Narrow-Band Dye Polymer Film Lamination for Uniform Lens Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for dyeing polyethylene terephthalate (PET) films with narrow band dyes are inefficient and unsuitable for mass production due to uneven dye application and time-intensive processes, which is a challenge in producing color enhancing lenses for applications like face shields and windows.
Innovation Solution
A removable lens stack design incorporating a base layer with a polymer film and a dye-containing adhesive coating, encapsulated by a protective layer, and optionally removable lens layers with low peel strength adhesives, allowing for uniform dye application and easy layer replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If PET film is dyed by immersing in solvent bath followed by washing and heating, then dye application is achieved, but the process is time-intensive and unsuitable for mass production
Solution Approach 1:
The patent combines multiple subprocesses (dyeing, washing, heating) into a single integrated coating step where dye-containing adhesive is applied directly to the PET film during lamination. This eliminates the need for separate solvent bath immersion, washing, and heating steps, thereby achieving both uniform dye application and high production efficiency suitable for mass production.
Solution Approach 2:
The dye is pre-mixed into the adhesive formulation before application. This preliminary incorporation of dye into the adhesive allows the coloring function to be achieved during the normal adhesive application process, eliminating subsequent time-intensive dyeing steps while ensuring uniform distribution of dye throughout the adhesive layer.
2Manufacturing precision
If dyes are mixed into PET resin solution prior to extrusion, then uniform dye distribution is achieved, but PET film shows uneven dye application due to its amorphous structure
Solution Approach 1:
The patent uses adhesive as an intermediary carrier to deliver the dye to the PET film. Instead of attempting to incorporate dye directly into the amorphous PET structure (which results in uneven distribution), the dye is dissolved or dispersed in the adhesive, which then uniformly coats the PET film surface, achieving even dye distribution without modifying the PET extrusion process.
3Reliability
If multiple time-intensive subprocesses are used for PET film dyeing, then dye application is achieved, but the process is unsuitable for mass production
Solution Approach 1:
The patent merges the dyeing function with the adhesive application process. The dye-containing adhesive is applied to the PET film in a single step that simultaneously provides both adhesion and coloring, eliminating multiple sequential subprocesses (immersion, washing, heating) and dramatically reducing process time while maintaining reliable dye application quality.
Solution Approach 2:
The dyeing action becomes continuous and integrated with the lamination process. Instead of discrete, time-intensive subprocesses with idle time between steps, the dye application occurs continuously as the adhesive is applied and bonded to the PET film, maintaining productive action throughout the entire process without interruption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, uniform dye application on PET films without time-intensive processes, facilitating mass production of color enhancing lenses with improved visual acuity and durability.
Implementation Method 1
color absorbing dyes that are designed to filter light in specific wavelength ranges with a relatively narrow bandwidth
Implementation Method 2
a coating on the first polymer film containing one or more dyes
Implementation Method 3
a protective layer encapsulating the coating
Data Source
AI summary
A lens stack may include a polymer film, a coating containing one or more dyes, and a protective layer covering or encapsulating the coating. Each of the one or more dyes may be a narrow band dye and may have a full width at half maximum (FWHM) absorption bandwidth of 40 nm or less, for example. The coating may be an adhesive, and the protective layer may be an additional polymer film adhered to the first polymer film by the adhesive. Alternatively, the protective layer may be a scratch resistant topcoat or other layer that covers or encapsulates the coating. The lens stack may be the base layer of a removable lens stack including one or more removable lens layers.