Polarized lenses containing a blend of NIR dyes for broad NIR protection

Abstract

To provide an optical element and a method for manufacturing the same.SOLUTION: An optical element contains two or more kinds of near infrared absorbents mixed in an optical base material and one or more functional films arranged on the optical base material. A method for manufacturing the optical element includes mixing two kinds of near infrared absorbers having different near infrared wavelength absorption ranges and residual colors with a precursor of the optical base material. The mixture is then processed to manufacture the optical element having a wide variety of near infrared wavelength absorption range, a high near infrared absorption level and / or a homogeneous color distribution.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an optical element and a manufacturing method thereof, and more particularly to an optical element containing a plurality of near-infrared absorbents mixed in an optical substrate and a functional film disposed on the optical substrate. [Background technology]

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

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

[0004] Optical filtering means are commonly incorporated into optical articles (e.g., sunglass lens materials) to reduce or prevent NIR light from reaching the retina. More specifically, two types of NIR filters can be used on optical lenses to provide eye protection against NIR radiation: an NIR-absorbing filter and an interference filter (e.g., a reflective filter). However, it has been shown that high NIR absorption can adversely affect the anti-reflection performance of optical filters, making it difficult to design a multifunctional filter with optimized NIR absorption performance along with other functions, including anti-reflection. NIR absorbers can be incorporated into optical coatings deposited on optical articles. However, directly incorporating NIR absorbers into optical coatings can significantly increase the manufacturing cost of the lens and simultaneously degrade the mechanical properties of the optical coating.

[0005] Another option for improving NIR protection is to incorporate NIR absorbers into the bulk substrate of an optical article by impregnating the substrate with the NIR absorber or mixing a substrate precursor with the NIR absorber. However, most commercially available NIR absorbers are thermally unstable under the conditions of the lens manufacturing process. For example, polarized lenses are generally manufactured by injection molding with a polarizing wafer placed on the front surface of the lens. The temperature during injection molding can reach temperatures above 300°C, at which point many commercially available NIR absorbers decompose, resulting in a loss of NIR protection in the manufactured lens. Furthermore, commercially available NIR absorbers mixed into the lens substrate can significantly reduce the light transmittance of the manufactured lens, resulting in the manufactured lens not meeting the specifications for transmission classification. Additionally, commercially available NIR absorbers generally have a residual color, which can change the color appearance of the lens. Summary of the Invention [Problem to be solved by the invention]

[0006] Generally, optical lenses or other optical elements that provide NIR protection exist, but in view of at least the above-mentioned shortcomings associated with these optical lenses or elements, there continues to be a need for improvements in this area. [Means for solving the problem]

[0007] A solution to the above-mentioned problems associated with optical elements with near-infrared (NIR) protection has been discovered. This solution is based on an optical element including an optical substrate having one or more functional films disposed on the front surface thereof and two or more near-infrared absorbers mixed in the optical substrate. The near-infrared absorbers can be mixed substantially homogeneously in the optical substrate. The two or more near-infrared absorbers in the optical element can have different near-infrared ranges so that the optical element can absorb near-infrared radiation over a broader wavelength range compared to conventional NIR-protected optical articles. Furthermore, the two or more near-infrared absorbers in the optical element can have different residual colors so that synergistic residual color intensity is minimized and changes in the color appearance of the optical element caused by the NIR absorbers are avoided. Furthermore, the NIR absorbers in the optical element are adapted to minimize synergistic decreases in light transmittance caused by the NIR absorbers and to withstand the manufacturing conditions of the optical element without decomposition. Thus, the optical element of the present invention provides a technical solution to at least some of the problems associated with conventional NIR-protected optical elements.

[0008] Some embodiments of the present invention relate to an optical element. In some embodiments, the optical element may include an optical substrate having a front surface and a back surface. The optical element may include two or more near-infrared absorbing agents substantially homogeneously mixed in the optical substrate. In some embodiments, the optical element may include one or more functional films disposed on the front surface and / or back surface of the optical element. In some embodiments, the two or more near-infrared absorbing agents have different near-infrared cutoff ranges and / or different residual colors.

[0009] Some embodiments of the present invention relate to a method for preparing an optical element. In some aspects, the method may include providing a precursor material for an optical substrate and two or more near-infrared absorbers. In some aspects, the method may include determining a concentration for each of the two or more near-infrared absorbers such that the two or more near-infrared absorbers synergistically produce an infrared cutoff range that is broader than the individual infrared cutoff ranges of each of the two or more near-infrared absorbers and / or an infrared absorption level that is higher than the individual infrared absorption ranges of each of the two or more near-infrared absorbers. In some aspects, the method may include mixing the precursor material and the two or more near-infrared absorbers at a concentration determined to form a substantially homogeneous mixture. In some aspects, the method may include using the mixture to manufacture an optical element comprising an optical substrate and a functional film disposed on the front and / or back surface thereof.

[0010] The term "about" or "approximately" is defined as close as understood by one of ordinary skill in the art. In one non-limiting embodiment, the term is defined to be within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0011] The terms "wt. %, "vol. %" or "mole %" refer to the weight, volume or mole percent, respectively, of a component based on the total weight, volume or moles of the material containing that component.

[0012] The term "substantially" and variations thereof are defined to include ranges of within 10%, within 5%, within 1%, or within 0.5%.

[0013] The terms "inhibit," "reduce," "prevent," or "avoid," and variations thereof, when used in the claims and / or specification, include any measurable reduction or complete inhibition to achieve a desired result.

[0014] The term "effective," as used in the specification and / or claims, means adequate to accomplish a desired, expected, or intended result.

[0015] The use of the terms "a" or "an," when used in conjunction with the terms "comprising," "including," "containing," or "having" in the claims or specification, can mean "one," but is also consistent with the meanings of "one or more," "at least one," and "one or more."

[0016] The terms "comprising" (and any form of "comprising", such as "comprise" and "comprises"), "having" (and any form of "having", such as "have" and "has"), "including" (and any form of "including", such as "includes" and "include"), or "containing" (and any form of "containing", such as "contains" and "contain") are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0017] The processes of the present invention can "comprise," "consist essentially of," or "consist of" certain ingredients, components, compositions, etc., disclosed throughout this specification.

[0018] Other objects, features, and advantages of the present invention will become apparent from the following drawings, detailed description, and examples. It should be understood, however, that the drawings, detailed description, and examples, while indicating specific embodiments of the present invention, are given by way of illustration only and are not intended to be limiting. Additionally, changes and modifications within the spirit and scope of the present invention will become apparent to those skilled in the art from this detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any other embodiment. In further embodiments, additional features may be added to the specific embodiments described herein.

[0019] For a more complete understanding, reference is now made to the following descriptions taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0020] [Figure 1] 1 shows a schematic flow chart of a method for manufacturing a functional film and an optical element containing two or more near-infrared absorbers according to disclosed embodiments. [Figure 2A-2B] 2A shows plots of the spectral transmittance of a lens containing Epolight™ 9837 near-infrared absorber (FIG. 2A) and a lens containing Epolight™ 3157 near-infrared absorber. [Figure 3A-3C] 3A shows plots of the spectral transmittance of polycarbonate lenses produced with Epolight™ 9837 near infrared absorber injection molded at 515°F (FIG. 3A), 555°F (FIG. 3B), and 590°F (FIG. 3C). [Figures 4A-4C] 4A-4C show plots of the spectral transmittance of polycarbonate lenses produced with Epolight™ 3157 near infrared absorber injection molded at 515°F (FIG. 4A), 555°F (FIG. 4B), and 590°F (FIG. 4C). [Figures 5A-5C]5A shows plots of the spectral transmittance of each lens configuration listed in Table 3 with lens bases of 1.50B (FIG. 5A), 4.25B (FIG. 5B), and 8.50B (FIG. 5C). [Figures 6A-6B] Photographs of high transmission polarized, standard polarized, and non-polarized lenses are shown, all containing Epolight™ 9837 and Epolight™ 3157 near-infrared absorbers. Figure 6A is a photograph of a -7.00 power lens with a center thickness of 1.3 mm, and Figure 6B is a photograph of a +4.00 power lens with a center thickness of 6.5 mm. DETAILED DESCRIPTION OF THE INVENTION

[0021] Currently available optical articles with NIR protection function have deficiencies, including decomposition of the near-infrared absorber during the manufacturing process, changes in color appearance caused by the near-infrared absorber, and insufficient NIR absorption wavelength range. The present invention provides a solution to at least some of these problems. This solution is based on an optical element containing two or more NIR absorbers mixed in an optical substrate. The two or more near-infrared absorbers can have different NIR absorption ranges, so that the optical element has a broader NIR absorption range than each of the near-infrared absorbers. Additionally, the two or more near-infrared absorbers have different residual colors, so that the near-infrared absorbers synergistically have a neutral residual color, thereby minimizing color changes in the optical article caused by the NIR absorbers. Furthermore, the NIR absorbers mixed in the optical substrate are thermally stable under the manufacturing conditions of the optical article, avoiding decomposition of the NIR absorber during high-temperature processes such as injection molding.

[0022] These and other non-limiting aspects of the present invention are discussed in more detail in the following sections.

[0023] A. Optical elements with near-infrared protection Near-infrared rays have been proven to cause eye damage. Optical elements such as ophthalmic lenses can incorporate near-infrared protection to protect the user's eyes. However, conventionally, near-infrared absorbers are generally incorporated into optical filters, which require additional processing to be applied to the optical element, or into optical coatings, whose mechanical strength may be adversely affected by the near-infrared absorber. Near-infrared absorbers can be incorporated into optical substrates. However, many commercially available near-infrared absorbers are thermally unstable under the manufacturing conditions of optical articles, which limits the manufacturing processes that can be used to manufacture optical articles. Near-infrared absorbers in optical articles can cause changes in the color of the optical article, thereby adversely affecting the aesthetic appearance of the optical article.

[0024] The optical elements disclosed herein are thermally stable at high processing temperatures for lens manufacturing processes, including injection molding. The optical elements can extend the near-infrared wavelength cutoff range of the optical elements and minimize the residual color of the near-infrared absorbing agent by incorporating two or more near-infrared absorbing agents with different absorption ranges and / or different residual colors into the optical substrate of the optical elements. Some embodiments include optical elements. In some examples, the optical elements can be ophthalmic lenses. Ophthalmic lenses can include sunglass lenses or substantially colorless clear lenses.

[0025] In embodiments of the present invention, the optical element can include an optical substrate including a front surface and a back surface. In some aspects, the front surface of the optical substrate can include the convex surface of an ophthalmic lens. In some aspects, the back surface of the optical element can include the concave surface of an ophthalmic lens. Non-limiting examples of optical substrates include polycarbonate, polyurethane, acrylic, polyamide, poly(methyl methacrylate), copolyester, cellulose triacetate, allyl diglycol carbonate, polyepisulfide, Trivex, polyacrylic, polyol, polyamine, polyanhydride, polycarboxilic acid, polyepoxide, polyisocyanate, polynorbornene, polysiloxane, polysilazane, polystyrene, polyolefin, polyester, polyimide, polyurethane, polythiourethane, polyallylic, polysulfide, polyvinyl ester, polyvinyl ether, polyarylene, polyoxide, polysulfone, polycycloolefin, polyacrylonitrile, polyethylene terephthalate, polyetherimide, polypentene, or any combination thereof.

[0026] In embodiments of the present invention, the optical element can include two or more near-infrared absorbing agents mixed in an optical substrate. In some embodiments, the two or more near-infrared absorbing agents can include polymethine, phthalocyanine, porphyrin, triphenylmethane, iminium, squarylium, croconium, dithiolene, quinone, polyperylene, pyrilium, thiopyrilium, cyanine, or any combination thereof. In some embodiments, the optical element has a saturation concentration of about 10 to 2000 ppm, as well as 10 to 20 ppm, 20 to 30 ppm, 30 to 40 ppm, 40 to 50 ppm, 50 to 60 ppm, 60 to 70 ppm, 70 to 80 ppm, 80 to 90 ppm, 90 to 100 ppm, 100 to 200 ppm, 200 to 300 ppm, 300 to 400 ppm, 400 to 500 ppm, 500 to 600 ppm, 600 to 700 ppm, 700 to 800 ppm m, 800 to 900 ppm, 900 to 1000 ppm, 1000 to 1100 ppm, 1100 to 1200 ppm, 1200 to 1300 ppm, 1300 to 1400 ppm, 1400 to 1500 ppm, 1500 to 1600 ppm, 1600 to 1700 ppm, 1700 to 1800 ppm, 1800 to 1900 ppm, and 1900 to 2000 ppm, and all ranges and values ​​therebetween.

[0027] In some examples, two or more near-infrared absorbing agents may be mixed substantially homogeneously in the optical substrate. In some examples, two or more near-infrared absorbing agents may be mixed at a higher concentration in the front and / or rear portions of the optical substrate than in the central portion of the optical substrate. In some embodiments, the front portion may comprise approximately one-third of the thickness of the optical substrate closest to the front surface of the optical substrate. In some embodiments, the rear portion may comprise approximately one-third of the thickness of the optical substrate closest to the rear surface of the optical substrate.

[0028] In some examples, the two or more near-infrared absorbers in the optical element are thermally stable to substantially avoid decomposition in the temperature range of 200 to 400°C, and all ranges and values ​​therebetween, including 200 to 210°C, 210 to 220°C, 220 to 230°C, 230 to 240°C, 240 to 250°C, 250 to 260°C, 260 to 270°C, 270 to 280°C, 280 to 290°C, 290 to 300°C, 300 to 310°C, 310 to 320°C, 320 to 330°C, 330 to 340°C, 340 to 350°C, 350 to 360°C, 360 to 370°C, 370 to 380°C, 380 to 390°C, and 390 to 400°C. In some embodiments, the two or more near-infrared absorbers have different near-infrared cutoff ranges and / or different residual colors. In some embodiments, the two or more near-infrared absorbers in the optical element are adapted to produce a synergistic color intensity that is lower than the individual color intensities of each of the two or more near-infrared absorbers. In some examples, the synergistic color intensity of the two or more near-infrared absorbers can be in the chroma range of 0 to 5, as well as all ranges and values ​​therebetween, including 0 to 0.5, 0.5 to 1, 1 to 1.5, 1.5 to 2, 2 to 2.5, 2.5 to 3, 3 to 3.5, 3.5 to 4, 4 to 4.5, and 4.5 to 5. In some examples, the two or more near-infrared absorbers are synergistically neutral in color, or preferably colorless.

[0029] In some embodiments, the optical element is configured to provide a wavelength range of 780 to 2000 nm, as well as 780 to 820 nm, 820 to 860 nm, 860 to 900 nm, 900 to 940 nm, 940 to 980 nm, 980 to 1020 nm, 1020 to 1060 nm, 1060 to 1100 nm, 1100 to 1140 nm, 1140 to 1180 nm, 1180 to 1200 nm, 1200 to 1240 nm, 1240 to 1280 nm, 1280 to 1320 nm, 1320 to 1360 nm, 1360 to 1400 nm, 1400 to 1500 nm, 1500 to 1600 nm, 1600 to 1700 nm, 1700 to 1800 nm, 1800 to 1900 nm, 1900 to 2000 nm, 2000 to 2100 nm, 2100 to 2200 nm, 2200 to 2300 nm, 2300 to 2400 nm, 2400 to 2500 nm, 2500 to 2600 nm, 2600 to 2700 nm, 2700 to 2800 nm, 2800 to 3000 nm, 3000 to 3100 nm, 3100 to 3200 nm, 3300 to 3300 nm, 3400 to 3500 nm, 3500 to 3600 nm, 3600 to 3700 nm, 3700 to 3800 It may be possible to absorb near-infrared radiation in all ranges and values ​​therebetween, including the ranges of 400 to 1440 nm, 1440 to 1480 nm, 1480 to 1520 nm, 1520 to 1560 nm, 1560 to 1600 nm, 1600 to 1640 nm, 1640 to 1680 nm, 1680 to 1720 nm, 1720 to 1760 nm, 1760 to 1800 nm, 1800 to 1840 nm, 1840 to 1880 nm, 1880 to 1920 nm, 1920 to 1960 nm, and 1960 to 2000 nm. In some embodiments, two or more near-infrared absorbers in an optical element are adapted to produce a synergistic infrared-cutting range that is broader than the individual infrared-cutting ranges of each of the two or more near-infrared absorbers.

[0030] In some embodiments, the two or more near-infrared absorbers in the optical element are adapted to generate a synergistic infrared absorption level that is higher than the individual near-infrared absorption level of any of the two or more near-infrared absorbers. In some embodiments, the synergistic near-infrared transmittance level of the two or more near-infrared absorbers is (TsIR 780-2000The transmittance can be in the range of 5-80% (determined as Tv%(D65)), and all ranges and values ​​therebetween, including 5-10%, 10-15%, 15-20%, 20-25%, 25-30%, 30-35%, 35-40%, 40-45%, 45-50%, 50-55%, 55-60%, 60-65%, 65-70%, 70-75%, and 75-80%. In some embodiments, the two or more near-infrared absorbers in the optical element are adapted to synergistically cause a decrease in average optical transmittance in the wavelength range of 380-780 nm (determined as Tv%(D65)) of less than 10 for the optical substrate, including ranges of 0-1%, 1-2%, 2-3%, 3-4%, 4-5%, 5-6%, 6-7%, 7-8%, 8-9%, and 9-10%.

[0031] In some embodiments, the optical element can include one or more functional films disposed on the front and / or back surface of the optical substrate. Non-limiting examples of functional films include polarizing films, photochromic films, color films, dyeable films, light filter films including blue-cut films, chrono-cut films, and any combination thereof. In some examples, the functional film includes a polarizing film having an average light transmittance level of less than about 50%. In some embodiments, the polarizing film can be prepared by forming a polarizing filter including at least one of a polyvinyl alcohol polarizing layer, a polyacetylene polarizing layer, a polyene polarizing layer, a polyvinylene polarizing layer, a polyethylene terephthalate (PET) polarizing layer, or a wire grid polarizing layer on a curved wafer. The polarizing film can have a single-layer structure or a multi-layer structure. In some examples, the polarizing film can include one or more protective or functional layers. Non-limiting examples of protective layers may include polycarbonate (PC) protective layers, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose triacetate (TAC), polymethyl methacrylate (PMMA), polyamide (PA), PET, cyclic olefin copolymer (COC), cyclic olefin polymer (COP), and combinations thereof. Non-limiting examples of functional layers may include photochromic layers, blue-cut layers, UV-cut layers, color enhancement layers, dyeable layers, mirror layers, or any combination thereof. In some embodiments, the polarizing film may include a high-transmission filter.

[0032] In some embodiments, the optical element has a substantially uniform color. In some embodiments, the optical element has an average light transmittance level greater than 8%, preferably 8-50%, and all ranges and values ​​therebetween, including 8-11%, 11-14%, 14-17%, 17-20%, 20-23%, 23-26%, 26-29%, 29-32%, 32-35%, 35-38%, 38-41%, 41-44%, 44-47%, and 47-50%. In some embodiments, the optical element has a Delta E value between the center and its edge of less than about 2. Delta E represents the difference in color between the center and edge of the optical element. The Delta E value is:

number

[0033] B. Method for manufacturing optical elements containing NIR absorbers Conventionally, the method for producing NIR absorbing optical elements includes mixing near-infrared absorbents in optical substrate precursors, and then using the mixture to produce optical elements.However, the process conditions for producing optical elements often include high temperatures at which near-infrared absorbents are thermally unstable, resulting in the loss of near-infrared absorbing ability of the produced optical elements.In addition, the near-infrared absorbents used in conventional methods can change the color appearance of optical elements, which can negatively affect the aesthetic appearance of optical elements.

[0034] The methods disclosed herein can avoid these drawbacks of conventional methods. As shown in FIG. 1 , embodiments include a method 100 for preparing the above-described optical element capable of absorbing near-infrared radiation. In some embodiments, the optical element can include an ophthalmic lens. In some examples, the optical element can be a sunglass lens or a clear ophthalmic lens.

[0035] In some embodiments, method 100 can include providing a precursor material for an optical substrate and two or more near-infrared absorbers, as shown in block 101. In some aspects, the precursor material includes a precursor for an optical substrate of polycarbonate, polyurethane, acrylic, polyamide, poly(methyl methacrylate), copolyester, cellulose triacetate, allyl diglycol carbonate, polyepisulfide, trivex, polyacrylic, polyol, polyamine, polyanhydride, polycarboxilic acid, polyepoxide, polyisocyanate, polynorbornene, polysiloxane, polysilazane, polystyrene, polyolefin, polyester, polyimide, polyurethane, polythiourethane, polyallylic, polysulfide, polyvinyl ester, polyvinyl ether, polyarylene, polyoxide, polysulfone, polycycloolefin, polyacrylonitrile, polyethylene terephthalate, polyetherimide, polypentene, or any combination thereof. In some embodiments, the two or more near-infrared absorbers have different near-infrared cutoff ranges and / or different residual colors, and are selected from the group consisting of polymethines, phthalocyanines, porphyrins, triphenylmethanes, iminiums, squaryliums, croconiums, dithiolenes, quinones, polyperylenes, pyriliums, thiopyriliums, cyanines, and combinations thereof.

[0036] In some embodiments, method 100 includes determining a concentration for each of two or more near-infrared absorbers, as shown in block 102. In some aspects, the two or more near-infrared absorbers synergistically produce an infrared cut range that is broader than the individual infrared cut ranges of each of the two or more near-infrared absorbers and / or an infrared absorption level that is higher than the individual infrared absorption ranges of each of the two or more near-infrared absorbers at the concentrations determined in block 102. In some examples, the two or more near-infrared absorbers include 10 to 2000 ppm of a first NIR absorber and 10 to 2000 ppm of a second NIR absorber. In some embodiments, the two or more near-infrared absorbers provided in block 102 are thermally stable at temperatures between 200 and 400°C, and all ranges and values ​​therebetween, including 200-210°C, 210-220°C, 220-230°C, 230-240°C, 240-250°C, 250-260°C, 260-270°C, 270-280°C, 280-290°C, 290-300°C, 300-310°C, 310-320°C, 320-330°C, 330-340°C, 340-350°C, 350-360°C, 360-370°C, 370-380°C, 380-390°C, and 390-400°C.

[0037] In some embodiments, the determining in block 102 is performed by a trial and error method that includes fabricating a plurality of optical elements with various concentrations of two or more near-infrared absorbers and selecting one or more combinations of concentrations of the two or more near-infrared absorbers based on one or more criteria. In some examples, the criteria may include one or more of: a synergistic color of the two or more near-infrared absorbers that is neutral or colorless; a synergistic near-infrared absorption level that is higher than the individual near-infrared absorption levels of each infrared absorber; a synergistic near-infrared cut range that is broader than the individual near-infrared cut range of each infrared absorber; a synergistic reduction in average optical transmittance in the wavelength range of 380 to 780 nm caused by less than 10% near-infrared absorbers; and substantial color uniformity of the fabricated optical elements containing the near-infrared absorbers.

[0038] In some embodiments, as shown in block 103, method 100 includes mixing the precursor material and two or more near-infrared absorbers at the determined concentrations obtained in block 102 to form a mixture. In some aspects, the mixture can be substantially homogeneous. In some embodiments, mixing can be carried out at a temperature ranging from 0 to 400°C, and all ranges and values ​​therebetween, including 0 to 20°C, 20 to 40°C, 40 to 60°C, 60 to 80°C, 80 to 100°C, 100 to 120°C, 120 to 140°C, 140 to 160°C, 160 to 180°C, 180 to 200°C, 200 to 220°C, 220 to 240°C, 240 to 260°C, 260 to 280°C, 280 to 300°C, 300 to 320°C, 320 to 340°C, 340 to 360°C, 360 to 380°C, and 380 to 400°C. In some embodiments, the mixing in block 103 can include optionally mixing a second amount of precursor material with one or more of an ultraviolet dye, a monomer, a catalyst, a release agent, or any combination thereof to produce a first mixture.

[0039] In some embodiments, as shown in block 104, method 100 includes manufacturing an optical element including an optically functional film disposed on its front and / or back surface using the mixture obtained in block 103. In some aspects, the manufacturing step can include forming the optical element by injection molding or casting under process conditions that have substantially no effect on the near-infrared absorption levels of the two or more near-infrared absorbers.

[0040] In some examples, manufacturing in block 104 includes producing a polarized polycarbonate ophthalmic lens by injection molding. In some embodiments, the injection molding process includes placing a polarized film on the inner surface of an injection mold, injecting a mixture containing molten polycarbonate and a near-infrared absorbing agent into the mold, and solidifying the mixture by cooling in the mold to produce a polarized polycarbonate lens. In some embodiments, the mixture is injected into the mold at a temperature of 25-170°C, as well as all ranges and values ​​therebetween, including 25-40°C, 40-55°C, 55-70°C, 70-85°C, 85-100°C, 100-115°C, 115-130°C, 130-145°C, 145-160°C, and 160-170°C. In some embodiments, method 100 can include cleaning the optical element produced in block 104.

[0041] Although embodiments of the present invention have been described with reference to the blocks of Figure 1, it should be appreciated that the operation of the present invention is not limited to the specific blocks and / or the specific order of blocks shown in Figure 1. Thus, some embodiments may provide the functionality described herein using various blocks in an order different from that of Figure 1.

[0042] Included below as part of the disclosure of the present invention are specific examples. These examples are for illustrative purposes only and are not intended to limit the present invention. One of ordinary skill in the art will readily recognize parameters that can be changed or modified to yield essentially the same results. [Example]

[0043] Example 1 (Evaluation of near-infrared absorbers) The properties, including NIR cut range, color properties, and thermal stability, of two near infrared absorbers in polycarbonate ophthalmic lenses were evaluated. The near infrared absorbers tested are listed in Table 1.

[0044] [Table 1]

[0045] Epolight™ 9837 (Epolin, USA) and Epolight™ 3157 (Epolin, USA) near-infrared absorbers were each mixed with PC pellets at a concentration of 50 ppm. The mixtures were injection molded into 2 mm (thick) flat lenses at three different injection molding temperatures, including 515°F (268.3°C), 555°F (290.5°C), and 590°F (310.0°C). Each lens sample was tested for near-infrared cutoff range and level, thermal stability during the injection molding process, and lens light transmission spectrum.

[0046] Figure 2A shows the spectral transmittance of a lens containing Epolight™ 9837 near-infrared absorber, and Figure 2B shows the spectral transmittance of a lens containing Epolight™ 3157 near-infrared absorber. The near-infrared absorption levels (NIR Cut (%)) and residual color properties are summarized in Table 2.

[0047] [Table 2]

[0048] The thermal stability results of the near-infrared absorbers are shown in Figures 3A-3C and 4A-4C. Figures 3A-3C show the optical spectral transmittance of polycarbonate lenses made with Epolight™ 9837 injection molded at 515°F (268.3°C), 555°F (290.5°C), and 590°F (310.0°C), respectively. Figures 4A-4C show the optical spectral transmittance of polycarbonate lenses made with Epolight™ 3157 injection molded at 515°F (268.3°C), 555°F (290.5°C), and 590°F (310.0°C), respectively. The results show that for the Epolight™ 9837 absorber, increasing the injection molding temperature from 515°F to 590°F decreased the near-infrared absorption level and broadened the near-infrared absorption range. For Epolight™ absorbers, near-infrared absorption levels did not change substantially in terms of near-infrared absorption level and range as the injection molding temperature increased from 515° F. to 590° F. Thus, Epolight™ 9837 is thermally unstable at 555° F. and 590° F., but is stable at 515° F. Epolight™ 3157 is stable at all three tested temperatures.

[0049] Example 2 (Polarized lenses with multiple near-infrared absorbing agents) Polycarbonate-based polarized lenses were manufactured by injection molding using Epolight™ 9837 and Epolight™ 3157 near-infrared absorbers. The concentration of each near-infrared absorber in each lens sample was 100 ppm. Both standard (Std.) transmission polarizing wafers and high-transmission (Hi-T) polarizing wafers were used. The polycarbonate pellets and two near-infrared absorbers mixture for each sample were injection molded at 515°F (268.3°C). During the injection molding process, the polarizing wafer was placed on the interior front (concave) surface of the mold. The ingredients for each set of lens samples are listed in Table 3.

[0050] [Table 3]

[0051] [Table 4]

[0052] The optical spectral transmittance of each sample was measured. The results are shown in Figures 5A-5C for the 1.50B, 4.25B, and 8.50B samples, respectively. The results show that all samples with both NIR absorbers have improved NIR absorption ranges and higher NIR absorption levels compared to samples without NIR absorbers.

[0053] Infrared transmittance TsIR of each lens sample in the range of 780 to 2000 nm 780-2000 was calculated using the following equation:

number

[0054] [Table 5]

[0055] The results in Table 5 show that the near-infrared absorbers in the polarized lens samples cause a slight decrease in total light transmission Tv (%), indicating that the near-infrared absorbers have a minimal synergistic effect on the wearer's visual perception. Table 5 further shows that lenses with both near-infrared absorbers have a significant increase in the near-infrared absorption level of the polarized lens samples. Furthermore, as shown in Figures 6A and 6B, the selected near-infrared absorbers (NIR dyes) synergistically neutralized the color with low color intensity. The two near-infrared absorbers do not significantly change the color of a -7.00 power polarized lens with a 1.3 mm center thickness (CT) (Figure 6A) or a +4.00 power lens with a 6.5 mm center thickness (CT) (Figure 6B).

[0056] Although the embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made therein without departing from the spirit and scope of the embodiments, as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the processes, procedures, machines, manufacture, compositions of matter, means, methods, and / or steps described in the specification. As those skilled in the art will readily recognize from the above disclosure, existing or future-developed processes, machines, manufacture, compositions of matter, means, methods, or steps that perform substantially the same function or achieve substantially the same results as the corresponding embodiments described herein may also be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. The present disclosure includes the following inventive aspects: <Aspect 1> an optical substrate including a front surface and a back surface; two or more near-infrared absorbing agents that are substantially homogeneously mixed in the optical substrate; one or more functional films disposed on the front and / or back surface of the optical substrate; An optical element comprising: An optical element in which the two or more near-infrared absorbents have different near-infrared cutoff ranges and / or different residual colors. <Aspect 2> 10. The optical element of embodiment 1, wherein the optical element comprises an ophthalmic lens. <Aspect 3> 2. The optical element of embodiment 1, wherein the two or more near infrared absorbers in the optical element are adapted to generate a synergistic near infrared absorption level that is higher than the near infrared absorption level of any of the two or more near infrared absorbers individually. <Aspect 4> 2. The optical element of embodiment 1, wherein the two or more near infrared absorbers in the optical element are adapted to produce a synergistic infrared-cutting range that is broader than the individual infrared-cutting ranges of each of the two or more near infrared absorbers. <Aspect 5> 2. The optical element of embodiment 1, wherein the two or more near infrared absorbers in the optical element are adapted to synergistically cause less than a 10% decrease in average optical transmittance in a wavelength range of 380 to 780 nm for the optical substrate. <Aspect 6> 2. The optical element of embodiment 1, wherein the optical substrate comprises polycarbonate, polyurethane, acrylic, polyamide, poly(methyl methacrylate), copolyester, cellulose triacetate, allyl diglycol carbonate, polyepisulfide, Tribex, polyacrylic, polyol, polyamine, polyanhydride, polycarboxylic acid, polyepoxide, polyisocyanate, polynorbornene, polysiloxane, polysilazane, polystyrene, polyolefin, polyester, polyimide, polyurethane, polythiourethane, polyallylic, polysulfide, polyvinyl ester, polyvinyl ether, polyarylene, polyoxide, polysulfone, polycycloolefin, polyacrylonitrile, polyethylene terephthalate, polyetherimide, polypentene, or any combination thereof. <Aspect 7> 2. The optical element of embodiment 1, wherein the two or more near infrared absorbers comprise a polymethine, a phthalocyanine, a porphyrin, a triphenylmethane, an iminium, a squarylium, a croconium, a dithiolene, a quinone, a polyperylene, a pyrylium, a thiopyrylium, a cyanine, or any combination thereof. <Aspect 8> 2. The optical element of embodiment 1, wherein the one or more functional films comprise a polarizing film, a photochromic film, a color film, a dyeable film, a blue cut film, a chrono cut film, a light filter film including a near-infrared filter film, or any combination thereof. <Aspect 9> 2. The optical element according to aspect 1, wherein the optical element comprises 10 to 2000 ppm of the two or more near-infrared absorbents. <Aspect 10> 10. The optical element of embodiment 1, wherein the optical element has a substantially homogeneous color. <Aspect 11> 11. The optical element of embodiment 10, wherein the functional film comprises a polarizing film having an average light transmittance level of less than about 50%. <Aspect 12> 11. The optical element of embodiment 10, wherein the optical element has an average light transmittance level greater than about 8%. <Aspect 13> 2. The optical element of embodiment 1, wherein the optical element has a Delta E value, representing the difference in color between the center and its edges, of less than about 2. <Aspect 14> A method for preparing the optical element according to any one of aspects 1 to 13, comprising: Providing a precursor material for the optical substrate and two or more of the near-infrared absorbents; determining a concentration of each of the two or more near infrared absorbents such that the two or more near infrared absorbents synergistically produce an infrared cut range that is broader than the individual infrared cut ranges of the two or more near infrared absorbents and / or an infrared absorption level that is higher than the individual infrared absorption ranges of the two or more near infrared absorbents; mixing the precursor material and the two or more near infrared absorbers at concentrations determined to form a substantially homogeneous mixture; using the mixture to manufacture the optical element comprising the optical substrate and the functional film disposed on the front and / or back surface thereof; A method comprising: <Aspect 15> 15. The method of embodiment 14, wherein the manufacturing step comprises forming the optical element by injection molding or casting under process conditions that have substantially no effect on the near infrared absorption level of the two or more near infrared absorbers.

Claims

1. an optical substrate including a front surface and a back surface; Two or more near-infrared absorbents mixed in the optical substrate; one or more functional films disposed on the front and / or back surface of the optical substrate; An ophthalmic lens comprising: the two or more near-infrared absorbents have different near-infrared cut ranges and / or different residual colors, the one or more functional films include a polarizing film; the two or more near-infrared absorbers comprise at least one near-infrared absorber selected from polymethine, phthalocyanine, porphyrin, triphenylmethane, iminium, squarylium, croconium, dithiolene, quinone, polyperylene, pyrylium, thiopyrylium, and cyanine, and at least one further near-infrared absorber selected from polymethine, porphyrin, triphenylmethane, iminium, squarylium, croconium, dithiolene, quinone, polyperylene, pyrylium, thiopyrylium, and cyanine; the at least one near infrared absorber and / or the at least one further near infrared absorber are thermally stable in a temperature range of 260 to 270°C and thermally unstable in a temperature range of 290 to 310°C; the two or more near infrared absorbers are adapted to cause a decrease in average optical transmittance Tv %D65 in the 380 to 780 nm wavelength range for the optical substrate of less than 10% compared to the average optical transmittance Tv %D65 of the ophthalmic lens not containing a near infrared absorber, the decrease being measured on an optical substrate having a center thickness (CT) of 1.9 mm, 1.8 mm, or 1.3 mm; the two or more near infrared absorbers are adapted to produce a near infrared absorption level that is higher than the individual near infrared absorption level of any of the two or more near infrared absorbers; Eye lenses.

2. 10. The ophthalmic lens of claim 1, wherein the two or more near-infrared absorbing agents in the ophthalmic lens are adapted to produce a near-infrared cut range that is broader than the individual near-infrared cut ranges of each of the two or more near-infrared absorbing agents.

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

4. The ophthalmic lens of claim 1 , wherein the one or more functional films comprise a photochromic film, a color film, a dyeable film, a blue cut film, a chrono cut film, a light filter film including a near-infrared filter film, or any combination thereof.

5. 2. The ophthalmic lens of claim 1, wherein the ophthalmic lens comprises 10 to 2000 ppm of the two or more near-infrared absorbing agents.

6. 2. The ophthalmic lens of claim 1, wherein the one or more functional films include a polarizing film having an average light transmittance Tv%D65 in the wavelength range of 380 to 780 nm of less than 50%.

7. The ophthalmic lens of claim 1 , wherein the ophthalmic lens has an average light transmission level greater than 8%.

8. said ophthalmic lens having a Delta E value, representing the difference in color between the center and its edge, of less than 2; The Delta E value is calculated using the CIE 76 formula: [Equation 1] (L, a, b are the color scales defined in CIE Publication 15.2 (1986), Section 4.2, L １ , a １ , b １ represents the central color scale, and L ２ , a ２ , b ２ represents the color scale at the edge) is calculated using The ophthalmic lens according to claim 1 .

9. A method for preparing the ophthalmic lens according to any one of claims 1 to 8, comprising: providing a precursor material for the optical substrate and two or more near-infrared absorbers, wherein the two or more near-infrared absorbers comprise at least one near-infrared absorber selected from polymethine, phthalocyanine, porphyrin, triphenylmethane, iminium, squarylium, croconium, dithiolene, quinone, polyperylene, pyrylium, thiopyrylium, and cyanine, and at least one further near-infrared absorber selected from polymethine, porphyrin, triphenylmethane, iminium, squarylium, croconium, dithiolene, quinone, polyperylene, pyrylium, thiopyrylium, and cyanine, wherein the at least one near-infrared absorber and / or the at least one further near-infrared absorber is thermally stable in a temperature range of 260 to 270°C and thermally unstable in a temperature range of 290 to 310°C; determining a concentration of each of the two or more near infrared absorbers, wherein the two or more near infrared absorbers at the concentration produce a near infrared absorption level that is higher than the individual near infrared absorption level of each of the two or more near infrared absorbers, and wherein the two or more near infrared absorbers at the concentration are adapted to cause a decrease in average optical transmittance Tv %D65 in the 380 to 780 nm wavelength range for the optical substrate of less than 10% compared to the average optical transmittance Tv %D65 of the ophthalmic lens not containing a near infrared absorber, wherein the decrease is measured on an optical substrate having a center thickness (CT) of 1.9 mm, 1.8 mm, or 1.3 mm; mixing the precursor material and the two or more near infrared absorbers at determined concentrations to form a mixture; using the mixture to manufacture the ophthalmic lens comprising the optical substrate and the functional film disposed on the front and / or back surface thereof; Including, the one or more functional films include a polarizing film; method.

10. 10. The method of claim 9, wherein said manufacturing step comprises forming said ophthalmic lens by injection molding or casting under process conditions that have no effect on the near infrared absorption level of said two or more near infrared absorbing agents.

11. 10. The method of claim 9, wherein the concentrations of each of the two or more near infrared absorbers are concentrations at which the two or more near infrared absorbers produce an infrared-blocking range that is broader than the infrared-blocking ranges of each of the two or more near infrared absorbers individually.

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