Methods and systems for making an optical functional film

1 . A method of manufacturing an eyeglass lens using a solution casting, lamination, or injection molding process, the method comprising:

providing a first soluble polymer solution;

providing a first dye solution comprising at least one dye having a property of attenuating one of 400 nm-455 nm violet-blue light, 570 nm-595 nm green-yellow light, or 760 nm-2000 nm infrared (IR) light;

adding the first dye solution to the first soluble polymer solution to form a first dyed solution;

casting the first dyed solution to form a first film;

providing a second soluble polymer solution;

providing a second dye solution comprising at least one dye having a property of attenuating one of 400 nm-455 nm violet-blue light with at least 30% absorption, 570 nm-595 nm green-yellow light with at least 20% absorption, or 760 nm-2000 nm infrared (IR) light with at least 20% absorption;

adding the second dye solution to the second soluble polymer solution to form a second dyed solution;

one of combining or fusing the second dyed solution onto the first film to form an at least two-layer film by one of the methods of i) surface coating, ii) dip coating, iii) spin coating, iv) slot die coating, v) scraper coating, vi) gravure coating, vii) spray coating, viii) roll coating, ix) brush coating, x) silk screening, xi) printing, xii) pad printing, or xiii) adhesive glueing;

optionally, adding a third layer comprising a same or different solution material as the second dye solution with or without a dye as the first film or second film to form the at least two-layer film to form an at least three-layer film;

optionally, bending the eyeglass lens to create a curved eyeglass lens; and

one of:

laminating or casting the at least two-layer film to make the eyeglass lens with a same or different sheet material, wherein the eyeglass lens comprises a thickness of between 0.02 mm-3.0 mm; or

gasket casting the at least two-layer film to the eyeglass lens, wherein the eyeglass lens comprises a thickness of between 0.7 mm-10 mm; or

co-injection molding the at least two-layer film to the eyeglass lens, wherein the eyeglass lens comprises a thickness of between 1.0 mm-10 mm.

2 . The method of claim 1 , wherein the first dye solution comprises a third dye having a property of attenuating one of 400 nm-455 nm violet-blue light, 570 nm-595 nm green-yellow light, or 760 nm-2000 nm infrared (IR) light.

3 . The method of claim 1 , wherein the first dye solution or second dye solution comprises one of a water-based dye or oil-based dye.

4 . The method of claim 1 , wherein the eyeglass lens comprises one or more of a glass or polymer material.

5 . The method of claim 1 , further comprising:

providing a compound for injection molding;

adding a third dye to the compound, the third dye having a property of attenuating one of 400 nm-455 nm violet-blue light, 570 nm-595 nm green-yellow light, or 760 nm-2000 nm infrared (IR) light;

injection molding the compound to form the eyeglass lens, wherein laminating or casting the two-layer film comprises laminating or casting onto the eyeglass lens formed by injection molding the compound.

6 . The method of claim 1 , further comprising:

providing a third soluble polymer solution;

adding a third dye solution to the third soluble polymer solution to form a third dyed solution, the third dyed solution comprising at least one dye having a property of attenuating one of 400 nm-455 nm violet-blue light, 570 nm-595 nm green-yellow light, or 760 nm-2000 nm infrared (IR) light;

casting the second dyed solution onto the two-layer film to form a three-layer film;

wherein the laminating or casting comprising laminating or casting the three-layer film to the eyeglass lens.

7 . A method of manufacturing an eyeglass lens using a solution casting, lamination, or co-injection molding with thermoplastic extrusions film or sheet process, the method comprising:

providing a first thermoplastic extrusion material;

providing a first dye comprising at least one dye having a property of attenuating one of 400 nm-455 nm violet-blue light, 570 nm-595 nm green-yellow light, or 760 nm-2000 nm infrared (IR) light;

adding the first dye to the first thermoplastic extrusion material to make a first dyed material compound;

extruding, using a thermoplastic extrusion machine, the first dyed material compound to make a thin film of between 0.1 mm-1.5 mm thickness;

providing a second soluble polymer solution;

adding a second at least one dye to the solution, the second dye providing a second dye solution comprising at least one dye having a property of attenuating one of 400 nm-455 nm violet-blue light with at least 30% absorption, 570 nm-595 nm green-yellow light with at least 20% absorption, or 760 nm-2000 nm infrared (IR) light with at least 20% absorption;

adding the second dye solution to the second soluble polymer solution to form a second dyed solution;

combining or fusing the second dye solution onto the thin film to form an at least two-layer film by one of the methods of i) surface coating, ii) dip coating, iii) spin coating, iv) slot die coating, v) scraper coating, vi) gravure coating, vii) spray coating, viii) roll coating, ix) brush coating, x) silk screening, xi) printing, xii) pad printing, or xiii) adhesive glueing;

optionally, adding a second layer comprising a same or different solution material as the second dye solution with or without a same dye as the at least two-layer film to form an at least three-layer film;

and

one of laminating or casting the at least two-layer film or the at least-three layer film to a substrate to form the eyeglass lens.

8 . The method of claim 7 , wherein the first dye solution comprises a third dye having a property of attenuating one of 400 nm-455 nm violet-blue light, 570 nm-595 nm green-yellow light, or 760 nm-2000 nm infrared (IR) light.

9 . The method of claim 7 , wherein the first dye solution or third dye solution comprises one of a water-based dye or oil-based dye.

10 . The method of claim 7 , wherein the substrate comprises one of a glass or polymer material.

11 . The method of claim 7 , further comprising:

providing a second soluble polymer solution;

adding a third dye solution to the second soluble polymer solution to form a second dyed solution, the second dyed solution having a property of attenuating one of 400 nm-455 nm violet-blue light with at least 30% absorption, 570 nm-595 nm green-yellow light with at least 20% absorption, or 760 nm-2000 nm infrared (IR) light with at least 20% absorption;

casting the second dyed solution to form a second film; and

casting or laminating the second film onto the eyeglass lens.