Method of making fresnelled optical element matrix

Claim 2

A process for producing the matrix of a fresnelled optical element from a matrix of discrete elements comprising the steps of: providing a plurality of discrete elongate elements, each element having first and second ends with a plurality of elongate side surfaces therebetween; aligning said elongate elements in side-by-side relation with said first ends forming a common surface and said elongate side surfaces of each element in contiguous contacting relation with adjacent elements, said side surfaces permitting relative movement between said elements in the direction of the elongation of said elements and said elongate side surfaces inhibiting relative rotation of said elements about the direction of elongation of said elements; holding the elements to prevent relative movement at said side surfaces in the direction of elongation of said elements, forming a continuous optical surface on the common surface defined by the first ends of said aligned elements; releasing said hold on said elements; realigning said elements in the direction of elongation of said elements to a second aligned position with the peak of the first common ends of each element being on a common surface, said elements during said realigning being maintained in said side-by-side relation with relative movement occurring at said contiguous contacting elongate side surfaces; and, holding the elements in fixed relative alignment in the second aligned position to form a fresnelled matrix of said continuous optical surface.

Claim 3

A process for producing an optical element from a matrix of elements comprising the steps of: providing a plurality of discrete elongate elements, each discrete elongate element having first and second ends with a plurality of elongate side surfaces therebetween; aligning said elongate elements in parallel, side-by-side relation with said first ends forming a common surface and said elongate side surfaces in continuous contacting relation, said side surfaces permitting relative movement between said elements in the direction of the elongation of said elements and said elongate side surfaces preventing relative rotation of said elements about said direction of elongation of said elements; disposing said aligned elongate elements in a first angular relationship with a preselected plane; holding the elements to prevent relative movement in the direction of elongation of said elements; forming a continuous optical surface on the common surface defined by the first ends of said aligned elements; releasing said hold on said elements; aligning said elements to a second angular relationship with respect to said preselected plane; realigning said elements in the direction of elongation of said elements by relative movement of said elements at said contiguous contacting surfaces to a second aligned position with the peak of the first common ends of each element being on a common surface, said elements during said realigning being maintained in said side-by-side relation with relative movement occurring at said contiguous contacting surfaces; and, holding the elements in fixed relative alignment in the second aligned position to form a fresnelled matrix of said continuous optical surface in said second realigned position.

Claim 4

A process for producing an optical element from a matrix of elements comprising the steps of: providing a plurality of discrete elongate elements, each discrete elongate element having first and second ends with a plurality of elongate side surfaces therebetween; aligning said elongate elements in parallel, side-by-side relation with said first ends forming a common surface and said elongate side surfaces in continuous contacting relation, said side surfaces permitting relative movement between said elements in the direction of the elongation of said elements and said elongate side surfaces preventing relative rotation of said elements about said direction of elongation of said elements; disposing said aligned elongate elements in a first angular relationship with a preselected plane; holding the elements to prevent relative movement in the direction of elongation of said elements; forming a continuous optical surface on the common surface defined by the first ends of said aligned elements; releasing said hold on said elements; aligning said elements to a second angular relationship with respect to said preselected plane; realigning said elements in the direction of elongation of said elements by relative movement of said elements at said contiguous contacting surfaces to a second aligned position with the peak of the first common ends of each element being on a common surface, said elements during said realigning being maintained in said side-by-side relation with relative movement occurring at said contiguous contacting surfaces; and, holding the elements in fixed relative alignment in the second aligned position to form a fresnelled matrix of said continuous optical surface in said second realigned position.

Claim 5

The process of claim 2 and wherein said preselected plane and said common surface are coincidental.

Claim 6

A process for producing a fresnel matrix of first and second optical elements for use in overlying relation, said process comprising the steps of: providing first and second sets of discrete elongate elements, each elongate element having first and second ends with a plurality of elongate side surfaces therebetween; aligning the elongate elements of each set in parallel side-by-side relation with said first ends of each element forming a common surface for each set of elements and said elongate side-by-side surfaces in each set of elements in contiguous contacting relation, said side surfaces permitting relative movement between the elements of each set in a direction of the elongation of said elements and said elongate side surfaces preventing relative rotation of said elements about said direction of elongation of said elements of each set; aligning the elements of both sets to a first angular relation with respect to a preselected plane; holding the elements of each set to prevent relative movement in the direction of elongation of said elements; forming first and second continuous optical surfaces on the common surfaces of said first and second element sets respectively; releasing said hold on said element sets; realigning said elements of each set in the direction of elongation of said elements to a second angular position with respect to said preselected plane; realigning said elements in the direction of elongation of said elements to a second aligned poSition with the peak of the first common ends of each element being on a common surface; said elements during said realigning being maintained in said side-by-side relation with relative movement occurring at said contiguous contacting surfaces; and, holding the elements of each of the first and second sets in fixed relative alignment in the second aligned positions to form a fresnelled matrix of said continuous optical surfaces on each element set in said second realigned position.

Claim 7

A process for producing a fresnel matrix of first and second optical elements for use in overlying relation, said process comprising the steps of: providing first and second sets of discrete elongate elements, each elongate element having first and second ends with a plurality of elongate side surfaces therebetween; aligning the elongate elements of each set in parallel side-by-side relation with said first ends of each element forming a common surface for each set of elements and said elongate side-by-side surfaces in each set of elements in contiguous contacting relation, said side surfaces permitting relative movement between the elements of each set in a direction of the elongation of said elements and said elongate side surfaces preventing relative rotation of said elements about said direction of elongation of said elements of each set; aligning the elements of both sets to a first angular relation with respect to a preselected plane; holding the elements of each set to prevent relative movement in the direction of elongation of said elements; forming first and second continuous optical surfaces on the common surfaces of said first and second element sets respectively; releasing said hold on said element sets; realigning said elements of each set in the direction of elongation of said elements to a second angular position with respect to said preselected plane; realigning said elements in the direction of elongation of said elements to a second aligned poSition with the peak of the first common ends of each element being on a common surface; said elements during said realigning being maintained in said side-by-side relation with relative movement occurring at said contiguous contacting surfaces; and, holding the elements of each of the first and second sets in fixed relative alignment in the second aligned positions to form a fresnelled matrix of said continuous optical surfaces on each element set in said second realigned position.

Claim 8

The process of claim 4 and wherein said common surface and said preselected planes are coincidental.