Lens structure and manufacturing method, and the manufacture of shaped polymer articles

Abstract

A method of manufacturing a shaped polymer device comprises forming a planar polymer layer over a substrate which has a lower coefficient of thermal expansion than the polymer layer; and shaping the polymer layer using a laser ablation process. This method uses a substrate with low thermal expansion to limit the expansion of the attached polymer layer when it is being shaped by a laser ablation process. In addition there is provided a lens structure for an *autostereoscopic display device comprising a substantially planar glass substrate and a polymer layer defining a lenticular arrangement provided over the glass substrate.

1 . A lens structure for an autostereoscopic display device comprising:
 a substantially planar glass substrate ( 43 ); and   a polymer layer ( 44 ) defining a lenticular arrangement provided over the glass substrate.   
   
   
       2 . A lens structure as claimed in  claim 1 , wherein the lenticular arrangement ( 44 ) has an area greater than 100 cm 2 . 
   
   
       3 . A lens structure as claimed in  claim 1 , wherein the lenticular arrangement ( 44 ) has an area greater than 400 cm 2 . 
   
   
       4 . A lens structure as claimed in  claim 1 , wherein the lenticular arrangement ( 44 ) has an area greater than 900 cm 2 . 
   
   
       5 . A lens structure according to  claim 1 , wherein the glass substrate ( 43 ) has a thickness at least as great as the maximum thickness of the polymer layer ( 44 ). 
   
   
       6 . A lens structure according to  claim 1 , wherein the polymer layer ( 44 ) has a maximum thickness less than 1 mm. 
   
   
       7 . A lens structure according to  claim 1 , wherein the polymer layer ( 44 ) is bonded to the glass layer using a pressure sensitive adhesive. 
   
   
       8 . A lens structure according to  claim 7 , wherein the pressure sensitive adhesive has a thickness less than 0.2 mm. 
   
   
       9 . A lens structure according to  claim 1 , wherein the lenticular arrangement comprises a lens layer ( 44 ) and a replica layer ( 47 ) arranged over the lens layer. 
   
   
       10 . An autostereoscopic display device comprising:
 a display panel ( 42 ) for producing a display; and   a lens structure according to  claim 1 .   
   
   
       11 . A method of manufacturing a shaped polymer device, comprising:
 forming a planar polymer layer ( 44 ; 54 ) over a substrate ( 43 ; 52 ) which has a lower coefficient of thermal expansion than the polymer layer ( 44 ; 54 ); and   shaping the polymer layer using a laser ablation process.   
   
   
       12 . A method as claimed in  claim 11 , wherein the shaped polymer layer ( 44 ) defines an array of lenticular elements. 
   
   
       13 . A method as claimed in  claim 12 , wherein the substrate ( 43 ) comprises glass. 
   
   
       14 . A method as claimed in  claim 12 , for manufacturing a lenticular array for an autosteroscopic display device. 
   
   
       15 . A method as claimed in  claim 11 , wherein the shaped polymer layer ( 54 ) defines a mould ( 50 ) for use in manufacturing an array of lenticular elements. 
   
   
       16 . A method as claimed in  claim 15 , wherein the substrate ( 52 ) comprises glass or metal. 
   
   
       17 . A method as claimed in  claim 15 , further comprising using the mould ( 50 ) to manufacture the array of lenticular elements for an autostereoscopic display device. 
   
   
       18 . A method as claimed in  claim 11 , wherein forming a planar polymer layer over the substrate comprises using a pressure sensitive adhesive.