US2005140033A1PendingUtilityA1

Process for making a coated optical article free of visible fining lines

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Assignee: ESSILOR INTPriority: Dec 31, 2003Filed: Dec 31, 2003Published: Jun 30, 2005
Est. expiryDec 31, 2023(expired)· nominal 20-yr term from priority
Inventors:Peiqi JiangSteven WeberFadi O. Adileh
B29C 2035/0827B29C 2043/3655B29C 66/71B29K 2995/0026B29L 2011/0016B29D 11/0073B29C 2043/3652B29K 2995/007B29K 2995/0072B29C 43/021B29C 66/73161B29C 2043/3649
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Claims

Abstract

The invention concerns a process for making a coated optical lens blank free of visible fining lines which comprises: (i) providing an optical article having at least one fined but unpolished geometrically defined main face; (ii) providing a mold part having an internal and external surface; (iii) depositing on said main face of said optical article or on the internal surface of the mold part a requisite amount of a liquid curable coating composition; (iv) moving relatively to each other the optical article and the mold part to either bring the coating composition into contact with the main face of the optical article or into contact with the internal face of the mold part; (v) applying pressure to the mold part to spread the liquid curable coating composition on said main face and form a uniform liquid coating composition layer onto the main face; (vi) curing the liquid coating composition layer; (vii) withdrawing the mold part; and (viii) recovering the free of visible fining lines coated optical article.

Claims

exact text as granted — not AI-modified
1 . A process for making a coated optical lens blank free of visible fining lines which comprises: 
 (i) providing an optical article having at least one fined but unpolished geometrically defined main face;    (ii) providing a mold part having an internal and external surface;    (iii) depositing on said main face of said optical article or on the internal surface of the mold part a requisite amount of a liquid curable coating composition;    (iv) moving relatively to each other the optical article and the mold part to either bring the coating composition into contact with the main face of the optical article or into contact with the internal face of the mold part;    (v) applying pressure to the mold part to spread the liquid curable coating composition on said main face and form a uniform liquid coating composition layer onto the main face;    (vi) curing the liquid coating composition layer;    (vii) withdrawing the mold part; and    (viii) recovering the free of visible fining lines coated optical article.    
     
     
         2 . The process of  claim 1 , wherein the liquid coating composition layer is cured under pressure.  
     
     
         3 . The process of  claim 1 , wherein said mold part is rigid and its internal face inversely replicates said main face of said optical article.  
     
     
         4 . The process of  claim 1 , wherein said mold part is flexible and the geometry of its internal face inversely replicates said main face of said optical article under the pressure applied in step (v).  
     
     
         5 . The process of  claim 1 , wherein the curable liquid coating composition is a UV curable composition.  
     
     
         6 . The process of  claim 1 , wherein the mold part is a transparent wafer.  
     
     
         7 . The process of  claim 5 , wherein the mold part is a UV transparent wafer.  
     
     
         8 . The process of  claim 4 , wherein the flexible part has a higher base curvature than the base curvature of the fined and unpolished optical article to be coated.  
     
     
         9 . The process of  claim 1 , wherein the pressure exerted onto the mold part ranges from 10 kPa to 350 kPa.  
     
     
         10 . The process of  claim 1 , wherein the pressure exerted onto the mold part ranges from 30 to 150 kPa.  
     
     
         11 . The process of  claim 4 , wherein the flexible mold part is an inflatable flexible membrane.  
     
     
         12 . The process of  claim 4 , wherein the flexible mold part has a thickness of 2 mm or less.  
     
     
         13 . The process of  claim 4 , wherein the flexible mold part is made of flexible plastic material.  
     
     
         14 . The process of  claim 4 , wherein the flexible plastic material comprises polycarbonate or poly(methylmethacrylate).  
     
     
         15 . The process of  claim 1 , wherein R q  of the fined but unpolished geometrically defined main face ranges from 0.01 to 1.5 μm.  
     
     
         16 . The process of  claim 1 , wherein R q  of the fined but unpolished geometrically defined main face ranges from 0.1 to 1.0 μm.  
     
     
         17 . The process of  claim 1 , wherein the optical article is made of polycarbonate.  
     
     
         18 . The process of  claim 13 , wherein said main face of the optical article has a R q  of about 0.5 μm.  
     
     
         19 . The process of  claim 1 , wherein the optical article is made of diethylene glycol bis-allylcarbonate, polycarbonate, polythiourethane or episulfide material.  
     
     
         20 . The process of  claim 19 , wherein said main face of the optical article has a surface roughness S q  of about 1.0 μm.  
     
     
         21 . The process of  claim 1 , wherein the cured coating has a thickness of 1 to 50 μm.  
     
     
         22 . The process of  claim 1 , wherein the cured coating has a thickness of 1 to 25 μm.  
     
     
         23 . The process of  claim 22 , wherein the cured coating has a thickness of 1 to 10 μm  
     
     
         24 . The process of  claim 23 , wherein the cured coating has a thickness of 1 to 5 μm.  
     
     
         25 . The process of  claim 24 , wherein the refractive index difference between the lens blank and the cured coating is up to 0.1.  
     
     
         26 . The process of  claim 1 , wherein the coating composition is an anti-abrasive hard coating composition.  
     
     
         27 . The process of  claim 1 , wherein the said main face of the lens blank is the back face of the lens blank.  
     
     
         28 . The-process of  claim 1 , wherein the lens blank is a tinted lens blank.  
     
     
         29 . The process of  claim 1 , further comprising applying an anti-reflective coating directly onto the cured coating.  
     
     
         30 . The process of  claim 1 , wherein said optical article is a lens or lens blank.  
     
     
         31 . The process of  claim 1 , wherein said optical article is a transparent lens mold.  
     
     
         32 . The process of  claim 30 , wherein said optical article is a tinted lens or lens blank.  
     
     
         33 . The process of  claim 31 , wherein said lens mold is a glass mold.  
     
     
         34 . The process of  claim 30 , wherein the said main face of the lens or lens blank is the back face of the lens or lens blank.  
     
     
         35 . The process of  claim 1 , further comprising applying an anti-reflective coating directly onto the cured coating.  
     
     
         36 . A process for making a coated article whose main surface has a surface state corresponding to a polished stated which comprises: 
 (i) providing an article having at least one fined but unpolished geometrically defined main face;    (ii) providing a mold part having an internal and external surface;    (iii) depositing on said main face of said article or on the internal surface of the mold part a requisite amount of a liquid curable coating composition;    (iv) moving relatively to each other the article and the mold part to either bring the coating composition into contact with the main face of the article or into contact with the internal face of the mold part;    (v) applying pressure to the mold part to spread the liquid curable coating composition on said main face and form a uniform liquid coating composition layer onto the main face of the article;    (vi) curing the liquid composition layer;    (vii) withdrawing the mold part; and    (viii) recovering the coating article having a surface state corresponding to a polished state.    
     
     
         37 . The process according to  claim 36 , wherein the surface of the coated article has a R q  under 0.01 μm.  
     
     
         38 . The process according to  claim 37 , wherein the coated article is a lens mold.  
     
     
         39 . The process according to  claim 38 , wherein the lens mold is not transparent.  
     
     
         40 . The process of  claim 1 , wherein the mold part is precoated by a release coating and/or protective coating.  
     
     
         41 . The process of  claim 1 , wherein the mold part has a microstructure or a pattern to be duplicated in the lens blank coating.  
     
     
         42 . The process of  claim 36 , wherein the mold part is precoated by a release coating and/or protective coating.  
     
     
         43 . The process of  claim 36 , wherein the mold part has a microstructure or a pattern to be duplicated in the lens blank coating.

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