Optical functional film manufacturing method and manufacturing system

Abstract

A method and apparatus for manufacturing eyeglass lenses using a solution casting process are provided. The method can include providing a first soluble polymer solution. The method can include providing a first dye solution including at least one dye. The method can include adding the first dye solution to the first soluble polymer solution to form a first dye solution. The method can include casting the first dye solution to form a first film. The method can include providing a second soluble polymer solution. The method can include providing a second dye solution including at least one dye. The method can include adding the second dye solution to the second soluble polymer solution to form a second dye solution. The method can include casting the second dye solution on the first film to form a two-layer film. The method can include laminating or casting the two-layer film onto the eyeglass lens.

Description

Cross-reference to related disclosures

[0001] This continuation-in-part application claims benefit of priority to the filing date of U.S. patent application Ser. No. 15 / 895,564, entitled "Methods and Systems for Making an Optical Functional Film," filed February 13, 2018, now U.S. Patent No. 10,807,328, which is a continuation-in-part application claiming benefit of priority to the filing date of U.S. patent application Ser. No. 14 / 886,078, entitled "Methods and Systems for Making an Optical Functional Film," filed October 18, 2015, and patented April 7, 2020, as U.S. Patent No. 10,611,106, which in turn claims benefit of priority to the filing date of U.S. patent application Ser. No. 14 / 806,579, entitled "Methods and Systems For Making An Optical Functional Film," filed July 22, 2015. No. 62 / 116,545, entitled "Solution Casting Method," filed February 15, 2015, which is a continuation-in-part application claiming benefit of priority under 35 U.S.C. 119(e) to the filing date of U.S. Provisional Patent Application No. 62 / 116,545, entitled "Solution Casting Method," filed February 15, 2015, all of which are incorporated herein by reference in their entireties. [Technical Field]

[0002] The present disclosure relates generally to optical components, and more particularly to methods and systems for making functional plastic films, functional polymer films, functional polyvinyl alcohol (PVA) films, or functional polyethylene terephthalate (PET) films. [Background technology]

[0003] It is well known that ultraviolet (UV) light can cause severe flash burns to the cornea from high-intensity light sources. Therefore, the eyes may require protection from these harmful UV rays. The eyes may need protection from UV light when welding, when exposed to sunlight at altitudes above 5,000 feet (1,524 m), or when exposed to glare from snow or water, or when sunburned.

[0004] Infrared (IR) radiation is also harmful. Wireless communications, electrical appliances, computers, lighting, and natural sources such as sunlight can emit different levels of harmful radiation. IR can make up more than half of sunlight's thermal spectrum radiation. At the zenith, sunlight can provide an irradiance of about 1 kilowatt per square meter at sea level, of which 527 watts is IR radiation. Once sunlight reaches the Earth's surface, almost all of the thermal radiation can be IR.

[0005] The energy of sunlight at earth's surface is divided into approximately 3% ultraviolet radiation, 44% visible light, and 53% infrared radiation. Therefore, when exposed to strong sunlight for long periods without protection, the eyes can experience a burning or stinging sensation, often accompanied by fatigue. This discomfort can be particularly noticeable for contact lens wearers, as contact lenses can absorb IR radiation and "warm up." Ophthalmologists will likely recommend that you get into the habit of wearing sunglasses when in the sun for extended periods.

[0006] Traditionally, protective lenses may be coated with one or more layers of IR and / or visible pigments to block harmful rays from light sources. Typically, soluble dyes and / or metal oxide pigments may be used in the coating to absorb or reflect light of specific frequencies, such as IR frequencies, UV frequencies, etc. Thus, the coated lenses may reduce or alleviate eye diseases such as cataracts and glaucoma.

[0007] Due to the importance of sunglasses and protective eyewear, many coating techniques have been invented. IR or visible coatings may be applied by dipping or spraying a solvent IR or visible dye onto another optical layer of the lens. However, the curvature of most lenses can present significant obstacles to the application of IR or visible coatings, as the application of the coating may be uneven, thus reducing the effectiveness of the protective layer.

[0008] Using conventional methods such as extrusion or injection, IR or visible dyes may be added during the process. Extrusion is a process that can be used to create objects of a fixed cross-sectional shape. The material can be pushed or pulled through a die of the desired cross-section. In a plastic extrusion process, the plastic may first be melted to a viscous, semi-liquid state. After softening, the plastic may be forced through a contoured opening. This technique can be used to create curved lenses by extruding a softened optical film through a contoured opening.

[0009] Injection molding can be a manufacturing process for producing parts by injecting material into a mold. The material for the part is fed into a heated barrel, mixed, and forced into the mold cavity, where it cools and hardens to the shape of the cavity. In the case of optical plastic films, whether extrusion or injection molding, heat can be used to soften the plastic film, allowing it to be curved and molded. Because pigments are heat sensitive, some degradation of the pigment can occur, reducing the effectiveness of the eye protection.

[0010] Another problem with these IR- or visible-light-coated lenses is that they are easily scratched and are not resistant to chemicals or elements. Over time, the protective layer loses its effectiveness and can become harmful if not detected and replaced. To overcome this problem, lens manufacturers have begun spraying, dipping, or injecting another protective layer over the IR / visible layer. However, the additional layer can make the lens thicker, which creates barriers to eyewear design and comfort.

[0011] Furthermore, conventional coating methods using injection or extrusion techniques can be aesthetically unappealing because the IR dye appears green in such coatings. Gray can be added to the PVA film to counteract or offset the undesirable green color. However, adding gray reduces light transmission and therefore significantly reduces visibility. Finally, adding gray to the PVA film on the lens increases the cost of the lens and therefore the cost of the final product. Therefore, inexpensive and rapid IR-absorbing lens materials and manufacturing processes may be desirable.

[0012] Recently, solution casting has been invented and is gaining popularity to overcome the shortcomings of extrusion and injection molding. This manufacturing technique can be unique in that it does not require traditional extrusion or injection molding techniques and can easily incorporate components and features traditionally produced by these processes. This method utilizes a mandrel, or inner diameter mold, which is immersed in a tank of polymer solution or liquid plastic specially designed for this process. Due to a combination of thermal and frictional properties, the polymer solution then forms a thin film around the mold. The mold can then be removed from the tank in a precisely controlled manner, followed by a curing or drying process.

[0013] Another casting device used in solution casting is the belt or drum machine. Typically, the support belt is 1.0–2.0 m wide and 10–100 m long. The stainless steel belt may be 1.0–2.0 mm thick. The drum is typically 4–8 m in diameter and 1.20–1.50 m wide. The belt channel can allow airflow in either the machine direction or the counter-machine direction. The drum may be tightly sealed to prevent vapor release and direct the airflow against the direction of drum movement. One of the two pulleys or drums may be connected to a drive system requiring extremely precise speed control to avoid even slight speed fluctuations. One drum is connected to a servo system that adjusts the belt tension, ensuring constant flatness and the absence of belt movement (vibration) in the critical area immediately behind the casting machine and controlling belt length expansion and dilation caused by temperature changes. Belt machines may have a guide system to prevent belt movement during operation. The belt may be guided by the horizontal movement of the support drum. Many different support materials have been used for belts, including copper, silver-plated copper, chrome-plated steel, stainless steel, metals coated with polyvinyl alcohol or gelatin, polyester films, polytetrafluoroethylene (PTFE) films, and other polymer films.

[0014] Currently, the most common substrate materials are stainless steel and chrome-plated surfaces. Important factors for belt and drum machines are the thermal conductivity of the material, the technological process used to create the required surface finish, and the option to repair minor surface defects. This casting technique allows for the simple production of films with structured surfaces. The belt surface can be clearly and accurately replicated on one side of the film. The techniques used to adapt the drum or belt surface to a high-gloss, structured, or matte film finish are proprietary.

[0015] Once the first layer of thin film has properly solidified, secondary features can be added to the product, such as braided or coiled wire, laser-cut hypotubes, or engineered metal reinforcements to prevent kinking, or imaging targets specific to the intended medical application. Multiple casting steps can then be performed to encapsulate the reinforcements, increase wall thickness, add additional lumens, and optimize column strength. The part is then removed from the mold after curing or solidification. This method can work with solvent polymers in liquid form without using excessive heat to harden the part. Because this method uses centrifugal force to mold the part with the correct flow ratio, very thin layers of IR or visible dye solution can be applied to the optical film without using excessive heat.

[0016] Another method for producing films is static methods such as cavity molding, plate casting, or other similar methods. Summary of the Invention

[0017] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the description of the present disclosure. This Summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0018] According to one aspect of the present disclosure, there is provided a method for manufacturing eyeglass lenses using a functional film. The method can include providing a polyvinyl alcohol (PVA) or polyvinyl butyral (PVB) material and adding a portion of water to the PVA or PVB material to form a solution. The method can further include providing a water-soluble blue blocker dye and a portion of a contrast dye, and adding a portion of water or methanol to the water-soluble dye to form a dye solution. The method can also include applying the dyed PVA or PVB solution onto a moving belt in a channel; solidifying the dyed PVA or PVB solution on the moving belt as an optical thin film by supplying an air flow into the channel; controlling the thickness, dryness, and absorption rate of the optical thin film by adjusting at least one of 1) the direction of the air flow, 2) the belt speed, or 3) the gap spacing of the belt channel; and removing the optical thin film from the moving belt. The method may include laminating or casting a thin optical film onto an eyeglass lens, wherein the PVA or PVB solution has a polymer concentration of 9% to 25%, and the dye solution has a dye concentration of 0.05% to 5%, and the eyeglass lens has an absorptivity for blue blocker or enhanced contrast including 30% to 99% for light having a wavelength of 400 nm to 455 nm, greater than 37% for light having a wavelength of 570 nm to 595 nm, and greater than 37% for light having a wavelength of 760 nm to 2000 nm.

[0019] The novel features of the present disclosure are set forth in the appended claims. In the following description, like parts will be designated throughout the specification and drawings with the same reference numerals. The drawings are not necessarily drawn to scale, and certain figures may be shown in exaggerated or generalized form for clarity and conciseness. The present disclosure itself, its preferred mode of use, further objects, and advantages thereof will best be understood by reference to the following detailed description of exemplary embodiments when read in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0020] [Figure 1] FIG. 1 is an illustration of the preparation of a polymer or PVA solution in a preferred solvent or water according to one embodiment of the present disclosure. [Figure 2] FIG. 2 is an illustrative diagram of the preparation of IR and / or laser dye, photochromic, visible dye solutions in preferred solvents or water according to one embodiment of the present disclosure. [Figure 3] FIG. 3 is an illustrative diagram of an exemplary solution casting method and apparatus according to one embodiment of the present disclosure. [Figure 4] FIG. 4 is an explanatory diagram of a process for producing a functional film using a solution casting method according to one embodiment of the present disclosure. [Figure 5] FIG. 5 is an exemplary illustration of laminating the new functional film as an optical component with other materials to create eyeglass optical lenses, camera lenses, microscope lenses, car windows, building windows, electronic screens, lamp cover protection, etc., according to one embodiment of the present disclosure. [Figure 6] FIG. 6 shows another embodiment of the present invention. [Figure 7A] FIG. 7A shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7B] FIG. 7B shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7C] FIG. 7C shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7D] FIG. 7D shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7E] FIG. 7E shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7F] FIG. 7F shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7G] FIG. 7G shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7H]FIG. 7H shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7I] FIG. 7I shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7J] FIG. 7J shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7K] FIG. 7K shows an exemplary spectrometer chart using an exemplary dye combination. [Figure 7L] FIG. 7L shows an exemplary spectrometer chart using an exemplary dye combination. DETAILED DESCRIPTION OF THE INVENTION

[0021] The above description is provided to enable any person skilled in the relevant art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments. Accordingly, the claims are not intended to be limited to the embodiments shown and described herein, but are to be accorded the full scope consistent with the language of the claims, and reference to an element in the singular is not intended to mean "one and only one," unless specifically stated otherwise, but rather "one or more." All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known, or that later become known, to those skilled in the relevant art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Furthermore, nothing disclosed herein is intended to be dedicated to the public, regardless of whether such disclosure is expressly recited in the claims.

[0022] The method for producing the dyed functional film includes the steps of providing a soluble polymer material, PVA powder, or PVA material; adding a solvent or water to the polymer material, PVA powder, or PVA material to produce a soluble polymer or PVA solution; providing a soluble dye; adding a solvent to the IR and / or laser dye, photochromic, or visible dye to produce a soluble dye solution; adding the dye solution to the polymer or PVA solution; and dyeing the dyed polymer or PVA solution. Solution Casting introducing the device into the device; Solution Casting The apparatus produces a dyed thin functional film from a dyed polymer or PVA solution; cast Removal from the device and allowing the film to dry and solidify.

[0023] In one embodiment, the dyed functional film is dried at a temperature of 40 to 100° C. In another embodiment, the thickness of the dyed functional film is 0.0025 mm to 2.0 mm.

[0024] In one aspect of the present application, a method for producing a dyed polymer solution or a dyed PVA solution is provided, comprising the steps of: providing a soluble polymer or PVA material; adding a polymer solvent to the polymer or PVA material to form a soluble polymer solution or a PVA solution; providing a soluble dye; adding a dye solvent to the soluble dye to form a soluble dye solution; adding a dye solution to the polymer solution or the PVA solution to form a dyed polymer solution or a dyed PVA solution; and dyeing the dyed polymer solution or the dyed PVA solution. Solution Casting introducing the device into the device; Solution CastingA method for producing a functional film is disclosed, including the steps of: causing an apparatus to produce a thin dyed optical film from a dyed polymer solution or a dyed PVA solution; removing the thin dyed optical film from the apparatus; and drying and solidifying the thin dyed optical film. In one embodiment, the dyed optical film is dried at a temperature of 40 to 100°C. In one embodiment, the thickness of the dyed optical film is 0.0025 mm to 2.0 mm. In one embodiment, the polymer is selected from the group consisting of TAC, cellulose acetate, cellulose propionate, polyurethane, PVC, silicone urethane copolymer, acrylic, COP, tetrafluoroethylene polymer, PC, PP, PE, polyethersulfone, polyetherimide, polyvinylidene fluoride, and the like, and is then added to a suitable solvent such as triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methyl cellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, and methylene chloride. In one embodiment, the polymer solvent is selected from the group consisting of triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methyl cellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, methylene chloride, and a mixture of water.

[0025] In one embodiment, the thin dyed optical film can function as an eyewear lens, a vehicle window, a camera lens, a microscope lens, a building window, an electronic screen, or lamp cover protection. In one embodiment, the thin dyed optical film is laminated to a glass lens or a plastic lens. In one embodiment, a vacuum coating is applied to the thin dyed optical film. In one embodiment, an anti-reflective coating is applied to the thin dyed optical film. In one embodiment, a hard coating is applied to the thin dyed optical film. In one embodiment, a water-resistant coating is applied to the thin dyed optical film. In one embodiment, a scratch-resistant coating is applied to the thin dyed optical film. In one embodiment, the thin dyed optical film is stretched into a PVA polarizing film. In one embodiment, the soluble dye is selected from the group consisting of an IR dye, a visible dye, a photochromic dye, or an absorbing dye. In one embodiment, the IR dye is selected from the group consisting of tetrakisammonium structures, iminium phthalocyanines, naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadratic acid derivatives, immonium dyes, perylenes, dianthrones, cyanines, heteroaromatics, metal dithiolenes, oxadiazoles, phthalocyanines, spiropyras, tetraaryldiamines, triarylamines, water-soluble phthalocyanine and / or naphthalocyanine dye chromophores or similar dyes.

[0026] In another aspect of the present application, a method for producing a functional film includes the steps of providing a soluble polymer, adding a polymer solvent to the soluble polymer to form a soluble polymer solution, providing a soluble dye, adding a portion of a PVA material to the soluble polymer solution, adding a dye solvent to the soluble dye to form a soluble dye solution, adding the dye solution to the polymer solution to form a dyed polymer solution, and dissolving the dyed polymer solution in a solvent. Solution Casting introducing the device into the device; Solution Casting The steps include causing the apparatus to produce a dyed thin optical film from the dyed polymer solution, removing the dyed thin optical film from the apparatus, and drying and solidifying the dyed thin optical film.

[0027] In another aspect of the present application, an eyewear lens is disclosed that includes a thin dye optical film, the thin dye optical film comprising: Solution Casting The dyed polymer solution is prepared in the device using a portion of the dyed polymer solution, the dyed polymer solution comprising a portion of the soluble dye solution and a portion of the soluble polymer solution, the soluble dye solution comprising a portion of the soluble dye and a portion of the dye solvent, and the soluble polymer solution comprising a portion of the polymer solvent and a portion of the soluble polymer.

[0028] In another aspect of the present application, an eyewear lens is disclosed that includes a thin dye optical film, the thin dye optical film comprising: Solution CastingA dyed PVA solution is prepared in the apparatus using a portion of the dyed PVA solution, the dyed PVA solution comprising a portion of the soluble dye solution and a portion of the soluble PVA solution, the soluble dye solution comprising a portion of the soluble dye and a portion of the dye solvent, and the soluble PVA solution comprising a portion of the polymer solvent and a portion of the PVA material. In one embodiment, the soluble polymer is selected from the group consisting of TAC, cellulose acetate, cellulose propionate, polyurethane, PVC, silicone urethane copolymer, acrylic, COP, tetrafluoroethylene polymer, PC, PP, PE, polyethersulfone, polyetherimide, polyvinylidene fluoride, and the like, and is then added to a suitable solvent such as triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methyl cellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, and methylene chloride. In one embodiment, the polymer solvent is selected from the group consisting of triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methyl cellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, methylene chloride, and a mixture of water.

[0029] In one embodiment, the soluble dye is selected from the group consisting of an IR dye, a visible dye, a photochromic dye, and an absorbing dye.

[0030] In one embodiment, the IR dye is selected from the group consisting of tetrakisammonium structures, iminium phthalocyanines, naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadratic acid derivatives, immonium dyes, perylenes, dianthrones, cyanines, heteroaromatic, metal dithiolenes, oxadiazoles, phthalocyanines, spiropyras, tetraaryldiamines, triarylamines, water-soluble phthalocyanine and / or naphthalocyanine dye chromophores.

[0031] In one embodiment, the polymer solvent is selected from the group consisting of triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methyl cellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, methylene chloride, and a mixture of water.

[0032] In one embodiment, the soluble dye is selected from the group consisting of IR dyes, visible dyes, photochromic dyes, and absorbing dyes. In one embodiment, the IR dye is selected from the group consisting of tetrakisammonium structures, iminium phthalocyanines, naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadratic acid derivatives, immonium dyes, perylenes, dianthrones, cyanines, heteroaromatic, metal dithiolenes, oxadiazoles, phthalocyanines, spiropyrases, tetraaryldiamines, triarylamines, and water-soluble phthalocyanine and / or naphthalocyanine dye chromophores.

[0033] In one embodiment of the present application, a method for producing a functional film includes the steps of: providing a PVA material; adding a portion of water to the PVA material to prepare a PVA solution; providing a portion of a water-soluble near-infrared dye; adding a portion of water or methanol to the water-soluble near-infrared dye to prepare a dye solution; adding the dye solution to the PVA solution to prepare a dyed PVA solution; and dissolving the dyed PVA solution. cast introducing said solution into an apparatus; castThe method includes the steps of forming a thin dyed optical film from the dyed PVA solution in an apparatus, removing the thin dyed optical film from the apparatus, and drying and solidifying the thin dyed optical film. In one embodiment, the dyed optical film is dried at a temperature of 40 to 100°C. In one embodiment, the dyed optical film has a thickness of 0.015 mm to 3.0 mm. In one embodiment, the water-soluble near-infrared dye has a composition selected from the group consisting of the following chemical formulas: C38H46ClNO2O6S2Na; or C43H47NO6S2Na; or C44H52NO6S3Na; or C38H49NO6S4Cl; C46H51NO6S2Cl; or C52H56NO6S3Na. In one embodiment, the thin dye optical film can function as an eyewear lens, a vehicle window, a camera lens, a microscope lens, a building window, an electronic screen, a lamp cover protection, a telephone screen, a TV screen, a computer screen, or an electrical appliance. In one embodiment, the thin dye optical film is laminated to a glass lens or a plastic lens. In one embodiment, a vacuum coating is applied to the thin dye optical film. In one embodiment, an anti-reflective coating is applied to the thin dye optical film. In one embodiment, a hard coating is applied to the thin dye optical film. In one embodiment, a water-resistant coating is applied to the thin dye optical film. In one embodiment, a scratch-resistant coating is applied to the thin dye optical film. In one embodiment, the thin dye optical film is stretched to become a PVA polarizing film. In another aspect of the present application, an eyewear lens comprising the thin dye optical film is disclosed, wherein the thin dye optical film is Solution CastingIn another embodiment, the water-soluble near-infrared dye is prepared in the device using a portion of a dyed PVA solution, the dyed PVA solution comprising a portion of a dye solution and a portion of a PVA solution, the dye solution comprising a portion of a water-soluble near-infrared dye and a portion of water, the PVA solution comprising a portion of water and a portion of a PVA material. In another embodiment, the water-soluble near-infrared dye has a composition selected from the group consisting of the following chemical formulas: C38H46ClNO,S2Na; or C43H47NO6S2Na; or C44H52NO6S3Na; or C38H49NO6S4Cl; C46H51NO6S2Cl; or C52H56NO6S3Na. A method for producing a functional film, comprising the steps of: providing a PVA material; adding a portion of water to the PVA material to prepare a PVA solution; providing a portion of a water-soluble near-infrared dye; adding a portion of water or methanol to the water-soluble near-infrared dye to prepare a dye solution; adding the dye solution to the PVA solution to prepare a dyed PVA solution; and dissolving the dyed PVA solution. Solution Casting introducing said solution into an apparatus; cast A method is disclosed that includes the steps of: causing an apparatus to produce a thin dyed optical film from the dyed PVA solution; removing the thin dyed optical film from the apparatus; and drying and solidifying the thin dyed optical film. In another embodiment, the dyed optical film is dried at a temperature of 40 to 100°C. In another embodiment, the dyed optical film has a thickness of 0.015 mm to 3.0 mm. In another embodiment, a portion of the water-soluble near-infrared dyes have a composition selected from the group consisting of: C38H46ClNO6S2Na; or C43H47NO6S2Na; or C44H52NO6S3Na; C38H49NO6S4Cl; C46H51NO6S2Cl; or C52H56NO6S3Na.

[0034] In another embodiment, the thin dye optical film can function as an eyewear lens, a vehicle window, a camera lens, a microscope lens, a building window, an electronic screen, a lamp cover protection, a telephone screen, a TV screen, a computer screen, or an appliance device. In another embodiment, the thin dye optical film is laminated to a glass lens or a plastic lens. In another embodiment, a vacuum coating is applied to the thin dye optical film. In another embodiment, an anti-reflective coating is applied to the thin dye optical film. In another embodiment, a hard coating is applied to the thin dye optical film. In another embodiment, a water-resistant coating is applied to the thin dye optical film. In another embodiment, a scratch-resistant coating is applied to the thin dye optical film. In another embodiment, the thin dye optical film is stretched to become a PVA polarizing film. In another aspect of the application, there is provided an eyewear lens comprising the thin dye optical film, wherein the thin dye optical film is Solution Casting An eyewear lens made in an apparatus using a portion of a dyed PVA solution, the dyed PVA solution comprising a portion of a dye solution and a portion of a PVA solution, the dye solution comprising a portion of a water-soluble near-infrared dye and a portion of water, the PVA solution comprising a portion of water and a portion of a PVA material. In another embodiment, the water-soluble near-infrared dye is selected from the group having the formula: C38H46ClNO,S2Na; or C43H47NO8S2Na; or C44H52NO8S3Na; or C38H49NO6S4Cl; C46H51NO8S2Cl; C52H56NO6S3Na.

[0035] In another aspect of the present application, a method for producing a functional film is disclosed, the method comprising the steps of: providing a soluble polymer; adding a polymer solvent to the polymer to form a soluble polymer solution; providing a soluble dye; adding a dye solvent to the soluble dye to form a soluble dye solution; adding the dye solution to the polymer solution to form a dyed polymer solution; and dissolving the dyed polymer solution in a solvent. Casting equipmentand introducing said solution into said Casting equipmentThe method includes the steps of forming a thin dyed optical film from the dyed polymer solution by a dyeing machine, removing the thin dyed optical film from the machine, and drying and solidifying the thin dyed optical film. In one embodiment, the dyed optical film is dried at a temperature of 40 to 150°C. In one embodiment, the thickness of the dyed optical film is 0.015 mm to 3.0 mm. In one embodiment, the polymer is selected from the group consisting of TAC, cellulose acetate, cellulose propionate, polyurethane, PVC, silicone urethane copolymer, acrylic, COP, tetrafluoroethylene polymer, PC, PP, PE, PET, polyethersulfone, polyetherimide, polyvinylidene fluoride, Polyox (ethylene oxide), etc., and then dissolving the dyed polymer solution in a solvent such as triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, etc. , MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methylcellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, methylene chloride, alcohols, phenol, o-chlorophenol, DMSO, trifluoroacetic acid (either pure or as a mixture with dichloromethane), 1,1,1,3,3,3-hexafluoro-2-propanol, o-chlorophenol, o-cresol, tetrachloroethane / phenol, dichloromethane (DCM) containing small amounts of dioxane, nitrobenzene, etc.In one embodiment, the polymer is added to a suitable solvent such as triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methyl cellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, methylene chloride, alcohols, phenol, o-chlorophenol, DMSO, trifluoroacetic acid (either pure or as a mixture with dichloromethane), 1,1,1,3,3,3-hexafluoro-2-propanol, o-chlorophenol, o-cresol, tetrachloroethane / phenol, dichloromethane (DCM) containing small amounts of dioxane, nitrobenzene, and the like. In one embodiment, the thin dyed optical film is laminated to a glass or plastic lens or sheet forming at least one layer, and then subjected to a bending or co-injection process. In one embodiment, the soluble dye is selected from the group consisting of an IR dye, a visible dye, a photochromic dye, or an absorbing dye. In one embodiment, a vacuum coating is applied to the thin dyed optical film. In one embodiment, an anti-reflective coating is applied to the thin dyed optical film. In one embodiment, a hard coating is applied to the thin dyed optical film. In one embodiment, a water-resistant coating is applied to the thin dyed optical film. In one embodiment, a scratch-resistant coating is applied to the thin dyed optical film. In one embodiment, the thin dyed optical film can function as an eyewear lens, a vehicle window, a camera lens, a microscope lens, a building window, an electronic screen, a lamp cover protection, a telephone screen, a TV screen, a computer screen, or an electrical appliance.

[0036] Some embodiments will be described in detail with reference to the associated drawings. Additional embodiments, features, and / or advantages will become apparent from the following description or may be learned by practicing the present application. The following description is not to be construed in a limiting sense, but is merely for the purpose of illustrating the general principles of the present application. The steps described herein for carrying out a method form one embodiment of the present application, and unless otherwise specified, not all of the steps must be performed to practice the application, nor must the steps be performed in the order listed. It should be noted that references to "an" or "one" or "some" embodiments in this disclosure are not necessarily to the same embodiment, and such references mean at least one.

[0037] In accordance with the practice of the present application, the method and system for making functional films disclosed herein offer many significant advantages over the prior art. Specifically, the present application results in functional films that are substantially isotropic, flat, and dimensionally stable. Furthermore, the functional films achieve maximum optical purity and extremely low haze. The films are also dyed to precise specifications without being susceptible to dye degradation issues. As a result, the functional films require less processing, fewer defects, less delamination, and less stress, resulting in optical lenses requiring fewer layers and shorter processing times. While offering many advantages, the present method uses easily incorporated blend components used in conventional methods. The present application does not increase material costs and, in certain cases, can actually reduce material costs by providing precise optical properties, specifications, and thin functional films, which in turn reduces the number of layers in optical lenses.

[0038] Referring to FIG. 1, a plastic polymer 101, such as TAC, cellulose acetate, cellulose propionate, polyurethane, PVC, silicone urethane copolymer, acrylic, COP, tetrafluoroethylene polymer, PC, PP, PE, polyethersulfone, polyetherimide, polyvinylidene fluoride, etc., is added to a suitable solvent 102, such as water, triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, teraphenyl, diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl, diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, terahydrofuran, ether, ester, polyimide, dimethylformamide, polyvinyl alcohol, methylcellulose, starch derivatives, gelatin, methyl ethyl ketone, terahydrofuran, methylene chloride, polyvinyl alcohol, etc., to create a first solution 100, Liquid A, the plastic polymer.

[0039] In other embodiments, a plastic polymer such as TAC, cellulose acetate, cellulose propionate, polyurethane, PVC, silicone urethane copolymer, acrylic, COP, tetrafluoroethylene polymer, PC, PP, PE, PET, polyethersulfone, polyetherimide, and polyvinylidene fluoride is added to a suitable solvent 102 such as triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyl phosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methylcellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, methylene chloride, polyvinyl alcohol, etc. to create a first solution 100, Liquid A, a plastic polymer.

[0040] In another embodiment, the PVA material 101 is added to a suitable solvent 102, such as water, to form a PVA solution.

[0041] Referring to FIG. 2, a dye 201, such as an IR and / or visible dye, a photochromic dye, or any absorbing dye, is added to a suitable solvent 202, such as triphenyl phosphate, diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methyl cellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, methylene chloride, water, to form a second solution 200, Liquid B, the dye solution.

[0042] In another embodiment, an aqueous dye 201, such as a water-soluble near-infrared dye, is added to a suitable solvent 202, such as water or methanol, to form an aqueous dye solution. In one embodiment, the water-soluble near-infrared dye is a composition having the formula: C38H46ClNO6S2Na; or C43H47NO6S2Na; or C44H52NO6S3Na; or C38H49NO6S4Cl; C46H51NO6S2Cl; C52H56NO6S3Na. In another embodiment, the water-soluble near-infrared dye is a near-infrared fluorescent dye. In another embodiment, the water-soluble near-infrared dye is Epolight™ 2735 water-soluble dye.

[0043] Referring to Figure 3, the polymer casting method used in this application is shown. A polymer material, PVA powder, or PVA material 301 is mixed with a solvent 302. In one embodiment, a low temperature below 100°C can be used to accelerate the dissolution of the polymer in the solvent. However, in another embodiment, other polymer materials, such as TAC, may not require heat for dissolution. The solution may be further processed to arrive at the solution required to create a functional film with specific optical properties. The final polymer or PVA solution is then introduced into a casting device 303, as shown. In one embodiment, the final polymer or PVA solution is deposited onto a moving belt 304 through a caster or spreader 305. The polymer or PVA solution is dried and solidified by airflow 306 flowing through belt channels 307 relative to the direction of the moving belt. It is understood that in other embodiments, airflow 306 may flow in the direction of the moving belt. It is also understood that the drying air, its direction, belt speed, belt channel spacing, etc., can be calibrated to achieve the desired thickness, dryness, and other qualities of the functional film. Additionally, by the time the functional film reaches the film take-off device 308, the input polymer or PVA solution must be solidified enough to be taken off the belt for further drying or processing.

[0044] Referring to Figure 4, the casting method shown in Figure 3 has been adapted for this application. Liquid A, i.e., the polymer solution, is made by adding polymer material 401 to a suitable solvent 402. Liquid B, i.e., the dye solution, is made by adding dye 403, which may be an IR or visible dye, a photochromic dye, or any absorbing dye, to a suitable solvent 404. In one embodiment, Liquid B contains 0.05% to 5% of the IR or visible dye, photochromic dye, or absorbing dye, with the remainder being a suitable solvent. In one embodiment, a preferred embodiment is Liquid B containing 3% dye. The resulting solutions are mixed together to make the dyed polymer solution 405. In one embodiment, the water-soluble PVA (polyvinyl alcohol) containing the IR dye may contain up to 10% of a solvent-soluble polymer in the mixture. In one embodiment, Liquid A is composed of approximately 9% to 25% polymer or PVA powder and 75% to 91% of a suitable solvent.

[0045] In another embodiment, the casting method shown in Figure 3 is adapted for this application. A PVA solution is made by adding PVA material 401 to suitable water or methanol 402. Liquid B, the water-soluble dye solution, is made by adding a portion of water-soluble near-infrared dye 403 to suitable water or methanol 404. In one embodiment, Liquid B contains 0.05% to 5% water-soluble near-infrared dye, with the remainder being suitable water or methanol. In one embodiment, a preferred embodiment is Liquid B containing 3% dye. The resulting solutions are mixed together to make dyed PVA solution 405.

[0046] The dyed PVA solution or dyed polymer solution 405 is then Casting equipmentThe film is then introduced into 406. This equipment utilizes a large belt 407 of a material and design appropriate for the desired functional film. In a preferred embodiment, the film is introduced into a dry environment where the temperature is between 40 and 150°C. The functional film is continuously removed from the moving belt for further drying, processing, rolling, or sheeting for storage until use. It is then used to manufacture eyeglass lenses, camera lenses, microscope lenses, automobile windows, building windows, electronic screens, lamp cover protection, and the like. In a preferred embodiment, the functional film has a thickness of 0.015 mm to 3.0 mm. Different films with different optical properties can be laminated together to obtain the desired eyewear lenses, camera lenses, microscope lenses, automobile windows, building windows, electronic screens, lamp cover protection, and the like. In one embodiment, referring to FIG. 5, a curved lens 503 is made in which a visible and / or IR dyed optical film 501 made using the present method as shown in FIG. 3 is laminated onto another transparent film or glass 500 with specific optical properties. Another scratch resistant optical glass 502 is laminated on top of the dyed functional film 501 to protect the IR / visible layer from scratches, chemicals, and / or the elements.

[0047] In one embodiment, the process for making the functional film may use a multi-head flow machine to cast the material, may use different dyes or materials, or may have different formats.

[0048] In another embodiment, the functional film may be stretched for orientation while it is being made.

[0049] In another embodiment, the functional film has the physical property of absorbing or reflecting 90% or more of light having a wavelength of 400 to 430 nm and more than 37% of light having a wavelength of 760 to 2000 nm.

[0050] In one embodiment, a functional film can be fabricated using an adapted solution casting method, and then the functional film can be formed to the curvature of the final product and further bonded with an epoxy layer by injection molding.

[0051] In another embodiment, the functional film is further laminated to another PVA film as an additional layer. This process can be repeated for multiple layers of PVA film to achieve the intended product design. It is understood that different functional films can also be laminated together to achieve specific optical properties.

[0052] In one embodiment, solution casting using a single layer of functional film or extra laminates (one or more layers of functional film) can also create the desired shape or curvature to be placed into a mold for the co-injected substrate (main support material).

[0053] In one embodiment, the functional film may be laminated to the top, bottom, or between any type of glass, plastic, and / or metal object.

[0054] In one embodiment, the functional film may be formed into any geometric shape or mold to achieve the intended design.

[0055] In one embodiment, the PVA aqueous solution material is used as the polarizing layer by itself and / or is laminated with additional polarizing layers.

[0056] (Eyeglass lenses, goggle lenses, protective shield sheets) contain organic pigments in the film that selectively absorb unwanted radiation in a narrow band, resulting in lens products with better low haze, transparency, and rich color contrast.

[0057] Then, at least one solvent cast film of absorbed IR radiation is added.

[0058] The lens products of the present application reduce eye strain and improve visual comfort.

[0059] In some other embodiments, the lens is a solution-cast functional film or a plurality of solutions. cast This includes functional films and laminated films, with or without grinding on the convex or (in other words) upper surface of the lens to a depth of 0.0-1.5 mm from the surface, without damaging the functional film, and a total lens thickness of 0.2-10.0 mm; and / or with an included or extra IR thin film of 0.02-0.18 mm on the convex or upper surface to a depth of 0.001-1.5 mm from the surface, with or without grinding, one of the layers without damaging the functional film, and a total lens thickness of 0.2-10.0 mm.

[0060] Much of the energy from the Sun reaches Earth in the form of IR radiation. At a power of 1366 watts / m², sunlight in space above Earth's atmosphere consists (by total energy) of about 50% IR light, 40% visible light, and 10% ultraviolet light. At ground level, this decreases to about 1120–1000 watts / m², consisting of 44% visible light, 3% ultraviolet (with the Sun at the zenith (directly overhead), but less at other angles), and the remainder IR. Thus, the composition of sunlight at Earth's surface per square meter when the Sun is at the zenith is about 527 watts of IR radiation, 445 watts of visible light, and 32 watts of ultraviolet radiation. The balance between absorbed and emitted IR radiation has a significant impact on Earth's climate.

[0061] The three main potential sources of damage to the human eye in natural light are ultraviolet, visible blue light, and near-infrared. At the same time, numerous types of radiation reach Earth together.

[0062] Light waves from natural and artificial sources can be damaging to the human eye. Excessive exposure to harmful light can cause deterioration and irreversible damage to the sensitive parts of the eye.

[0063] Spectacle lenses are used to protect the human eye from excessive solar radiation, reduce eye strain, and enhance visual comfort. Standard lens treatments are applied with the intention of blocking harmful light by including color pigments. These common treatments reduce the overall amount of visible light that passes through the lens, significantly reducing the clarity the human eye can see. Lenses are still waiting for improvement.

[0064] A problem with prior art approaches is that they also significantly block many of the visible light wavelengths, reducing the visible light transmission (VLT) through the lens or panel and adversely affecting the wearer's vision.

[0065] Broadband glasses have non-selective filtering lenses that scatter and reflect light.

[0066] These broad wavelength shields impose severe limitations on the wearer's visibility, even in broad daylight. This problem becomes even more pronounced as the level of available light in the surrounding environment decreases. The reduction in available visible light significantly impacts the wearer's ability to perform certain functions, impairs the wearer's depth perception, and impairs the wearer's ability to perceive certain colors.

[0067] Another alternative to manufacturing protective filters or lenses has been to apply a coating to the exterior surface of the lens after it has been formed. This coating process dramatically increases the cost of the lens, while the absorbed selective dyes make the coating too thin to be effective. Applying thicker coatings can result in uneven layers and cracks.

[0068] Special care must be taken to protect human eyes from UV radiation. Even on cloudy days, we should wear sunglasses to reduce the amount of UV radiation that reaches our eyes. UV radiation is invisible to us and consists of three main wavelengths: UVA, UVB, and UVC. UVB rays are mostly absorbed by the cornea (the outermost layer at the front of the eye) and therefore do not penetrate to the retina, unlike UVA radiation, which passes through the cornea of ​​the eye to reach the lens and retina. UVC radiation is filtered out by the Earth's atmosphere. Table 1 below shows the three main components of the UV spectrum.

[0069] [Table 1]

[0070] (UV Pigments) Ultraviolet (UV) and visible (Vis) dyes may be incorporated into coatings, solutions, and plastics. UV (A) radiation (315-400 nm) reaches Earth, so blocking this radiation is important. Current UV protection technology is highly advanced, dating back 40 years, and easily applied to lenses. Naturally, appropriate UV powders and good processing are necessary for lenses that can effectively block UV light. However, light in the blue region, as well as blue and violet photons, have shorter wavelengths, allowing molecules to easily absorb them. Molecules only retain the photons for a moment and then re-emit them in random directions. This is why the sky appears blue. Many of these scattered photons travel toward Earth, making the sky appear bright. They can also cause damage to the human eye.

[0071] Blue light comes from both natural sources (sunlight) and artificial sources (screens, LED lights, appliances, etc.) Exposure to blue light can result in eye strain and fatigue and can trigger a series of chemical reactions that cause irreversible degenerative damage to photoreceptor cells in the retina.

[0072] Blue light between 400 and 455 nm emits more neon violet and blue light, which scatters easily, resulting in greater visual fatigue and blurred vision. Several organic dyes are available, including blue-absorbing organic dyes with peak blue light absorption between 400 and 455 nm. For special tasks, visual needs, or personal preferences that require blocking blue light between 400 and 495 nm, additional dye powders can be added.

[0073] In some cases, blue light can have serious and harmful effects on the human eye. Blue light wavelengths range from 400 nm to 480 nm, with light between 400 nm and 455 nm being the most harmful, especially between 410 and 430 nm. This is because near-violet blue light contains very little neon ultraviolet light, which has faster and shorter wavelengths and has a greater impact on the eye. With recent technological developments, human eyes are exposed to more blue light throughout the day, and we need protection from this light spectrum.

[0074] The well-known techniques for anti-blue light in the 400-455 nm range are broadband techniques such as dyeing, dipping, injection, extrusion, film coating, and coating. The broad bandwidth is not sharp enough, which affects the color. The hue value and saturation also increase the dimness.

[0075] The wavelength frequency range of indigo is approximately 425-450 nm, with a frequency of 670-700 terahertz (THz). Indigo can be considered a subset of violet. The low color range explains why this color is difficult to distinguish in the spectral band. Since indigo is not recognized scientifically as a separate color, any wave with a wavelength below 450 nm is considered violet.

[0076] Some embodiments may provide area-enhancing contrast. The sun's maximum radiation is approximately 580 nm, so blocking 580 nm radiation may be advantageous. One embodiment of the present disclosure may include a new high-contrast method to provide anti-blue light lenses that make it easier for people to see clearly, easily, quickly, and at a distance.

[0077] If the frame is the skeleton of the glasses, the lens is the soul of the glasses, and the quality of the lens can determine the future of the human eye. Therefore, as an important line of defense for eye protection, we must consider three major potential factors that can damage the human eye under natural light: ultraviolet, blue, and near-infrared rays.

[0078] Near-Infrared Exposure and Cataracts: One of the most common eye diseases associated with near-infrared radiation is cataracts. Long-term exposure to IR radiation causes gradual but irreversible opacification of the lens. Another form of eye damage from IR exposure is stoma, a loss of vision due to damage to the retina. Even low levels of IR absorption can cause symptoms such as eye redness, swelling, or bleeding. Because infrared radiation penetrates clouds more strongly than visible light, its relatively high transmittance causes greater eye damage. Cataracts caused by near-infrared radiation have historically been noted in glassblowers and furnace workers. Radiation between 800 and 1,200 nm is most likely to cause an increase in temperature in the lens itself due to its spectral absorption characteristics. Visible wavelengths may also contribute to the problem, as heat absorbed by the iris can lead to heat transfer to the lens.

[0079] Coating methods with inorganic IR absorption may include dye immersion, which may not adequately absorb radiation in the N-IR spectral region, and viewers wearing these glasses may see a loss of clarity.

[0080] When absorbed, IR radiation causes an increase in temperature. IR light is also beyond the detection limit of the human eye. It can be important to recognize that optical radiation acts as a catalyst in the oxidation of materials, especially organic artifacts. The eyes are particularly sensitive to the effects of heat. Suitable protective goggles can protect the eyes from excessive exposure to IR radiation. The biological effects of IR are primarily thermal. IR is easily absorbed by dark objects. High-intensity IR causes tissue necrosis and protein coagulation. Far-infrared rays penetrate only 0.5 cm into tissue and are almost completely absorbed by the cornea and aqueous humor. Near-infrared rays penetrate 3 cm into tissue to reach the retina and are absorbed by the iris and retinal pigments.

[0081] Glass materials for glass lenses may have slight IR blocking properties. Melting the glass and mixing it with rare-earth IR-absorbing pigments requires temperatures exceeding 800°C. If damaged, the pigments may only absorb radiation with wavelengths of 750 nm, 810 nm, or 890 nm. Lenses can be made using injection or extrusion, but this process can require temperatures exceeding 230°C, which can melt the polymer plastic, damage the pigment structure, and reduce color. Furthermore, lenses must be at least 0.4 mm thick, and injecting the pigment into thick plastic reduces the concentration of the absorbing pigment, reducing lens performance. To maintain lens performance requirements and the requirement that haze (the percentage of scattered incident light that passes through the lens) not exceed 1.0, cast films may be used with injection or cast substrates. Appropriate material selection and technology, depending on cost considerations, demands, or high impact resistance, can be crucial.

[0082] Infrared rays are invisible electromagnetic waves that penetrate the sun. Ultraviolet, visible, and IR electromagnetic waves, with wavelengths between 280 and 10,000 nm, interfere with various electromagnetic waves, particularly IR waves between 800 and 1,200 nm, making it important to implement optimal methods to protect human eyes. Because IR-absorbing lenses are not readily available, there is little information available about them. Research is also difficult, and infrared-absorbing pigment materials are expensive. While there are several products on the market, they do not perform well. Considering the aforementioned potential sunlight or artificial light sources that can effectively block harmful light waves, this application provides numerous improvements for sunglass lenses, prescription solar lenses, and optical sheets.

[0083] Embodiments for eyeglass lenses, goggle lenses, shields or sheets Embodiments are provided for eyeglass lenses, goggle lenses, shields, or sheets that may contain organic pigmented (visible narrow-band absorber) films, where narrow-bandwidth wavelength attenuation (absorption) of unwanted radiation is selective, particularly for low haze, clarity, and / or colorful enhancement contrast.

[0084] It also adds at least an organic absorbing IR dye protection layer, which reduces eye strain, increases visual comfort, and improves scene clarity in high-resolution color.

[0085] The lens includes either a cast functional film or multiple cast functional films and laminated films on its convex surface, or (in other words) to a depth of 0.0 to 1.5 mm from the surface of the lens, with or without grinding and without damaging the functional film, and the total thickness of the lens is 0.2 to 10.0 mm. Using an IR thin film, an additional 0.02 to 0.18 mm is added to the convex portion, or the film is recessed 0.0 to 1.5 mm into the surface, with or without grinding and without damaging the functional film, and the total thickness of the lens is 0.2 to 10.0 mm. The present invention relates to a manufacturing method.

[0086] Dyes with a full width at half maximum (FWHM) of 10-80 nm are generally not easily dissolved in organic solvents. The only solvent that can dissolve them is less than 0.1%-0.2% of the mixture, and the coating has a recommended common solvent. The thickness is about 0.05-0.08 mm. If the dye content is too low, the desired effect may not be achieved. If a solvent with too strong a dissolving power is used, the coating mixture and the coating substrate will be damaged by the strong solvent. However, the solution cast For films, it may be preferable to use strongly solvent soluble dyes and polymeric moieties. Casting Method When using a strong solvent to produce a film, the thickness of the film can be increased by 5 to 30 times, which means that the dye content also increases by 5 to 30 times, and the dissolving power of the strong solvent for the dye can also increase by 3 to 15 times.

[0087] The area of ​​400-455 nm is more than 8% smaller than that of 480-550 nm. The special requirement for 440-490 nm is less than 5% in the 400-440 nm region. To enhance the contrast, you can choose a suitable dye for 570-595 nm.

[0088] The NIR organic dye is selected from 700-1200 nm, and the 1200-2000 nm organic IR dye is waiting to be added to the lens.

[0089] Important application factors 1. FWHM - A lens contains at least one soluble functional dye with absorbance between 10 and 50 nm (visible narrow band absorber) FWHM along with a polymer. Haze should be less than 1.0.

[0090] 2. Solution cast Functional film lenses are a solution cast Functional film or multiple solutions cast Either the functional film or the laminate film is contained on the convex surface or (in other words) on the top surface of the lens.

[0091] 3. If a convex, or (in other words) 0.0-1.5 mm deep functional layer is formed on the lens surface by grinding, and if grinding can be done without damaging the functional layer, or if grinding can be done without damaging the functional layer, the total lens thickness will be 0.2-10.0 mm.

[0092] 4. High contrast or enhanced contrast, this application increases contrast and (C) focuses radiation wavelengths absorbed between 570-590 nm, helping the human eye to better distinguish objects and extending scene clarity in high-resolution color.

[0093] 5. Laminated absorbing IR-emitting thin films. Advantages include ease of handling, ease of application, ease of storing functional films with fewer types of films, ease of raw material preparation, reduced layer film, and reduced risk of separation. Other advantages may include increased yield. Other advantages may include a reduction in processing costs and good quality.

[0094] The functional film is concentrated in the upper half of the outer contour. The function is centralized. The functional color mode of the semi-Rx lens significantly reduces the cut rate, the function is more average, and the color is relatively flat.

[0095] solution cast Film, injection molding, gasket casting, and lamination are different processes that can be selected alone or in combination. The function may be to protect the layer barrier, and layers of the same, similar, or different functions may be stacked, if necessary, to achieve a penetration of 0.001% or more, 0.0001% or more, or even higher than 0.00001% absorption transmittance.

[0096] The functional dyes may be mixed together or separately on one film, and the film materials may be varied.

[0097] At least one Solution Casting The film is laminated, co-injected, or co-cast onto the lens, shield, or sheet.

[0098] Or, it is a combination of lens components.

[0099] Attenuate selective wavelength regions. These (AB) UV-VIS dyes can be used alone or in combination to create custom spectral filters for multiple applications. UV dyes are also the most easily combined with most dye mixtures used.

[0100] (B) Filter out the highest energy wavelengths from 420 to 455 nm. At 400 to 420 nm, (A) if the UV 400 dye absorbs some of it, the 420 to 455 nm wavelength becomes very important, but it is easy for the dye in this region to absorb and interfere with other color regions, so Solution Casting The correct method of injection, casting, and using the correct dye must be used, or one layer may use a narrow bandwidth (FWHM) 40 nm dye, mixed with one or more different functional dyes.

[0101] (C) - This application aims to solve the problem of reduced vision when wearing protective eyewear, with the sun's maximum radiation at approximately 580 nm. This application increases contrast and focuses radiation wavelengths absorbed between 570 and 590 nm (C), thus helping the human eye better distinguish objects. Eyeglass lenses with high or medium contrast enhancement provide better transmission values ​​in the red and green visible spectral ranges.

[0102] (B) Regular (broad) color-forming dyes for 400-760 nm absorb visible light and can be selected and used. Some necessary adjustments are to brighten the color and darken the lens.

[0103] The new high-contrast, medium-contrast, or low-contrast methods added to blue light protection lenses, or blue blocker lenses, make it easier for people to see clearly, easily, in detail, quickly, and at a distance. Visible radiation can be filtered by attenuating a portion of the light transmitted by the lens within one or more ranges of the filtered portion of visible radiation. The optical filter can include means configured to increase the average saturation value of a narrow notch with a 40 nm ± 30 nm bandwidth and uniform intensity with light radiation at least partially transmitted through a portion of the lens.

[0104] In combination with other dyes, it selectively transmits certain primary color wavelengths.

[0105] A suitable mixture of two or more dyes may be required to absorb between 400 and 470 nm.

[0106] New lenses with multi-functional capabilities, lighter for indoors, rainy or early mornings, and darker for sunny days and outdoors.

[0107] (D) Absorbance near-infrared function.

[0108] Organic IR dyes absorb near-infrared light between 760 and 1100 nm. This function is more efficient than inorganic IR dyes. Inorganic IR dyes contain haze and are particulate, so they cannot be used at too high a concentration or transparency may decrease.

[0109] The newly developed IR absorbing dye has higher transparency in the visible light range compared to conventional products.

[0110] Current organic IR dyes are very good for the NIR 700-1400 nm range, but for wavelengths above 1400 nm they need to be mixed with inorganic IR dyes.

[0111] The high temperature glass lens is melted with the IR dye. With respect to absorbance between 760 and 1400 nm, it can only absorb peaks at 750 nm, 810 nm, and 890 nm portions of the radiation.

[0112] The transparency, high-performance absorption, clarity, comfort, haze, and quality of organic NIR dyes in the 760-1400 nm range were in the medium range.

[0113] To absorb between 400 and 470 nm, a suitable mixture of two or more dyes is required. Solution Casting , injection, or cast The correct method of using a 40 nm dye with a narrow bandwidth (FWHM) is used. Mixing with one or more dyes.

[0114] (D) The lens absorbed more than 38% in the 760–1100 nm region, while the same lens absorbed more than 20% in the 1100–2000 nm region.

[0115] 1. A lens contains at least one functional film (B) blue blocker film, and (D) NIR absorbing film is laminated, or (B) and (D) dye mixture are contained in one film. Optionally, with or without coloring dye, add layer(s) and any kind of process.

[0116] 2. A lens contains at least one functional film (B) blue blocker film, and (C) contrast enhancement film is laminated, or (B) and (C) dye mixture are contained in one film. If necessary, add layer(s) and any kind of process, with or without coloring dye.

[0117] 3. A lens contains at least a laminate of functional films (B) blue blocker film, (C) contrast enhancement film, and (D) NIR absorptance film, or any one of these dye combination films, with or without added color pigments.

[0118] 4. One lens includes at least a functional film laminated with (C) a contrast enhancing film, (D) an NIR absorbing film, with or without the addition of a coloring dye.

[0119] 5. For special needs, it is necessary to have a (B) NIR absorbing film that is protected from blue light 400-495 nm and one or more additional functional dyes or normal coloring (broad) dyes, in combination with or without any functional dye (C), to enhance contrast (D).

[0120] 6. Different dyes can be combined on the same film.

[0121] 7. Functional films with co-injected substrates.

[0122] 8. The above may be added with or without (A) UV powder pigment or may be included with / without polarization.

[0123] Manufacturing Method Steps: Example A. A lens comprising a polymer material and at least two filters incorporated into the polymer material of the lens, the two filters being combined to block most (A) UV light and selectively filter blue and violet light according to a sharp cut-on filter that substantially blocks wavelengths shorter than 400 nm to 455 nm. (Film)

[0124] The multiple organic dyes include a blue-absorbing organic dye with a blue light absorption peak center wavelength from 400 nm to 455 nm. (B) Filters the highest energy wavelengths from 420 to 455 nm. The 420-455 nm wavelength range becomes very important if the UV 400 dye absorbs part of it. However, it is easy for the dye to absorb in this range and interfere with other color regions. Therefore, it is necessary to use the correct dye by using the correct solution casting, injection, or casting method, and by using a narrow bandwidth (FWHM) 40 nm dye. It can be mixed with one or more dyes (film lamination or mixed injection layer process).

[0125] The requirement of absorbing between 400 and 470 nm can also determine the appropriate mixture of two or more dyes.

[0126] B. A blue blocker narrow-bandwidth dye-polymer film having selective narrow-bandwidth wavelength attenuation (absorption) of undesired radiation, with greater than 80-99% absorption from about 400-430 nm, or about 85-95% absorption from about 430-455 nm. The blue blocker functional film may be included on the top surface of the lens portion, with the functional film being about 0-0.7 mm thick without grinding. In some cases where prescription is desired (semi-Rx), a thicker optical lens with grinding may be desired, with a total lens thickness of about 0.05-8.0 mm.

[0127] C. A high-contrast or enhanced-contrast functional polymer film containing an organic dye that absorbs more than 20% of the selective narrow-bandwidth wavelength attenuation (absorption) of unwanted radiation from 570 to 590 nm, the functional polymer film on the upper 0 to 0.7 mm of the lens portion without grinding, or a half-Rx thickness optical lens with grinding but not reaching the functional film surface, with a total lens thickness of 0.05 to 8.0 mm.

[0128] D. A functional polymer film consisting of an IR organic dye selectively attenuating (absorbing) unwanted radiation of 800-1200 nm in a narrow bandwidth, with over 60% absorption, and an IR functional film on the upper 0-0.7 mm portion of the lens without grinding, or a half-Rx thickness optical lens with grinding but not reaching the functional film surface, with a total lens thickness of 0.05-8.0 mm.

[0129] B+C+D FWHM

[0130] This application describes an eyeglass lens product comprised of a multilayer wafer, which may or may not include an injection-molded thermoplastic or thermoset plastic inner portion. The multilayer wafer blue blocker enhances contrast. The IR-absorbing layer. This application further describes a method for obtaining the multilayer wafer. It exhibits high optical density filtering characteristics over a narrowly selected infrared wavelength range between approximately 750 nm and 1400 nm, with full width at half maximum values ​​of 80 nm to less than 10 nm.

[0131] Option 1: Photochromic. The photochromic dye is mixed into a polyurethane (PU) adhesive that is laminated between polymer films.

[0132] Example 1 A coating material containing a tetraazaporphyrin compound as a functional dye was prepared by mixing in the following ratio, and applied to the surface of the inner glass lens by spin coating.

[0133] (1) 100.0 parts by mass of acrylic polyol containing 4-hydroxybutyl acrylate (Hyper Clear, manufactured by Rock Paint Co., Ltd.) (2) 33.3 parts by mass of polyisocyanate (3) 16.7 parts by mass of cyclohexane (4) 0.8 parts by mass of tetraazaporphyrin compound (TAP-2, manufactured by Yamada Chemical Industry Co., Ltd.) (5) 0.7 parts by weight of silane coupling agent (Tura Ace, manufactured by Chisso Corporation)

[0134] Option 2: Glue adhesive Optical adhesives are used to bond or join optical components together or into optical systems for many optical applications. Optical adhesives may be used with a curing lamp to ease or speed the bonding process. Optical adhesives allow for precise positioning of optical components within a system by firmly securing the components in a desired location or position. Optical adhesives reduce the need to purchase additional components by allowing existing components to be manually assembled or positioned.

[0135] Optical Adhesives: Optical adhesives are used to bond or join optical components together or into optical systems for many optical applications. Optical adhesives may be used with a curing lamp to facilitate or speed the bonding process. Optical adhesives allow for precise positioning of optical components within a system by firmly securing the components in a desired location or position. Optical adhesives reduce the need to purchase additional components by allowing existing components to be manually assembled or positioned.

[0136] A 100% solids epoxy system used as a structural adhesive or EK-93 type sealant.

[0137] Adhesion is an essential technological process in many industrial technologies. State-of-the-art adhesives are specifically designed to suit a wide range of highly specialized applications. They simplify the bonding process and ensure high processing speeds combined with high reliability.

[0138] Option 3: Coating Coating methods: screen, spray, floating, roller print, immersion, slot die nozzle coating.

[0139] Option 4: Dye A. UV dye Eporin QCR Exicton B. Blue Blocker Dye Benzoxazolium iodide Iodide Indolium chloride Benzo[e]indolium hexafluorophosphate Benzo[e]indolium 4-methylbenzenesulfonate Indolium chloride Indolium tetrafluoroborate Indolium Perchlorate Methyl benzenesulfonate Indolium bistrifluoromethanesulfonimidate Tetrahydropyrimidine-4-olate & Choose from Eporin QCR-exciton. C. High contrast dyes of choice for application Yamada Eporin Exhibition D. IR Dyes for Selection for Application Eporin QCR

[0140] Some examples of IR oil-based soluble dyes include tetrakisammonium structures, naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadratic acid derivatives, immonium dyes, perylenes, dianthrones, cyanines, heteroaromatics, metal dithiolenes, oxadiazoles, phthalocyanines, spiropyrases, tetraaryldiamines, triarylamines, diimmonium, polymethine-based dyes, squarylium-based dyes, indoanilines, subammonium-based pigments, anionic compounds, cis-morpholino dyes, and inorganic oxides.

[0141] E. Water-soluble dyes for selection for application QCR FEW

[0142] Examples of dyes include hydroxide, inner salt, sodium salt, benzoxazolium hydroxide, inner salt, sodium salt, indolium hydroxide, inner salt, sodium salt, triethylammonium salt, ium hydroxide, inner salt, triethylammonium salt, indolium hydroxide, inner salt, sodium salt, indolium hydroxide, inner salt, trisodium salt, benzo[e]indolium hydroxide, inner salt, triethylammonium salt, benzo[e]indolium hydroxide, inner salt, trisodium salt.

[0143] Other examples include C38 H46 Cl N2 O6 S2 Na, C43 H47 N2 O6 S2 Na, C44 H52 N3 O6 S3 Na, C38 H49 N3 O6 S4 Cl, C46 H51 N2 O6 S2 Cl, C52 H56 N3 O6 S3 Na, C20H26O5, C20H18, N403, C24H29N3O7, C32H4BrN2O2, C36H44BrN3O4, C33H42N2O5S, C43H53N3O7S, water-soluble cyanine dyes, inorganic dyes, powdered dyes, etc.

[0144] F. Laser Dyes for Selection TIFF0007783876000002.tif72161

[0145] G. Photochromic dyes for selection for application Exemplary photochromic dyes include, but are not limited to, triarylmethanes, stilbenes, azastilbenes, nitrones, fulgides, spiropyrans, naphthopyrans, spirooxazines, quinones, and the like.

[0146] Option 5: Apply for polymer of choice. water soluble PVA, PVB

[0147] Dimethyl sulfoxide (DMSO), glycerol, styrene-acrylic, pure acrylic emulsion, rosin plastic sizing, or other additives to help the solution more easily form as the desired film.

[0148] Solvent solubility for selection for application: PETG Easterman

[0149] Other exemplary polymers may include TAC, cellulose acetate, cellulose propionate, polyurethane, PVC, silicone urethane copolymer, acrylic, COP, tetrafluoroethylene polymer, PC, PP, PE, PET, polyethersulfone, polyetherimide, polyvinylidene fluoride, Polyox, nylon, modified nylon.

[0150] Option 6: Apply for choice of organic solvent (oil-based). 1,3-Dioxolane; Chlorobenzene; Chlorinated benzene; Monochlorobenzene; 5-Chlorobenzotriazole; 5-Chloro-1,5-chlorobenzotriazole; 6-Chloro-1H-benzotriazole; Solvents Chlorinated hydrocarbons; Acetic acid dimethylacetamide; Chloroform; Tetrachloromethane; Carbon tetrachloride; Trichloroethylene; Triphenyl phosphate, diphenyl phosphate, methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate, butanol, biphenyl diphenyl phosphate, trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC, cyclohexanone, tetrahydrofuran, ethers, esters, polyimides, dimethylformamide, polyvinyl alcohol, methyl cellulose, starch derivatives, gelatin, methyl ethyl ketone, tetrahydrofuran, and methylene chloride.

[0151] Option 6-1: Apply water solvent for selection. Mixtures with water or alcohol Methanol Ethanol

[0152] In some embodiments, various options, methods, processes, etc. may be used to create suitable glasses (e.g., using film or injection molding or any other suitable process) having desired light transmission properties. Solution Casting Combinations of pigments may be used in glasses (e.g., eyeglasses). In one embodiment, a combination of pigments that absorb or block light in the visible range may be used. Pigments that absorb or block light in the infrared region may also be used. Other pigments with properties at various wavelengths across the entire light spectrum may also be used based on user preference and design. Various combinations of film and / or injection molding materials may provide benefits to manufacturing and end users. Some exemplary advantages include speed, efficiency, configurability of the manufacturing process, and end results.

[0153] In one example, dyes associated with significant solar ranges (e.g., at the Earth's surface), such as the blue light range (about 400 nm), the solar peak at about 580 nm, and the infrared range, can be combined for beneficial use in glass films. Those skilled in the art will understand that any combination of dyes associated with various light spectrum ranges can be used.

[0154] Some exemplary combinations are shown in Table 2 below. The dye type is listed in the first row. EM1, EM2, EM3, EM4, EM5, EM6, and EM7 are exemplary embodiments with possible types of processes used for each dye. For example, embodiment 1 (EM1) includes a 400 nm dye and a 580 nm dye injection molded onto a substrate, with the IR dye deposited on a film (e.g., laminated onto the film). The film may be combined with a substrate including the 400 nm and 580 nm dyes. In other embodiments, each dye may be deposited on its own separate substrate with the substrate subsequently combined. In other embodiments, each dye may be deposited by casting onto its own film substrate. In this manner, one or more dyes may be included on a substrate with one or more substrates combined, and similarly, one or more dyes may be included on any combination of one or more films. The film, casting, and substrate may be combined in any operational order.

[0155] EM 2 to EM 4 show other exemplary combinations of injection molding and film. The examples in Table 2 are merely illustrative, and one skilled in the art will recognize that any combination of pigments can be used in any combination to deposit the pigments on a substrate (film, glass, etc.). One skilled in the art will recognize that any number of layers and any number of pigments may be used.

[0156] [Table 2]

[0157] In some instances, a UV dye may be combined. In other instances, the UV dye may be omitted. Any method for depositing the dye onto the film may be used, including dyeing, dipping, pouring, extrusion, film coating, coating, etc.

[0158] 7A-L show some exemplary spectrometer charts using various exemplary dye combinations. Solution Casting It will be understood that other methods may be used, although unless otherwise indicated, the chart may use a Y-axis with "%T" or percent light transmittance, and an X-axis representing the wavelength of light in nanometers.

[0159] 7A shows a spectrometer output 700a when a blue dye with near-infrared absorbing properties (blue blocker) is used in conjunction with a contrast-enhancing dye. The spectrometer output exhibits little or no transmission in the UV range, with a peak in the visible spectrum and a valley in the near-infrared range.

[0160] Figure 7B shows another spectrometer output 700b of a film using a blue dye (blue blocker) along with a contrast-enhancing dye. The spectrometer output shows little or no transmission in the blue light range of about 400-430 nm, with a trough band (about ±15 nm) at about 580 nm. Other examples that can provide similar results include adding an organic dye that absorbs NIR radiation, or a co-injection or gasket casting substrate mixture containing a blue blocker dye and a contrast-enhancing dye.

[0161] Figure 7C shows another spectrometer output 700c when using at least two functional dyes effective in the 420-700 nm range. The spectrometer output shows a sharp rise near 400 nm and a slight valley near 570 nm.

[0162] 7D shows another spectrometer output 700d for a liquid coating technology including an inorganic pigment. The spectrometer output shows that the pigment absorbs less NIR radiation and can produce higher levels of haze.

[0163] Figures 7E-7F show other spectrometer outputs 700e-710f when higher temperatures above 800 degrees are used to melt the dye mixture. The results show that the higher temperatures used do not result in greater absorption of NIR radiation in the 760-1400 nm range.

[0164] FIG. 7G shows another spectrometer output 700g when a film is made containing a blue blocker effective at 400-430 nm along with a contrast enhancing dye effective in the 580 nm range (+ / - 15 nm).

[0165] Figure 7H shows another spectrometer output 700h when two or more functional narrowband dyes are used in conjunction with an organic NIR material to create a lens by injection molding. The output shows higher transmittance near 700 nm and attenuates at the edges.

[0166] Figure 7I shows another spectrometer output 700i, produced using a combination of solution casting (into a film) and plastic injection molding. In this example, the film contains 0.5% organic NIR dye, and the plastic contains 0.05% blue blocker dye effective from 400-455 nm, along with 0.03% contrast-enhancing dye effective in the 570 nm range (+ / - 15 nm). The result shows a favorable output with high levels of light blocking (or lower transmission) at approximately 400 nm, 570 nm, and the MR range.

[0167] 7J shows another spectrometer output 700j produced using various concentrations of organic NIR dye: 0.15% ("1"), 0.20% ("2"), 0.42% ("3"), and 0.60% ("4"). The chart shows the lowest concentration ("1") as the top curve with the highest transmittance (or lowest absorbance) across wavelength, the chart shows the next lowest concentration ("2") as the second highest curve with the highest transmittance (or lowest absorbance) across wavelength, the chart shows the next lowest concentration ("3") as the second lowest curve with the second lowest transmittance across wavelength, and the chart shows the highest concentration ("4") as the lowest curve with the lowest transmittance (or highest absorbance) across wavelength.

[0168] Figures 7K-7L show other spectrometer outputs 700 K-710 L generated comparing the difference between using a non-vacuum coating process and using a vacuum coating process. The results show that the vacuum coating process results in increased absorption of NIR radiation compared to the non-vacuum coating process.

[0169] The above description is provided to enable any person skilled in the relevant art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments. Accordingly, the claims are not intended to be limited to the embodiments shown and described herein, but are to be accorded the full scope consistent with the language of the claims, and reference to a singular element is not intended to mean "one and only one," unless specifically stated otherwise, but rather "one or more." All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known, or later become known, to those skilled in the relevant art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Furthermore, nothing disclosed herein is intended to be dedicated to the public, regardless of whether such disclosure is expressly recited in the claims.

Claims

1. A method for manufacturing eyeglass lenses, goggle lenses, or shields using solution casting, comprising providing at least three layers including an infrared (IR) film layer, a violet-blue light layer, and a green-yellow light layer, wherein the violet-blue light layer and the green-yellow light layer are formed by any one of injection molding, film making, or solution casting; providing a first soluble polymer solution; providing a first dye solution containing a dye that attenuates infrared (IR) light in the range of 760 nm to 2000 nm by at least 20% absorption; adding the first dye solution to the first soluble polymer solution to form a first dye solution; casting the first dye solution to form the IR film layer; (A) providing a second soluble polymer solution for film or solution casting, providing a second dye solution containing a dye having properties of attenuating violet-blue light in the range of 400 nm to 455 nm, and adding the second dye solution to the second soluble polymer solution to form a second dye solution, thereby forming a violet-blue light layer; (a) casting the second dye solution directly onto the film layer to form at least a two-layer film; or (b) casting the second dye solution to form at least a second film element, which is further laminated to form at least a two-layer film; (B) providing an injection molding compound for injection molding, adding a second dye to the compound, the second dye having a property of attenuating violet-blue light of 400 nm to 455 nm, and injection molding the compound to form an eyeglass lens, and (A) providing a film or solution casting process by providing a third soluble polymer solution to provide a third dye solution containing at least one dye having properties of attenuating green-yellow light between 570 nm and 595 nm, adding the third dye solution to the third soluble polymer solution to form a third dye solution to form a green-yellow light layer, and casting the third dye solution directly onto the IR film or violet-blue light layer to form an at least two-layer film; or (b) casting a second dye solution to form at least a second or third film element, which are further laminated to form an at least two-layer film; (B) A method for producing eyeglass lenses, goggle lenses, or shields by providing a separate compound for injection molding for the injection molding process, or by using an available compound of the violet-blue light layer, adding a third dye to the compound, where the third dye has the property of attenuating green-yellow light of 570 nm to 595 nm, and injection molding the compound to form eyeglass lenses, or co-injection molding the compound to form eyeglasses, and laminating or casting at least two layers of film to produce eyeglass lenses, goggle lenses, or shields, or applying at least one layer of film to the inside of a co-injection mold to produce eyeglass lenses, goggle lenses, or shields.

2. 10. The method of claim 1, wherein the first dye solution or the second dye solution comprises one of an aqueous dye or an oil-based dye.

3. 10. The method of claim 1, wherein the eyeglass lens comprises one of a glass or polymer material.

4. A method for making eyeglass lenses, goggle lenses, or shields using solution casting, comprising providing a first soluble polymer solution; i) a dye that attenuates narrowband visible or infrared light having a full width at half maximum (FWHM) of absorbance from 10 nm to 80 nm, the dye having the property of attenuating one of violet-blue light from 400 nm to 455 nm with at least 70% absorption, green-yellow light from 570 nm to 595 nm with at least 60% absorption, or infrared (IR) light from 760 nm to 2000 nm with at least 30% absorption, but not limited to FWHM attenuation from 10 nm to 80 nm; and ii) a dye that attenuates one of violet-blue light from 400 nm to 455 nm with at least 30% absorption, green-yellow light from 570 nm to 595 nm with at least 20% absorption, or infrared (IR) light from 760 nm to 2000 nm with at least 30% absorption, but not limited to FWHM attenuation from 10 nm to 80 nm. a dye having a property of attenuating one of violet-blue light from 400 nm to 455 nm, green-yellow light from 570 nm to 595 nm, or infrared (IR) light from 760 nm to 2000 nm, and adding a first dye solution to a first soluble polymer solution to form a first dye solution, and casting the first dye solution to form a film for laminating on a surface; providing an injection molding compound; adding a second at least one dye to the compound, the second at least one dye having a property of attenuating one of violet-blue light from 400 nm to 455 nm, green-yellow light from 570 nm to 595 nm, or infrared (IR) light from 760 nm to 2000 nm; providing a second soluble polymer solution; and adding a third dye solution to the second soluble polymer solution to form a second dye solution, the second dye solution attenuating one of violet-blue light from 400 nm to 455 nm, green-yellow light from 570 nm to 595 nm, or infrared (IR) light from 760 nm to 2000 nm.a second dye solution having a property of attenuating one of infrared (IR) light of 1000 nm, and casting a second dye solution to form a second film; and laminating or casting the laminated first and second films, along with any one or more additional films, onto a substrate formed by injection molding the compound to form an eyeglass lens; or injecting the laminated first and second films, along with any one or more additional films, into a coinjection molding mold using the compound to produce an eyeglass lens, a goggle lens, or a shield.

5. 5. The method of claim 4, wherein the first dye solution includes a third dye having a property of attenuating one of violet-blue light of 400 nm to 455 nm, green-yellow light of 570 nm to 595 nm, or infrared (IR) light of 760 nm to 2000 nm.

6. 5. The method of claim 4, wherein the first dye solution or the third dye solution comprises one of an aqueous dye or an oil-based dye.

7. The method of claim 4 , wherein the compound comprises one of a glass or a polymeric material.

8. 10. The method of claim 1, further comprising adding a dye adhesive, wherein laminating or casting the film onto the eyeglass lens is by lamination using a dye adhesive.

9. 5. The method of claim 4, further comprising adding a dye adhesive, wherein laminating or casting the film to the substrate is by lamination using a dye adhesive.

10. A method for making eyeglass lenses, goggle lenses, or shields using a solution casting process, comprising providing a first soluble polymer solution; i) a dye that attenuates narrowband visible or infrared light having a full width at half maximum (FWHM) of absorbance between 10 nm and 80 nm, the dye having the property of attenuating one of violet-blue light between 400 nm and 455 nm with at least 70% absorption, green-yellow light between 570 nm and 595 nm with at least 60% absorption, or infrared (IR) light between 760 nm and 2000 nm with at least 30% absorption, but not limited to a FWHM attenuation between 10 nm and 80 nm; and ii) a dye that attenuates one of violet-blue light between 400 nm and 455 nm with at least 30% absorption, green-yellow light between 570 nm and 595 nm with at least 20% absorption, or infrared (IR) light between 760 nm and 2000 nm with at least 20% absorption, but not limited to a FWHM attenuation between 10 nm and 80 nm. a dye not limited to a FWHM attenuation in the range of 400 nm to 455 nm, a dye not limited to a FWHM attenuation in the range of 570 nm to 595 nm, and a first dye solution added to the first soluble polymer solution to form a first dye solution, and casting the first dye solution to form a first film, adding a second soluble polymer solution to provide a second dye solution containing at least one dye having properties to attenuate one of violet-blue light from 400 nm to 455 nm, green-yellow light from 570 nm to 595 nm, or infrared (IR) light from 760 nm to 2000 nm, and adding the second dye solution to the second soluble polymer solution to form a second dye solution, and one of (a) casting the second dye solution directly onto the first film to form at least two layers of film, or (b) casting the second dye solution to form at least a second film element and further laminating into at least two layers of film, nm to 20005. The method of claim 4, further comprising providing a third dye solution containing at least one dye having a property of attenuating one of infrared (IR) light of 1000 nm, adding the third dye solution to a third soluble polymer solution to form a third dye solution, and one of (a) directly casting the third dye solution onto at least two layers of film to form at least three layers of film, or (b) casting the third dye solution to form at least a third film element and further laminating at least two layers of film, and laminating or casting the at least three layers of film onto an eyeglass lens to produce an eyeglass lens.

11. 1. A method for making eyeglass lenses, goggle lenses, or shields using a solution casting process, comprising providing a first soluble polymer solution comprising: i) a dye that attenuates narrowband visible or infrared light having a full width at half maximum (FWHM) of absorbance between 10 nm and 80 nm, the dye attenuating one of violet to blue light from 400 nm to 455 nm with at least 70% absorption, green to yellow light from 570 nm to 595 nm with at least 60% absorption, or infrared (IR) light from 760 nm to 2000 nm with at least 30% absorption, but not limited to a FWHM attenuation between 10 nm and 80 nm; or ii) a dye that attenuates one of violet to blue light from 400 nm to 455 nm with at least 30% absorption, green to yellow light from 570 nm to 595 nm with at least 20% absorption, or infrared (IR) light from 760 nm to 2000 nm with at least 20% absorption, but not limited to a FWHM attenuation between 10 nm and 80 nm; 5. The method of claim 4, further comprising: providing a first dye solution comprising at least one of a dye having a property of attenuating one of violet-blue light between 400 nm and 455 nm, a dye having a FWHM attenuation in nm between 570 nm and 595 nm, or an infrared (IR) light between 760 nm and 2000 nm; adding the first dye solution to a first soluble polymer solution to form a first dye solution; casting the first dye solution to form a first film; and casting or laminating the first film onto an eyeglass lens; and producing at least one film for laminating onto the eyeglass lens by repeating the following steps twice: providing each soluble polymer solution; adding at least one dye having a property of attenuating one of violet-blue light between 400 nm and 455 nm, green-yellow light between 570 nm and 595 nm, or infrared (IR) light between 760 nm and 2000 nm; adding each dye solution to each soluble polymer solution to form each dye solution; and casting each dye solution to form each film, which are then laminated into an eyeglass lens.

12. 5. The method of claim 4, wherein the laminating or casting comprises laminating or casting an additional colored film, a transparent film, or a functional dye mixture film together with the film onto the eyeglass lens, goggle lens, or shield, or adhering at least one single-layer film to the inside of a coinjection molding mold to produce the eyeglass lens, goggle lens, or shield.

13. 5. The method according to claim 4, wherein an additional color film, clear film, or functional dye mixture film is laminated or cast onto the eyeglass lens, goggle lens, or shield together with the film by lamination or casting means, or at least one single-layer film is applied to the inside of a coinjection mold to produce the eyeglass lens, goggle lens, or shield.

14. 11. The method according to claim 10, wherein an additional color film, clear film, or functional dye mixture film is laminated or cast onto the lens, goggle lens, or shield together with the film by lamination or casting means, or at least one single-layer film is applied inside a mold for coinjection molding to produce a spectacle lens, goggle lens, or shield.

15. 12. The method according to claim 11, wherein an additional color film, clear film, or functional dye mixture film is laminated or cast onto the eyeglass lens, goggle lens, or shield together with the film by lamination or casting means, or at least one single-layer film is applied to the inside of the mold for co-injection molding to produce the eyeglass lens, goggle lens, or shield.

Images