Patent Application
20160238859
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.
It is well known that Ultraviolet (UV) light can cause serious flash burns to the cornea from high intensity light sources. Thus 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.
Not just UV light, infrared is also harmful. 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.
The energy of sunlight on the ground can be categorized into approximately 3% Ultraviolet (UV) rays, 44% visible rays, and 53% Infrared (IR) rays. Therefore, when exposed to intense sunlight for a lengthy period of time without protection, human eyes may experience a burning or stinging sensation that is often accompanied by fatigue. Such discomfort can be especially noticeable for those wearing contact lenses, as the infrared can be absorbed by the contact lenses causing them to “warm up”. Eye doctors always encourage a habit of putting on sunglasses when staying out in the sun for a period.
Traditionally, for protection lens to block harmful rays from a light source, the lenses must be coated with one or more layers of IR and/or visible dyes. Usually, 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. Thus, coated lens would reduce or mitigate eye diseases such as cataract and glaucoma.
Because of the importance of sunglasses and protecting eyewear, there have been many coating techniques invented. IR or visible coating can be applied by dipping or spraying a solvent IR or visible dyes on another optical layer of a lens. However, because the majority of lenses are curved, 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.
Using traditional methods like extrusion or injection, IR or visible dyes are added during the processes. 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. For optical plastic films, whether it is an extrusion or injection method, 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.
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.
Furthermore, traditional coating methods by injection or extrusion methods are aesthetically less appealing because infrared dye appears green in such a coating. In order to counteract or offset the undesirable green color, gray colors may be added to the PVA film. The addition of such gray colors, however, reduces the penetration of light, and therefore the visibility for the viewers, significantly. Finally, 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.
Recently, to overcome the drawbacks of extrusion and injection methods, solution casting method has been invented and preferred. 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. Typically, 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. Important items for belt and drum machines are the material's heat conductivity, the technical processes used to create the required surface finish and the options for repairing small surface defects. This cast technique permits simple production of films with structured surfaces. The belt surface is clearly and accurately replicated on one surface of the film. The techniques used to adapt the surface of the drums or belts to highly glossy, structured or matt film finishes are proprietary methods.
Once the first layer of thin film is appropriately solidified, secondary features can be added to the product such as braided or coiled wire, laser-cut hypotubes or engineered metal reinforcements to prevent kinking, or imaging targets specific to the intended medical application. Multiple casting steps can then be 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.
Accordingly, it is the object of this invention to provide a method and system for manufacturing functional films.
It is also the object of the present invention to make optical films that have maximum optical purity and extremely low haze, using readily incorporated mixture components.
It is also the object of the present invention to make virtually isotropic functional films that have excellent flatness and dimensional stability.
It is also the object of the present invention to make functional films with absorbing dye soluble and offers more precision.
It is also the object of the present invention to make functional films without damaging or degrading heat-sensitive dyes.
It is also the object of the present invention to makedyed functional films without an additional liquid coated layer, thus no protection layer is exposed to scratches or chemicals or elements.
It is also the object of the present invention to manufacture functional films that have less treatment, less layers, less defect, and less delamination, and save process time.
It is also the object of the present invention to manufacture functional films that are easily processed, have better quality and good function.
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;
In one embodiment, 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.
In one aspect of the invention, a method to manufacture a functional film is disclosed which 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. In one embodiment, 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. In one embodiment, 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, EAC, BAC, CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides, Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starch derivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, Methylene Chloride. In one embodiment,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. In one embodiment, 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. In one embodiment, the thin dyed optical film is laminated to a glass lens or a plastic lens. In one embodiment, a vacuum coating is applied to the thin dyed optical film. In one embodiment, an anti-Reflective coating is applied to the thin dyed optical film. In one embodiment, a hard coating is applied to the thin dyed optical film. In one embodiment, a water resistant coating is applied to the thin dyed optical film. In one embodiment, a scratch resistant coating is applied to the thin dyed optical film. In one embodiment, the thin dyed optical film is stretched to become a PVA polarized film. In one embodiment, the soluble dye is selected from a group consisting of an IR dye, a visible dye, a photochromic dye, or an absorbing dye. In one embodiment, the IR dye is selected from 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.
In another aspect of the invention, a method to manufacture a functional film is disclosed which is 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.
In another aspect of the invention, an eyewear lens comprising a thin dyed optical film is disclosed wherein 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.
In another aspect of the invention, 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. In one embodiment, 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, Polyvinylalcohol, Methyl Cellulose, Starch derivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, Methylene Chloride. In embodiment, 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. In one embodiment, soluble dye is selected from a group consisting of an IR dye, a visible dye, a photochromic dye, or an absorbing dye. In one embodiment, the IR dye is selected from 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. In one embodiment, 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. In one embodiment, soluble dye is selected from a group consisting of an IR dye, a visible dye, a photochromic dye, or an absorbing dye. In one embodiment, the IR dye is selected from 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.
These and other features and advantages of the invention will not be described with reference to the drawings of certain preferred embodiments, which are intended to illustrate and not to limit the invention, and in which
Some embodiments are described in detail with reference to the related drawings. Additional embodiments, features, and/or advantages will become apparent from the ensuing description or may be learned by practicing the invention. The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The steps described herein for performing methods form one embodiment of the invention, and, unless otherwise indicated, not all of the steps must necessarily be performed to practice the invention, nor must the steps necessarily be performed in the order listed.. It should be noted that references to “an” or “one” or “some” embodiment(s) in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
In accordance with the practice of the present invention, 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. Although yielding many advantages, 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.
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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. In a preferred embodiment, 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. In a preferred embodiment, 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. In one embodiment, referring to
This application claims the benefit of priority under 35 U.S.C. 119(e) to the filing date of U.S. provisional patent application No. 62/116,545 “Solution Casting Method” which was filed on Feb. 15, 2015, and which are incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62116545 | Feb 2015 | US |
