Fabrication of a polycarbonate laminate lens having UV curable hard coats

• US 20010000331A1
• Filed: 11/29/2000
• Published: 04/19/2001
• Est. Priority Date: 10/07/1999
• Status: Abandoned Application

• Current Assignee: Sola International Holdings, Ltd.
• Original Assignee: Sola International Holdings, Ltd.
• Inventors: Ram, Sunder, Lin, Shi
• Application Number:
  US09/726,970
• Publication Number:
  US 20010000331A1
• Time in Patent Office: Days
• US Class Current: 428/423.1
• CPC Class Codes: C08F 283/006 on to polymers provided for in C08G18/00 C08F283/004 takes precedence
• CPC Class Codes: C08F 290/06 Polymers provided for in subclass C08G
• CPC Class Codes: C08F 290/067 Polyurethanes; Polyureas
• CPC Class Codes: C08J 2433/00 Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
• CPC Class Codes: C08J 7/0427 with only one layer of a composition containing a polymer binder with more layers C08J7/042
• CPC Class Codes: C08J 7/043 Improving the adhesiveness of the coatings per se, e.g. forming primers adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50
• CPC Class Codes: C08J 7/044 Forming conductive coatings; Forming coatings having anti-static properties
• CPC Class Codes: C08J 7/046 Forming abrasion-resistant coatings; Forming surface-hardening coatings
• CPC Class Codes: C08L 2666/54 Inorganic substances
• CPC Class Codes: C09D 175/16 having terminal carbon-to-carbon unsaturated bonds
• CPC Class Codes: C09D 4/06 Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09D159/00 - C09D187/00
• CPC Class Codes: G02B 1/105 Protective coatings
• CPC Class Codes: G02B 1/14 Protective coatings, e.g. hard coatings
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Abstract

The preparation of a laminated polycarbonate ophthalmic lens with wafers coated with radiation curable coatings is described. The coated wafers are laminated using UV/visible adhesive to produce a finished lens within normal tolerance for such a lens. The wafer also comprises a peelable coating at the interface of laminating surface.

Claims

1. A light transmitting plastic wafer for use in fabricating a laminated lens, said wafer having an optical surface and a bonding surface which can be bonded to the surface of a second wafer by a transparent adhesive during fabrication of said laminated lens, wherein

(a) said optical surface is coated with a first multilayer that comprises:

(1) a first abrasion resistant coating on said optical surface wherein the coating is formed by radiation curing a layer of a first composition on the optical surface; and

(2) an anti-reflection coating that is formed on the first abrasion resistant coating; and

wherein

(b) said bonding surface is coated with a second multilayer that comprises;

(1) a second abrasion resistant coating on said bonding surface wherein the coating is formed by radiation curing a layer of a second composition; and

(2) self-supporting removable film that is formed on the second abrasion resistant coating, wherein the first and second compositions each comprises;

(i) 20% to 90% of an acrylated aliphatic urethane;

(ii) 5% to 75% of a functionalized colloid silica;

(iii) 1% to 20% photoinitiator; and

(iv) a solvent, wherein the percentages are by weight.

2. The wafer of

claim 1

wherein for the first and second compositions the acrylated aliphatic urethane has a molecular weight of between 500 to 1600 Dalton.

3. The wafer of

claim 1

wherein each of the first and second compositions further comprises an effective amount of a light stabilizer.

4. The wafer of

claim 1

wherein the first and second compositions further comprise an effective amount of a flow additive.

5. The wafer of

claim 1

wherein for the first and second compositions the acrylated aliphatic urethanes comprise at least two polymerizable carbon-carbon double bonds per molecule.

6. The wafer of

claim 1

wherein for the first and second compositions the acrylated aliphatic urethanes are hexafunctional urethane acrylates.

7. The wafer of

claim 1

wherein for the first and second compositions the functionalized colloidal metal oxides are acrylic or methacrylic based silica organosol.

8. The wafer of

claim 1

characterized in that there is no adhesion layer between the first resistant coating and optical surface or between the second abrasion resistant coating and bonding surface.

9. The wafer of

claim 1

further comprising a hard coating situated between the first abrasion resistant layer and the anti-reflection layer.

10. The wafer of

claim 1

wherein the wafer is an ophthalmic lens wafer.

11. The wafer of

claim 1

wherein each abrasion resistant coating has a thickness of about 1 μ

m to 15 μ

m.

12. The wafer of

claim 1

wherein the wafer is made of polycarbonates.

13. A method of fabricating a light transmitting plastic wafer for use in fabricating a laminated lens, said wafer having an optical surface and a bonding surface which can be bonded to the surface of a second lens wafer component by a transparent adhesive during fabrication of said laminated lens, wherein the method comprises the steps of:

(a) providing a plastic wafer;

(b) forming a first multilayer coating on the optical surface of the plastic wafer by;

(1) applying a first radiation curable composition onto the optical surface;

(2) curing the first composition to form a first abrasion resistant coating;

(3) forming an anti-reflection coating on the first abrasion resistant coating; and

(c) forming a second multilayer coating on the bonding surface of the plastic wafer by;

(1) applying a second radiation curable composition onto the bonding surface; and

(2) curing the second composition to form a second abrasion resistant coating; and

(3) forming self-supporting removable film on the second abrasion resistant coating, wherein the first and second compositions each comprises;

(1) 20% to 90% of an acrylated aliphatic urethane;

(2) 5% to 75% of a functionalized colloidal metal oxide;

(3) 1% to 20% of a photoinitiator; and

(4) a solvent, wherein the percentages are by weight.

14. The method of

claim 13

wherein for the first and second compositions the acrylated aliphatic urethane has a molecular weight of between 500 to 1600 Dalton.

15. The method of

claim 13

the first and second compositions further comprise an effective amount of a light stabilizer.

16. The method of

claim 13

the first and second compositions further comprise an effective amount of a flow additive.

17. The method of

claim 13

wherein for the first and second compositions the acrylated aliphatic urethane comprises at least two polymerizable carbon-carbon double bonds per molecule.

18. The method of

claim 13

wherein for the first and second compositions the acrylated aliphatic urethane is a hexafunctional urethane acrylate.

19. The method of

claim 13

wherein for the first and second compositions the functionalized colloidal metal oxide is an acrylic or methacrylic based silica organosol.

20. The method of

claim 13

characterized in that the there is no adhesion layer between the first abrasion resistant coating and optical surface or between the second abrasion resistant coating and bonding surface.

21. The method of

claim 13

further comprising forming a hard coating situated between the first abrasion resistant layer and the anti-reflection layer.

22. The method of

claim 13

wherein the steps of curing the compositions comprise exposing the compositions to UV radiation.

23. The method of

claim 13

wherein the wafer is an ophthalmic lens wafer.

24. The method of

claim 13

wherein each abrasion resistant coating has a thickness of about 1 μ

m to 15 μ

m.

25. The method of

claim 13

wherein the wafer is made of polycarbonates.

26. A method of fabricating a laminated lens that comprises the steps of:

(a) providing a front plastic wafer having a first optical side and a first bonding side wherein (1) said first optical surface is coated with a first multilayer that comprises;

(i) a first abrasion resistant coating on the first optical surface wherein the coating is formed by radiation curing a layer of a first composition; and

(ii) an anti-reflection coating that is formed on the first abrasion resistant coating; and

wherein (2) said first bonding surface is coated with a second multilayer that comprises;

(i) a second abrasion resistant coating on first bonding surface wherein the coating is formed by radiation curing a layer of a second composition; and

(ii) first self-supporting removable film;

(b) providing a back plastic wafer having a second optical side and a second bonding side wherein (1) said second optical surface is coated with a third multilayer that comprises;

(i) a third abrasion resistant coating on a the second optical surface wherein the coating is formed by radiation curing a layer of a third composition;

(ii) an anti-reflection coating that is formed on the abrasion resistant coating; and

wherein (2) said second bonding surface is coated with a fourth multilayer that comprises;

(i) a fourth abrasion resistant coating on the second bonding surface wherein the coating is formed by radiation curing a layer of a fourth composition; and

(ii) second self-supporting removable film, wherein the first, second, third, and fourth compositions each comprises;

20% to 90% of an acrylated aliphatic urethane;

5% to 75% of a functionalized colloid silica;

1% to 20% of a photoinitiator; and

a solvent, wherein the percentages are by weight;

(c) removing the first self-supporting removable film from the first plastic wafer thereby exposing a surface of the second abrasion resistant coating on the first bonding surface of the first plastic wafer;

(d) removing the second self-supporting removable film from the second plastic wafer thereby exposing a surface of the fourth abrasion resistant coating on the second bonding surface of the second plastic wafer; and

(e) laminating the first and second wafers by attaching the first bonding surface of the first wafer to the second bonding surface of the second wafer with a transparent adhesive.

27. The method of

claim 26

wherein for the first, second, third, and fourth compositions the acrylated aliphatic urethane has a molecular weight of between 500 to 1600 Dalton.

28. The method of

claim 26

the first, second, third, and fourth compositions further comprise an effective amount of a light stabilizer.

29. The method of

claim 26

the first, second, third, and fourth compositions further comprise an effective amount of a flow additive.

30. The method of

claim 26

wherein for the first, second, third, and fourth compositions the acrylated aliphatic urethane comprises at least two polymerizable carbon-carbon double bonds per molecule.

31. The method of

claim 26

wherein for the first, second, third, and fourth compositions the acrylated aliphatic urethane is a hexafunctional urethane acrylate.

32. The method of

claim 26

wherein for the first, second, third, and fourth compositions the functionalized colloidal metal oxide is an acrylic or methacrylic based silica organosol.

33. The method of

claim 26

characterized in that the there is no adhesion layer between the first abrasion resistant coating and first optical surface, between the second abrasion resistant coating and first bonding surface, between the third abrasion resistant coating and second optical surface, or between the fourth abrasion resistant coating and second bonding surface.

34. The method of

claim 26

further comprising forming a hard coating between the first abrasion resistant layer and the anti-reflection layer.

35. The method of

claim 26

wherein the steps of curing the compositions comprise exposing the compositions to UV radiation.

36. The method of

claim 26

wherein the front and back wafers are ophthalmic lens wafers.

37. The method of

claim 26

wherein each abrasion resistant coating has a thickness of about 1 μ

m to 15 μ

m.

38. The method of

claim 26

wherein the wafers are made of polycarbonates.