US20160238859A1 - Methods And Systems For Making An Optical Functional Film - Google Patents

Methods And Systems For Making An Optical Functional Film Download PDF

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Publication number
US20160238859A1
US20160238859A1 US14/806,579 US201514806579A US2016238859A1 US 20160238859 A1 US20160238859 A1 US 20160238859A1 US 201514806579 A US201514806579 A US 201514806579A US 2016238859 A1 US2016238859 A1 US 2016238859A1
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Prior art keywords
dye
solution
polymer
soluble
dyed
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US14/806,579
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English (en)
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Roger Wen Yi Hsu
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Individual
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Individual
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Priority to US14/806,579 priority Critical patent/US20160238859A1/en
Priority to AU2015382374A priority patent/AU2015382374A1/en
Priority to JP2017529382A priority patent/JP2018507792A/ja
Priority to CN201580065781.5A priority patent/CN107206712A/zh
Priority to EP15882257.7A priority patent/EP3256301A4/en
Priority to PCT/US2015/047973 priority patent/WO2016130177A1/en
Priority to US14/886,078 priority patent/US10611106B2/en
Publication of US20160238859A1 publication Critical patent/US20160238859A1/en
Priority to US17/019,243 priority patent/US11541616B2/en
Priority to US18/092,436 priority patent/US20230150215A1/en
Abandoned legal-status Critical Current

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    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/10—Filters, e.g. for facilitating adaptation of the eyes to the dark; Sunglasses
    • G02C7/108—Colouring materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00634—Production of filters
    • B29D11/00644—Production of filters polarizing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/0073—Optical laminates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00865—Applying coatings; tinting; colouring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00865—Applying coatings; tinting; colouring
    • B29D11/00894—Applying coatings; tinting; colouring colouring or tinting
    • B29D11/00913—Applying coatings; tinting; colouring colouring or tinting full body; edge-to-edge
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00865—Applying coatings; tinting; colouring
    • B29D11/00923—Applying coatings; tinting; colouring on lens surfaces for colouring or tinting
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/12—Polarisers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00634—Production of filters
    • B29D11/00653—Production of filters photochromic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
    • B29K2029/04—PVOH, i.e. polyvinyl alcohol
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/11—Anti-reflection coatings
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/14—Protective coatings, e.g. hard coatings
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/18—Coatings for keeping optical surfaces clean, e.g. hydrophobic or photo-catalytic films
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C2202/00—Generic optical aspects applicable to one or more of the subgroups of G02C7/00
    • G02C2202/16—Laminated or compound lenses

Definitions

  • the present invention relates generally to an optical component, and more particularly it is directed to methods and system of making functional plastic film, functional Polymer film, or functional PVA film.
  • UV light can cause serious flash burns to the cornea from high intensity light sources.
  • Our eyes need protection from these harmful UV lights.
  • the situations where our eyes definitely need protection from UV lights are welding, exposing to sunlight at elevation above 5000 ft (1524 m), or when the sun glares off snow or water, tanning, etc.
  • UV light is also harmful.
  • Wireless communication, appliances, computer, and lights all emit different levels of harmful radiation.
  • infrared such as those from sunlight.
  • Sunlight is composed of thermal-spectrum radiation that is slightly more than half infrared.
  • sunlight provides an irradiance of approximately 1 kilowatt per square meter at sea level, of which 527 watts is infrared radiation. Once the sunlight reaches the surface of Earth, almost all thermal radiation are of infrared.
  • UV Ultraviolet
  • IR Infrared
  • the lenses must be coated with one or more layers of IR and/or visible dyes.
  • soluble dyes and/or metallic oxide pigments are used for coating to absorb or reflect light of certain frequencies, eg., IR frequencies, UV frequencies, etc.
  • coated lens would reduce or mitigate eye diseases such as cataract and glaucoma.
  • IR or visible coating can be applied by dipping or spraying a solvent IR or visible dyes on another optical layer of a lens.
  • the curvature of the lenses presents a significant obstacle in the application of the IR or visible coating, as the application of the coating may be uneven. As a consequence, the uneven application of the coating on a curved surface would reduce the effectiveness of the protection layers.
  • Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or pulled through a die of the desired cross-section. In a plastic extruding process, plastic is first melted into a viscous, semi-liquid state. After it softens, the plastic is pressed through a contoured opening. Using this technique, a curved lens may be created by pushing a softened optical film through a contoured opening.
  • Injection molding is a manufacturing process for producing parts by injecting material into a mold. Material for the part is fed into a heated barrel, mixed, and forced into a mold cavity, where it cools and hardens to the configuration of the cavity.
  • material for the part is fed into a heated barrel, mixed, and forced into a mold cavity, where it cools and hardens to the configuration of the cavity.
  • heat is needed to soften the plastic films so they can be shaped curvaceously. Since dyes are sensitive to heat, some dye degradation occurs, and the effectiveness of eye protection reduces.
  • IR or visible coated lens Another problem with these IR or visible coated lens is that they are easily scratched and are not resistant to chemicals or elements. Over time the protection layers lose their effectiveness and become harmful if not detected and replaced. To overcome this problem lens manufacturers have put another protection layer on top of the IR/visible layer either by spraying, dipping, or injection. However, as a consequence, additional layers make the lens thicker and to have a minimum thickness, which is a barrier for eyewear design and comfort.
  • This manufacturing technology is unique in that the process does not require conventional extrusion or injection molding technologies, yet it readily incorporates components and features traditionally produced by these processes.
  • This method utilizes a mandrel, or inner diameter mold, that is immersed in a tank of polymer solution or liquid plastic that has been specifically engineered for the process. Due to a combination of thermal and frictional properties, the polymer solution then forms a thin film around the mold. The mold is then extracted from the tank in a precisely controlled manner, followed by a curing or drying process.
  • Other casting devices being used in a solution casting method are a belt or drum machines.
  • supporting belts are 1.0 to 2.0 m wide and 10 to 100 m long.
  • Stainless steel belts are between 1.0 and 2.0 mm thick.
  • Drums are typically 4 to 8 m in diameter and 1.20 to 1.50 m wide.
  • the belt channel allows a stream of air to flow in machine direction or counter direction.
  • the drum is tightly sealed to prevent vapor emissions and to direct the air stream against the direction of drum movement.
  • One of the two pulleys or drums is connected to a drive that requires extremely accurate speed control to avoid even slight speed variations.
  • One drum is connected to a servo system that adjusts belt tension in order to ensure constant flatness and “absence” of belt movements (vibrations) in the critical area just behind the caster, and to control the expansion and dilatation of the belt length caused by temperature changes.
  • Belt machines have a guide system to avoid belt shifting during operation. The belt is guided by horizontal movements of the support drums.
  • Many different support materials have been used for belts: Copper, silver-plated copper, chromium-plated steel, stainless steel, metal coated with polyvinylalcohol or gelatin, polyester film, PTFE film and other polymer films. At present the commonest support materials are stainless steel and chromium-plated surfaces.
  • 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 repeated to encapsulate the reinforcements, build up wall thickness, add additional lumens and optimize column strength.
  • the part is then removed from the mold after it is cured or solidified. This method works with liquid forms of solvent polymers without using excessive heat to cure the part. Since this method uses centrifugal force to shape the part, with the right liquidity ratio, a very thin layer of IR or visible dye solution can be added to an optical film without using excessive heat.
  • Another method to make the film is a static method such as cavity mold or plate casting or other similar method.
  • optical films that have maximum optical purity and extremely low haze, using readily incorporated mixture components.
  • a method to make a dyed functional film comprising 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 make a soluble polymer or PVA solution; providing a soluble dye; adding a solvent to the IR and/or laser dye, photochromic, visible dye to make a soluble dye solution; adding the dye solution to the polymer or PVA solution; introducing the dyed polymer or PVA solution to a solution casting device; letting the solution casting device make a thindyed functional film from the dyed polymer or PVA solution; removing the thin dyed functional film from the casting device; letting the film dry and solidified;
  • the dyed functional film is dried in a temperature between 40-100° C. In another embodiment, the dyed functional film thickness is between 0.0025 mm-2.0 mm.
  • a method to manufacture a functional film comprises the steps of: providing a soluble polymer or a PVA material; adding a polymer solvent to the polymer or the PVA material to make a soluble polymer solution or a PVA solution; providing a soluble dye; adding a dye solvent to the soluble dye to make a soluble dye solution; adding the dye solution to the polymer solution or the PVA solution thereby making a dyed polymer solution or a dyed PVA solution; introducing the dyed polymer solution or the dyed PVA solution to a solution casting device; allowing the solution casting device to make a thin dyed optical film from the dyed polymer solution or the dyed PVA solution; removing the thin dyed optical film from the device; allowing the thin dyed optical film to dry and to solidify.
  • the dyed optical film is dried in a temperature between 40-100° C. In one embodiment, the dyed optical film thickness is between 0.0025 mm-2.0 mm.
  • the polymer is selected from a group consisting of TAC, Cellulose acetate, Cellulose propionate, Polyurethane, PVC, Silicon urethane copolymer, Acrylic, COP, Tetrafluoroethylene polymer, PC, PP, PE, Polyethersulfon, Polyetherimide, Polyvinylidene fluoride, etc., is added to an appropriate 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, E
  • the polymer solvent is selected from a 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, Ether, Esters, Polyimides, Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starch derivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, Methylene Chloride, water.
  • the thin dyed optical film is capable to function as an eyewear lens, a vehicle window, a camera lens, a microscope lens, a building window, an electronic screen or a lamp cover protection.
  • the thin dyed optical film is laminated to a glass lens or a plastic lens.
  • a vacuum coating is applied to the thin dyed optical film.
  • an anti-Reflective coating is applied to the thin dyed optical film.
  • a hard coating is applied to the thin dyed optical film.
  • a water resistant coating is applied to the thin dyed optical film.
  • a scratch resistant coating is applied to the thin dyed optical film.
  • the thin dyed optical film is stretched to become a PVA polarized film.
  • the soluble dye is selected from a group consisting of an IR dye, a visible dye, a photochromic dye, or an absorbing dye.
  • the IR dye is selected from a group consisting of Tetrakis ammonium structure, Iminium phthalocyanines, naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadratic acid derivatives, immonium dyes, perylenes Dianthrones Cyanines Heteroaromatics Metal Dithiolenes Oxadiazoles Phthalocyanines Spiropyra Tetraaryldiamines Triarylamines, Water soluble phthalocyanine and/or naphthalocyanine dye chromophores or similar dye.
  • a method to manufacture a functional film comprising the steps of: providing a soluble polymer; adding a polymer solvent to the a soluble polymer to make a soluble polymer solution; providing a soluble dye; adding a portion of PVA material to the soluble polymer solution; adding a dye solvent to the soluble dye to make a soluble dye solution; adding the dye solution to the polymer solution thereby making a dyed polymer solution; introducing the dyed polymer solution to a solution casting device; allowing the solution casting device to make a thin dyed optical film from the dyed polymer solution; removing the thin dyed optical film from the device; allowing the thin dyed optical film to dry and to solidify.
  • an eyewear lens comprising a thin dyed optical film
  • the thin dyed optical film is made with a portion of dyed polymer solution in a solution casting device wherein the dyed polymer solution is comprised of a portion of soluble dye solution and a portion of soluble polymer solution wherein the soluble dye solution is comprised of a portion of soluble dye and a portion of dye solvent and wherein the soluble polymer solution is comprised of a portion of polymer solvent and a portion of soluble polymer.
  • an eyewear lens comprising a thin dyed optical film wherein the thin dyed optical film is made with a portion of dyed PVA solution in a solution casting device wherein the dyed PVA solution is comprised of a portion of soluble dye solution and a portion of soluble PVA solution wherein the soluble dye solution is comprised of a portion of soluble dye and a portion of dye solvent and wherein the soluble PVA solution is comprised of a portion of polymer solvent and a portion of PVA material.
  • the soluble polymer is selected from a group consisting of TAC, Cellulose acetate, Cellulose propionate, Polyurethane, PVC, Silicon urethane copolymer, Acrylic, COP, Tetrafluoroethylene polymer, PC, PP, PE, Polyethersulfon, Polyetherimide, Polyvinylidene fluoride, etc., is added to an appropriate 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, Ether, Esters, Polyimides, Dimethylformamide, Polyvinylalco
  • the polymer solvent is selected from a 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, Ether, Esters, Polyimides, Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starch derivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, Methylene Chloride, water.
  • soluble dye is selected from a group consisting of an IR dye, a visible dye, a photochromic dye, or an absorbing dye.
  • the IR dye is selected from a group consisting of Tetrakis ammonium structure, Iminium phthalocyanines, naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadratic acid derivatives, immonium dyes, perylenes Dianthrones Cyanines Heteroaromatics Metal Dithiolenes Oxadiazoles Phthalocyanines Spiropyra Tetraaryldiamines Triarylamines, Water soluble phthalocyanine and/or naphthalocyanine dye chromophores.
  • the polymer solvent is selected from a 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, Ether, Esters, Polyimides, Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starch derivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, Methylene Chloride, water.
  • soluble dye is selected from a group consisting of an IR dye, a visible dye, a photochromic dye, or an absorbing dye.
  • the IR dye is selected from a group consisting of Tetrakis ammonium structure, Iminium phthalocyanines, naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadratic acid derivatives, immonium dyes, perylenes Dianthrones Cyanines Heteroaromatics Metal Dithiolenes Oxadiazoles Phthalocyanines Spiropyra Tetraaryldiamines Triarylamines, Water soluble phthalocyanine and/or naphthalocyanine dye chromophores.
  • FIG. 1 is an illustrative view of the preparation of a polymer or PVA solution in a preferred solvent or water.
  • FIG. 2 is an illustrative view of the preparation of an IR dye and/or laser dye, photochromic, visible dye solution in a preferred solvent or water.
  • FIG. 3 is an illustrative view of a typical solution casting method and apparatus.
  • FIG. 4 is an illustrative view of the process of making a functional film using Solution Casting Method.
  • FIG. 5 is an illustrative view of laminating a new functional film as an optical component with other materials to make an eyewear optical lens, camera lens, microscope lens, car windows, building windows, electronic screen, lamp cover protection, etc.
  • the methods and system of making a functional film disclosed herein provides many important advantages over those of prior arts. Specifically, the current invention yields a virtually isotropic, flat, and dimensionally stable functional film. Furthermore, the functional film achieves maximum optical purity and extremely low haze. The film is also dyed to a precise specification without affected by dye degradation problem. As a result, the present functional film has less treatment, less defect, less delamination, and less stress, and, thus, the optical lens requires fewer layers, and process time is shorter.
  • the current method uses readily incorporated mixture components used in the traditional methods. The current invention does not increase material costs, and, in certain cases, it actually reduces material costs because it yields accurate optical properties/specification, and thinness functional films, which in turn reduce the number of layers in an optical lens.
  • a plastic polymer or PVA material 101 such as TAC, Cellulose acetate, Cellulose propionate, Polyurethane, PVC, Silicon urethane copolymer, Acrylic, COP, Tetrafluoroethylene polymer, PC, PP, PE, Polyethersulfon, Polyetherimide, Polyvinylidene fluoride, etc.
  • an appropriate solvent 102 such as water, 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, Ether, Esters, Polyimides, Dimethylform
  • a solute 102 such as IR and/or visible dye, photochromic dye, or any absorbing dyes
  • an appropriate 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, Ether, Esters, Polyimides, Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starch derivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, Methylene Chloride, water, etc., to make the second solution 200 , liquid B, a dye
  • Polymer material, PVA powder, or PVA material 301 is mixed with a solvent 302 .
  • low heat under 100° C. may be used to speed up the dissolving of the polymer in the solvent.
  • other polymer materials, such as TAC may not need any heat to dissolve.
  • the solution may be further processed to arrive at the required solution for making a functional film with certain optical properties.
  • the final polymer or PVA solution is then introduced to the casting device 303 as depicted. 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 a stream of air 306 flowing in a belt channel 307 against the direction of the moving belt. It is appreciated that in other embodiments the stream of air 306 may flow in the direction of the moving belt. It is also appreciated that dry air, its direction, belt speed, space of the belt channel, etc. are calibrated such that the functional film achieve a desired thickness, dryness, and other qualities. Moreover, by the time the functional film reaches the film take-off 308 the input polymer or PVA solution must be solidified enough to be taken off the belt for further drying or processing.
  • a liquid A a polymer or PVA solution
  • Liquid B a dye solution
  • a dye 403 which can be IR or visible dye, photochromic dye, or any absorbing dyes
  • the Liquid B is comprised of between 0.05% to 5% of IR or visible dye, or photochromic dye or absorbing dye and the rest being in appropriate solvent.
  • the preferred embodiment is Liquid B comprising 3% of the dye.
  • the resulting solutions are mixed together to make dyed polymer solution 405 .
  • water soluble PVA polyvinyl alcohol
  • IR dye may also contain few percent of solvent soluble polymer, less than 10% of solvent soluble polymer, in the mix.
  • the Liquid A is comprised of approximately. 9% to 25% of Polymer or PVA powder and 75% to 91% of appropriate solvent.
  • the dyed polymer solution 405 is next introduced into a solution casting device 406 .
  • This device would utilize a large belt 407 whose material and design are made appropriate for a desired functional film.
  • the film is introduced to a dry environment where the temperature is between 40-100° C.
  • the functional film is continuously taken off the moving belt for further drying, processing, rolled or sheeted. It is then used to produce an eyewear lens, camera lens, microscope lens, car windows, building windows, electronic screen, lamp cover protection, etc.
  • the functional film thickness is between 0.015 mm-3.0 mm. Different films with different optical properties can be laminated together to obtain the desired eyewear lens, camera lens, microscope lens, car windows, building windows, electronic screen, lamp cover protection, etc.
  • a curved lens 503 is made wherein visible and/or IR dyed optical film 501 , which is made using the present method as depicted in FIG. 3 , is laminated on another clear film or glass 500 , which has certain 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.

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  • Engineering & Computer Science (AREA)
  • Ophthalmology & Optometry (AREA)
  • Health & Medical Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • General Physics & Mathematics (AREA)
  • General Health & Medical Sciences (AREA)
  • Eyeglasses (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Moulding By Coating Moulds (AREA)
  • Polarising Elements (AREA)
US14/806,579 2015-02-15 2015-07-22 Methods And Systems For Making An Optical Functional Film Abandoned US20160238859A1 (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US14/806,579 US20160238859A1 (en) 2015-02-15 2015-07-22 Methods And Systems For Making An Optical Functional Film
AU2015382374A AU2015382374A1 (en) 2015-02-15 2015-09-01 Methods and systems for making an optical functional film
JP2017529382A JP2018507792A (ja) 2015-02-15 2015-09-01 機能性光学フィルムを製造するための方法およびシステム
CN201580065781.5A CN107206712A (zh) 2015-02-15 2015-09-01 制造光学功能膜的方法和系统
EP15882257.7A EP3256301A4 (en) 2015-02-15 2015-09-01 METHOD AND SYSTEMS FOR PRODUCING AN OPTICAL FUNCTIONAL FILM
PCT/US2015/047973 WO2016130177A1 (en) 2015-02-15 2015-09-01 Methods and systems for making an optical functional film
US14/886,078 US10611106B2 (en) 2015-02-15 2015-10-18 Methods and systems for making an optical functional film
US17/019,243 US11541616B2 (en) 2015-02-15 2020-09-12 Methods and systems for making an optical functional film
US18/092,436 US20230150215A1 (en) 2015-02-15 2023-01-02 Methods and systems for making an optical functional film

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CN110065187A (zh) * 2019-04-28 2019-07-30 安徽帝显电子有限公司 一种新型无翘曲导光膜的生产设备

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CN110900921A (zh) * 2019-12-10 2020-03-24 湖南工业大学 一种pva液相成膜装置
CN112457508B (zh) * 2020-11-04 2023-04-07 乐凯光电材料有限公司 一种有色三醋酸纤维素酯薄膜的制备方法及制成的薄膜

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US10611106B2 (en) * 2015-02-15 2020-04-07 Roger Wen Yi Hsu Methods and systems for making an optical functional film
CN108456417A (zh) * 2018-01-09 2018-08-28 天津科技大学 高渗透染色pu膜
CN110065187A (zh) * 2019-04-28 2019-07-30 安徽帝显电子有限公司 一种新型无翘曲导光膜的生产设备

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