Crazing resistant coating and method thereof

• US 10,317,701 B2
• Filed: 03/18/2016
• Issued: 06/11/2019
• Est. Priority Date: 03/18/2015
• Status: Active Grant

• Current Assignee: Hoya Optical Labs Of America, Inc.
• Original Assignee: Vision Ease, LP (Hoya Corporation)
• Inventors: Brown, Jeff, Marshall, Michael, Moxon, John T.
• Primary Examiner(s): Alexander, William R
• Assistant Examiner(s): Madonna, Jeffrey E
• Application Number:
  US15/074,149
• Publication Number:
  US 20160274276A1
• Time in Patent Office: 1,180 Days
• CPC Class Codes: G02B 1/113 using inorganic layer materials only
• CPC Class Codes: G02B 1/14 Protective coatings, e.g. hard coatings
• CPC Class Codes: G02C 7/02 Lenses; Lens systems ; Methods of designing lenses

Abstract

An anti-reflective coating system configured to resist crazing resulting from applied compressive forces, and an optical article employing the anti-reflective coating system; and methods of forming the same.

Claims

1. An optical article having anti-reflective properties comprising:

a bulk material having a first and a second optical surface;

a first anti-reflective coating formed of a plurality of layers of a high, mid, and/or low refractive index material applied over the first optical surface;

a second anti-reflective coating formed of a plurality of layers of a high, mid, and/or low refractive index material applied over the second optical surface, a total number of layers of the plurality of layers of the high, mid, and/or low refractive index material of the second anti-reflective coating greater than a total number of layers of the plurality of layers of the high, mid, and/or low refractive index material of the first anti-reflective coating; and

a reflection spectrum of the second anti-reflective coating substantially the same as a reflection spectrum of the first anti-reflective coating and a mechanical property of the second anti-reflective coating distinct from a mechanical property of the first anti-reflective coating.

2. The optical article of claim 1 wherein the bulk material is a cast lens or an injection molded lens.

3. The optical article of claim 1 wherein the bulk material comprises an optically functional laminate.

4. The optical article of claim 1 wherein the first optical surface is convex.

5. The optical article of claim 1 wherein the second optical surface is concave.

6. The optical article of claim 1 wherein the plurality of layers of the first anti-reflective coating comprises a total of four layers.

7. The optical article of claim 1 wherein the plurality of layers of the first anti-reflective coating comprises at least one layer formed of a high refractive index material having a thickness greater than approximately 100 nanometers.

8. The optical article of claim 1 wherein the plurality of layers of the second anti-reflective coating comprises a total of six layers.

9. The optical article of claim 1 further comprising a hard-coating applied directly on the first and the second optical surface.

10. The optical article of claim 1 wherein the second anti-reflective coating substantially resists crazing when the second optical surface is exposed to a change in diopter of greater than 5 diopter due to a compressive force applied to the optical surface.

11. The optical article of claim 1 further comprising a UV cured hard-coating applied directly on the second optical surface.

12. The optical article of claim 1 wherein the first anti-reflective coating comprises a Bayer abrasion resistance greater than 1.5.