(12) United States Patent
`Wilson et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 6,536,045 B1
`Mar. 25, 2003
`
`US006536045B1
`
`(54) TEAR-OFF OPTICAL STACK HAVING
`PERIPHERAL SEAL MOUNT
`Inventors: Seth Wilson, San Juan Capistrano, CA
`(US); Stephen S. Wilson, San Juan
`Capistrano, CA (US); Bart Wilson’ San
`Juan CaPi5traH0> CA (US)
`
`(75)
`
`(73) Assignee: Racing Optics, San Clemente, CA (US)
`.
`.
`.
`.
`.
`( * ) NOI1CC'
`Sub ect to an disclaimer the term of this
`'
`J
`.
`y
`’.
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) App1' N07 10/039519
`(22) Filed:
`Jan. 3, 2002
`
`Related U.S. Application Data
`
`.
`.
`.
`.
`.
`(63) C0nt1nuat10n‘1n‘PaTt Of aPP11°at1011 N0~ 09/4499318; filed 011
`NOV‘ 24’ 1999’ now Pat‘ No‘ 633889813‘
`[m_ C]_7 . . . . . .
`. . . . . . . . . . . . . N A6111‘ 9/00
`(51)
`
`................. ..
`.. 2/15; 2/424; 2/434
`(52) U.s. Cl.
`(58) Field of Search ........................ .. 2/9, 15, 424, 432,
`2/434; 351/44’ 47; 359/359’ 630’ 631
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`,
`
`,
`
`4,716,601 A *
`2 *
`*
`2 *
`3
`3
`*
`6,085,358 A
`* cited by examiner
`
`....................... .. 2/434
`1/1988 McNeal
`aewig ......................... 3:
`. . . . .
`00 s
`. . . . . . ..
`
`........................ .. 2/424
`§/Ie11b_ef
`11010
`7/2000 Cogan ......................... .. 2/424
`
`Primary Exammer_J0hn J. Calvert
`Assistant Examiner—Katherine Moran
`
`(74) Attorney, Agent, or Firm—Stetina Brunda Garred &
`Brucker
`
`(57)
`ABSTRACT
`An optical stack of laminated removable lens for affixing to
`a face shield is disclosed. The stack includes a plurality of
`superposed removable lens adhesively affixed to one
`another, wherein each of the removable lens is held to each
`
`successive lens with a clear uninterrupted adhesive layer
`interposed between each lens. Each of the lens has a removal
`tab portion on one end which does not have any adhesive
`layer on either side thereof. This allows the wearer of the
`face shield to quickly grasp the removal tab portion for
`removing the top lens and exposing a Clean lens dnecny
`underneath. The bottom-most removable lens of the stack
`has a band of adhesive formed around the periphery thereof
`for attachment of the stack to the face shield. The band of
`adhesive forms a seal which eliminates any moisture from
`the interface between the bottom-most lens and the shield.
`
`4,076,373 A *
`4,138,746 A *
`
`2/1978 Moretti ...................... .. 350/61
`2/1979 Bergmann ................... .. 2/424
`
`11 Claims, 3 Drawing Sheets
`
`EXHIBIT
`
`AEVOE CORP.
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`AEVOE CORP. IPR2016-01166, Ex. 1004, p. 1 of 7
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`

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`U.S. Patent
`
`Mar. 25,2003
`
`Sheet 1 of3
`
`US 6,536,045 B1
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`AEVOE CORP.
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`AEVOE CORP. IPR2016-01166, Ex. 1004, p. 2 of 7
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`

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`U.S. Patent
`
`Mar. 25,2003
`
`Sheet 2 of3
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`US 6,536,045 B1
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`AEVOE CORP.
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`U.S. Patent
`
`Mar. 25, 2003
`
`Sheet 3 of3
`
`US 6,536,045 B1
`
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`20
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`Fig. 4
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`AEVOE CORP.
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`

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`US 6,536,045 B1
`
`1
`TEAR-OFF OPTICAL STACK HAVING
`PERIPHERAL SEAL MOUNT
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a continuation-in-part of U.S. appli-
`cation Ser. No. 09/449,318, now U.S. Pat. No. 6,388,813
`entitled OPTICAL STACK OF LAMINATED REMOV-
`ABLE LENSES FOR FACE SHIELDS, WINDOWS AND
`DISPLAY filed Nov. 24, 1999, the entire contents of which
`are incorporated by reference herein.
`
`STATEMENT RE: FEDERALLY SPONSORED
`RESEARCH/DEVELOPMENT
`
`(Not Applicable)
`
`BACKGROUND OF THE INVENTION
`
`The present invention generally relates to the field of eye
`protectors or face shields having a lens cover plate, and in
`particular to peripheral seal mounts for a tear-off stack of
`laminated removable lens covers adhered to face shields and
`the like.
`
`It is common practice to wear face shields in environ-
`ments where injury of the eyes or face may occur from
`contamination. For example, face shields are worn by phy-
`sicians working in the operating room. They are sometimes
`worn by those playing games where injury to the eyes may
`occur. For example, in the game of Paint Ball contestants
`employ weapons that fire at one another pellets or balls of
`paint as ammunition. When a ball of paint strikes a
`participant, it becomes readily apparent that they have been
`hit by a “tell-tale” blotch of paint. Obviously, it is desirable
`for contestants to wear some form of protection over their
`face and eyes.
`In such environments as the Paint Ball game or the
`operating room, it is most likely that any face protection lens
`being worn will become covered with contaminants, which
`obscures the view. The solution would appear to be to simply
`clean off the lens. This is not always an option, especially for
`a physician performing an operation who cannot stop for
`such cleaning. An example of a recent solution to a similar
`problem is the use of a multi-ply transparent lens over
`goggles in order to facilitate rapid removal of dirt or grime
`in contaminated environments. That is, when the goggles
`become contaminated, a single layer of the multi-ply trans-
`parent lens is removed. The goggles are now clean and when
`they again become contaminated another layer of the multi-
`ply transparent
`lens is removed. This process can be
`repeated many times, depending upon the number of layers
`applied to the goggles. An example of this process and the
`materials used is disclosed in our application Ser. No.
`09/449,318 filed Nov. 24, 1999 now U.S. Pat. No. 6,388,813
`entitled OPTICAL STACK OF LAMINATED REMOV-
`ABLE LENSES FOR FACE SHIELDS, WINDOWS, AND
`DISPLAYS. The disclosure of which is expressly incorpo-
`rated herein by reference.
`In our above-cited patent, the problem we overcame was
`caused by reduced visibility as a result of the additive effect
`of the optical index of refraction for each layer applied. We
`overcame this problem by eliminating the air space between
`each successive layer of the multi-ply transparent lens and
`by inserting an adhesive layer between each lens layer. Thus,
`we created an adhesively laminated multi-layered clear film
`adapted to be used on a wearer’s goggles, face shield or the
`like. However, when this same film is used for large area
`
`2
`face protectors other problems arise. For example, when the
`bottom-most layer is adhered directly to the lens bubbles
`will appear, which bubbles are not easily removed because
`of the multi-layers over the bottom-most layer. Moreover, if
`the adhesive is omitted from the bottom-most layer, then we
`are back to the original refraction problem of an air gap
`between the eye-protector lens and the bottom-most layer of
`the multi-ply transparent lens. In addition, if the adhesive
`layer is removed from the interface between the bottom-
`most layer of the multi-ply stack and the lens of the face
`protector,
`then there remains the problem with the lens
`fogging up in the presence of moisture.
`Accordingly, there is a need for a multi-ply transparent
`lens that will not produce bubbles when applied to the face
`protector’s lens and will not reduce visibility due to a
`fogging up of the lens by moisture seeping into the interface
`between the bottom-most layer of the removable lens and
`the lens of the eye protector.
`BRIEF SUMMARY OF THE INVENTION
`
`Accordingly, a feature of the present invention is the use
`of selective areas of adhesive around the periphery of the
`bottom-most layer of a multi-ply transparent optical lens
`stack for attachment
`to a large area face protector.
`Preferably, the lenses and adhesive layers have an index of
`refraction between 1.40 and 1.52.
`
`Another feature of the present invention is a method for
`the removal of a peripheral race around the edges of the
`bottom-most layer of a multi-ply transparent
`lens stack,
`thereby exposing adhesive around the periphery only. The
`peripheral adhesive area may then be used for affixing the
`multi-layer transparent lens to the face protector. Thus, the
`central area of the bottom-most
`layer of the multi-ply
`transparent
`lens remains in place,
`thereby avoiding the
`bubble problem. Also, the adhesive on the periphery solves
`the fogging up problem by sealing out any moisture.
`Yet another feature of the present invention is an alternate
`method of forming the adhesive strip by applying a thin strip
`of adhesive directly to the bottom-most lens of the optical
`stack around the periphery thereof.
`Still another feature of the present invention is the pro-
`vision of an optical stack of removable lenses that may be
`used for windshields of vehicles, windows of all types, or
`video displays.
`These and other features, which will become apparent as
`the invention is described in detail below, are provided by an
`optical stack of laminated removable lenses that may be
`affixed to a face shield. The stack includes a plurality of
`superposed removable lenses adhesively affixed to one
`another, wherein each of the removable lenses is held to each
`successive lens with a clear uninterrupted adhesive layer
`interposed between each lens. Each of the lens has a removal
`tab portion on one end which does not have any adhesive
`layer on either side thereof. This allows the wearer of the
`face shield to quickly grasp the removal tab portion for
`removing the top lens and exposing a clean lens directly
`underneath. The bottom-most removable lens of the stack
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`has a band of adhesive formed around the periphery thereof
`for attachment of the stack to the face shield. The band of
`
`60
`
`adhesive forms a seal which eliminates any moisture from
`the interface between the bottom-most lens and the shield.
`
`65
`
`Still other features and advantages of the present inven-
`tion will become readily apparent to those skilled in the art
`from the following detailed description, wherein is shown
`and described only the preferred embodiment of the
`invention, simply by way of illustration of the best mode
`
`AEVOE CORP.
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`US 6,536,045 B1
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`3
`the invention. As will be
`contemplated of carrying out
`realized,
`the invention is capable of other and different
`embodiments, and its several details are capable of modifi-
`cations in various obvious respects, all without departing
`from the invention. Accordingly, the drawings and descrip-
`tion are to be regarded as illustrative in nature, and not as
`restrictive, and what is intended to be protected by Letters
`Patent is set forth in the appended claims.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`10
`
`The general purpose of this invention, as well as a
`preferred mode of use, its objects and advantages will best
`be understood by reference to the following detailed descrip-
`tion of an illustrative embodiment with reference to the
`
`accompanying drawings in which like reference numerals
`designate like parts throughout the figures thereof, wherein:
`FIG. 1 is a perspective view of a face protector that may
`employ the multi-ply transparent lens stack according to the
`teachings of the present invention.
`FIG. 2 is a perspective view of a face protector having
`attached thereto the multi-ply transparent optical stack
`according to the teachings of the present invention.
`FIG. 3 is a partially exploded view of the multi-ply
`transparent optical stack showing the peripheral cut in the
`bottom-most layer, which cut exposes a periphery of adhe-
`sive for application to the face protector shown in FIG. 2.
`FIG. 4 is a partial cross-sectional view taken along line
`4—4 in FIG. 3 showing a detail of the alternating film layers
`with adhesive layers between the film layers.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`Referring now to the drawings and FIG. 1 in particular, a
`large area face protector 10 is shown in perspective view.
`The face protector may include an adjustable headband 11
`and a frontal member 12 for supporting a lens 13. The frontal
`member 12 and lens 13 may be adjusted at an angle with the
`headband 11. Adjustment knobs 14 and 15 are available for
`holding the member 12 and lens 13 at the desired angle.
`Although a particular face protector is depicted,
`those
`skilled in the art will recognize that all face protectors,
`goggles and the like are contemplated for use in the present
`invention.
`
`Referring now to FIG. 2, a perspective view of the face
`protector 10 is shown with a multi-ply transparent
`lens
`optical stack 16 attached thereto. The lens optical stack 16
`is made and attached to the lens 13 according to the
`teachings of the present invention, amplified herein below.
`The lens optical stack 16 preferably includes tabs 17, which
`are employed by a wearer for removal of an individual layer
`of the lens optical stack 16. It is preferable that the removal
`tabs 17 do not have any adhesive on either side thereof so
`that a user will not pick up the adhesive on their fingers or
`gloves (if worn).
`During use for example, when the lens optical stack 16
`becomes contaminated and blocks the user’s view, then one
`simply reaches up and grabs an individual tab 17 and peels
`off an outer layer of the lens optical stack 16. This process
`may be repeated as many times as there are layers in the lens
`optical stack 16.
`Referring now to FIG. 3, a partially exploded view of the
`multi-ply transparent optical stack 16 is shown. This figure
`illustrates removable Mylar lenses or film layers 30, 32, 34,
`36 .
`.
`. alternating with adhesive layers 31, 33, 35 .
`.
`. That
`is, the film layer 30 is held to the film layer 32 by the clear
`
`15
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`20
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`25
`
`30
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`35
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`40
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`45
`
`50
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`55
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`60
`
`65
`
`4
`uninterrupted adhesive layer 31 interposed there between.
`The next film layer 34 is held to the film layer 32 by
`interposing the adhesive layer 33 there between, and so forth
`for formation of the entire lens optical stack 16.
`The preferred material used to form the film layers 30, 32,
`34, etc.
`is preferably a clear polyester. The layers are
`preferably fabricated from sheets of plastic film sold under
`the registered trademark Mylar owned by the DuPont Com-
`pany and more particularly a type of Mylar made from a
`clear polymer polyethylene terephalate, commonly referred
`to as PET. Preferably, the lenses and clear adhesive layers
`have an index of refraction between 1.40 and 1.52. The
`
`preferred adhesive layers 31, 33, 35 etc. used to laminate the
`lenses together sequentially is a clear optical
`low tack
`material. The thickness of each film layer typically ranges
`from 0.5 mil to 7 mil (1 mil is 0.001“). The preferred
`thickness is 2 mil. Even after the adhesive material is applied
`to a 2 mil thickness layer, the thickness of the 2 mil thickness
`layer will still be 2 mil due to the adhesive film layer having
`only a nominal thickness. The term “wetting” can be used to
`describe the relationship between the laminated film layers.
`When viewing through the laminated layers, it appears to be
`one single piece of plastic film. No reflections are evident.
`The adhesive material 20 comprises a water based acrylic
`optically clear adhesive or an oil based clear adhesive, with
`the water based adhesive being the preferred embodiment.
`After the film layers 30, 32, 34 etc. are laminated or
`otherwise, bonded together with the interposed adhesive
`layers 31, 33, 35 etc., the thickness of each adhesive layer is
`negligible even though the adhesive layers are illustrated in
`as distinct
`layers. A preferred adhesive layer/film layer
`construction is disclosed in our pending application Ser. No.
`09/449,318 filed Nov. 24, 1999 entitled Optical Stack of
`Laminated Removable Lenses for Face Shields, Windows,
`and Displays. The disclosure of which is expressly incor-
`porated herein by reference.
`In accordance with a first
`embodiment of the present invention, a cut is made around
`the periphery of the bottom-most film layer 30,
`thereby
`exposing a narrow strip 20 of the adhesive layer 31. The strip
`20 is used for adhesively affixing the optical stack 16 to the
`face protector 10. It is preferable to make the peripheral cut
`after the optical stack 16 is assembled into the multiple
`alternating layers in order to maintain proper registration of
`the individual layers. However, those skilled in the art will
`recognize the narrow strip 20 may be applied separately to
`the bottommost film layer 30 as well.
`Referring now to FIG. 4, a partial cross-sectional view
`taken along line 4-4 of FIG. 3 illustrates a detail of alter-
`nating film layers 30, 32, 34, 36 .
`.
`. , with the adhesive layers
`31, 33, 35, .
`.
`. interposed between each the film layers. It is
`noted that the peripheral cut exposing the strip 20 only
`removes a portion of the bottom-most film layer 30. This
`narrow peripheral strip 2- is preferably W‘ to 1/2“ in width,
`or wider. The more narrow the strip the more likely the stack
`will not stay in place on the face protector and the wider the
`strip the more likely the bubble problem, discussed above,
`will occur. Hence, I have discovered that the preferred width
`is as stated above, i.e., W‘ to 1/2“ in width.
`As will be recognized, the multiply transparent optical
`stack 16 of the present invention can be easily applied to any
`desired face protector 10 by positioning the bottom-most
`film layer 30 having the narrow strip 20 of adhesive layer
`disposed about the periphery thereof adjacent to the front
`surface of the face protector. A user may then press the
`narrow strip 20 of the adhesive layer 31 against the outer
`surface of the face protector 10 causing the stack to be
`rapidly mounted thereto. In the preferred embodiment, the
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`US 6,536,045 B1
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`5
`narrow strip 20 is attached to the face protector 10 adjacent
`one end thereof and subsequently spread or pressed tightly
`against the front surface of the face protector 10. In view of
`the large optical area of bottom-most film layer 30 being
`devoid of any adhesive, air bubbles or the like are not
`presented at the interface of the optical stack 16 and the face
`protector 10. However, because the optical stack 16 has
`adhesive layers there between, reflection between the film
`layers 30 is substantially reduced. During use, as unwanted
`material is splashed or presented to upper most film layer,
`the user may quickly remove the upper most film layer from
`the stack exposing a clean film layer there below. As such,
`it will be recognized that the present invention allows an
`effective optical stack to be rapidly deployed upon any
`optical surface and be rapidly used by a user.
`Although the invention has been described with reference
`to a specific embodiment, this description is not meant to be
`construed in a limiting sense. Various modifications of the
`disclosed embodiment as well as alternative embodiments of
`
`the invention will become apparent to one skilled in the art
`upon reference to the description to the invention.
`It is
`therefore contemplated that the appended claims will cover
`any modifications of the embodiments that fall within the
`true scope of the invention.
`What is claimed is:
`
`1. An improved optical stack of laminated removable
`lenses for adhering to a face shield comprising:
`(a) a plurality of superposed removable lenses adhesively
`affixed to one another;
`(b) each said removable lens being held to each succes-
`sive lens with a clear uninterrupted adhesive layer
`interposed between each said removable lens;
`(c) each said lens having a removal tab portion on at least
`one end which does not have any adhesive layer on
`either side of said tab portion for allowing the wearer
`of the face shield to quickly grasp said removal tab
`portion for removing the top lens and exposing a clean
`lens directly underneath said removed top lens; and,
`(d) the bottom-most removable lens of said stack having
`a band of adhesive formed around the periphery thereof
`for attachment of said stack to said face shield, wherein
`said band of adhesive forms a seal thereby eliminating
`any moisture from the interface between said bottom-
`most lens and said shield.
`
`2. The optical stack as in claim 1 wherein said band of
`adhesive is formed by making a cut to the depth of the
`bottom-most lens, inside the periphery and contiguous to the
`lens shape, whereby the outer most generally annulus por-
`tion is then removed, thereby exposing the adhesive of the
`previous layer, which aids in mounting said lens to said face
`shield.
`
`3. The optical stack as in claim 1 wherein said band of
`adhesive is applied to the periphery of said bottom-most
`lens.
`
`5
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`6
`4. The optical stack as in claim 1 wherein said removable
`lenses and said clear adhesive layers have an index of
`refraction between 1.40 and 1.52.
`5. An optical stack of removable lenses for adhering to an
`optical window comprising:
`a) a plurality of generally rectangular superposed remov-
`able lenses adhesively adhered to one another so as to
`form said optical stack;
`b) each said removable lens being held to each successive
`lens with a clear uninterrupted adhesive layer inter-
`posed between each said removable lens;
`c) a plurality of staggered tabs extending from a corner of
`each of said film layers, said tabs being disposed to
`assist
`in allowing each film layer to be peeled off
`successively; and
`d) the bottom-most removable lens of said stack having a
`band of adhesive formed around the periphery thereof
`for attachment of said stack to said optical window,
`wherein said band of adhesive forms a seal thereby
`eliminating any moisture from the interface between
`said bottom-most lens and said optical window.
`6. The optical stack as in claim 5 wherein said stack of
`removable lenses is adapted to be mounted on a windshield,
`window, face shield or a video display.
`7. The optical stack as in claim 5 wherein said band of
`adhesive is formed by making a cut to the depth of the
`bottom-most lens, inside the periphery and contiguous to the
`lens shape, whereby the outer most generally annulus por-
`tion is then removed, thereby exposing the adhesive of the
`previous layer, which aids in mounting said lens to said
`optical window.
`8. The optical stack as in claim 5 wherein said band of
`adhesive is applied to the periphery of said bottom-most
`lens.
`
`9. The optical stack as in claim 5 wherein said removable
`lenses and said clear adhesive layers have an index of
`refraction between 1.40 and 1.52.
`
`10. The optical stack as in claim 5 wherein said tabs do
`not have adhesive attached thereto.
`
`lens stack for
`11. A method for forming an optical
`attachment to an optical window, said method comprising
`the steps of:
`a) laminating together a multiplicity of optical lens layers
`while interposing a clear uninterrupted adhesive layer
`between each optical lens layer being laminated;
`b) forming a tab extension from each optical lens layer
`and omitting said adhesive layer
`from said tab
`extension, whereby each of said lens layer may be
`peeled off individually; and,
`c) cutting around the perimeter and to a depth of one
`optical lens ply the bottom-most layer of said optical
`stack, thereby exposing a strip of adhesive for adhering
`said optical stack to said optical window.
`*
`*
`*
`*
`*
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`AEVOE CORP.
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