Highly efficient polarized lenses with color enhancement

Abstract

A filter element comprises: at least one layer, a first layer of the at least one layer being stretched along a strain direction and comprising a first narrow-band dye, the first narrow-band dye comprising a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth; and a first dichroic dye configured to absorb polarized light, the first dichroic dye comprising a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth, molecules of the first dichroic dye being at least partially oriented along the strain direction.

Description

Technical Field

[0001] The present disclosure relates to a color-enhanced polarizing film with high polarization efficiency, including a dichroic dye for absorbing polarized light and a narrow-band dye for color enhancement. Background Art

[0002] The "background" description provided herein is intended to generally introduce the context of the present disclosure. To the extent that the work of the presently named inventors is described in this background section, and aspects of this description that may not be identified as prior art at the time of filing, are neither explicitly nor implicitly admitted to be prior art against the present disclosure.

[0003] Color-enhanced polarized lenses for optical sunglass can be used to provide protection against sunlight and light that is polarized, such as after scattering from non-metallic surfaces, while also filtering out light of predetermined wavelengths to promote a more aesthetically pleasing, less eye-straining, or a combination of both. Certain color-enhanced polarized lenses can be made by combining a polarizing film (e.g., a PVA polarizer) with a tinted film, wherein the polarizing film has a high transmittance of, for example, 30-35%. Adding a tinted film can improve color enhancement while reducing transmittance to, for example, about 15%, resulting in sunglass lenses generally referred to as Class 3. However, in order to achieve high transmittance, the dichroic dye loading of the PVA polarizer is reduced, and this causes the polarization efficiency (PE) to decrease from greater than 99% PE (which can be obtained with a PVA polarizer with %T<20%) to less than 97% PE. The lower PE may cause some glare to scatter from very high polarization glare surfaces, penetrate the sunglass lens and reduce the user's vision. Therefore, a color-enhanced polarized filter element having color enhancement properties while maintaining high polarization efficiency is desired.

[0004] Aspects of the present invention may address some of the above-mentioned shortcomings in the art, in particular through the solutions set out in the claims. Summary of the invention

[0005] The present invention relates to a filter element, comprising: at least one layer, a first layer of the at least one layer is stretched along a strain direction and comprises a first narrow-band dye, the first narrow-band dye comprises a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth; and a first dichroic dye configured to absorb polarized light, the first dichroic dye comprises a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth, and molecules of the first dichroic dye are at least partially oriented along the strain direction.

[0006] A second layer of the at least one layer may be integrated with the first layer of the at least one layer, the second layer of the at least one layer being a polarizing film configured to absorb polarized light.

[0007] At least 25% of the first dichroic dye can be aligned along the strain direction; and the polarization efficiency of the filter element is greater than 97%. In some embodiments, the filter element is as described in the claims.

[0008] The present disclosure additionally relates to a method of forming a filter element, the method comprising: extruding a first layer, the first layer comprising a first narrow-band dye, the first narrow-band dye comprising a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth, and a first dichroic dye configured to absorb polarized light, the first dichroic dye comprising a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth; and stretching the first layer along a strain direction, molecules of the first dichroic dye being at least partially oriented along the strain direction. In some embodiments, the method of forming a filter element is as described in the claims.

[0009] Note that this Summary of the Invention section does not specify every feature and / or added novel aspect of the present disclosure or claimed invention. Rather, this Summary of the Invention only provides a preliminary discussion of different embodiments and corresponding novel points. For additional details and / or possible perspectives of the present invention and embodiments, the reader is referred to the Detailed Description section of the present disclosure and the corresponding drawings discussed further below. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Various embodiments of the present disclosure, presented as examples, will be described in detail with reference to the following drawings, in which:

[0011] Figure 1 is a schematic cross-sectional view of an extrusion apparatus within the scope of the present disclosure.

[0012] Figure 2 is a schematic cross-sectional view of a stretching apparatus within the scope of the present disclosure.

[0013] Figure 3 is a schematic cross-sectional view of a lamination of a color-enhanced polarizing film with additional layers within the scope of the present disclosure.

[0014] Figure 4 is a schematic cross-sectional view of thermoforming of a color enhanced, high polarization efficiency laminate within the scope of the present disclosure.

[0015] Figure 5 is a cross-sectional schematic diagram of injection molding within the scope of the present disclosure.

[0016] Figure 6 Shown are transmission graphs for two lenses within the scope of the present disclosure. DETAILED DESCRIPTION

[0017] The following disclosure provides many different variations or examples for implementing different features of the subject matter provided. Specific examples of components and arrangements are described below to simplify this disclosure. Of course, these are only examples and are not intended to limit or be unable to operate together in any arrangement. Unless otherwise specified, the features and embodiments described herein can operate together in any arrangement. For example, forming a first feature on or on a second feature in the following description may include an embodiment in which the first feature and the second feature are directly contacted and formed, and may also include an embodiment in which an additional feature can be formed between the first feature and the second feature, so that the first feature and the second feature may not be in direct contact. In addition, the present disclosure may repeat the reference numerals and / or letters in various examples. This repetition is for the purpose of simplicity and clarity, and does not itself specify the relationship between the various embodiments and / or configurations discussed. Further, for ease of description, spatial relative terms such as "top", "bottom", "below", "below", "lower", "above", "above", etc. may be used herein to describe the relationship between an element or feature as shown in the figure and another (multiple) element or feature. In addition to the orientation depicted in the figure, spatial relative terms are intended to include different orientations of the device when used or operated. The present invention may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0018] For the sake of clarity, the order of discussion of the different steps as described herein has been presented. Generally, these steps can be performed in any suitable order. In addition, although each of the different features, techniques, configurations, etc. herein can be discussed in different places of this disclosure, it is intended that each concept can be performed independently of each other or in combination with each other. Therefore, the present invention can be implemented and observed in many different ways.

[0019] Combinations of color contrast enhancement and polarized light filtering in sunglass lenses and methods of making sunglass lenses are described herein. Color-enhancing photochromic lenses can be manufactured by a number of processes to produce lenses that filter light of a predetermined wavelength range and polarized light with greater than 97% polarization efficiency (PE).

[0020] Figure 1 An exemplary cross-sectional schematic diagram of an exemplary extrusion device useful within the scope of the present disclosure is shown. The extrusion device can be a screw extruder and can include a hopper, a screw and / or a first set of rollers. Figure 1As shown, the hopper can receive pellets of one or more materials or a mixture of materials separately. For example, the hopper can receive a mixture of polycarbonate pellets and dye pellets 101. Subsequently, the dye pellet 101 material can be heated and fed to the screw. The heating can heat the dye pellets 101 to above the glass transition temperature of the dye pellets 101, thereby mixing the dye pellets 101 when more than one dye pellet 101 material is mixed in the hopper. The screw (which can also be a twin-screw or multi-screw arrangement) can push the dye pellet 101 material from the hopper to one or more nozzles of the extrusion device, where the molten dye pellets 101 can leave, cool and be pulled by a first set of rollers. The first set of rollers can pull or extrude the dye pellet 101 material into a color enhancement film. The color enhancement film can be substantially flat, for example, with a flatness within 5%, 2.5% or 1%, and / or a roughness R A The first narrow-band dye 101a may include a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth, and the first dichroic dye 101b may be configured to absorb polarized light, and the first dichroic dye 101b may include a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth.

[0021] Figure 2 An exemplary cross-sectional schematic diagram of the present invention of an exemplary stretching device is shown. The stretching device may include a second, third or another set of rollers. In a non-limiting example, the stretching device may be a machine direction orienter (MDO). The stretching device may be configured to stretch the color enhancement film by feeding the color enhancement film through a series of rollers in the second set of rollers that heat, stretch, anneal and cool the color enhancement film. It is noteworthy that the color enhancement film may be stretched or elongated, for example, along the strain direction, thereby also aligning the molecules of the first dichroic dye 101b along the strain direction to produce a color enhancement polarizing film (CEPF) 105 when it leaves the stretching device. That is, when the color enhancement film is fed through the stretching device to form the stretched CEPF 105, the strain direction may be along the stretching or elongation direction of the color enhancement film. It is understood that different stretching devices may be used to stretch the color enhancement film to produce the CEPF 105, so that the stretching direction is different from the direction in which the color enhancement film is fed through the stretching device. For example, the stretching device may include a series of clamps configured to pull the color enhancement film in a direction orthogonal to the direction in which the color enhancement film is fed into the stretching device. In such an example, the strain direction (or stretching direction) is orthogonal to the direction in which the film travels through the stretching device.

[0022] The materials used to make the color enhancement film and CEPF 105 can be selected from various optical grade thermoplastics, such as polycarbonate (PC), polyamide (such as nylon), thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), or any combination thereof. The stretch ratio of CEPF 105 can be, for example, between 1:1.1 and 1:10, or 1:1.5 and 1:8, or 1:2 and 1:6. In the case where CEPF 105 is not fully stretched or not stretched at all, the first dichroic dye 101b will generally be more randomly oriented and the PE of the final lens product will increase less. In order to observe the maximum increase in PE, the first dichroic dye 101b should typically be fully oriented. It will be appreciated that additional narrow-band dyes, dichroic dyes, and broadband dyes can be included to produce a predetermined absorption spectrum of the final lens product while maintaining a high PE. Further, the first narrow-band dye 101a can be configured to absorb light of a predetermined wavelength (i.e., the first narrow-band dye peak absorption wavelength). For example, the first narrow-band dye peak absorption wavelength is 500nm or 598nm, anywhere in the range of 475nm to 525nm, 490nm to 510nm, 495nm to 505nm, or 498nm to 502nm, or anywhere in the range of 575nm to 625nm, 585nm to 610nm, 590nm to 600nm, or 595nm to 599nm.

[0023] Figure 3 An exemplary inventive cross-sectional schematic diagram of the lamination of a CEPF 105 with additional layers is shown. The CEPF 105 can be laminated with a polarizing film 107 and a transparent film 109. For example, the polarizing film 107 can be a PVA polarizing film, and the transparent film 109 can be a transparent polycarbonate film. The CEPF 105 can be laminated to the polarizing film 107 so that the first side of the CEPF 105 faces away from the polarizing film 107 and the second side of the CEPF 105 can contact the first side of the polarizing film 107. Similarly, the second side of the polarizing film 107 can contact the first side of the transparent film 109. Therefore, the polarizing film 107 can be laminated between the CEPF 105 and the transparent film 109.

[0024] Polarizing film 107 and transparent film 109 can also be stretched in one direction, i.e. unidirectional or uniaxial stretching, such as stretching in the strain direction. Subsequently, CEPF 105, polarizing film 107 and transparent film 109 can be laminated in a manner that aligns the three layers in the strain direction. That is, the stretching axes of the three layers are parallel during lamination. When laminated, the resulting three-layer structure is a color enhanced high polarization efficiency (CEHPE) laminate 110.

[0025] Figure 4An exemplary cross-sectional schematic diagram of the present invention of the thermoforming of a CEHPE laminate 110 is shown. The CEHPE laminate 110 can optionally be cut into a predetermined size using a punching machine. For example, the predetermined size can be based on a specific eyeglass frame design. The CEHPE laminate 110 can be thermoformed using a thermoforming machine to introduce a base curvature into the CEHPE laminate 110. For example, a heating device can be used to preheat the CEHPE laminate 110 to a glass transition temperature just below the CEHPE laminate 110. Heat can make the CEHPE laminate 110 more amorphous and flexible for subsequent steps. After preheating, the CEHPE laminate 110 can be loaded into a thermoforming machine with a predetermined base curvature. A vacuum force can be applied to pull the CEHPE laminate 110 onto the surface of the thermoforming machine to adopt the base curvature of the thermoforming machine, thereby producing a thermoformed CEHPE laminate 110a. The CEPF 105 becomes the concave surface of the CEHPE laminate 110a, and the transparent film 109 becomes the convex surface of the CEHPE laminate 110a.

[0026] Figure 5 An exemplary cross-sectional schematic diagram of the present invention for exemplary injection molding is shown. The thermoformed CEHPE laminate 110a can then be molded to the convex side of a semi-finished (SF) lens using a standard SF wafer overmolding process. As shown, a first mold side including a concave mold insert 510 can be configured to be coupled to a second mold side including a convex mold insert 520. After coupling, the concave mold insert 510 and the convex mold insert 520 can form a cavity that is connected to a hollow pipeline formed by coupling the first mold side and the second mold side. The pipeline can be configured to receive a polymer 115, for example, via a screw feeder or the like. The polymer 115 can be, for example, a transparent polycarbonate resin or other polymer, particularly a thermoplastic, or a composition of polymers, for example, having a transparency of at least 90%, 95% or 97.5%. The cavity can be configured to receive a thermoformed CEHPE laminate 110a. The curvature of the concave mold insert 510 and the curvature of the convex mold insert 520 can determine the lens power of the resulting lens. For SF lenses, the curvature along the convex side of the lens is fixed, and the concave side of the lens can be modified after molding, such as via grinding and polishing.As previously described, polymer 115 can be injected onto the first side of CEPF 105 of thermoformed CEHPE laminate 110a to produce color enhanced high polarization efficiency lens 500.

[0027] The color-enhanced high polarization efficiency lens 500 can be manufactured using the aforementioned process, but instead thermoforming can be performed so that the transparent film 109 and the CEPF 105 are located on opposite sides of the polarizing film 107. That is, the CEPF 105 becomes the convex surface of the CEHPE laminate 110a, and the transparent film 109 becomes the concave surface of the CEHPE laminate 110a. Therefore, during injection molding, the polymer 115 can be injected and fused to the transparent film 109.

[0028] The first narrow-band dye 101a and the first dichroic dye 101b can be integrated into a coating matrix that can be aligned along the strain direction. The coating matrix can be applied to a polarized lens (e.g., a Class 2 polarized lens), and the dichroic dye can then be aligned. First, an alignment layer can be spin-coated onto the polarized lens. Polarized UV light exposure can then cause alignment of the alignment layer, wherein the alignment layer includes liquid crystal molecules aligned along the polarization direction. The coating matrix including the first narrow-band dye 101a and the dichroic dye 101b can be spin-coated onto the alignment layer. The aligned liquid crystal molecules in the alignment layer can then interact with the molecules of the first dichroic dye to align the molecules of the first dichroic dye along the same strain direction as the liquid crystal molecules. Subsequently, an optional protective layer can be spin-coated on the coating matrix.

[0029] Note that Class 4 may refer to a transmittance below 8%, Class 3 may refer to a transmittance between 8% and 18%, Class 2 may refer to a transmittance between 18% and 43%, and Class 1 may refer to a transmittance between 43% and 75%.

[0030] The first narrow-band dye 101a and the first dichroic dye 101b can be integrated into a solution that can be aligned along the strain direction. First, the sol-gel coating can be spin-coated onto a polarized lens (e.g., a Class 2 polarized lens). The surface can be mechanically scribed to produce microgrooves along the scribe direction, i.e., the strain direction. The microgrooves can be retained when the sol-gel coating is cured. Subsequently, a solution containing the first narrow-band dye 101a and the first dichroic dye 101b can be spin-coated onto the sol-gel coating. Then the first dichroic dye 101b molecules can be aligned along the strain direction of the microgrooves and provide a polarization function. An optional protective layer can be spin-coated on the top.

[0031] The CEHPE laminate 110 and the resulting color-enhanced high polarization efficiency lens 500 can provide, for example, greater than 97%, greater than 97.5%, greater than 98%, greater than 98.5%, or greater than 99% PE. Non-limiting examples of dyes that can be used to make the CEHPE laminate 110 and the resulting color-enhanced high polarization efficiency lens 500 are described below.

[0032] First narrow-band dye 101a: narrow-band absorber, such as Epolight 5841, Epolight 5819 and Epolight 6698 (Epolin).

[0033] First dichroic dye 101b: Dichroic dyes compatible with optical thermoplastic polymers and melt extrudate blending: Blue AB2, Blue AB3, Blue AB4, Orange AO1, Orange AZO1, Yellow AG1, Red AR1, and Cyan AC1 (Nematel, Gmbh).

[0034] CEPF 105 can be manufactured by blending a combination of a first narrow band dye 101a and a first dichroic dye 101b to achieve a desired absorption spectrum and extruding an optical quality film using an extrusion device. Other dyes having similar absorption spectra and dichroic properties may also be used.

[0035] Example

[0036] Example 1:

[0037] The relative absorption spectra of various first dichroic dyes 101b in solution and the relative absorption spectra of various color contrast enhancing first narrowband dyes 101a in polycarbonate were used to simulate a color enhancing lens with very high polarization efficiency. The results of this simulation are shown below:

[0038] Description of dyes used in CEPF membrane (thickness of membrane = 0.300 mm):

[0039]

[0040] Table 1

[0041] *Dichroic dye values ​​obtained from solution spectral data

[0042] Lens characteristics

[0043]

[0044] Table 2

[0045]

[0046] Table 3

[0047] Note: 100% alignment represents a film in which the dichroic dye is optimally aligned in the stretching direction; 0% alignment represents a film in which the dichroic dye is randomly oriented.

[0048] Figure 6A graph of the transmittance of two exemplary inventive lenses is shown. As shown, the color enhanced lens having high polarization efficiency includes absorption peaks located at approximately 498 nm and 585 nm.

[0049] In the foregoing description, specific details have been set forth, such as the specific geometry of the processing system and the description of the various components and processes used therein. However, it should be understood that the technology herein can be practiced in other embodiments that are separated from these specific details, and these embodiments are for illustrative rather than limiting purposes. The embodiments disclosed herein have been described with reference to the accompanying drawings. Similarly, for the purpose of explanation, specific numbers, materials, and configurations have been set forth to provide a thorough understanding. However, the embodiments can be practiced without these specific details. Components having substantially the same functional structure are represented by the same reference numerals, so any redundant description can be omitted.

[0050] Various techniques have been described as multiple discrete operations to help understand various embodiments. The order of description should not be interpreted as implying that these operations are necessarily dependent on the order. In fact, these operations do not need to be performed in the order presented. Unless otherwise explicitly stated, the described operations can be performed in an order different from the specific description. Various additional operations can be performed and / or the described operations can be omitted.

[0051] It will also be appreciated by those skilled in the art that many changes may be made to the operation of the above-mentioned techniques while still achieving the same objectives of the present invention. Such changes are intended to be covered by the scope of this disclosure. Therefore, the foregoing description of the embodiments of the present invention is not intended to be restrictive. Rather, any limitations to the embodiments of the present invention are set forth in the following claims.

[0052] Embodiments of the present disclosure may also be described as follows in brackets.

[0053] (1) A filter element comprising: at least one layer, such as two layers, three layers, four layers, five layers or more layers, a first layer of the at least one layer being stretched along a strain direction and comprising a first narrow-band dye, the first narrow-band dye comprising a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth; and a first dichroic dye configured to absorb polarized light, the first dichroic dye comprising a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth, molecules of the first dichroic dye being at least partially oriented along the strain direction.

[0054] (2) The element according to (1), wherein a second layer of the at least one layer is integrated with a first layer of the at least one layer, and the second layer of the at least one layer is a polarizing film configured to absorb polarized light.

[0055] (3) An element as described in (1) or (2), wherein the peak absorption wavelength of the first narrow-band dye is approximately 498 nm, for example, 450 nm to 550 nm, 475 nm to 525 nm, 490 nm to 510 nm, or 495 nm to 499 nm; and the bandwidth of the first narrow-band dye is less than 40 nm, 30 nm, 20 nm or 10 nm.

[0056] (4) An element as described in any of (1) to (3), wherein at least 25%, 30%, 35% or 50% of the first dichroic dye is oriented along the strain direction; and the polarization efficiency of the filter element is greater than 97%, 98%, 99% or 99.5%.

[0057] (5) The element as described in any one of (1) to (4), further comprising: a lens integrated with the at least one layer, wherein the third layer of the at least one layer is integrated with the second layer of the at least one layer, and the third layer of the at least one layer is a transparent film.

[0058] (6) A filter element comprises: a lens; and at least one layer, the at least one layer comprising a first layer, a second layer and a third layer, wherein the first layer of the at least one layer is stretched along a strain direction and comprises a first narrow-band dye, the first narrow-band dye comprising a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth; and a first dichroic dye configured to absorb polarized light, the first dichroic dye comprising a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth, the molecules of the first dichroic dye being at least partially oriented along the strain direction, the second layer of the at least one layer being integrated with the first layer of the at least one layer, the second layer of the at least one layer being a polarizing film configured to absorb polarized light, the third layer of the at least one layer being integrated with the second layer of the at least one layer, the third layer of the at least one layer being a transparent film, and the lens is integrated with the at least one layer.

[0059] (7) An element as described in (6), wherein the peak absorption wavelength of the first narrow-band dye is approximately 498 nm, for example, 450 nm to 550 nm, 475 nm to 525 nm, 490 nm to 510 nm, or 495 nm to 499 nm; and the bandwidth of the first narrow-band dye is less than 40 nm, 30 nm, 20 nm or 10 nm.

[0060] (8) An element as described in (6) or (7), wherein at least 25%, 30%, 35% or 50% of the first dichroic dye is oriented along the strain direction; and the polarization efficiency of the filter element is greater than 97%, 98%, 99% or 99.5%.

[0061] (9) The element as described in any one of (6) to (8), wherein the first narrow-band dye is dichroic and is configured to absorb polarized light.

[0062] (10) An element as described in any one of (6) to (9), wherein the first layer of the at least one layer further includes a second narrow-band dye, the second narrow-band dye including a second narrow-band dye peak absorption wavelength equal to approximately 585 nm, for example, 525 nm to 633 nm, 550 nm to 615 nm, 575 nm to 595 nm, or 580 nm to 590 nm, and the second narrow-band dye bandwidth is less than 40 nm, 30 nm, 20 nm or 10 nm.

[0063] (11) A method of forming a filter element, comprising: extruding a first layer, the first layer comprising a first narrow-band dye, the first narrow-band dye comprising a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth, and a first dichroic dye configured to absorb polarized light, the first dichroic dye comprising a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth; and stretching the first layer along a strain direction, the molecules of the first dichroic dye being at least partially oriented along the strain direction.

[0064] (12) The method as described in (11) further includes: laminating the stretched first layer to a second layer, the second layer being configured to absorb polarized light perpendicular to the polarization axis of the second layer; laminating a third layer to the second layer, the third layer being optically transparent; forming the first stretched layer, the second layer and the third layer into a chip having a predetermined curvature; and optically coupling the thermoformed chip to the lens.

[0065] (13) A method as described in (11) or (12), wherein the peak absorption wavelength of the first narrow-band dye is approximately 498 nm, for example, 450 nm to 550 nm, 475 nm to 525 nm, 490 nm to 510 nm, or 495 nm to 499 nm; and the bandwidth of the first narrow-band dye is less than 40 nm, 30 nm, 20 nm or 10 nm.

[0066] (14) A method as described in (11) or (12), wherein the first layer includes a second narrow-band dye, the second narrow-band dye includes a second narrow-band dye peak absorption wavelength equal to approximately 585 nm, for example, 525 nm to 633 nm, 550 nm to 615 nm, 575 nm to 595 nm, or 580 nm to 590 nm, and the second narrow-band dye bandwidth is less than 40 nm, 30 nm, 20 nm or 10 nm.

[0067] (15) A method as described in (11) or (12), wherein at least 25%, 30%, 35% or 50% of the first dichroic dye is oriented along the strain direction; and the polarization efficiency of the filter element is greater than 97%, 98%, 99% or 99.5%.

[0068] (16) A method for forming a filter element, comprising: coating a polarizing lens with a first layer, the first layer being configured to align molecules of a first dichroic dye; coating the first layer with a second layer, the second layer comprising a first narrow-band dye, the first narrow-band dye comprising a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth, and a first dichroic dye configured to absorb polarized light, the first dichroic dye comprising a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth; and coating the second layer with a third layer, the third layer being configured to prevent damage to the first layer and the second layer.

[0069] (17) A method as described in (16), wherein coating the lens with the first layer further includes: exposing the first layer to polarized UV light, wherein the polarized UV light is configured to align liquid crystal molecules in the first layer, and these liquid crystal molecules interact with molecules of the first dichroic dye in the second layer to align the molecules of the first dichroic dye along the direction of these liquid crystal molecules.

[0070] (18) A method as described in (16) or (17), wherein coating the second layer on the first layer further includes: forming a plurality of grooves in the surface of the second layer along the strain direction; and curing the second layer, wherein the molecules of the first dichroic dye in the second layer are aligned along the strain direction.

[0071] (19) A method as described in any one of (16) to (18), wherein the peak absorption wavelength of the first narrow-band dye is approximately 498 nm, for example, 450 nm to 550 nm, 475 nm to 525 nm, 490 nm to 510 nm, or 495 nm to 499 nm; and the bandwidth of the first narrow-band dye is less than 40 nm, 30 nm, 20 nm or 10 nm.

[0072] (20) A method as described in any of (16) to (19), wherein at least 25%, 30%, 35% or 50% of the first dichroic dye is oriented along the strain direction; and the polarization efficiency of the filter element is greater than 97%, 98%, 99%, 99.5%, 99.9% or 99.95%.

[0073] (21) The method as described in any one of (16) to (20), wherein the coating is performed via spin coating.

[0074] (22) The method according to any one of (16) to (21), wherein the first layer is a sol-gel layer.

[0075] (23) The method as described in any one of (16) to (22), wherein the transmittance range of the polarized lens is in the range of 18% to 45%, 20 to 40%, or 25 to 33%.

[0076] (24) The element of any one of (2) to (5), wherein the stretch ratio of the at least one layer is between 1:2 and 1:6, 1:2.5 to 1:5, or 1:3 to 1:4.

[0077] (25) An element as described in any of (2) to (5), wherein at least 75%, 80%, 85% or 90% of the first dichroic dye is oriented along the strain direction; and the polarization efficiency of the filter element is greater than 97%, 98%, 99%, 99.5%, 99.9% or 99.95%.

[0078] (26) The element as described in any one of (2) to (5), wherein the second layer of the at least one layer has a polarization efficiency greater than 96%, 97%, 98%, 99% or 99.5%.

Claims

1. A filter element, comprising: at least one layer, a first layer of the at least one layer being stretched in a strain direction and comprising a first narrow-band dye comprising a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth; as well as a first dichroic dye configured to absorb polarized light, the first dichroic dye comprising a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth, molecules of the first dichroic dye being at least partially aligned along the strain direction, wherein the second layer of the at least one layer is integrated with the first layer of the at least one layer, the second layer of the at least one layer is a polarizing film configured to absorb polarized light, and the polarizing film is laminated with the first layer of the at least one layer, At least 25% of the first dichroic dye is aligned along the strain direction; and The polarization efficiency of the filter element is greater than 97%.

2. The filter element according to claim 1, wherein: The first narrow-band dye peak absorption wavelength is 498 nm; and The bandwidth of the first narrow-band dye is less than 40 nm.

3. The filter element according to claim 1, further comprising: A lens integrated with said at least one layer, wherein A third layer of the at least one layer is integrated with the second layer of the at least one layer, and the third layer of the at least one layer is a transparent film.

4. The filter element according to claim 3, wherein: The first narrow-band dye peak absorption wavelength is 498 nm; and The bandwidth of the first narrow-band dye is less than 40 nm.

5. The filter element according to claim 3, wherein: The first narrow band dye is dichroic and is configured to absorb polarized light.

6. The filter element according to claim 3, wherein: The first layer of the at least one layer further includes a second narrow-band dye including a second narrow-band dye peak absorption wavelength equal to 585 nm, and the second narrow-band dye bandwidth is less than 40 nm.

7. A method of forming a filter element, comprising: extruding a first layer, the first layer comprising a first narrow-band dye comprising a first narrow-band dye peak absorption wavelength having a first narrow-band dye bandwidth, and a first dichroic dye configured to absorb polarized light, the first dichroic dye comprising a first dichroic dye peak absorption wavelength having a first dichroic dye bandwidth; stretching the first layer along a strain direction, molecules of the first dichroic dye being at least partially aligned along the strain direction; as well as The stretched first layer is laminated to a second layer, the second layer being a polarizing film configured to absorb polarized light perpendicular to a polarization axis of the second layer, at least 25% of the first dichroic dye is oriented along the strain direction; and the filter element has a polarization efficiency greater than 97%.

8. The method of claim 7, further comprising: laminating a third layer to the second layer, the third layer being optically clear; forming the stretched first layer, the second layer, and the third layer into a wafer having a predetermined curvature; as well as The wafer is optically coupled to a mirror.

9. The method of claim 7, wherein: The first narrow-band dye peak absorption wavelength is 498 nm; and The bandwidth of the first narrow-band dye is less than 40 nm.

10. The method of claim 7, wherein: The first layer includes a second narrow-band dye including a second narrow-band dye peak absorption wavelength equal to 585 nm, and the second narrow-band dye bandwidth is less than 40 nm.

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