Curved lenses and related methods

A method of making a formed lens, the method comprising:

• obtaining a lens blank comprising, in superposed relation, a linear polarizer layer laminated together with a plurality of polymeric layers, the linear polarizer layer having a polarization axis;
• placing the lens blank between a continuously rotating cylindrical roller and a belt;
• heating the lens blank to a forming temperature by pressing the lens blank at a pressure between the cylindrical roller and belt, the cylindrical roller being at the forming temperature;
• maintaining the pressure while heating at the forming temperature for allowing the lens blank to conform to the shape of the cylindrical roller;
• reducing the temperature to a reduced temperature while maintaining the pressure for allowing the lens blank to become a rigid lens having a convex side and a concave side;
• and
• removing the rigid lens from between the cylindrical roller and belt.

A method of making eyewear, the method comprising:

• (a) obtaining a first lens and a second lens, the first lens and second lens comprising, in superposed relation, a linear polarizer layer laminated together with a plurality of polymeric layers, the linear polarizer layer having a polarization axis, the first lens and second lens being formed from lens blanks into a desired shape according to the following steps:
• (i) engendering rotational motion about a rotational axis of a roller having a forming surface thereon and lateral motion of a belt in contact with the forming surface, wherein the lateral motion is non-parallel to the rotational axis;
• (ii) heating and pressing the lens blanks separately between the belt and the forming surface at a pressure, the pressure being supplied by tension on the belt member;
• (iii) maintaining the pressure for a time sufficient to allow the lens blank to conform to the shape of the roller;
• and
• (b) placing the first lens and second lens into an eyeglass frame.