move horizontally. However, the beam should not be thick enough to pass through cells and into other cells than where they were received. If the cells 260 are small, the thickness can also be kept small and the screen 262 can also be made very flexible. 26 shows a thin flexible screen 262 composed of small cells 260.

The embodiment of the present invention shown in the figure uses a film suspension to fabricate an array of cylindrical lenses and reflectors. This is a useful and unique form that is easy to form and separate the shape of the reflector surface (see: Films 165 or 248) may be slightly in contact with the tools 134 or 246 as shown in FIGS. As long as it floats across these negative tool marks, separation of finish and form persists). Although film flotation has particular advantages, the present invention contemplates the use of other shaping methods that can be obtained with injection molding, plating, deposition, etching and other chemical and mechanical techniques.

In a preferred embodiment, a convenient tool 134 or 246 for the floating of the transparent film 254 and the reflective film 258 across the spans between the series of ridges as shown in FIGS. 10 and 22. Is ready. The shape of the top of the ridge oblique to the linear orientation may be of any construction suitable for the application, but generally a thin crest is preferred. In the present invention, as described above, the shape of the ridges along the expansion need not be straight. Indeed, the present invention is expected to benefit within some environments that provide curvature in the ridges at depth, side or both.

Floating film 165 or 248 is transformed into the desired shape (shape) using the application of force imposed by gravity, centrifugal force, magnetic field, electric field, differential pressure, or a combination thereof. In the case of gravity and centrifugal forces causing deformation, the elasticity and mass of the film 165 or 248 are the main elements of the deformation resulting from such force. In magnetic and electrical technology, the span of the underside of the tool and the strength of the magnetic and electric fields between the film are the main factors coupled with the elasticity of the film.

In the case of differential pressure, the film 165 or 248 is surrounded by a fluid (gas, liquid or a mixture of both) that can be separated from the side of each of the films 165 or 248. Fluid differential pressure is applied to the opposite side of the film 165 or 248 to form a uniform deformation to the desired shape.

The properties of the film 165 or 248 in all or part of the generation of forces described above for deforming the film 165 or 248 to the desired shape are dependent upon the temperature at which the film 165 or 248 depends and other variables in the physical and chemical environment. Can be changed by their application. The present invention contemplates the use of such conditions.

The ridge series used as the edges of the film suspension shown in FIGS. 10 and 22 are designed sufficiently high with respect to the depth of span between the ridges and during the transformation into a preferred form, the film 165 or 248 Prevents contact with the tool 134 or 246 in the area under the float. If contact occurs, the pressure on the tool will be so weak that the finish of the tool will not be converted (imposed) in the form of a film (165 or 248). Both cases are expected by the present invention.)

Once the desired shape is brought about by the force exerted on the suspended film 165 or 248, a bulk transparent material is applied. This material is cured or solidified (via cooling, chemical reactions, etc.) to preserve the shape of the lens. The chemical, optical and physical properties of the film 165 or 246 used for the manufacture of the cylindrical lens surface may differ significantly from that of the bulk material used to preserve the desired optical form of the lens. This difference can be an advantage. For example, if the optically transparent bulk material 256 is a standard epoxy, there are several transparent film chemistries that can provide greater protection against environmental and mechanical damage to the lens array. It is possible. Moreover, as set forth above, the refractive index of the film 165 or 248 may be moderately less than that of the bulk material, thereby producing a rigid antireflective shield for the bulk material.

Arrays of cylindrical reflectors are fabricated in a similar way to the manufacture of cylindrical lenses. That is, the film 165 or 248 is suspended over a series of ridges and deformed into one of the shapes depicted in lens array processing and solidified to a uniform shape by the use of a bulk substrate. In this case, however, the film 165 or 248 is made to reflect before, during, or after suspension and solidification. The orientation of the array is different).

In a preferred embodiment, lens film 254 and reflector film 258 are suspended simultaneously with two tools facing each other. Barrier walls are placed near the edges of the two tools. Bulk material 256 allows two films 254 and 258 to simultaneously lock and single pieces, as can be envisioned by the three elements shown in FIG. 24 collapsing together. It may be poured between two films 254, 258 so as not to leak between the films 254, 258 to be shaped. The present invention may provide a bulk filling material 256 through multiple steps in which pieces are attached together rather than in a single process.

This preferred embodiment includes visually making at least one suspension tool from the ultraviolet transparent material 256. This allows visual inspection of the films 254, 258 and bulk fill material 256 following UV-curing of suitable polymers if the film's appearance and bulk material are acceptable during processing.

A general feature of the invention allows for differences in the form (curvature) of the refractive and reflective structures. In fact, they can often be designed differently.

Moreover, the selection of the shape of the transparent bulk fill 256, which produces a small prism that facilitates reflected light canting during structure selection, may be an advantage. This means that the screen 262 with high gain does not need to be formed within any curvature to achieve the desired viewer volume over the entire area of the large projection screen 262. The present invention takes advantage of these prisms to provide a film that is tautly clean against the wall above the height stair-casing and the neutral side of the floating ridges, where the projection light does not shine as the back of the resulting prism. This can be accomplished by pulling a portion of 254. One of the stair-casing embodiments is an alternative to embed a prism with a refractive index that is different from the refractive index of the bulk fill 256.

The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention do not go beyond the scope of the invention. Such variations are not to be regarded as a departure from the intent and scope of the present invention.

Claims (16)

A first array of independent axial optical elements; And, A second array of independent layered optical elements in electromagnetic communication with the first array of independent layered optical elements, the incoming parallel light being positioned relatively such that multiple focal points are created to produce multiple images; Optical system, characterized in that. The method of claim 1, And the first array of independent axial optical elements has a shape of any one of sine wave shape, bent shape, baffled shape, planar shape, vertex shape, and non-uniformly bent shape. The method of claim 1, And the second array of independent axial optical elements has a shape of any one of sine wave shape, bent shape, baffled shape, planar shape, vertex shape, and non-uniformly bent shape. Transparent film; And, And a solidified fill material secured to the transparent film. The method of claim 4, wherein Wherein said array of independent layered optical elements has any one of sinusoidal shape, bent shape, baffled shape, planar shape, vertex shape, and non-uniformly curved shape. Array of fields. Reflective film; And, And a solidified fill material secured to said reflective film. The method of claim 4, wherein Wherein said array of independent layered optical elements has any one of sinusoidal shape, bent shape, baffled shape, planar shape, vertex shape, and non-uniformly curved shape. Array of fields. A first array of independent axial optical elements; And, And a second array of independent axial optical elements coupled to the first array. The method of claim 8, The first array comprises a transparent film and a solidified fill material, And said second array comprises a transparent film and a solidified fill material. The method of claim 8, The first array comprises a transparent film and a solidified fill material, And said second array comprises a reflective film and a solidified fill material. The method of claim 8, And the first array of independent axial optical elements has a shape of any one of sine wave shape, bent shape, baffled shape, planar shape, vertex shape, and non-uniformly bent shape. The method of claim 8, And the second array of independent axial optical elements has a shape of any one of sine wave shape, bent shape, baffled shape, planar shape, vertex shape, and non-uniformly bent shape. Manufacturing a series of parallel cuts in the optical material to form a series of curved axial optical elements. Manufacturing a series of parallel cuts in the mold material to form a mold of the series of bent axial optical elements. Floating the film onto the tool; Applying a differential pressure to the film to move portions of the film to the bent position; And, Applying a filler material to one side of the film to form a layered optical array. The method of claim 15, And wherein said array of axial optical elements has any one of a sinusoidal shape, a bent shape, a baffled shape, a planar shape, a vertex shape, and a non-uniformly bent shape.

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