Mix of NIR dyes for broader NIR cut and better aesthetic value

Abstract

To provide a solution to problems associated with optical elements with near infrared (NIR) protection.SOLUTION: Disclosed are optical elements that contain two or more near infrared absorbers and methods of producing the same. Two near infrared absorbers with different near infrared wavelength absorption ranges and residual colors are mixed with a precursor of an optical substrate. The resulting mixture is subsequently processed to produce optical elements that have a broad near infrared wavelength absorption range and a neutral residual color.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an optical element and a manufacturing method thereof, and more particularly to an optical element containing a plurality of near-infrared dyes in an optical substrate, and a manufacturing method thereof. [Background technology]

[0002] Infrared (IR) radiation is electromagnetic radiation with wavelengths longer than visible light. Infrared radiation generally has wavelengths in the range of 780 nm to 1 mm, which can be divided into three subranges, including the near infrared (NIR) range with wavelengths of 780 to 3000 nm; the mid infrared (MIR) range with wavelengths of 3 μm to 50 μm; and the far infrared (FIR) range with wavelengths of 50 to 1000 μm.

[0003] Extensive research has been carried out to evaluate the effects of NIR radiation on the eye. Research results have shown that NIR is absorbed by the retinal pigment epithelium. Depending on the fluence rate, total dose and spectral characteristics of NIR, structural retinal damage may occur through at least one of photomechanical (photoacoustic), photothermal (heating) and photochemical processes. Furthermore, many research results have shown a strong correlation between chronic NIR exposure and the development of ocular cataracts. Therefore, it is desirable to limit the exposure of the eye to NIR radiation.

[0004] Optical filtering means are generally incorporated into optical articles (e.g., ophthalmic lens materials) to reduce or prevent the arrival of NIR light to the retina. More specifically, two types of NIR filters can be used on optical lenses to provide eye protection against NIR radiation, including NIR absorbing filters and interference filters (e.g., reflective filters). However, it is difficult to design a multifunctional filter with optimized NIR absorbing performance together with other functions, including anti-reflection function, as it has been proven that high NIR absorption adversely affects the anti-reflection performance of optical filters. NIR absorbers can be incorporated into optical coatings deposited on optical articles. However, the direct incorporation of NIR absorbers into optical coatings can significantly increase the manufacturing cost of lenses and at the same time reduce the mechanical properties of optical coatings.

[0005] Another option for improving NIR protection is to incorporate NIR absorbers into the bulk substrate of the optical article by impregnating the substrate with NIR absorbers or mixing substrate precursors with NIR absorbers.However, commercially available NIR absorbers generally have a relatively narrow NIR absorption range, resulting in lenses or other optical articles with insufficient NIR protection.In addition, these absorbers also generally absorb visible light in the wavelength range of 380-780 nm, thereby imparting color to lenses or other optical articles, affecting the wearer's color perception and changing the aesthetic aspects of the lenses that use the absorbers. Summary of the Invention [Problem to be solved by the invention]

[0006] Generally, optical lenses or other optical articles having NIR protection and methods for making the same exist, but in view of at least the above-mentioned shortcomings associated with these optical lenses or optical articles, a need persists for improvements in this field. [Means for solving the problem]

[0007] A solution to the above problems associated with optical elements having near infrared (NIR) protection has been discovered. The solution is by an optical element comprising a polymer matrix and two or more near infrared absorbers. The near infrared absorbers can be substantially homogeneously mixed in the polymer matrix. Thus, no additional filters or coatings are used for NIR protection. This results in a reduction in the manufacturing cost of the optical article compared to optical articles using filters or optical coatings for NIR absorption. Furthermore, the two or more near infrared absorbers in the optical element can have different near infrared ranges, so that the optical article can absorb near infrared radiation in a broader wavelength range compared to conventional NIR protective optical articles. Furthermore, the two or more near infrared absorbers in the optical element can have different residual colors, so that synergistic residual color intensity is minimized to improve the aesthetic aspects of the optical article having NIR protective absorbers. Thus, the optical element of the present invention provides a technical achievement over at least some of the problems associated with currently available NIR protective optical articles.

[0008] Some embodiments of the present invention relate to an optical element. The optical element may include an optical substrate and two or more near infrared ray absorbents mixed in the optical substrate. The two or more near infrared ray absorbents may have different near infrared ray cutoff ranges and different residual colors.

[0009] Some embodiments of the present invention relate to a method for preparing an optical element. The method may include providing a precursor material for an optical substrate and two or more near infrared absorbers having different near infrared cut ranges and / or different residual colors. The method may include determining a concentration for each of the two or more near infrared absorbers in the optical substrate, where the synergistic color intensity of the two or more near infrared absorbers is lower than the individual color intensity of any of the two or more near infrared absorbers. The method may include mixing the precursor material with the two or more infrared absorbers at a concentration determined to produce a substantially homogenous mixture. The method may include using the mixture of the optical substrate and the two or more infrared absorbers to produce an optical element.

[0010] Some embodiments of the present invention relate to a method for preparing an optical element. The method may include providing a precursor material for an optical substrate and two or more near infrared absorbers having different near infrared cut ranges and / or different residual colors. The method may include determining a concentration for each of the two or more near infrared absorbers in the substrate at which the synergistic color intensity of the two or more near infrared absorbers is lower than the individual color intensity of any of the two or more near infrared absorbers. The method may include dissolving the two or more infrared absorbers in a first amount of precursor material to produce a near infrared dye master batch. The method may include mixing a second amount of precursor material with one or more of an ultraviolet dye, a monomer, a catalyst, and a release agent under reduced pressure at a temperature of 23-27°C to produce a first mixture that is substantially homogenous. The method may include cooling the first mixture to a temperature of 0-4°C. The method may include flowing an inert gas over the cooled first mixture. The method may include mixing the near infrared dye masterbatch into the first mixture under reduced pressure at a temperature of 0-4°C and all ranges and values ​​therebetween to produce a second mixture. The second mixture can be a substantially homogenous mixture having each of the two or more near infrared absorbers at their determined concentrations. The method may include producing an optical element using the second mixture by casting.

[0011] The term "about" or "approximately" is defined as close as would be understood by one of ordinary skill in the art. In one non-limiting embodiment, the term is defined to be within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0012] The terms "wt. %, "vol. %, "or "mol. %" refer to the weight, volume, or mole percent, respectively, of a component based on the total weight, volume, or moles of the material that includes that component.

[0013] The term "substantially" and variations thereof are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.

[0014] The terms "inhibit," "reduce," "prevent," or "avoid," or variations thereof, as used in the claims and / or specification, include any measurable reduction or complete inhibition to achieve a desired result.

[0015] The term "effective," as used in the specification and / or claims, means adequate to accomplish a desired, expected, or intended result.

[0016] The use of the terms "a" or "an," when used in conjunction with the terms "comprising," "including," "containing," or "having" in a claim or the specification, can mean "one," but is also consistent with the meaning of "one or more," "at least one," and "one or more."

[0017] The terms "comprising" (and any form of comprising, such as "comprise" and "comprises"), "having" (and any form of having, such as "have" and "has"), "including" (and any form of including, such as "includes" and "include"), or "containing" (and any form of containing, such as "contains" and "contain") are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0018] The processes of the present invention can "comprise", "consist essentially of", or "consist of" certain ingredients, components, compositions, etc. disclosed throughout this specification.

[0019] Other objects, features and advantages of the present invention will become apparent from the following figures, detailed description and examples. However, it should be understood that the figures, detailed description and examples, while showing specific embodiments of the present invention, are described by way of illustration only and are not intended to be limiting. Additionally, changes and modifications within the spirit and scope of the present invention will become apparent to those skilled in the art from this detailed description. In further embodiments, features from a particular embodiment may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any other embodiment. In further embodiments, additional features may be added to the particular embodiments described herein.

[0020] For a more complete understanding, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: [Brief description of the drawings]

[0021] [Figure 1] 1 shows a schematic flow chart of a method for making an optical element containing two or more near infrared absorbing agents according to disclosed embodiments. [Figure 2A] Figure 2A shows a residual color comparison between an ophthalmic lens containing two or more near infrared absorbers and an ophthalmic lens containing one near infrared absorber. Figure 2A shows a residual color comparison between an ophthalmic lens containing S2007 and 920A near infrared absorbers and an ophthalmic lens containing one of S2007 and 920A near infrared absorbers. [Figure 2B] Figure 2B shows the residual color comparison between the ophthalmic lens containing two or more near infrared absorbers and the ophthalmic lens containing one near infrared absorber. Figure 2B shows the residual color comparison between the ophthalmic lens containing 920A and IR765 near infrared absorbers and the ophthalmic lens containing one of 920A and IR765 near infrared absorbers. [Figure 2C]Figure 2C shows the residual color comparison between the ophthalmic lens containing two or more near infrared absorbing agents and the ophthalmic lens containing one near infrared absorbing agent. Figure 2C shows the residual color comparison between the ophthalmic lens containing Epolight 4831 and IR765 near infrared absorbing agent and the ophthalmic lens containing one of Epolight 4831 and IR765 near infrared absorbing agent. [Figure 3A] 3A shows the spectral transmittance plots of a lens containing a single near infrared absorber and a lens containing two near infrared absorbers. FIG. 3A shows the spectral transmittance of an ophthalmic lens containing both Epolight 4831 and Epolight 3169 near infrared absorbers, an ophthalmic lens containing Epolight 4831 near infrared absorber, and an ophthalmic lens containing Epolight 3169 near infrared absorber. [Figure 3B] 3A shows the spectral transmittance plots of a lens containing a single near infrared absorber and a lens containing two near infrared absorbers. FIG. 3B shows the spectral transmittance of an ophthalmic lens containing both Epolight 4831 and Epolight 3157 near infrared absorbers, an ophthalmic lens containing Epolight 4831 near infrared absorber, and an ophthalmic lens containing Epolight 3157 near infrared absorber. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Currently available optical articles with NIR protection function have deficiencies including complicated manufacturing processes, high manufacturing costs, insufficient protection against NIR wavelength ranges, effects on user color perception, and color changes of optical articles. The present invention provides a solution to at least some of these problems. The solution is premised on an optical element comprising two or more NIR absorbers mixed in a polymer matrix. The two or more NIR absorbers can have different NIR absorption ranges, so that the optical element has a broader NIR absorption range than each of the NIR absorbers. Additionally, the two or more NIR absorbers can have different residual colors, so that the NIR absorbers have a synergistic intermediate residual color.

[0023] These and other non-limiting aspects of the present invention are discussed in greater detail in the following sections.

[0024] A. Optical elements with near infrared protection Near infrared rays have been proven to cause eye damage. Optical elements such as ophthalmic lenses can incorporate near infrared protection functions to protect the eyes of users. However, conventionally, near infrared absorbers are generally incorporated into optical filters, which require additional processes to be applied on optical elements, or into optical coatings, whose mechanical strength may be adversely affected by near infrared absorbers. Furthermore, near infrared absorbers may affect the color perception of users and may change the aesthetic appearance of optical elements.

[0025] The optical elements disclosed herein can extend the near infrared wavelength cut range of the optical element and minimize the residual color of the optical element by incorporating two or more near infrared absorbing agents having different absorption ranges and / or different residual colors into the substrate of the optical element. Some embodiments include an optical element. In some examples, the optical element can be an ophthalmic lens. The optical element can include a front surface and a back surface. The front surface of the optical element can include the convex surface of the ophthalmic lens. The back surface of the optical element can include the concave surface of the ophthalmic lens.

[0026] In an embodiment of the present invention, the optical element can include an optical substrate and two or more near infrared absorbing agents mixed in the optical substrate. In some embodiments, the two or more near infrared absorbing agents can have different near infrared cut ranges and / or different residual colors. Non-limiting examples of optical substrates include allyl diglycol carbonate, polyurethane, acrylic, polycarbonate, polyamide, poly(methyl methacrylate), copolyester, cellulose triacetate, polyepisulfide, trivex, polyacrylic, polyol, polyamine, polyanhydride, polycarboxilic acid, polyepoxide, polyisocyanate, polynorbornene, polysiloxane, polysilazane, polystyrene, polyolefin, polyester, polyimide, polyurethane, polythiourethane, polyallylic, polysulfide, polyvinyl ester, polyvinyl ether, polyarylene, polyoxide, polysulfone, polycycloolefin, polyacrylonitrile, polyethylene terephthalate, polyetherimide, polypentene, or any combination thereof. Non-limiting examples of near infrared absorbing agents can include polymethine, phthalocyanine, porphyrin, triphenylmethane, iminium, squarylium, croconium, dithiolene, quinone, polyperylene, pyrilium, thiopyrilium, cyanine, or any combination thereof.

[0027] In some embodiments, the total concentration of the two or more near infrared absorbing agents can be in the range of 1 to 500 ppm, and all ranges and values ​​therebetween, including 1 to 25 ppm, 25 to 50 ppm, 50 to 75 ppm, 75 to 100 ppm, 100 to 125 ppm, 125 to 150 ppm, 150 to 175 ppm, 175 to 200 ppm, 200 to 225 ppm, 225 to 250 ppm, 250 to 275 ppm, 275 to 300 ppm, 300 to 325 ppm, 325 to 350 ppm, 350 to 375 ppm, 375 to 400 ppm, 400 to 425 ppm, 425 to 450 ppm, 450 to 475 ppm, and 475 to 500 ppm. In some embodiments, the two or more near infrared absorbing agents can be substantially homogeneously mixed in the optical substrate. Alternatively, the two or more near infrared absorbing agents may be mixed inhomogeneously in the optical substrate. In some embodiments, the two or more near infrared absorbing agents may have a concentration gradient (increasing or decreasing) along any direction in the optical substrate, including the horizontal, vertical, and depth directions of the optical substrate. In some examples, the two or more near infrared absorbing agents may be mixed at a higher concentration in the front and / or back portion of the optical substrate than in the central portion of the optical substrate. The front portion may comprise about one-third of the thickness of the optical substrate closest to the front side of the optical substrate. The back portion may comprise about one-third of the thickness of the optical substrate closest to the back side of the optical substrate.

[0028] In some embodiments, the two or more near infrared absorbers in the optical substrate can be adapted to generate a synergistic infrared absorption level that is higher than the individual near infrared absorption level of any of the two or more near infrared absorbers. The optical element can be used in the wavelength range of 780 to 2000 nm, as well as 780 to 820 nm, 820 to 860 nm, 860 to 900 nm, 900 to 940 nm, 940 to 980 nm, 980 to 1020 nm, 1020 to 1060 nm, 1060 to 1100 nm, 1100 to 1140 nm, 1140 to 1180 nm, 1180 to 1200 nm, 1200 to 1240 nm, 1240 to 1280 nm, 1280 to 1320 nm, 1320 to 1360 nm, 1360 to 1400 nm, 140 ... 40nm, 1440-1480nm, 1480-1520nm, 1520-1560nm, 1560-1600nm, 1600-1640nm, 1640-1680nm, 1680-1720nm, 1720-1760nm, 1760-1800nm, 1800-1840nm, 1840-1880nm, 1880-1920nm, 1920-1960nm, 1960-2000nm, and all ranges and values ​​therebetween. In some embodiments, the two or more near infrared absorbers in the optical substrate are adapted to generate a synergistic infrared absorption level that is higher than the individual near infrared absorption level of any of the two or more near infrared absorbers. In some examples, the two or more near infrared absorbers are combined to generate a synergistic infrared absorption level that is higher than the individual near infrared absorption level of any of the two or more near infrared absorbers. 780-2000 The two or more near infrared absorbers can be adapted to synergistically reduce the intensity of near infrared radiation (determined as Tv%(D65)) by 15-95%, and all ranges and values ​​therebetween, including the ranges of 15-20%, 20-25%, 25-30%, 30-35%, 35-40%, 40-45%, 45-50%, 50-55%, 55-60%, 60-65%, 65-70%, 70-75%, 75-80%, 80-85%, 85-90%, and 90-95%. In some embodiments, the two or more near infrared absorbers are adapted to synergistically cause a decrease in the average optical transmittance in the wavelength range of 380-780 nm for the optical substrate (determined as Tv%(D65)) of less than 10%.

[0029] In some embodiments, the two or more near infrared absorbers in the optical substrate can be adapted to produce a synergistic color intensity that is lower than the individual color intensity of each of the two or more near infrared absorbers. In some examples, the synergistic color intensity of the two or more infrared absorbers in the optical substrate can be in the range of 0 to 5, and all ranges and values ​​therebetween, including the ranges of 0 to 0.5, 0.5 to 1, 1 to 1.5, 1.5 to 2, 2 to 2.5, 2.5 to 3, 3 to 3.5, 3.5 to 4, 4 to 4.5, and 4.5 to 5. In some embodiments, the two or more near infrared absorbers in the optical substrate are synergistically neutral in color, or preferably colorless. In some examples, the optical substrate of the optical element can be colorless (or achromatic), and the optical substrate and the optical element comprising the two or more near infrared absorbers can be neutral in color, or preferably achromatic.

[0030] Alternatively, in some examples, the optical element may be a pair of ophthalmic sunglasses, and the two or more near infrared absorbing agents have a high synergistic chroma. The two or more near infrared absorbing agents may be adapted to cause a reduction in the average optical transmittance in the wavelength range of 380-780 nm for the optical element (determined as Tv%(D65)) of 10-95%, as well as all ranges and values ​​therebetween, including 10-15%, 15-20%, 20-25%, 25-30%, 30-35%, 35-40%, 40-45%, 45-50%, 50-55%, 55-60%, 60-65%, 65-70%, 70-75%, 75-80%, 80-85%, 85-90% and 90-95%.

[0031] In some embodiments, the optical element may further include one or more additional coatings in overlying relationship with the front and / or back surface of the optical element. Non-limiting examples of the one or more additional coatings may include a polarizing coating, a mirror coating, an anti-reflective coating, an abrasion-resistant coating, a photochromic coating, an anti-smudge coating, an anti-fog coating, a dyeable coating, a self-healing coating, an anti-rain coating, an anti-static coating, an anti-UV coating, an anti-blue light coating, or any combination thereof.

[0032] B. Method for manufacturing optical elements having NIR absorbers Conventionally, near-infrared light absorbing optical elements (e.g., ophthalmic lenses) can be manufactured by incorporating multifunctional optical filters that integrate near-infrared absorption and exert anti-reflection effects on the surface of the optical element, or by depositing optical coatings that incorporate near-infrared absorbers into conventional optical coatings (e.g., anti-reflection coatings). However, for optical filters, high NIR absorption levels can be detrimental to the anti-reflection performance of the optical filters. For optical coatings that contain near-infrared absorbers, the manufacturing costs can be high and at the same time the mechanical properties of the optical coatings can be reduced.

[0033] The method disclosed herein avoids the use of optical filters and optical coatings for near infrared absorption purposes by directly mixing near infrared absorbers in the optical substrate. Furthermore, the method disclosed herein selects two or more near infrared absorbers with different absorption ranges (NIR cut ranges) and / or different residual colors, which results in a broader near infrared absorption range and neutral color for the optical element produced. As shown in FIG. 1, an embodiment includes a method 100 for preparing an optical element capable of absorbing near infrared radiation. In some embodiments, the optical element may include an ophthalmic lens.

[0034] In some embodiments, as shown in block 101, method 100 may include providing a precursor material for an optical substrate and two or more near-infrared absorbing agents having different near-infrared cut ranges and / or different residual colors. Non-limiting examples of precursor materials for optical substrates include allylic monomers including allyl diglycol carbonate and thiourethane polymer precursors (e.g., blends of isocyanates and thiols), polyurethanes, acrylics, polycarbonates, polyamides, poly(methyl methacrylate), copolyesters, cellulose triacetate, polyepisulfides, trivex, polyacrylics, polyols, polyamines, polyanhydrides, polycarboxilic acids, polyepoxides, polyisocyanates, polynorbornenes, polysiloxanes, polysilazanes, polystyrenes, polyolefins, polyesters, polyimides, polyurethanes, polythiourethanes, polyaryls, polysulfides, polyvinyl esters, polyvinyl ethers, polyarylenes, polyoxides, polysulfones, polycycloolefins, polyacrylonitriles, polyethylene terephthalates, polyetherimides, polypentenes, or any combination thereof. Non-limiting examples of near infrared absorbing agents can include polymethine, phthalocyanine, porphyrin, triphenylmethane, iminium, squarylium, croconium, dithiolene, quinone, polyperylene, pyrilium, thiopyrilium, cyanine, or any combination thereof.In some embodiments, non-limiting examples of isocyanates include 1,3-bis(isocyanatomethyl)cyclohexane, 1,4-bis(isocyanatomethyl)cyclohexane, m-xylylene diisocyanate, 5-isocyanato-1-(isocyanatomethyl)-1,3,3-trimethylcyclohexane, 4,4'-methylenedicyclohexyl diisocyanate, 4,4'-methylenebis(phenylisocyanate), hexane-1,6-diisocyanate, trans-1,4 -diisocyanatocyclohexane, toluene diisocyanate, 1,5-pentamethylene diisocyanate, 2,5-bicyclo[2,2,1]heptane bis(methyl isocyanate), bis(isocyanatomethylethyl)benzene, and for thiols: 4,8-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 5,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,7-dimercaptomethyl-1, 11-dimercapto-3,6,9-trithiaundecane, 2,3-bis(2-mercaptoethylthio)propane-1-thiol, or 4-mercaptomethyl-3,6-dithia-1,8-octanedithiol, bis(2,2-sulfhydryl)ethyl tetrasulfide, pentaerythritol tetrakis(3-mercaptopropionate), pentaerythritol tetrakis(3-mercaptoacetate), thiodiglycol mercaptan, or 3-thiapentane-1,5-diol, Examples of such mercaptomethylthio compounds include 2,5-dimercaptomethyl-1,4-dithiane, 1,5-dimercapto-3-thiapentane, propane trithiol, bis(b-epithiopropyl)sulfide, bis(b-epithiopropyl)disulfide, 4,6-(mercaptomethylthio)-1,3-dithiane, 4,5-(mercaptomethylthio)-1,3-dithiolane, 1,1,3,3-tetrakis(mercaptomethylthio)ethane, and 1,1,3,3-tetrakis(mercaptomethylthio)propane.Non-limiting examples of near infrared absorbing agents can include polymethines, phthalocyanines, porphyrins, triphenylmethanes, iminiums, squaryliums, croconiums, dithiolenes, quinones, polyperylenes, pyriliums, thiopyriliums, cyanines, or any combination thereof. In some embodiments, providing in block 101 can include selecting two or more near infrared absorbing agents in view of a target near infrared wavelength absorption range and / or a target residual color.

[0035] In some embodiments, as shown in block 102, method 100 can include determining a concentration for each of the two or more near infrared absorbers in the optical substrate at which the synergistic color intensity of the two or more near infrared absorbers is lower than any individual color intensity of the two or more near infrared absorbers. In some embodiments, the two or more near infrared absorbers can be adapted to produce a synergistic infrared absorption range that is wider than the individual infrared absorption range of each of the two or more near infrared absorbers. In some embodiments, determining can include a trial and error method to obtain a concentration of each near infrared absorber that can achieve a target synergistic near infrared absorption range, a target synergistic near infrared absorption level, and / or a target synergistic residual color.

[0036] In some embodiments, as shown in block 103, the method 100 may include mixing the precursor material with two or more infrared absorbing agents at the concentrations determined in block 102 to produce a mixture. In some embodiments, the mixture can be substantially homogenous. In some embodiments, the mixing in block 103 may include dissolving the two or more infrared absorbing agents in a first amount of the precursor material to produce a near infrared dye master batch. The infrared dye master batch may include two or more near infrared absorbing agents in the range of about 10-45 ppm, and all ranges and values ​​therebetween, including 10-15 ppm, 15-20 ppm, 20-25 ppm, 25-30 ppm, 30-35 ppm, 35-40 ppm, and 40-45 ppm. In some embodiments, the mixing in block 103 may include optionally mixing a second amount of the precursor material with one or more of the ultraviolet dye, monomer, catalyst, and release agent, or any combination thereof, to produce a first mixture. The first mixture may be prepared at a temperature of 23-27°C and all ranges and values ​​therebetween. The first mixture may be prepared under reduced pressure. In some examples, the first mixture may be substantially homogenous. In some embodiments, the mixing in block 103 may include cooling the first mixture to a temperature of 0-4°C and all ranges and values ​​therebetween, including 0-0.5°C, 0.5-1.0°C, 1.0-1.5°C, 1.5-2.0°C, 2.0-2.5°C, 2.5-3.0°C, 3.0-3.5°C, 3.5-4.0°C. The first mixture may be cooled by a water bath from room temperature to about °C.

[0037] In some embodiments, the mixing in block 103 may include flowing an inert gas over the cooled first mixture. In some examples, the inert gas may include nitrogen, argon, or any combination thereof. The inert gas may be adapted to prevent moisture in the air from contaminating the cooled first mixture. In some embodiments, the mixing in block 103 may include mixing a near infrared dye master batch into the cooled first mixture to produce a second mixture with each of the two or more near infrared absorbers at their concentrations determined in block 202. The second mixture may be produced at a temperature ranging from 0 to 4°C, as well as all ranges and values ​​therebetween, including 0 to 0.5°C, 0.5 to 1.0°C, 1.0 to 1.5°C, 1.5 to 2.0°C, 2.0 to 2.5°C, 2.5 to 3.0°C, 3.0 to 3.5°C, and 3.5 to 4.0°C. The second mixture may be produced under reduced pressure. In some examples, the second mixture is substantially homogeneous.

[0038] In some embodiments, method 100 may include manufacturing an optical element using the second mixture, as shown in block 104. In some aspects, the optical element may be manufactured by casting, injection molding, film extrusion, extrusion compression molding, compression molding, transfer molding, 3D printing, or any combination thereof. In some examples, the casting process in block 104 may be carried out at a casting temperature of 20-25°C, and all ranges and values ​​therebetween, including 21°C, 22°C, 23°C, and 24°C. In some examples, the injection molding process in block 104 may be carried out at a molding temperature in the range of 200-400°C and all ranges and values ​​therebetween, including 200-210°C, 210-220°C, 220-230°C, 230-240°C, 240-250°C, 250-260°C, 260-270°C, 270-280°C, 280-290°C, 290-300°C, 300-310°C, 310-320°C, 320-330°C, 330-340°C, 340-350°C, 350-360°C, 360-370°C, 370-380°C, 380-390°C, and 390-400°C. In some embodiments, the method 100 may include mixing one or more ultraviolet light absorbing dyes, color adjusting dyes, color enhancing dyes, blue light absorbing dyes, and other visible light absorbing dyes with the precursor material prior to the manufacturing step at block 104.

[0039] Although embodiments of the present invention have been described with respect to the blocks of Figure 1, it should be appreciated that the operation of the present invention is not limited to the specific blocks and / or to the specific order of blocks shown in Figure 1. Thus, some embodiments may provide the functionality described herein using various blocks in an order different from that of Figure 1.

[0040] As part of the disclosure of the present invention, specific examples are included below. These examples are for illustrative purposes only and are not intended to limit the present invention. One of ordinary skill in the art will readily recognize parameters that can be changed or modified to achieve essentially the same results. EXAMPLES

[0041] Example 1 (Preparation of Near-Infrared Absorbing Lenses with MR8™ Precursors) Various near infrared absorbing agents and precursor materials for optical substrates were used to manufacture ophthalmic lenses with infrared absorbing capabilities. The effects of ophthalmic lenses with two near infrared absorbing agents on infrared absorption wavelength range and lens residual color were tested. The specific near infrared absorbing agents, precursor materials, UV absorbers, and catalysts used to manufacture the ophthalmic lenses are listed in Table 1 (λ max denotes the highest peak in the NIR dye spectrum).

[0042] [Table 1]

[0043] Table 2 shows the composition of each sample using S2007 and / or 920A near infrared absorbers. The control sample did not contain any near infrared absorbers. Table 3 shows the composition of each sample using 920A and / or IR765 near infrared absorbers, along with the control sample not containing any near infrared absorbers. Table 4 shows the composition of each sample using Epolight 4831 and / or IR785 near infrared absorbers, along with the control sample not containing any near infrared absorbers.

[0044] [Table 2]

[0045] [Table 3]

[0046] [Table 4]

[0047] All samples were prepared using a biplanar mold assembled using a taping process. The center thickness of the mold was adjusted to 2 mm. Near infrared master batches were prepared by dissolving the selected near infrared absorber in MR8™-A or MR8™-B2 monomer precursor. The UV absorbers (Stan DMC™ and Zelec UN™) were then mixed with the MR8-A precursor in a duran bottle at room temperature under vacuum until a homogenous mixture was formed. The homogenous mixture was then cooled to 2° C., after which the vacuum was released and nitrogen gas was allowed to flow over the mixture. The near infrared dye master batch, additional MR8™-B1 and MR8™-B2, and the cooled homogenous mixture were mixed under vacuum at 2° C. until the final mixture was homogenous. The final mixture was then filled into the biplanar mold by a clean syringe. Lens samples were then formed according to the polymerization temperature profile shown in Table 5. For each composition, both uncoated (UNC) and hard multi-coated (HMC) lenses were produced. The manufactured lenses were cleaned. Using a Lambda™ 950 UV spectroscopy (PerkinElmer, USA), the transmittance of each lens sample in the wavelength range of 300 to 2000 nm was measured. Additionally, the TsIR, TvD65, YI, and C of each lens sample were measured. * , h * and UV cut were tested. TsIR is the transmittance % from 780 to 2000 nm, TvD65 is the transmittance % from 380 to 780 nm. YI is the yellowness index, C * is the saturation, and h * is the color shade.

[0048] [Table 5]

[0049] The appearance of the lens samples is shown in Figures 2A-2C. As shown in Figures 2A-2C, the lenses containing two near infrared absorbers (S2007 and 920A for Figure 2A, 920A and IR765 for Figure 2B, and Epolight 4831 and IR765 for Figure 2C) showed reduced residual color compared to the lens samples containing only one near infrared absorber.

[0050] Table 6 shows the TsIR, TvD65, YI, and C for uncoated (UNC) lens samples containing NIR S2007 and 920A near infrared absorbers. * , h * Table 7 shows the TsIR, TvD65, YI, and UV cut test results for hard multi-coated lens samples containing NIR S2007 and 920A near infrared absorbers. * , h * The results of the hard multi-coated and uncoated lenses containing 5 ppm S2007 and 5 ppm 920A show the best infrared absorption properties and the least residual color. These two samples have the best neutral color closest to a clear lens.

[0051] [Table 6]

[0052] [Table 7]

[0053] Table 8 shows the TsIR, TvD65, YI, and C for uncoated (UNC) lens samples containing 930A and IR765 near infrared absorbers. * , h * Table 9 shows the TsIR, TvD65, YI, and UV cut test results for uncoated (UNC) lens samples containing 930A and IR765 near infrared absorbers. * , h *The results of the tests for infrared absorption and UV protection are shown in Table 1. These results show that the hard multi-coated lens containing 10 ppm of 920A and 4 ppm of IR765 exhibited the best infrared absorption properties and the least residual color. These two samples have the best neutral color closest to a clear lens.

[0054] [Table 8]

[0055] [Table 9]

[0056] Table 10 shows the TsIR, TvD65, YI, C for uncoated (UNC) lens samples containing Epolight 4831 and / or IR785 near infrared absorbers. * , h * Table 11 shows the TsIR, TvD65, YI, and UV cut test results for hard multi-coated (HMC) lens samples containing Fpolight 4831 and / or IR785 near infrared absorbers. * , h * The test results of the hard multi-coated lens containing 45 ppm Epolight 4831 and 6 ppm IR765 are shown in Tables 6 to 11. The results show that for the lenses containing Epolight 4831 and / or IR785 near infrared absorbers, the hard multi-coated lens containing 45 ppm Epolight 4831 and 6 ppm IR765 shows the best results, since these two samples have the best intermediate color closest to the clear lens. Overall, the results in Tables 6 to 11 show that the MR8 monomer-based lens with two near infrared absorbers improves the absorption level and absorption wavelength range, and reduces the residual color of the lens compared to the lens containing only one near infrared absorber.

[0057] [Table 10]

[0058] [Table 11]

[0059] Example 2 (Preparation of near-infrared absorbing lenses using polycarbonate precursors) Polycarbonate-based lenses with different infrared absorbing agents were prepared to test the synergistic effect of two infrared absorbing agents on the infrared absorbing properties and residual color of the lenses. The near infrared absorbing agents used are shown in Table 12.

[0060] [Table 12]

[0061] In each polycarbonate lens sample, two of these near infrared absorbing agents are mixed with polycarbonate pellets.The mixture is then injection molded into an ophthalmic lens.The light transmittance and color properties of each lens sample are measured using a Lambda 900 (Perkin Elmer, USA).

[0062] The compositions of the polycarbonate lens samples containing two near infrared absorbers and the corresponding comparative examples are listed in Table 13. The first set of polycarbonate lenses contained Epolight 4831 and Epolight 3169 near infrared absorbers. The second set of polycarbonate lenses contained Epolight 4831 and Epolight 3157 near infrared absorbers.

[0063] [Table 13]

[0064] The test results of the first set of polycarbonate lenses containing Epolight 4831 and Epolight 3169 near infrared absorbers are listed in Table 14. The light transmission results of each sample are plotted in FIG. 3A. FIG. 3A shows that the polycarbonate lenses containing both Epolight 4831 and Epolight 3169 near infrared absorbers have a wider near infrared wavelength cut range than the lenses containing only one of these near infrared absorbers. Additionally, as shown in Table 14, the residual color intensity of the polycarbonate lenses containing both Epolight 4831 and Epolight 3169 near infrared absorbers is lower (gray) than the lenses containing only one of these near infrared absorbers (blue or brown).

[0065] [Table 14]

[0066] The test results of the second set of polycarbonate lenses containing Epolight 4831 and Epolight 3157 near infrared absorbers are listed in Table 15. The light transmission results of each sample are plotted in FIG. 3B. FIG. 3B shows that the polycarbonate lenses containing both Epolight 4831 and Epolight 3157 near infrared absorbers have a wider near infrared wavelength cut range than the lenses containing only one of these near infrared absorbers. Additionally, as shown in Table 15, the residual color intensity of the polycarbonate lenses containing both Epolight 4831 and Epolight 3157 near infrared absorbers is lower (gray) than the lenses containing only one of these near infrared absorbers (blue or yellow-green).

[0067] [Table 15]

[0068] Although the embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the embodiments, as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the processes, procedures, machines, manufacture, compositions, means, methods and / or steps described herein. As one skilled in the art will readily recognize from the above disclosure, existing or future developed processes, machines, manufacture, compositions, means, methods or steps that perform substantially the same function or achieve substantially the same results as the corresponding embodiments described herein may also be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions, means, methods or steps.

Claims

1. An optical element comprising an optical substrate and two or more near-infrared absorbing agents mixed in the optical substrate, the two or more near-infrared absorbing agents having different near-infrared cut ranges and different residual colors.

2. The optical element of claim 1 , wherein the two or more near infrared absorbing agents are substantially homogeneously mixed in the optical substrate.

3. 2. The optical element of claim 1, wherein the two or more near infrared absorbing agents in the optical substrate are adapted to generate a synergistic infrared absorption level that is higher than the near infrared absorption level of any of the two or more near infrared absorbing agents individually.

4. 2. The optical element of claim 1, wherein the two or more near infrared absorbers in the optical substrate are adapted to produce a synergistic infrared absorption range that is broader than the individual infrared absorption ranges of each of the two or more near infrared absorbers.

5. 2. The optical element of claim 1, wherein the two or more near infrared absorbing agents in the optical substrate are adapted to produce a synergistic color intensity that is lower than the color intensity of each of the two or more near infrared absorbing agents individually.

6. 6. The optical element according to claim 5, wherein the two or more near infrared absorbing agents in the optical substrate are synergistically neutral in color, or preferably colorless.

7. 2. The optical element of claim 1, wherein the two or more near infrared absorbing agents are adapted to synergistically cause less than a 10% decrease in average optical transmittance in the wavelength range of 380 to 780 nm for the optical substrate.

8. The optical element of claim 1 , wherein the optical element comprises an ophthalmic lens.

9. 2. The optical element of claim 1, wherein the optical substrate comprises allyl diglycol carbonate, polyurethane, acrylic, polycarbonate, polyamide, poly(methyl methacrylate), copolyester, cellulose triacetate, polyepisulfide, Tribex, polyacrylic, polyol, polyamine, polyanhydride, polycarboxylic acid, polyepoxide, polyisocyanate, polynorbornene, polysiloxane, polysilazane, polystyrene, polyolefin, polyester, polyimide, polyurethane, polythiourethane, polyallylic, polysulfide, polyvinyl ester, polyvinyl ether, polyarylene, polyoxide, polysulfone, polycycloolefin, polyacrylonitrile, polyethylene terephthalate, polyetherimide, polypentene, or any combination thereof.

10. 2. The optical element of claim 1, wherein the two or more near infrared absorbing agents comprise polymethine, phthalocyanine, porphyrin, triphenylmethane, iminium, squarylium, croconium, dithiolene, quinone, polyperylene, pyrylium, thiopyrylium, cyanine, or any combination thereof.

11. The optical substrate according to claim 1 , wherein the optical element comprises 1 to 500 ppm of the two or more near infrared absorbing agents.

12. A method for preparing an optical element according to any one of claims 1 to 11, comprising the steps of: providing a precursor material for the optical substrate, and the two or more near infrared absorbing agents having different near infrared cutoff ranges and / or different residual colors; determining a concentration for each of the two or more near infrared absorbers in the optical substrate, where the synergistic color intensity of the two or more near infrared absorbers is less than the individual color intensity of any of the two or more near infrared absorbers; mixing the precursor material with the two or more infrared absorbing agents in concentrations determined to produce a substantially homogenous mixture; producing the optical element using the mixture of the optical substrate and the two or more near infrared absorbing agents; The method includes:

13. 13. The method of claim 12, wherein the manufacturing step comprises casting, injection molding, extrusion compression molding, compression molding, transfer molding, 3D printing, or any combination thereof.

14. 13. The method of claim 12, further comprising mixing one or more ultraviolet light absorbing dyes, color adjusting dyes, color enhancing dyes, blue light absorbing dyes, and other visible light absorbing dyes with the precursor material prior to the manufacturing step.

15. A method for preparing an optical element according to any one of claims 1 to 11, comprising the steps of: Providing a precursor material for the optical substrate and two or more near infrared absorbing agents having different near infrared cutoff ranges and / or different residual colors; determining a concentration for each of the two or more near infrared absorbers in the substrate, where the synergistic color intensity of the two or more near infrared absorbers is less than the individual color intensity of any of the two or more near infrared absorbers; dissolving the two or more infrared absorbing agents in a first amount of the precursor material to produce a near infrared dye masterbatch; mixing a second amount of the precursor material with one or more of an ultraviolet dye, a monomer, a catalyst, and a release agent under reduced pressure at a temperature between 23 and 27° C. to produce a substantially homogenous first mixture; cooling the first mixture to a temperature of 0-4°C; flowing an inert gas over the cooled first mixture; mixing the near infrared dye masterbatch into the first mixture under reduced pressure at a temperature of 0-4° C. to produce a second mixture that is a substantially homogenous mixture of each of the two or more near infrared absorbers at its determined concentration; producing the optical element using the second mixture by casting; The method includes:

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