US 11,679,533 B2
Methods and apparatuses for casting optical polymer films
Jeremy Lee Sevier, Austin, TX (US); Matthew S. Shafran, Fletcher, NC (US); Satish Sadam, Round Rock, TX (US); Roy Matthew Patterson, Hutto, TX (US); Kangkang Wang, Austin, TX (US); Chieh Chang, Cedar Park, TX (US); and Charles Scott Carden, Austin, TX (US)
Assigned to Magic Leap, Inc., Plantation, FL (US)
Filed by Magic Leap, Inc., Plantation, FL (US)
Filed on Mar. 12, 2021, as Appl. No. 17/200,239.
Claims priority of provisional application 62/988,704, filed on Mar. 12, 2020.
Prior Publication US 2021/0283806 A1, Sep. 16, 2021
Int. Cl. B29C 39/44 (2006.01); B29C 71/04 (2006.01); B29C 39/10 (2006.01); B29L 11/00 (2006.01)
CPC B29C 39/44 (2013.01) [B29C 39/10 (2013.01); B29C 71/04 (2013.01); B29L 2011/0066 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A method of forming an optical film for an eyepiece, the method comprising:
dispensing a curable material into a space between a first mold surface and a second mold surface opposite the first mold surface;
measuring, using a plurality of sensors, a position of the first mold surface relative to the second mold surface, wherein measuring the position of the first mold surface relative to the second mold surface comprises:
determining a first relative distance along a first measurement axis between a first point on a planar portion of the first mold surface and a first point on a planar portion of the second mold surface using a first of the sensors;
determining a second relative distance along a second measurement axis between a second point on the planar portion of the first mold surface and a second point on the planar portion of the second mold surface using a second of the sensors; and
determining a third relative distance along a third measurement axis between a third point on the planar portion of the first mold surface and a third point on the planar portion of the second mold surface using a third of the sensors,
wherein the first, second, and third measurement axes are parallel to each other, the first, second, and third points define corresponding triangles on the first and second mold surfaces, respectively, and the space between the first and second mold surfaces is located within the triangles;
determining, based on the first relative distance along a first measurement axis, the second relative distance along a second measurement axis, and the third relative distance along a third measurement axis:
coordinates (x1,y1,z1) of the first point on the planar portion of the first mold surface or the first point on the planar portion of the second mold surface with respect to a Cartesian coordinate system,
coordinates (x2,y2,z2) of the second point on the planar portion of the first mold surface or the second point on the planar portion of the second mold surface with respect to the Cartesian coordinate system,
coordinates (x3,y3,z3) of the third point on the planar portion of the first mold surface or the third point on the planar portion of the second mold surface with respect to the Cartesian coordinate system, and
wherein the one or more adjustments are determined according to a relationship

OG Complex Work Unit Math
wherein Z corresponds to the translation of at least one of the first mold surface or the second mold surface along an axis of translation,
wherein Rx corresponds to the rotation of at least one of the first mold surface or the second mold surface about a first axis of rotation, and
wherein Ry corresponds to the rotation of at least one of the first mold surface or the second mold surface about a second axis of rotation;
adjusting the position of the first mold surface relative to the second mold surface based on the measured position; and
curing the curable material in the space to form the optical film.