# US 2014/0196762 A1 · Methods for forming optimized lenses and devices thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0196762 A1 - Document ID: US20140196762A1 - Status: Published application - Kind: A1 - Application number: 14/124,543 - Filed: 2012-06-15 - Published: 2014-07-17 - Earliest claimed: 2011-06-17 - Assignees: Orafol Americas Inc. - Inventors: Arthur J. Davis; Steve Scott - Web page: https://patentgrep.com/patent/US20140196762A1 ## CPC - G02B 3/08: with discontinuous faces, e.g. Fresnel lens {(diffractive Fresnel lenses G02B5/1876)} - H10F 77/484: {Refractive light-concentrating means, e.g. lenses} - Y02E 10/52: PV systems with concentrators - Y10T 82/10: Process of turning - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS - H10F: INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract This technology relates generally to methods for the fabrication of high performance lenses, in particular, lenses including a glass carrier and an at least partially transmissive layer with one or more slope facets coupled together by one of more draft facets on a surface of the glass carrier. The methods involve identifying geometric errors in the slope and draft facets to create correction factors and forming corrected slope and draft facets based on the correction factors. This technology also relates to the resulting lenses and lens arrays. ## Claims ### Claim 1 A method for making a lens, the method comprising: providing a first glass carrier; providing a first at least partially transmissive layer on a surface of the first glass carrier; forming one or more slope facets coupled together by one or more draft facets on a surface of the first at least partially transmissive layer; identifying geometric errors in the one or more slope facets and one or more draft facets of the first at least partially transmissive layer to create correction factors; and forming corrected one or more slope facets coupled together by one or more draft facets on a surface of a second at least partially transmissive layer on a surface of a second glass carrier using the correction factors. ### Claim 2 (depends on 1) The method as set forth in claim 1 wherein the first and second at least partially transmissive layer is silicone. ### Claim 3 (depends on 1) The method as set forth in claim 1 wherein the first and second at least partially transmissive layer has a cure temperature which is substantially the same as a selected operating temperature range of the lens. ### Claim 4 (depends on 1) The method as set forth in claim 1 wherein the forming one or more slope facets coupled together by one or more draft facets further comprises: obtaining a first master machined with a machine tool to form the one or more slope facets coupled together by one or more draft facets in the at least partially transmissive layer; and forming with the first master the one or more slope facets coupled together by one or more draft facets in the at least partially transmissive layer. ### Claim 5 (depends on 4) The method as set forth in claim 4 wherein the first master has less than two microns of peak and valley rounding. ### Claim 6 (depends on 4) The method as set forth in claim 4 wherein the obtaining the first master comprises machining the first master with a machine tool with structural stiffness, positional accuracy, repeatability of rotational and translation axes, and vibration isolation. ### Claim 7 (depends on 1) The method as set forth in claim 1 wherein the forming corrected one or more slope facets coupled together by one or more draft facets further comprises: obtaining a second master with a machine tool to form the corrected one or more slope facets coupled together by one or more draft facets in the second at least partially transmissive layer; and forming with the second master the corrected one or more slope facets coupled together by one or more draft facets in the second at least partially transmissive layer. ### Claim 8 (depends on 7) The method as set forth in claim 7 wherein the second master has less than two microns of peak and valley rounding. ### Claim 9 (depends on 7) The method as set forth in claim 7 wherein the obtaining the second master comprises machining the second master with a machine tool with structural stiffness, positional accuracy, repeatability of rotational and translation axes, and vibration isolation. ### Claim 10 (depends on 1) The method as set forth in claim 1 wherein the correction factors are based on inaccuracies in a machine tool used to manufacture a first master for forming the one or more slope facets coupled together by one or more draft facets. ### Claim 11 (depends on 1) The method as set forth in claim 1 wherein the correction factors are based on replication induced dimensional changes. ### Claim 12 (depends on 1) The method as set forth in claim 1 wherein the correction factors are based on material processing induced dimensional changes of the first at least partially transmissive layer. ### Claim 13 (depends on 1) The method as set forth in claim 1 wherein the corrected one or more slope facets coupled together by one or more draft facets form a Fresnel optical structure. ### Claim 14 (depends on 1) The method as set forth in claim 1 further comprising providing a surface finish for the corrected one or more slope facets below five Angstrom RMS. ### Claim 15 (depends on 1) The method as set forth in claim 1 further comprising providing a surface finish for the corrected one or more slope facets below three Angstrom RMS. ### Claim 16 A lens comprising: a glass carrier; and an at least partially transmissive layer on a surface of the glass carrier, wherein the at least partially transmissive layer has one or more slope facets coupled together by one or more draft facets on a surface thereof, wherein the one or more slope facets coupled together by one or more draft facets are corrected slope and draft facets formed with correction factors determined by geometric errors identified in facets of a lens structure. ### Claim 17 (depends on 16) The lens as set forth in claim 16 wherein the at least partially transmissive layer is silicone. ### Claim 18 (depends on 16) The lens as set forth in claim 16 wherein the at least partially transmissive layer has a cure temperature which is substantially the same as a selected operating temperature range of the lens. ### Claim 19 (depends on 16) The lens as forth in claim 16 wherein the at least partially transmissive layer with one or more slope facets coupled together by one or more draft facets forms a Fresnel optical structure. ### Claim 20 (depends on 16) The lens as set forth in claim 16 wherein the correction factors are based on inaccuracies in a machine tool used to manufacture a master for forming the one or more slope facets coupled together by one or more draft facets. ### Claim 21 (depends on 16) The lens as set forth in claim 16 wherein the correction factors are based on replication induced dimensional changes. ### Claim 22 (depends on 16) The lens as set forth in claim 16 wherein the correction factors are based on material processing induced dimensional changes of the at least partially transmissive layer. ### Claim 23 (depends on 16) The lens as set forth in claim 16 wherein a surface finish of the corrected one or more slope facets is below five Angstrom RMS. ### Claim 24 (depends on 16) The lens as set forth in claim 16 wherein a surface finish of the corrected one or more slope facets is below three Angstrom RMS. ### Claim 25 (depends on 16) A system comprising: an array of lenses according to claim 16; and an array of photovoltaic cells configured with respect to the array of lenses to convert light energy passing through the array of lenses into electricity.