Anti-reflective lenses and methods for manufacturing the same
First Claim
1. A mold with an optical surface having an anti-reflective coating that is transferable to an optical surface of a lens, comprising:
- (a) a deposition layer of a fluoride or oxide material deposited to the optical surface;
(b) a layer of a hydrophobic material over the deposition layer wherein the hydrophobic material consists essentially of a super hydrophobic material and a dipodal silane;
(c) a first layer of SiO2 that is deposited without using ion assist and with a thickness of about 5 to 40 nm deposited to the layer of hydrophobic material;
(d) an anti-reflective coating layered structure deposited to the first layer of SiO2;
(e) a layer of a silane coupling agent that is deposited using vapor deposition and with a monolayer thickness deposited over the anti-reflective coating layered structure or by dip coating using a solution of silane coupling agent in an aprotic solvent, and(f) a scratch resistant hard coating,wherein the dipodal silane is different from the super hydrophobic material, and an amount of the dipodal silane is effective to prevent the anti-reflective coating layered structure from crazing.
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Accused Products
Abstract
The present invention relates to a method of applying an anti-reflective coating to an optical surface of a mold. In one embodiment, the method includes the steps of: providing a lens mold having an optical surface; forming a layer of a super hydrophobic material with a thickness of about 30 to 40 nm over the optical surface, wherein the super hydrophobic material contains dipodal silane; forming an anti-reflective coating layered structure over the layer of the super hydrophobic material; and forming a layer of a cyclic azasilane coupling agent that is deposited with a monolayer thickness to the anti-reflective coating layered structure using vapor deposition or by dip coating using a solution of cyclic azasilane coupling agent in an aprotic solvent.
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Citations
24 Claims
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1. A mold with an optical surface having an anti-reflective coating that is transferable to an optical surface of a lens, comprising:
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(a) a deposition layer of a fluoride or oxide material deposited to the optical surface; (b) a layer of a hydrophobic material over the deposition layer wherein the hydrophobic material consists essentially of a super hydrophobic material and a dipodal silane; (c) a first layer of SiO2 that is deposited without using ion assist and with a thickness of about 5 to 40 nm deposited to the layer of hydrophobic material; (d) an anti-reflective coating layered structure deposited to the first layer of SiO2; (e) a layer of a silane coupling agent that is deposited using vapor deposition and with a monolayer thickness deposited over the anti-reflective coating layered structure or by dip coating using a solution of silane coupling agent in an aprotic solvent, and (f) a scratch resistant hard coating, wherein the dipodal silane is different from the super hydrophobic material, and an amount of the dipodal silane is effective to prevent the anti-reflective coating layered structure from crazing. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A mold with an optical surface having an anti-reflective coating that is transferable to an optical surface of a lens, comprising:
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(a) a layer of a hydrophobic material deposited over an optical surface of the mold, wherein the hydrophobic material consists essentially of a super hydrophobic material and a dipodal silane; (b) an anti-reflective coating layered structure deposited over the layer of the hydrophobic material; (c) a layer of a coupling agent that is deposited with a monolayer thickness over the anti-reflective coating layered structure using vapor deposition or by dip coating using a solution consisting of a coupling agent in an aprotic solvent, and (d) a scratch resistant hard coating, wherein the dipodal silane is different from the super hydrophobic material, and an amount of the dipodal silane is effective to prevent the anti-reflective coating layered structure from crazing. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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Specification