Composite lenses

• US 5,702,819 A
• Filed: 05/17/1996
• Issued: 12/30/1997
• Est. Priority Date: 03/18/1994
• Status: Expired due to Fees

• Current Assignee: Essilor International SA (EssilorLuxottica SA)
• Original Assignee: Innotech, Inc. (Bimeda Holdings Ltd.)
• Inventors: Nagg, Paul J., Iyer, Venkatramani S., Blum, Ronald D., Gupta, Amitava
• Primary Examiner(s): Kiliman, Leszek
• Application Number:
  US08/649,354
• Time in Patent Office: 592 Days
• Field of Search: 264/1.7, 264/1.8, 428/412, 428/522
• US Class Current: 428/412
• CPC Class Codes: B29C 33/0016 Lost moulds, e.g. staying on the moulded object flexible bags without particular shape filled with expandable material B29C44/182; single use mandrels for winding and forming B29C53/822
• CPC Class Codes: B29C 35/0888 using transparant moulds
• CPC Class Codes: B29C 39/00 Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor B29C41/00 takes precedence
• CPC Class Codes: B29C 39/003 characterised by the choice of material
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part
• CPC Class Codes: B29D 11/00009 Production of simple or compound lenses
• CPC Class Codes: B29D 11/0073 Optical laminates
• CPC Class Codes: B29L 2011/0033 Multifocal lenses
• CPC Class Codes: G02C 7/02 Lenses; Lens systems ; Methods of designing lenses
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A method for making improved optical quality lenses is described which includes arranging a mold having a molding surface, a curable optical quality resin composition, and a plastic lens preform of optical quality material such that the resin composition is disposed between, and in contact with, the plastic lens preform and the mold; upon curing, the resin composition forms a cured plastic attached portion that is bonded to the plastic lens preform. The resin composition and plastic lens preform are selected such that the attached portion has a higher scratch resistance, a lower chromatic aberration, and/or a higher ease of edging than the lens preform.

Claims

1. A composite plastic optical quality lens, comprising:

a plastic lens preform portion of optical quality material; and

a cured plastic attached portion of a resin composition that is bonded to said plastic lens preform portion, said cured plastic attached portion having higher scratch resistance than said plastic lens preform portion, and said resin composition having a refractive index within about 0.05 units of the refractive index of said plastic lens preform portion.

2. The composite plastic optical quality lens of claim 1 wherein said cured plastic attached portion comprises a non-prescription carrier layer.

3. The composite plastic optical quality lens of claim 1 wherein said cured plastic attached portion comprises a non-prescription carrier layer and a prescription segment.

4. The composite plastic optical quality lens of claim 1 wherein said cured plastic attached portion comprises a prescription carrier layer.

5. The composite plastic optical quality lens of claim 1 wherein said cured plastic attached portion comprises a prescription carrier layer and a prescription segment.

6. The composite plastic optical quality lens of claim 3 wherein said prescription segment corresponds to a bi-focal, multi-focal or progressive region.

7. The composite plastic optical quality lens of claim 1, further comprising an additional scratch-resistant layer on the surface of said preform portion, said cured plastic attached portion, or both.

8. The composite plastic optical quality lens of claim 1 wherein said plastic lens preform portion comprises an aromatic polycarbonate polymer;

and said cured plastic attached portion comprises (a) a first resin portion comprising a bisallyl carbonate and (b) a second resin portion selected from the group consisting of one or more multi-functional acrylates, one or more methacrylates, and a mixture of one or more multi-functional acrylates and one or more methacrylates.

9. The composite plastic optical quality lens of claim 8, wherein said cured plastic attached portion comprises about 0.5 to 8 weight % photoinitiator;

about 25 to 85 weight % bisallyl carbonate; and

a remainder selected from the group consisting of methacrylates, one or more multi-functional acrylates, and a mixture of one or more methacrylates and one or more multi-functional acrylates.

10. The composite plastic optical quality lens of claim 8, wherein said cured plastic attached portion comprises about 1 to 5 weight % photoinitiator;

about 50 to 85 weight % bisallyl carbonate; and

a remainder selected from the group consisting of one or more methacrylates, one or more multi-functional acrylates, and a mixture of one or more methacrylates and one or more multi-functional acrylates.

11. The composite plastic optical quality lens of claim 9 wherein said photoinitiator is selected from the group consisting of

2-hydroxy-2-methyl-1-phenyl-propan-1-one and 1-hydroxycyclohexylphenyl ketone.

12. The composite plastic optical quality lens of claim 8, wherein said aromatic polycarbonate polymer is selected from the group consisting of bisphenol A polycarbonate, ortho-methoxy bisphenol A polycarbonate and α

,α

'"'"'-dichloro bisphenol A polycarbonate.

13. The composite plastic optical quality lens of claim 8, wherein said bisallyl carbonate is selected from the group consisting of diethylene glycol bisallyl carbonate and bisphenol A bisallyl carbonate.

14. The composite plastic optical quality lens of claim 8, wherein said multi-functional acrylates are selected from the group consisting of ethylene glycol diacrylate, ethoxylated trimethylol propane triacrylate, pentaerythritol tetracrylate, di-pentaerythritol pentacrylate and ethoxylated aliphatic diacrylate;

and said methacrylates are selected from the group consisting of methyl methacrylate, allyl methacrylate, and bisphenol A dimethacrylate.

15. The composite plastic optical quality lens of claim 1, wherein said aromatic polycarbonate polymer has a refractive index of about 1.5 to 1.6.

16. A composite plastic optical quality lens comprising:

a plastic lens preform portion comprising an aromatic polycarbonate polymer; and

a cured plastic attached portion of a resin composition comprising (a) a first resin portion comprising a bisallyl carbonate and (b) a second resin portion selected from the group consisting of one or more multi-functional acrylates, one or more methacrylates, and a mixture of one or more multi-functional acrylates and one or more methacrylates;

said cured plastic attached portion having higher scratch resistance than said plastic lens preform portion, and said resin composition having a refractive index within about 0.05 units of the refractive index of said plastic lens preform portion.

17. The composite plastic optical quality lens of claim 16 wherein said cured plastic attached portion comprises a non-prescription carrier layer.

18. The composite plastic optical quality lens of claim 16 wherein said cured plastic attached portion comprises a non-prescription carrier layer and a prescription segment.

19. The composite plastic optical quality lens of claim 16 wherein said cured plastic attached portion comprises a prescription carrier layer.

20. The composite plastic optical quality lens of claim 16 wherein said cured plastic attached portion comprises a prescription carrier layer and a prescription segment.

21. The composite plastic optical quality lens of claim 16 wherein said prescription segment corresponds to a bi-focal, multi-focal or progressive region.

22. The composite plastic optical quality lens of claim 16, further comprising an additional scratch-resistant layer on the surface of said preform portion, said cured plastic attached portion, or both.

23. The composite plastic optical quality lens of claim 16, wherein said cured plastic attached portion comprises about 0.5 to 8 weight % photoinitiator;

about 25 to 85 weight % bisallyl carbonate; and

a remainder selected from the group consisting of methacrylates, one or more multi-functional acrylates, and a mixture of one or more methacrylates and one or more multi-functional acrylates.

24. The composite plastic optical quality lens of claim 16, wherein said cured plastic attached portion comprises about 1 to 5 weight % photoinitiator;

about 50 to 85 weight % bisallyl carbonate; and

a remainder selected from the group consisting of one or more methacrylates, one or more multi-functional acrylates, and a mixture of one or more methacrylates and one or more multi-functional acrylates.

25. The composite plastic optical quality lens of claim 23, wherein said photoinitiator is selected from the group consisting of

2-hydroxy-2-methyl-1-phenyl-propan-1-one and 1-hydroxycyclohexylphenyl ketone.

26. The composite plastic optical quality lens of claim 16, wherein said aromatic polycarbonate polymer is selected from the group consisting of bisphenol A polycarbonate, ortho-methoxy bisphenol A polycarbonate and α

,α

'"'"'-dichloro bisphenol A polycarbonate.

27. The composite plastic optical quality lens of claim 16, wherein said bisallyl carbonate is selected from the group consisting of diethylene glycol bisallyl carbonate and bisphenol A bisallyl carbonate.

28. The composite plastic optical quality lens of claim 16, wherein said multi-functional acrylates are selected from the group consisting of ethylene glycol diacrylate, ethoxylated trimethylol propane triacrylate, pentaerythritol tetracrylate, di-pentaerythritol pentacrylate and ethoxylated aliphatic diacrylate;

and said methacrylates are selected from the group consisting of methyl methacrylate, allyl methacrylate, and bisphenol A dimethacrylate.

29. The composite plastic optical quality lens of claim 16, wherein said aromatic polycarbonate polymer has a refractive index of about 1.5 to 1.6.