Process to mold a plastic optical article with integrated hard coating

• US 20040125335A1
• Filed: 08/07/2003
• Published: 07/01/2004
• Est. Priority Date: 08/07/2002
• Status: Active Grant

• Current Assignee: Hoya Optical Labs Of America, Inc.
• Original Assignee: Vision-Ease Lens Inc.
• Inventors: Vu, Hannah
• Granted Patent: US 7,025,458 B2
• Time in Patent Office: Days
• US Class Current: 351/159
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 35/02 Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mouldcold vulcanisation B29C35/18 ; vulcanising tyres, presses therefor B29D30/0601
• CPC Class Codes: B29C 37/0032 the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat B29C44/14 and B29C44/32 take precedence
• CPC Class Codes: B29C 43/184 shaped by the compression of the material during moulding
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29D 11/00432 Auxiliary operations, e.g. machines for filling the moulds B29D11/00125 takes precedence
• CPC Class Codes: B29D 11/0073 Optical laminates
• CPC Class Codes: B29D 11/00865 Applying coatings; tinting; colouring printing, marking or copying processes B41M; identification in general G09F3/00; producing decorative effects in general B44C; positioning or marking of lenses B24B13/0055
• CPC Class Codes: B29K 2105/243 Partially cured
• CPC Class Codes: B29K 2995/0087 Wear resistance
• CPC Class Codes: B29L 2011/0016 Lenses

Abstract

Disclosed is a process for molding plastic optical articles with a hard coated film, comprising steps of coating one side of an optical film with a hard coating, pre-curing the hard coating to a tack free state while still maintaining the coating flexibility, making an insert from the coated film for the desired optical article, molding the plastic resin onto the insert through insert injection molding, and post-curing the molded article. The utilization of the pre-curing and post-curing steps have been found to eliminate hard coating cracks during the insert making and the molding step, while providing a hard coating with desired properties. Such an optical article possesses a hard coating integrated on its surface, thus, eliminating the need to further coat the optical article.

Claims

1. A method of producing a molded optical article comprising:

applying a hard coating to one side of an optical film;

precuring the hard coating;

forming the optical film to a desired shape;

placing the optical film in a mold cavity and injection molding a resin material; and

curing the hard coating.

2. The method of producing a molded optical article of claim 1, wherein the hard coating is thermally curable.

3. The method of producing a molded optical article of claim 1, wherein the hard coating is UV curable or radiation curable.

4. The method of producing a molded optical article of claim 1, wherein the hard coating is applied to the optical film with a web coating process.

5. The method of producing a molded optical article of claim 1, wherein the hard coating is applied to the optical film by a spin coating process.

6. The method of producing a molded optical article of claim 1, wherein the optical film is comprised of a material thermally fusible to the resin material.

7. The method of producing a molded optical article of claim 1, wherein the resin material is selected from a group consisting of polycarbonates, (meth)acrylate resins, styrene-(meth)acrylate copolymers, polysulfones, polyarylates, cyclo-olefin copolymer resins, or cellulose esters.

8. The method of claim 7, wherein the optical film is comprised of a material selected from a group consisting of polycarbonates, (meth)acrylate resins, styrene-(meth)acrylate copolymers, polysulfones, polyarylates, cyclo-olefin copolymer resins, or cellulose esters.

9. The method of producing a molded optical article of claim 1, wherein the optical article is an ophthalmic lens.

10. The method of producing a molded optical article of claim 1, wherein the optical article is a sport goggle plate.

11. The method of producing a molded optical article of claim 1, wherein the optical film is a functional plate.

12. The method of claim 11, wherein the optical film is thermally fusible to the optical article resin material.

13. The method of claim 12, wherein the optical film is a polarizing plate.

14. The method of claim 13, wherein the optical film is a photochromic plate.

15. An eye lens comprising:

a lens substrate;

an optical film joined with the lens substrate; and

a hard coating disposed upon the optical film, the hard coating having been pre-cured prior to said optical film being joined with said lens substrate.

16. An optical element formed by injection molding comprising:

a lens substrate;

an optical film disposed upon the lens substrate; and

a hard coating disposed upon the optical film, the hard coating having been pre-cured prior to disposing said optical film on said lens substrate;

said hard coating being substantially free of wrinkles and cracks.