Systems and methods for optical devices with antireflective treatments

Abstract

A method may include stretching a deformable bounding element into a stretched state. The method may further include coating the deformable bounding element with at least one layer of an anti-reflective material while the deformable bounding element is in the stretched state and assembling an optical lens assembly including the deformable bounding element, such that the optical lens assembly adjusts at least one optical property by controlling a shape of the deformable bounding element. The deformable bounding element may have less tension when in a neutral state than the deformable bounding element has when in the stretched state. The method may additionally include coating the deformable bounding element with at least one layer of an anti-reflective material while the deformable bounding element is not in a stretched state. Various other apparatuses, systems, and methods are also disclosed.

What is claimed is: 
     
         1 . A system comprising:
 a head-mounted device comprising a pair of optical lens assemblies, wherein each of the pair of optical lens assemblies comprises:   a deformable bounding element bonded to a structural support element; and   at least one layer of an anti-reflective material applied to a surface of the deformable bounding element.   
     
     
         2 . The system of  claim 1 , wherein:
 the at least one layer of an anti-reflective material withstands repeated cycles of deformation of up to two percent engineering strain without yield strain or yield failure; and   a refractive index of each layer of the at least one layer of an anti-reflective material differs from an adjacent layer of an anti-reflective material by at least 0.05.   
     
     
         3 . A method comprising:
 coating a deformable bounding element with at least one layer of an anti-reflective material, wherein the at least one layer of an anti-reflective material has an elastic modulus of less than about fifty gigapascals; and   assembling an optical lens assembly comprising the deformable bounding element, such that:   the optical lens assembly adjusts at least one optical property by controlling a shape of the deformable bounding element; and   the at least one layer of an anti-reflective material withstands repeated cycles of deformation without yield strain or yield failure.   
     
     
         4 . The method of  claim 3 , wherein coating the deformable bounding element with the at least one layer of an anti-reflective material comprises:
 fixing the deformable bounding element to a support in a chamber;   filling the chamber with a first monomer and a first monomer initiator;   heating the first monomer and the first monomer initiator, thereby activating the first monomer initiator and polymerizing the first monomer into a first polymer; and   applying a layer of the first polymer to the deformable bounding element.   
     
     
         5 . The method of  claim 4 , wherein coating the deformable bounding element with the at least one layer of an anti-reflective material further comprises:
 removing the first monomer from the chamber;   filling the chamber with a second monomer and a second monomer initiator;   heating the second monomer and the second monomer initiator, thereby activating the second monomer initiator and polymerizing the second monomer into a second polymer; and   applying a layer of the second polymer to the deformable bounding element.   
     
     
         6 . The method of  claim 3 , wherein coating the deformable bounding element with the at least one layer of an anti-reflective material comprises:
 fixing the deformable bounding element to a support in a chamber;   filling the chamber with a first monomer;   applying activation energy to a first monomer initiator, thereby activating the first monomer initiator and polymerizing the first monomer into a first polymer; and   applying a layer of the first polymer to the deformable bounding element.   
     
     
         7 . The method of  claim 6 , wherein applying the activation energy comprises applying the activation energy by at least one of a heat source, an x-ray source, an electron beam, an ultraviolet light source, or a visible light source. 
     
     
         8 . The method of  claim 6 , wherein coating the deformable bounding element with the at least one layer of an anti-reflective material further comprises:
 filling the chamber with a second monomer;   applying the activation energy to a second monomer initiator, thereby activating the second monomer initiator and polymerizing the second monomer into a second polymer; and   applying a layer of the second polymer to the deformable bounding element.   
     
     
         9 . The method of  claim 3 , wherein coating the deformable bounding element with the at least one layer of an anti-reflective material comprises:
 fixing the deformable bounding element to a support in a chamber   applying an anti-reflective material to the deformable bounding element; and   rotating the support, thereby applying a centrifugal force to the anti-reflective material and causing the anti-reflective material to spread over a surface of the deformable bounding element, wherein the anti-reflective material comprises a polymer and a plurality of ceramic nanoparticles.   
     
     
         10 . The method of  claim 3 , wherein a refractive index of each layer of the at least one layer of an anti-reflective material differs from a refractive index of an adjacent layer of an anti-reflective material by at least 0.05. 
     
     
         11 . The method of  claim 3 , wherein the at least one layer of an anti-reflective material withstands repeated cycles of deformation of up to twelve percent engineering strain without yield strain or yield failure. 
     
     
         12 . The method of  claim 3 , wherein an average reflectivity of the at least one layer of an anti-reflective material for frequencies of light between four hundred nanometers and six hundred and fifty nanometers which enters a surface of the at least one layer of an anti-reflective material at an angle of incidence normal to a major plane of the surface of the at least one layer of an anti-reflective material is less than two percent. 
     
     
         13 . The method of  claim 3 , wherein the deformable bounding element has an elastic modulus of less than one gigapascal. 
     
     
         14 . The method of  claim 3 , wherein the at least one layer of an anti-reflective material is non-porous. 
     
     
         15 . The method of  claim 3 , wherein:
 the at least one layer of an anti-reflective material has a reflection haze of less than one percent for five hundred and fifty nanometer collimated light outside a two-degree cone; and   a longitudinal axis of the two-degree cone is normal to a major plane of a surface of the at least one layer of an anti-reflective material.   
     
     
         16 . The method of  claim 3 , further comprising:
 feeding the deformable bounding element from a first roller before coating the deformable bounding element; and   feeding the deformable bounding element onto a second roller after coating the deformable bounding element.   
     
     
         17 . The method of  claim 3 , wherein the at least one layer of an anti-reflective material comprises at least one of a nanocomposite material, a polycarbonate material, or a polyurethane material.