Methods of forming localized positive optical power units a substrate

Abstract

Screen apparatuses are provided which include a first lens or holographic optical element layer and a second mask layer. The first layer substantially collimates image light rays to impinge on the mask layer. The mask layer provides an array or matrix of projecting members. Each of the projecting members receives and focuses the substantially collimated light rays to corresponding focal points. The mask layer includes a mask that blocks light transmission except where openings are located. The openings allow the light focused through the focal joints to substantially pass through the mask to form an image. The screen apparatuses can be advantageously employed in display apparatuses.

What is claimed is:  
     
         1 . A method of forming localized positive optical power units in a substrate, comprising: 
 forming a master in the form of a complement to a desired arrangement of localized positive optical power units on a substrate; and    molding a plurality of localized positive optical power units onto a substrate using the master.    
     
     
         2 . The method of  claim 1 , wherein the master is designed using one of computer aided design or an optical ray tracing program.  
     
     
         3 . The method of  claim 2 , wherein the master is manufactured using precision milling or is ground to form a press or planar mold.  
     
     
         4 . The method of  claim 1 , wherein the master is formed of a thermal plastic material which is hardened to retain its shape.  
     
     
         5 . The method of  claim 4 , wherein the master is formed of photo-polymer that is polymerized with ultraviolet light.  
     
     
         6 . The method of  claim 1 , wherein the master comprises a substrate having a first layer comprising aluminum deposited thereon and a second layer comprising nickel deposited on the first layer.  
     
     
         7 . The method of  claim 1 , wherein the master is configured to wrap around a cylinder or roller, which is then used to mold a plurality of bead-like projecting members onto a substrate.  
     
     
         8 . The method of  claim 1 , wherein the step of molding a plurality of localized positive optical power units onto a substrate using the master comprises heating the master and then embossing a plurality of localized positive optical power units onto a substrate using the heated master.  
     
     
         9 . The method of  claim 1 , wherein the step of forming a master in the form of a complement to a desired arrangement of localized positive optical power units on a substrate comprises providing a base substrate; and projecting microdroplets of a hot liquid ink onto the base substrate, thereby forming a complement of a desired arrangement of localized positive optical power units on the base substrate.  
     
     
         10 . The method of  claim 9 , wherein the localized positive optical power units comprise projecting members.  
     
     
         11 . The method of  claim 10 , wherein the projecting members are spherical, or approximately spherical.  
     
     
         12 . The method of  claim 9 , wherein the substrate is metal, or plastic.