WO2016010593A1 - Procédés et systèmes de fabrication de lentilles absorbant le rayonnement infrarouge (ir) - Google Patents

Procédés et systèmes de fabrication de lentilles absorbant le rayonnement infrarouge (ir) Download PDF

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Publication number
WO2016010593A1
WO2016010593A1 PCT/US2015/022958 US2015022958W WO2016010593A1 WO 2016010593 A1 WO2016010593 A1 WO 2016010593A1 US 2015022958 W US2015022958 W US 2015022958W WO 2016010593 A1 WO2016010593 A1 WO 2016010593A1
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Prior art keywords
layer
lens
epoxy
adjacent
functional
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Roger Wen Yi Hsu
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Eye Ojo Corp
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Eye Ojo Corp
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Priority claimed from US14/521,430 external-priority patent/US20160116718A1/en
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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/003—Light absorbing elements
    • 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

Definitions

  • the present invention relates generally to an optical component, and more particularly it is directed to method and system of coating and producing infrared (IR) absorbing lens.
  • IR infrared
  • Infrared is invisible radiant energy. It is electromagnetic radiation with electromagnetic spectrum extending from wavelengths of approximately 0.7 um to 1000 ⁇ , which is between the upper limit of the visible radiation region and the lower limit of the microwave region. Most of the thermal radiation emitted by object near room temperature is infrared. Infrared is everywhere. For example, wireless communication, appliances, computer, and lights all emit different levels of harmful radiation. In fact, there are also plenty of natural infrared, such as those from sunlight. Sunlight is composed of thermal- spectrum radiation that is slightly more than half infrared. At zenith, 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
  • IR-absorbing Dye mixed with other materials windows and automotive windows with an outer layer thickness of 0.8- 1.5mm (EP0989419 US7957077 US8441724 US6893689); IR absorber mixed with glass material (US20080186565
  • IR-absorbing Dye that can withstand higher temperature will result in lower clarity of lenses.
  • IR-absorbing Dye cannot be packed densely on a thin surface, and IR-absorving Dye will disperse on a thick surface. Therefore, they will be ineffective and will cause discomfort to the user.
  • Liquid coating composition that absorb near infrared electromagnetic radiation (US6794431).
  • the process is not suitable for laminating, strengthening, or protecting the surface, nor does it reach the required level of optical quality.
  • the carrier needs three or more polymer mixed according to specific proportion with polymerization process to produce the IR absorbing layer.
  • the problem with these anti-IR lenses liquid is that they are limited to formulas that include IR-absorbing agent.
  • the carrier that used required at least three kind of polymer, with specific proportion using polymerization process to form the layer.
  • infrared radiation is sometimes broken into three sub-regions: near- infrared radiation with wavelengths between 0.7-1 ⁇ , intermediate-infrared radiation with wavelengths between 1-20 ⁇ , and far-infrared radiation with wavelengths between 20-1000 ,um.
  • the intermediate-infrared radiation region is often further broken into the short-wave (SWIR) region with wavelength limits of 1-3 um, mid- wave (MWIR) region with wavelength limits of 3-5 ⁇ , and the long-wave (LWIR) region with wavelength limits of 8-14 ⁇ .
  • SWIR short-wave
  • MWIR mid- wave
  • LWIR long-wave
  • Infrared radiation is produced principally by electromagnetic emissions from solid materials as a result of thermal excitation.
  • the detection of the presence, distribution, and direction of infrared radiation requires techniques which are unique to this spectral region.
  • the wavelengths of infrared radiation are such that optical methods may be used to collect, filter, and direct the infrared radiation.
  • Photosensitive devices convert heat, or infrared electromagnetic radiation, into electrical energy and are often used as infrared sensitive elements. Such photosensitive devices respond in proportion to the number of infrared photons within a certain range of wavelengths to provide electrical energy.
  • An infrared absorbing lens is transmissive to the wavelengths of radiation to be detected.
  • Materials for a lens are wavelength matched to the desired spectrum coverage.
  • suitable materials may be selected based on the range of IR wavelengths, other material characteristics can impact the manufacturing of IR absorbing lenses.
  • the optical characteristics of silicon are advantageous for use as the material for IR absorbing lenses. Silicon can be cut into the desired lens geometry, using, for example, a diamond tool to manufacture the surface. However, the hardness of silicon results in slow material removal and wears the diamond tool faster than other IR materials like germanium. In extreme cases, the cost of manufacturing silicon into IR absorbing lenses can negate the cost savings from the bulk material and cause optical materials used in the IR spectral range to be expensive and require expensive manufacturing processes.
  • gray colors may be added to the PVA film.
  • the addition of such gray colors reduces the penetration of light, and therefore the visibility of the viewers, significantly.
  • the addition of the gray colors to the PVA films on the lens results in higher costs for the lenses, and thus higher costs for the end products. Therefore, material and manufacturing processes for IR absorbing lenses that are inexpensive and quick are desirable.
  • the new invention provides a NIR absorbing layer on top or the under of substrate.
  • the hardness of the IR absorbing layer should be lower than 1.5 H (H was used as a unit for pencil hardness gage, H represents the hardness, the high the number the harder the material) in order to form a layer that later on can be combined with other layer to form a complete lens that is sturdy, transparent, no particles, and no bubbles can stand for scratching, washing, and could be used for at least three years.
  • a method to manufacture infrared lens comprising the steps of: providing a portion of polyurethane (PU) material wherein the portion of polyurethane (PU) material is comprised of NCO (Cyanate) compound; providing a portion of IR dye and mixing the IR dye to the portion of polyurethane (PU) material to form a portion of IR PU solution; mixing a portion of catalyst wherein the catalyst is comprised of OH (Hydroxide) compound with the IR PU solution to form a portion of OH (Hydroxide) IR PU material; providing a portion of solvent and mixing the OH (Hydroxide) IR PU material to the solvent to form a portion of OH (Hydroxide) IR PU liquid solution; applying the OH (Hydroxide) IR PU liquid solution to a lens layer;
  • the portion of polyurethane (PU) material is comprised of isocyanurate or polyisocyanate.
  • the invention further comprising the step of allowing the OH (Hydroxide) IR PU liquid solution to solidify between 4-8 hours.
  • the ratio of the portion of solvent to the portion of polyurethane (PU) material is 2: 1.
  • the portion of IR dye is between 1-3 % of the portion of IR PU solution.
  • the catalyst is selected from a group consisting of polyester polyol or hydroxyl-bearing polyacrylate.
  • the ratio of the NCO (Cyanate) compound to the OH (Hydroxide) compound is between 1 : 0.3 to 1 :16. In one embodiment, the ratio of the NCO (Cyanate) compound to the OH (Hydroxide) compound is 1 :5.
  • the IR functional lens layer is between 0.03-0.12 mm in thickness.
  • the solvent 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
  • the invention further comprising the step of applying a layer of isolation layer between the IR functional layer to the lens layer.
  • the isolation layer is selected from a group consisting of PU, acrylic, silicon and epoxy compounds.
  • the isolation layer is comprised of PU, acrylic, silicon and epoxy compounds.
  • the invention furthering comprising the step of applying a reinforcement layer between the IR functional lens layer and the lens layer.
  • the invention comprising the step of applying a reinforcement layer between the IR functional lens layer and the IR isolation layer.
  • the reinforcement layer is comprised of epoxy compound wherein the epoxy compound further comprises acrylic resin.
  • an infrared absorbing lens apparatus comprising: a base substrate; a IR functional lens layer wherein the IR functional lens layer comprises a portion of PU wherein the portion of PU further comprising a portion of NCO (Cyanate) compound, a portion of IR dye, and a portion of catalyst wherein the catalyst further comprising a portion of OH (Hydroxide) compound.
  • the apparatus further comprising a PVA film layer.
  • the apparatus further comprising an epoxy layer.
  • the apparatus further comprising a hard coating layer.
  • the apparatus further comprising a isolation layer.
  • the apparatus further comprising a reinforcement layer.
  • the reinforcement layer is comprised of PU, acrylic, silicon and epoxy compounds
  • a method to manufacture infra red absorbing lens comprising: providing a portion of silicon material; providing a portion of solvent and mixing the portion of solvent to the portion of silicon material to form a portion of silicon solution; providing a portion of IR dye and mixing the portion of IR dye to the portion silicon solution to form a portion of IR silicon solution; providing a portion of acid to the portion of IR silicon solution to form a portion of acid IR silicon solution; applying the portion of acid IR silicon solution to a lens layer; heating the acid IR silicon solution to allowing the acid IR silicon solution to solidify to form a IR functional lens layer.
  • the ratio of the portion of acid to the portion of IR silicon solution is 1 to 500.
  • the invention further comprising heating the portion of acid IR silicon solution to 85-100 degree Celsius. In one embodiment, the invention further comprising heating the portion of IR silicon solution for 1-3 hours. In one embodiment, the thickness of the IR functional lens layer is between 0.03-0.12 mm.
  • the solvent 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,.
  • the invention further comprising applying a layer of isolation layer between the IR functional lens layer to the lens layer.
  • the isolation layer is comprised of PU, acrylic, silicon, epoxy or similar material.
  • the invention is furthering applying a reinforcement layer between the IR functional lens layer and the lens layer.
  • the reinforcement layer is comprised of an epoxy compound wherein the epoxy ground comprises acrylic resin.
  • an IR lens apparatus comprising: a first layer of hard coating comprising a first surface and a second surface wherein the first surface of the first layer of hard coating is furthest away from a user; a second layer of hard coating comprising a first surface and a second surface wherein the 2nd hard coating second surface is closest to the user; a layer of IR isolation layer having a first surface and a second surface where the first surface of IR isolation layer is adjacent to the second surface of the first coating layer; an IR functional layer having a first surface and a second surface wherein the functional layer first surface is adjacent to the second surface of the IR isolation layer; a layer of PVA film comprising a first surface and a second surface wherein the first surface of the PVA film layer adjacent to the second surface of the IR functional layer; a layer of epoxy comprising a first surface and a second surface wherein the first surface of the epoxy layer is adjacent to the second surface of PVA film layer; a base lens layer comprising a first surface
  • An IR lens apparatus comprising: a first layer of hard coating comprising a first surface and a second surface wherein the first surface of the first layer of hard coating is furthest away from a user; a second layer of hard coating comprising a first surface and a second surface wherein the 2nd hard coating second surface is closest to the user; a first layer of epoxy comprising a first surface and a second surface wherein the first surface of the first layer of epoxy is adjacent to the second surface of the first layer of coating; a layer of IR isolation layer having a first surface and a second surface where the first surface of IR isolation layer is adjacent to the second surface of the first epoxy layer; an IR functional layer having a first surface and a second surface wherein the functional layer first surface is adjacent to the second surface of the IR isolation layer; a layer of PVA film comprising a first surface and a second surface wherein the first surface of the PVA film layer adjacent to the second surface of the IR functional layer; a layer of second epoxy comprising a first
  • an IR lens apparatus comprising: a first layer of hard coating comprising a first surface and a second surface wherein the first surface of the first layer of hard coating is furthest away from a user; a second layer of hard coating comprising a first surface and a second surface wherein the 2nd hard coating second surface is closest to the user; a layer of epoxy comprising a first surface and a second surface wherein the first surface of the layer of epoxy is adjacent to the second surface of the first layer of coating; a layer of IR reinforcement layer having a first surface and a second surface where the first surface of IR reinforcement layer is adjacent to the second surface of the epoxy layer; a layer of IR isolation layer having a first surface and a second surface where the first surface of IR isolation layer is adjacent to the second surface of the reinforcement layer; a first IR functional layer having a first surface and a second surface wherein the first functional layer first surface is adjacent to the second surface of the IR isolation layer; a layer of PVA film comprising a
  • an IR lens apparatus comprising: a first layer of hard coating comprising a first surface and a second surface wherein the first surface of the first layer of hard coating is furthest away from a user; a second layer of hard coating comprising a first surface and a second surface wherein the 2nd hard coating second surface is closest to the user; a layer of first epoxy comprising a first surface and a second surface wherein the first surface of the layer of first epoxy is adjacent to the second surface of the first layer of coating; a layer of IR isolation layer having a first surface and a second surface where the first surface of IR isolation layer is adjacent to the second surface of the first epoxy layer; a first IR functional layer having a first surface and a second surface wherein the first functional layer first surface is adjacent to the second surface of the IR isolation layer; a layer of second epoxy comprising a first surface and a second surface wherein the first surface of the second epoxy layer adjacent to the second surface of the IR functional layer; a base lens layer comprising a
  • FIG. 1 is an illustrative view of the preparation of the solute being dissolved in the solvent.
  • FIG. 2. is an illustrative view of the preparation of IR dye being dissolved in the mixture.
  • FIG. 3 is an illustrative view of the preparation of the PVA film being treated with the IR dye liquid.
  • FIG. 4 is an illustrative view of an alternative method of preparation of the PVA film being coated with the mixture.
  • FIG. 5 is an illustrative view of the application of the IR absorbing layer on a curved surface of a lens.
  • FIG. 6 is an illustrative view of a curved lens with an IR absorbing layer applied within the lens.
  • FIG. 7 is a diagram of the casting method.
  • FIG. 8 is a diagram of the O-ring controller for a mold.
  • FIG. 9 is a continuation of the above diagram.
  • FIG. 10 is a continuation of the sequential steps of the above diagram
  • FIG. 11 is a diagram of the supporter.
  • FIG. 12 is a diagram of the next step of the procedure involving the supporter.
  • FIG. 13 is a diagram of procedural steps in the rim-lock method with epoxy drops.
  • FIG. 14 is a diagram of the next step of the rim- lock method.
  • FIG. 15 is a diagram of the next step of the rim-lock method,
  • FIG. 16 is the rim-lock method with epoxy injection procedural diagram.
  • FIG. 17 depicts one embodiment of the cross-sectional view of a layered lens produced by the present claimed methods.
  • FIG. 18 depicts one embodiment of the cross-sectional view of a layered lens produced by the present claimed methods.
  • FIG. 19 depicts one embodiment of the cross-sectional view of a layered lens produced by the present claimed methods.
  • FIG. 20 depicts one embodiment of the cross-sectional view of a layered lens produced by the present claimed methods.
  • the IR absorbing lens can absorb infrared while maintaining high clarity, high color saturation, and low haziness.
  • the IR absorbing lens protects the eyes of the user from eye injury as a result of absorbing various lights harmful to the eyes—including but not limited to infrared light in the 780nm-2000nm and UV ABC 100nm-400nm spectrum. In fact, even visible light in the 380nm-780nm should be selectively absorbed as according to need.
  • the manufacturing of the lens uses a thin 0.003mm-0.15mm oil-bone Liquid composition to make a thin film or multi-layered film.
  • IR functional layer is formed by having the Liquid composition applied on top, below, or between a non-polarized lens or a polarized lens, which contains a PVA film.
  • the lens surface has had surface treatment and the Liquid composition can be disposed on the surface using various methods.
  • UV absorb dye can be applied to absorb ultraviolet light, and visible absorb dye can absorb visible light.
  • These functional layer or layers do not erode as it is resistant to chemical solvents. Therefore, in the process of making or coating, the layer will not be diluted or destroyed, and it is able to maintain its function.
  • the invention can be practiced in two ways:
  • Chemical solvent functional layer is formed with solute being that is mixed with PU material containing polyisocyanate or isocyanurate which contains molecules NCO (Cyanate) and with catalyst that contains molecules OH (Hydroxide) to form a chemical bond. Furthermore, in order to strengthen its protection, additional layers of isolation layer and or a reinforcing layer, or two layers may be applied.
  • the Silicon acidic solvent mixture is added and heat of about 80-100 degrees Celsius is applied to allow the acidic solvent to mix with the Silicon in a chemical reaction that forms a hardened layer, wherein additional layers, reinforcing layers, or two layers may be applied.
  • the above procedure can be applied to lens or the PVA lens or non-PVA lens.
  • the layer can be bent through injection into the a cast or through the use of casting.
  • the invention disclosed herein can be used in sun glasses or optical film. It can also be widely used in electronic display, architectural windows, car windows, car panels, mobile phone panels, telescope, aerospace science, camera optical lens films, TV screens or TV protection screen, and lighting lamp housing.
  • I. Infrared (IR) absorbing lens for use as sunglasses lens, optical or light color lens, and optical blue blocker lens
  • the infrared (IR) absorbing lenses disclosed herein is composed of a liquid composition that includes polyurethane (PU)-like resin with solvent to dissolve and dilute the IR absorbing dye.
  • IR absorbing dye is an organic dye material.
  • Suitable solvents for the IR absorbing dye may include materials such as 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, etc.
  • the polyurethanes polymer liquid contains polyisocyanate or isocyanurate having NCO (Cyanate) molecules mixed with having OH (Hydroxide) molecules forming a chemical resistant bond. This will provide a thickness of only 0.03-0.12mm at its most densely packed IR-absorbing functional layer. Furthermore, because of it's chemical resistance property, in the process of adhesion or bonding, the layer will not erode. Moreover, anti-UV, visible light absorbing, and pH buffer modifying material can be added to the top or bottom of the IR-absorbing dye functional layer. Finally, liquid coating isolating layer, cover layer, or reinforcing layer can also be added. IR lenses manufactured or made according to the method and system provided herein can be used in various applications, including but not limited to sunglasses lens, optical lens or light color lens, and optical blue blocker lens.
  • the human eye locks on to the green zone around the range of 550nm when it initially sees things or landscape.
  • the 780nm - 2000nm infrared ray interference causes imbalance in the green zone.
  • the eyes have more difficulty focusing, wasting energy and causing fatigue.
  • a functional layer is added to lenses.
  • the functional layer plays an important role in lowering temperature through absorbing the heat generated by infrared. This can reduce the damages to eyes, and reduce interference and scattering.
  • visible light absorbing material and UV light absorbing material can also be added.
  • the IR absorbing lens can absorb over 70% of the infrared in the 780nm - 1300nm wavelength range, and absorb over 30% of the infrared in the 1300m, - 2000nm wavelength range.
  • the IR dye will weigh about 1 - 3% of the total weight of the liquid.
  • the lenses can absorbed over 70% of visible light in the 400nm - 780nm wavelength.
  • the lens can absorb over 95% of UV A, B, and C in the lOOnm - 400nm wavelength.
  • the IR absorbing lens can absorb over 60% of the infrared in the 780nm - 1300nm wavelength range, and absorb over 20% of the infrared in the 1300nm - 2000nm wavelength range.
  • the IR absorbing dye will weigh about 1 - 2.5% of the total weight of the liquid. This is because IR dye itself already has color, therefore, IR dye concentration in optical lens and light color lens need to be reduce to prevent the lens from becoming too tinted for its intended purposes.
  • the lens can absorbed over 20% of visible light in the 400nm - 780nm wavelength. Also, with the addition of visible light absorbing dye (part of which is the dye color of the IR) on the functional layer, in the glue, on the surface of the lens, in the material, or in any layer, the lens can absorbed over 25% of visible light in the 550nm - 600nm wavelength.
  • the lens can absorb over 95% of UV A, B, C in the lOOnm - 400nm wavelength.
  • Blue light has a very short wavelength and is detectable by the human eye. In fact, blue light accounts for approximately 50% of visible light.
  • electronic devices in use today such as cellular phones, tablets, and laptop computers, has drastically increased people's exposure to blue light.
  • computer monitor, light, mobile phone, tablet, wi-fi, communication, electrical appliances will scatter UV in the 380nm - 460nm wavelength or even stronger blue light, as well as yellow-green light in the in the 550nm - 500nm wavelength.
  • Increase exposure to large amounts of blue light can be harmful to the eyes. This is because blue light may cause oxidative damage to the eyes, and may play an integral role in causing age-related macular degeneration, which can lead to significant vision loss. Therefore, lens that can protect the eyes from blue lights, or optical blue blocker lens, is necessary.
  • the lens can absorb over 60% of the infrared in the 780nm - 1300nm wavelength range, and absorb over 20% of the infrared in the 1300m, - 2000nm wavelength range.
  • the IR absorbing dye will weigh about 1 - 2.5% of the total weight of the liquid. This is because the IR dye itself has color, therefore, IR dye concentration in optical lens and light color lens needs to be reduce.
  • the lens can absorbed over 35% of visible light in the 400nm - 460nm wavelength.
  • the addition of visible light absorbing dye (part of which is the dye color of the IR) on the functional layer, in the glue, on the surface of the lens, in the material, or in any layer the lens can absorbed over 25% of visible light in the 550nm - 600nm wavelength.
  • the lens can absorb over 95% of UV A, B, and C in the lOOnm - 400nm wavelength.
  • the IR absorbing lens is composed of the functional layer, glue layer, liquid composition layer, substrate layer, epoxy layer, and the hard coating layer.
  • the functional layer is formed first by forming IR liquid composition by mixing solute Polyurethane (PU) containing polyisocyanate (or isocyanurate) having NCO (Cyanate) molecules and mixing it with solvent.
  • Solvent can be any of the listed here in: Acetone Benzene Cyclohexanone Ethanol Methanol MEK Alcohols Ketones Ethanol N-methylpyrrolidone (NMP) Chlorofor DMF Dioxane Ethyl Acetate Methylene Chlorid Methyl Ethyl Ketone Octane.
  • the ideal mixing ration should be 60-70% solvent and 30%-40% PU.
  • IR dye can be of Tetrankis ammonium structure or Iminium phthalocyanines, naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadratic acid derivatives, immonium dyes, perylenes Dianthrones Cyanines Heteroaromatics Metal Dithiolenes Oxadiazoles Phthalocyanines Spiropyra Tetraaryldiamines Triarylamines.
  • a catalyst is then added to the solution.
  • the catalyst is comprised of polyester polyol or hydroxyl-bearing polyacrylate.
  • the catalyst would need to include a portion of OH (Hydroxide).
  • ultra violet light absorber dye can be added to the mixture as well as color dye can be added to the mixture.
  • ratio of NCO (Cyanate) to OH (Hydroxide) should be between 1 :0.3 to 1 : 16 in the context of
  • IR functional layer can be applied on any lens at any place with any shape.
  • the functional layer can be applied on the following:
  • the IR liquid composition is made by adding apportion of silicon polymer mixing with solvent. In the process, a portion of IR absorber dye is added to the mixture.
  • the IR absorber dye can be organic dye such as Tetrankis ammonium structure or Iminium phthalocyanines, naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadratic acid derivatives, immonium dyes, perylenes Dianthrones Cyanines Heteroaromatics Metal Dithiolenes Oxadiazoles
  • Phthalocyanines Spiropyra Tetraaryldiamines Triarylamines.
  • the solvent can be Acetone, Benzene, Cyclohexanone, Ethanol Methanol, MEK Alcohols, Ketones Ethanol, N-methylpyrrolidone (NMP), Chlorofor, DMF Dioxane, Ethyl Acetate, Methylene Chlorid, Methyl Ethyl, Ketone, Octane and Alcohol.
  • the mixture is next heated to 85-100 degree Celsius for 1-3 hours which will induce the solidification of the mixture to eventually for the IR functional layer.
  • the ideal thickness of the IR functional layer can be anywhere between 0.03 to 0.12 mm.
  • the amount of acid as a percentage to the mixture is 0.20%.
  • ultra violet light absorber dye can be added to the mixture as well as color dye can be added to the mixture.
  • a layer of isolation can be optionally applied.
  • the IR isolation layer can be applied either on top of the IR functional layer or it be applied to the bottom of the IR functional layer. In another embodiment, it can be applied to both the top and the bottom of the IR functional layer. It is better to add isolation layer, it can protect the absorbing power of IR absorbing layer. Without the IR isolation layer, the IR functional layer can have visible micro residue and is likely to degrade under the Sun.
  • An IR isolation layer can be made with PU, acrylic, silicon, epoxy or similar material.
  • a IR reinforcement layer can be added to the IR functional layer and the IR isolation layer.
  • a IR reinforcement layer is made with materials comprising epoxy compounds further comprising acrylic resin. IR reinforcement layer can be applied to top of bottom of IR functional layer or top of bottom of the isolation layer as stated above.
  • the substrate can be selected from PC, Acrylic, PU, Glass, Nylon, or CR 39 or high index lens material.
  • the substrate lens can have a gradient color.
  • the liquid composition dispose on substrate through the method of dipping, flowing, spraying, spinning, or impressing or casting mold.
  • the process may be applied to substrate lens on the concave or convex side through vacuum coating.
  • the process can also be applied to multilayer lens.
  • liquid polymer includes, but is not limited to, polyurethane, silicon, epoxy, etc.
  • Inorganic luminophore luminophore is an atom or atomic grouping or compounds that manifests luminescence, which is the emission of light not resulting from heat. Luminophore is a form of cold body radiation. Luminophores can also be divided into organic and inorganic luminophores.
  • inorganic luminophores with near infrared or visible emission may be added to the lens as well.
  • the inorganic luminophores can be added on any layer such as the glue layer, IR liquid composition layer, substrate layer, epoxy layer, or the hard coating layer.
  • V. Processes for manufacturing IR absorbing lens The manufacturing IR absorbing lens can be categorized into three types of processes: (A) non-polarized lens or polymer sheet; (B) Polarized plastic curved lens or flat sheet; (C) polarized curved glass lens or flat glass lens.
  • the layer can be applied in different locations or positions.
  • the primer may be directly mixed with the near infrared (NIR) dye liquid composition having chemical resistance and/or mix with visible dye and/or UV dye. This will result in one less step in the manufacturing process.
  • NIR near infrared
  • NIR near infrared
  • Part 1 relates to processes for the PVA film and part 2 relates to the processes for the lens substrate.
  • Part 1: PVA Film Part 1 involves the manufacturing of PVA film.
  • the processes for manufacturing PVA film can also be separated into two types: (a) with the use of primer and (b) without the use of primer.
  • the first method involves the use of primer. First, place the PVA film or flat PVA film on a holder. Then, spin to coat the primer. Next, then apply one or multiple layers of NIR dye liquid composition having chemical resistant and/or mix with (a) visible dye and/or (b) UV dye.
  • the second method for manufacturing PVA film is without the use of primer. After placing the PVA film and flat PVA film on a holder, apply one layer of NIR dye liquid composition having chemical resistant and/or mix with (a) visible dye and/or (b) UV dye. Alternatively, apply many layers of NIR dye liquid composition having chemical resistant layer and/or mix with visible dye and/or UV dye.
  • Part 2 relates to the manufacturing processes for the lens substrate. First, inspect a lens substrate. Then, etch the lens substrate. Next, glue them together.
  • Part 1 relates to processes for the PVA film and part 2 relates to the processes for the lens substrate.
  • Part 1 involves the manufacturing of PVA film.
  • the processes for manufacturing PVA film can also be separated into two types: (a) with the use of primer and (b) without the use of primer.
  • the first method involves the use of primer. First, place the PVA film or flat PVA film on a holder. Then, spin to coat the primer. Next, then apply one layer of NIR dye liquid composition having chemical resistant and/or mix with (a) visible dye and/or (b) UV dye. Alternatively, apply many layers of NIR dye liquid composition having chemical resistant layer and/or ix with visible dye and/or UV dye.
  • the second method for manufacturing PVA film is without the use of primer. After placing the PVA film and flat PVA film on a holder, apply one layer of NIR dye liquid composition having chemical resistant and/or mix with (a) visible dye and/or (b) UV dye. Alternatively, apply many layers of NIR dye liquid composition having chemical resistant layer and/or mix with visible dye and/or UV dye.
  • Part 2 relates to the manufacturing processes for the lens substrate. First, apply glue to the bottom side of a glass lens or glass sheet to form part 2a. Then, apply glue to the top side of another lens or glass sheet to form part 2b. Then, glue 2a to the top of the PVA film from part 1 and glue 2b to the bottom the PVA film of part 1.
  • the glass lens or glass sheet is coated with one or more layer through vacuum mirror coating or color mirror coating. Then, the convex side of the lens from part 2 is glued to the adhesive side of the PVA film from part 1. Finally, dispose the glue.
  • the glass lens or glass sheet is coated with one or more layer through vacuum mirror coating or color mirror coating. Then, the concave side of the lens from part 2 is glued to the adhesive side of the PVA film from part 1. Finally, dispose the glue.
  • the NIR liquid composition can be applied to the substrate through mold casting methods to be discussed in further detail next.
  • FIG. 1 the figure illustrates a preparation of the solute 101
  • PU Polyurethane
  • IR dye liquid solution 200 wherein the infrared dye 201 is dissolved into the previously prepared solution 202. More specifically, the IR dye absorb powder 201 can be dissolved in a solvent based solution with solid polymers such as acrylic, epoxy, PU, PVA, Polyurethane, etc. Thereafter, catalyst containing OH (Hydroxide) molecules 203 is added to the solvent mix 202 and form the IR dye liquid solution 200. Catalyst can be comprised of polyester polyol or hydroxyl-bearing polyacrylate.
  • Fig. 3 which illustrates an application of the IR dye liquid 300 onto a PVA film 301 to form a PVA film with IR dye liquid coating 302. More specifically, the PVA film 301 is dipped into an IR dye liquid 300, wherein IR dye bonds with the PVA film 301 to form a PVA film with infrared dye liquid coating 302.
  • Fig. 4 which illustrates an alternative application of the water soluble infrared dye liquid 400 onto a PVA film 401 to form a PVA film with IR dye liquid coating 402.
  • the PVA film 401 is sprayed with infrared dye liquid solution 400, wherein the infrared dye bonds with the PVA film 401 to form a PVA film with infrared dye coating 402.
  • the IR dye liquid can be coated through other various methods such as flowing, spinning, etc.
  • Fig. 5 which illustrates an application of a IR dye absorbed coating layer 501 onto a curved surface of a lens 503, wherein the lens 503 is made up of multiple layers 500, 501, 502, and one of the layers is the infrared dye absorbed coating 501 that is the result of the PVA film with IR dye liquid coating as depicted in Fig. 3 and Fig. 4.
  • Fig. 6 illustrates a typical lens 600 comprises of layers including an outer, convex hard coating, a layer of hard epoxy, a PVA film with a infrared dye absorbed coating 601, a layer of hard epoxy, a PVA film, a layer of soft epoxy, a layer of adhesive, a base material and an inner concave hard coating.
  • FIG. 7 is a diagram of the casting method which there are four types to control the thickness of the substrate.
  • epoxy 700 is added to polarized film 701 and pre-formed substrate 722 (including but not limited to epoxy, PU, PC, AC, nylon, CR39).
  • FIG. 8 is a diagram of the 0-ring controller for a mold
  • the circularly polarized film 800 is placed upon epoxy liquid 802 applied to the bottom mold 803.
  • the O-ring 801 is constructed of PU (polyurethane) or silicon may be adjusted to control the thickness of the lens.
  • the top mold 903 is placed upon the circularly polarized film 900 which rests above a layer of epoxy 901 upon the bottom mold 902.
  • FIG. 10 is a continuation of the sequential steps of the above diagram, 1000 the molds are pressed together in order to shape the circularly polarized lens 1001.
  • a waiting period 1002 occurs, during which the curing process occurs.
  • the mold may be removed after 10-30 hours. After 30-72 hours, the lens will be fully set and the finished product 1003 is hardened and removed.
  • the circularly polarized lens 1100 is placed upon a layer of epoxy liquid 1102 on top of the bottom mold 1103.
  • a leg 1101 on either end of the mold lends support in the vertical direction.
  • the circular polarized layer 1100 is placed upon the readied mold.
  • FIG. 12 is a diagram of the next step of the procedure involving the supporter
  • the polarized layer 1200 has been placed atop the epoxy layer 1201 on the mold.
  • the two molds are pressed together with the polarized layer 1200 sandwiched in between.
  • the polarized layer is sandwiched between two layers of epoxy 1202.
  • a waiting period of 10-30 hours commences 1205. The curing process occurs and the mold may then be removed. The lens will then be fully set.
  • a rim-lock 1300 is attached on either side of a bottom glass mold 1301.
  • epoxy 1303 is added on top of the glass mold.
  • FIG. 14 is a diagram of the next step of the rim- lock method, a curved circularly polarized layer 1401 is added on top of the epoxy 1400.
  • FIG. 15 is a diagram of the next step of the rim- lock method
  • an upper glass mold 1500 is pressed downwards upon an additional layer of epoxy 1501 over the circularly polarized layer 1502.
  • clippers 1503 are used to secure the combined layers together firmly.
  • the layers now include a circularly polarized layer 1502 sandwiched in between layers of epoxy 1501.
  • the finished product is removed from the mold and includes a cured circularly polarized layer 1502 sandwiched between layers of epoxy 1501.
  • a rim lock 1605 is attached to either side of a bottom glass mold 1604.
  • Epoxy 1603 is introduced into the system above the bottom mold 1604 via an epoxy injection tube 1602.
  • a circularly polarized layer 1601 is placed upon the epoxy 1603, and a top glass mold 1600 is pressed down upon the entire combination of layers.
  • a clamp 1606 secures the combination of layers, which now include the top mold 1600, two layers of epoxy 1603 surrounding a circularly polarized layer 1601, and a bottom mold 1604.
  • the epoxy was injected into the system via a dropper or syringe-like device 1607 in the preceding step 1608.
  • a cap 1609 plugs the epoxy injection port after epoxy injection.
  • FIG. 17 discloses a cross-sectional view of a layered lens produced by the claimed methods where the convex surface of the first hard coating 1700 is the surface furthest away from the eyes of the wearer and the concave surface of the second hard coating 1708 is the surface closest surface to the eyes of the wearer.
  • the convex surface of the first hard coating 1700 is the surface furthest away from the eyes of the wearer and the concave surface of the second hard coating 1708 is the surface closest surface to the eyes of the wearer.
  • the IR lens are made of the following layers: a first hard coating 1700, an IR isolation layer 1701, an IR functional layer 1702, aPVA layer 1703, the epoxy layer 1704, glue or cell casting or insert injection 1705, base lens (PC, ACRY, NYLON, PU, Thermosetting plastic, Glass) 1706, with or without glued pre-formed anti-fog layer 1707, and a second hard coating 1708.
  • FIG. 18 disclose a cross-sectional view of a layered lens produced by the claimed methods where the convex surface of the first hard coating 1800 is the surface furthest away from the eyes of the wearer and the concave surface of the second hard coating 1809 is the surface closest surface to the eyes of the wearer.
  • the convex surface of the first hard coating 1800 is the surface furthest away from the eyes of the wearer
  • the concave surface of the second hard coating 1809 is the surface closest surface to the eyes of the wearer.
  • the IR lens are made of the following layers: a first hard coating 1800, a 1st epoxy layer 1801, an IR isolation layer, an IR functional layer 1803, a PVA layer 1804, a second epoxy layer 1805, glue or cell casting or insert injection 1806, base lens (PC, ACRY, NYLON, PU, Thermosetting plastic, Glass) 1807, with or without glued pre-formed anti- fog layer 1808, and a second hard coating 1809.
  • a first hard coating 1800 a 1st epoxy layer 1801, an IR isolation layer, an IR functional layer 1803, a PVA layer 1804, a second epoxy layer 1805, glue or cell casting or insert injection 1806, base lens (PC, ACRY, NYLON, PU, Thermosetting plastic, Glass) 1807, with or without glued pre-formed anti- fog layer 1808, and a second hard coating 1809.
  • FIG. 19 disclose a cross-sectional view of a layered lens produced by the claimed methods where the convex surface of the first hard coating 1900 is the surface furthest away from the eyes of the wearer and the concave surface of the second hard coating 1910 is the surface closest surface to the eyes of the wearer.
  • the convex surface of the first hard coating 1900 is the surface furthest away from the eyes of the wearer
  • the concave surface of the second hard coating 1910 is the surface closest surface to the eyes of the wearer.
  • the IR lens is made up of the following layers: a first hard coating 1900, an epoxy layer 1901, an IR reinforcement layer 1902, and IR isolation layer 1903, a first IR functional layer, a PVA layer 1905, a second IR functional layer 1906, glue or cell casting or insert injection 1907, base lens (PC, ACRY, NYLON, PU, Thermosetting plastic, Glass) 1908, with or without glued pre-formed anti-fog layer 1909, and a second hard coating 1910.
  • a first hard coating 1900 an epoxy layer 1901, an IR reinforcement layer 1902, and IR isolation layer 1903
  • a first IR functional layer a PVA layer 1905
  • a second IR functional layer 1906 glue or cell casting or insert injection 1907
  • base lens PC, ACRY, NYLON, PU, Thermosetting plastic, Glass
  • the IR lens are made up of the following layers: a first hard coating 2000, a second epoxy layer 2001, an IR isolation layer 2002, an IR functional layer 2003, a first epoxy layer, glue or cell casting or insert injection 2005, base lens (PC, ACRY, NYLON, PU,
  • Thermosetting plastic, Glass 2006, with or without glued pre-formed anti-fog layer 2007, and a second hard coating 2008.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Optical Filters (AREA)

Abstract

L'invention concerne un procédé de fabrication de lentilles infrarouge comprenant les étapes consistant à : fournir une partie de matériau de polyuréthane (PU); mélanger une partie de composé d'OH dans ledit matériau de PU pour former une partie de matériau d'OH PU; fournir une partie de solvant et mélanger ledit matériau d'OH PU avec ledit solvant pour former une partie de solution de PU; fournir une partie de colorant IR et mélanger ledit colorant IR avec ladite solution de PU pour former une partie de solution d'IR PU; fournir une partie de catalyseur et mélanger ledit catalyseur avec une partie de composé de NCO pour former une partie de catalyseur de NCO; mélanger ledit catalyseur de NCO avec ladite solution d'IR PU pour former une partie de solution liquide d'IR PU; appliquer ladite solution liquide d'IR PU à une couche de lentille; laisser ladite solution liquide de PU se solidifier pour former une couche de lentille à fonctionnalité IR.
PCT/US2015/022958 2014-07-16 2015-03-27 Procédés et systèmes de fabrication de lentilles absorbant le rayonnement infrarouge (ir) Ceased WO2016010593A1 (fr)

Applications Claiming Priority (4)

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US201462025183P 2014-07-16 2014-07-16
US62/025,183 2014-07-16
US14/521,430 US20160116718A1 (en) 2014-10-22 2014-10-22 Methods and System for Manufacturing Infrared (IR) Absorbing Lens
US14/521,430 2014-10-22

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WO2016010593A1 true WO2016010593A1 (fr) 2016-01-21

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4211510A4 (fr) * 2020-09-12 2024-11-20 Roger Wen Yi Hsu Procédés et systèmes de fabrication d'un film optique fonctionnel

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CN101467074A (zh) * 2006-06-08 2009-06-24 Ppg工业俄亥俄公司 偏振光学元件和制备含聚氨酯的膜的方法
US20100118263A1 (en) * 2007-04-13 2010-05-13 Talex Optical Co., Ltd. Infrared absorbing spectacle lens and method for producing such lens
US20130088772A1 (en) * 2011-10-06 2013-04-11 Roger Wei-Yi Hsu System and Method of Applying Infrared Dye on Sunglasses and Other Lenses
WO2013073714A1 (fr) * 2011-11-18 2013-05-23 Fujifilm Corporation Composition de blindage contre le rayonnement infrarouge, film de blindage contre le rayonnement infrarouge, procédé de formation de motifs et dispositif d'imagerie à l'état solide
CN103616737A (zh) * 2013-11-11 2014-03-05 成都市晶林电子技术有限公司 红外镀膜镜片

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Publication number Priority date Publication date Assignee Title
CN101467074A (zh) * 2006-06-08 2009-06-24 Ppg工业俄亥俄公司 偏振光学元件和制备含聚氨酯的膜的方法
US20100118263A1 (en) * 2007-04-13 2010-05-13 Talex Optical Co., Ltd. Infrared absorbing spectacle lens and method for producing such lens
US20130088772A1 (en) * 2011-10-06 2013-04-11 Roger Wei-Yi Hsu System and Method of Applying Infrared Dye on Sunglasses and Other Lenses
WO2013073714A1 (fr) * 2011-11-18 2013-05-23 Fujifilm Corporation Composition de blindage contre le rayonnement infrarouge, film de blindage contre le rayonnement infrarouge, procédé de formation de motifs et dispositif d'imagerie à l'état solide
CN103616737A (zh) * 2013-11-11 2014-03-05 成都市晶林电子技术有限公司 红外镀膜镜片

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4211510A4 (fr) * 2020-09-12 2024-11-20 Roger Wen Yi Hsu Procédés et systèmes de fabrication d'un film optique fonctionnel

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