阅读说明：本技术 眼科镜片的底漆 (Primer for ophthalmic lenses ) 是由 A·贾卢里 P·弗罗芒坦 H-W·邱 R·瓦勒里 R·贝松 于 2021-05-12 设计创作，主要内容包括：披露了一种眼科镜片,所述眼科镜片包括用于将功能元件接合到镜片基材上的与基材无关的粘性底漆。特别地,眼科镜片包括：至少一个聚合镜片基材,所述至少一个聚合镜片基材包含至少一种热固性单体；功能部件,所述功能部件包括至少一个热塑性层,所述至少一个热塑性层的表面面向所述聚合镜片基材；以及底漆涂层,所述底漆涂层沉积到所述至少一个热塑性膜的面向所述聚合镜片基材的所述表面上。(An ophthalmic lens is disclosed that includes a substrate independent tacky primer for bonding a functional element to a lens substrate. In particular, an ophthalmic lens comprises: at least one polymeric lens substrate comprising at least one thermosetting monomer; a functional component comprising at least one thermoplastic layer, a surface of the at least one thermoplastic layer facing the polymeric lens substrate; and a primer coating deposited onto the surface of the at least one thermoplastic film facing the polymeric lens substrate.)

1. An ophthalmic lens, comprising:

at least one polymeric lens substrate comprising at least one thermosetting monomer;

a functional component comprising at least one thermoplastic layer, a surface of the at least one thermoplastic layer facing the polymeric lens substrate; and

a primer coating deposited onto the surface of the at least one thermoplastic film facing the polymeric lens substrate.

2. The ophthalmic lens of claim 1, wherein the functional component comprises at least one dye selected from the group consisting of: photochromic dyes, dichroic dyes, blue light cut dyes, infrared cut dyes, ultraviolet cut dyes, selective wavelength cut dyes, color enhancement dyes, polarizing dyes, and filter dyes.

3. The ophthalmic lens of claim 2, wherein the functional component comprises a functional layer having the photochromic dye as the at least one dye and being one of a polyether block amide functional layer or a thermoplastic polyurethane functional layer.

4. The ophthalmic lens of claim 2, wherein the functional component comprises a functional layer having the polarizing dye as the at least one dye and being a polyvinyl alcohol functional layer.

5. The ophthalmic lens of claim 4,

the at least one thermoplastic film of the functional component is two thermoplastic films and the functional polyvinyl alcohol layer is arranged between the two thermoplastic films,

each of the two thermoplastic films is selected from the group consisting of a polycarbonate film, a triacetyl cellulose film, and a polyamide film.

6. The ophthalmic lens of claim 1, wherein the at least one polymeric lens substrate is adhered to the convex surface of the functional component.

7. The ophthalmic lens of claim 1, wherein the at least one polymeric lens substrate is adhered to the concave surface of the functional component.

8. The ophthalmic lens of claim 1, wherein at least one thermoplastic film of the functional component is a polycarbonate film.

9. The ophthalmic lens of claim 1, wherein the primer coating comprises

At least one first reactive monomer,

At least one second reactive monomer and

at least one photoactive catalyst.

10. The ophthalmic lens of claim 9, wherein the at least one photoactive catalyst is reactive to ultraviolet light.

11. The ophthalmic lens of claim 9, wherein the at least one second reactive monomer of the primer coating is an alkoxysilane.

12. The ophthalmic lens of claim 9, wherein the at least one second reactive monomer of the primer coating comprises a reactive group selected from the group consisting of: allyl, vinyl, acrylic, thiol, isocyanate, epoxy, and amine.

13. The ophthalmic lens of claim 12, wherein the reactive group is an epoxy group.

14. The ophthalmic lens of claim 9, wherein the at least one photoactive catalyst comprises a cationic photoinitiator and a free-radical photoinitiator.

15. The ophthalmic lens of claim 9, wherein the at least one first reactive monomer of the primer coating is an acrylic monomer or a mixture of acrylic monomers.

Technical Field

The present disclosure relates to the field of ophthalmic lenses, including ophthalmic lenses containing functional elements for eyeglasses and sunglasses.

Description of the related Art

Additional functions (e.g., filtering or optical functions) may be integrated into the ophthalmic lens by incorporating functional elements (e.g., films, wafers, or laminates).

One of the problems associated with integrating thermoplastic-based functional elements into ophthalmic thermoset lenses is the compatibility of the thermoplastic functional element with the lens casting material or surrounding lens substrate. The functional element should not be damaged by the lens casting material and should have good adhesion. Compatibility issues may arise during the manufacturing process, during the finishing process, or during use. During the manufacturing process, it is highly desirable to develop a degree of connectivity with the casting monomer. A strong adhesive bond can help, for example, improve component output and efficiency. During the finishing process, it is highly desirable to have a degree of connectivity with the casting resin. The lens finish machining step comprises lens blocking, frame fixing, back curve generation, back curve refining and polishing, lens edging and deblocking. These processing steps can impart high levels of stress to the lens and can lead to delamination of the functional elements. There is a need to provide ophthalmic lenses with good adhesion and optical clarity to customers.

Current castingThe polarizing lens is manufactured using a fragile polyvinyl alcohol (PVA) polarizing film having a thickness of about 30 μm. These thin polarizing films are susceptible to damage during handling. For example, during the production of polarized lenses, many manual handling steps are required, which increases the likelihood of damage.

To this end, PVA film may be laminated in a more durable film, such as triacetyl cellulose (TAC). A primer is applied to the polarizing laminate to castGood adhesion is obtained in the lens, resulting in a more robust TAC/PVA/TAC polarizing element with improved handling durability compared to a single layer PVA film. However, when used with polycarbonate/PVA/polycarbonate laminates, current industrial primers may deteriorate the optical quality of the Polycarbonate (PC) polarizing laminate and do not provide sufficient adhesion, and may obscure the laminate, impeding the manufacturing process. Despite advances in the art of polarizing film tack primers, there remains a need for primers that provide improved adhesion and function well during manufacturing and finishing and throughout a variety of lens substrates. Such a primer would enable the production of robust functional elements that can be universally applied to ophthalmic lenses.

The foregoing "background" description is intended to generally introduce the background of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

Background

Disclosure of Invention

The present disclosure relates to an ophthalmic lens.

According to an embodiment, the present disclosure further relates to an ophthalmic lens comprising: at least one polymeric lens substrate comprising at least one thermosetting monomer; a functional component comprising at least one thermoplastic layer, a surface of the at least one thermoplastic layer facing the polymeric lens substrate; and a primer coating deposited onto the surface of the at least one thermoplastic film facing the polymeric lens substrate. In embodiments, the primer coating comprises at least one first reactive monomer, at least one second reactive monomer, and at least one photoactive catalyst.

The preceding paragraphs have been provided as a general introduction and are not intended to limit the scope of the claims below. The described embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.

Drawings

A more complete appreciation of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a cross-sectional schematic view of a casting unit according to an exemplary embodiment of the present disclosure;

figure 2A is a diagram of a treated functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

figure 2B is a diagram of a treated functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

figure 2C is a diagram of a treated functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

figure 3A is a flow chart of a method of a functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

FIG. 3B is a flow chart of a sub-process of a method of a functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

figure 4A is a flow chart of a method of a functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

FIG. 4B is a flow chart of a sub-process of a method of a functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

figure 5A is an illustration of a method of functional elements of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

figure 5B is an illustration of a method of functional elements of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

figure 6A is a flow chart of a method of a functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

FIG. 6B is a flow chart of a sub-process of a method of a functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure; and

figure 7 is an illustration of a method of functional elements of an ophthalmic lens according to an exemplary embodiment of the present disclosure.

Detailed Description

The terms "a" or "an," as used herein, are defined as one or more than one. The term "plurality", as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). Reference throughout this document to "one embodiment," "certain embodiments," "an embodiment," "an implementation," "an example" or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the present disclosure. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.

The terms "about" and "approximately" are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, these terms are defined as being within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

The term "laminate" or "laminated lens" or variations of these terms, when used in the claims and/or the specification, refer to similar structures.

The term "substantially" and variations thereof are defined as including ranges within 10%, within 5%, within 1%, or within 0.5%.

The terms "inhibit" or "reduce" or "prevent" or "avoid" or any variation of these terms, when used in the claims and/or specification, includes any measurable reduction or complete inhibition to achieve a desired result.

The term "effective," when used in the specification and/or claims, means sufficient to achieve a desired, expected, or expected result.

The methods of the present disclosure may "comprise," "consist essentially of" … … or "consist of … …" the particular ingredients, components, compositions, etc. disclosed throughout this specification.

The terms "primer" and "primer coating" may be used interchangeably in the specification and/or claims, but are intended to express the same or similar materials.

The terms "functional component" and "functional element" may be used interchangeably in the specification and/or claims, but are intended to express the same or similar material. The term "functional component" or "functional element" may be used as a high-level term to refer to each of the following, as appropriate for a given embodiment: (1) a thermoplastic layer, (2) a thermoplastic layer and a functional layer, and (3) a thermoplastic layer, a functional layer and a thermoplastic layer.

The present disclosure relates to an ophthalmic lens featuring a primer independent of the lens substrate for adhering a functional element to one or more lens substrates, wherein the functional element may be one of a film, a wafer, or a laminate.

This is particularly important because the optical functions of certain filter systems and functional elements that have been built into Polycarbonate (PC) lens substrates (e.g., color enhancement, polarization, blue light filtering, near infrared filtering, photochromic properties and myopic defocus, among others) are not readily used with thermoset lens substrates. For example, functional elements including polycarbonate films may be damaged by the thermoset lens substrate precursor during casting, resulting in reduced adhesion and visually eroded and hazy ophthalmic lenses. Thus, it will be appreciated that a significant amount of development time is required to design a solution for optical filters that is compatible with the surrounding monomer body or lens substrate precursor. Furthermore, since thermoset lens substrates are common in lens production, innovative technical solutions that can be easily implemented in thermoset lens substrates for functional elements manufactured for PC lens substrates are of great interest.

The introduction of functional elements having optical filtering and/or optical functions into the lens substrate requires consideration of the compatibility of the functional element with the surrounding body or lens substrate to achieve the desired performance. To this end, a method is used to add a lens baseThe functional element is incorporated into the lens substrate by disposing the functional element in the casting mold prior to the precursor. As an alternative to placing functional elements of triacetylcellulose and polyvinyl alcohol in a casting cavity (which may be considered as a lens substrate specific solution), thermoplastic functional elements including PC film may be placed in the casting cavity prior to addition of the lens substrate precursor with the intention of providing universally applicable PC-based functional elements that may be applied in various lens substrate systems. However, although the adhesion between the PC-based functional element and the lens substrate may be sufficient, since the lens substrate precursor isSo that the PC-based functional element is also bonded toContact of the lens substrate precursor degrades. The degradation may lead to insufficient blur and visual clarity, among other things.

Thus, exemplary embodiments of the present disclosure describe primers that provide protection to the functional element and promote adhesion between the functional element and the thermoset lens substrate (via the thermoset lens substrate precursor). For example, the primer may include an Ultraviolet (UV) curable epoxy and acrylate based primer.

According to embodiments, a primer may be applied to one or more surfaces of the PC-based functional element and adhered to the corresponding one or more thermosetting lens substrates or one or more thermosetting monomers.

According to embodiments, the present disclosure describes a treatment of a PC-based functional element that prepares and protects the surface of the PC-based functional element for contact with a thermoset lens substrate precursor.

The benefits provided by the ophthalmic lenses of the present disclosure include (1) consistent and uniform optical filtering performance across a variety of lens substrate materials (e.g., thermoplastic lens substrates, thermoset lens substrates), and (2) reduced manufacturing complexity in handling multiple types of functional elements and different lens substrate materials by using a single, generally compatible functional element design.

Turning now to the drawings, FIG. 1 provides a schematic cross-sectional view of a functional element 150 within a casting mold 140. The functional element 150 may include a resin including an optical filter that imparts visual characteristics and optical functionality on the functional element 150. For example, the dye may be one of the following: photochromic dyes, dichroic dyes, blue light cut dyes, infrared cut dyes, UV cut dyes, selective wavelength cut dyes, color enhancement dyes, or combinations thereof, among others. The functional element 150 may have a thickness between 0.5 μm and 500 μm. In embodiments, the functional element 150 may comprise at least one thermoplastic film or at least one thermoplastic layer. The at least one thermoplastic film may be one of a PC film, a triacetyl cellulose (TAC) film, and a Polyamide (PA) film, among others. In an embodiment, the casting mold 140 is substantially cylindrical.

In an embodiment, the casting mold 140 includes a shim 145 and first and second casting inserts 141 and 142. The first casting insert 141 and the second casting insert 142 may define at least one void therebetween. During casting, the at least one void may be filled with lens substrate monomer. In an example, a desired ophthalmic lens can include a functional element having a lens substrate on either surface of the functional element. This example reflects the schematic of fig. 1. In this example, the at least one void may be a first void 148 and a second void 149, and the lens substrate monomer may fill the first void 148 and the second void 149 to produce the desired ophthalmic lens, the curvature of the lens substrate being defined by the curvature of the first casting insert 141 and the curvature of the second casting insert 142. In another example, a desired ophthalmic lens may include a functional element having a lens substrate on only a single surface of the functional element. In this example, the functional element may abut either of the first casting insert 141 or the second casting insert 142, and the at least one void may be either of the first void 148 or the second void 149. The lens substrate monomer may fill the first void 148 or the second void 149 to prepare a desired ophthalmic lens, and the curvature of the lens substrate may be defined by the first casting insert 141 or the second casting insert 142.

In embodiments, the lens substrate monomer can be a thermoset polyurethane, allyl diglycol carbonate, polythiourethane, an episulfide polymer, an epoxy resin, a poly (meth) acrylate, a polythiomethacrylate, or a combination thereof. The lens substrate of the ophthalmic lens may be a thermoset lens substrate.

In an embodiment, the curvature of the first casting insert 141 and the curvature of the second casting insert 142 may determine the lens power of the ophthalmic lens. For semi-finished (SF) lenses, the curvature along the convex side of the SF lens is fixed, and the curvature along the concave side of the SF lens can be modified after casting by, for example, grinding and polishing.

In an embodiment, and prior to placement in casting mold 140 and ophthalmic lens integration, functional element 150 may be a flat functional element and may be thermoformed via, for example, a thermoformer into a spherical dome shape of thermoformed functional element 150. During thermoforming, a flat functional element may be placed onto the heated thermoformed insert and a vacuum force may be applied to secure the flat functional element to the thermoformed insert. By adjusting the temperature of the applied heat and the force of the applied vacuum, the flat functional element can be formed into the curved shape of the thermoformed insert to produce the thermoformed functional element 150.

In embodiments, thermoforming a flat functional element can create a curved structure and define the curvature of either or both surfaces of the functional element.

According to an embodiment, the functional element 150 of fig. 1, in order to improve the adhesion between the functional element 150 and the lens substrate monomer, as described above, the functional element 150 may be treated by a primer coating on at least one surface of the functional element 150.

While the following figures will describe a method of applying a primer coating, fig. 2A through 2C introduce illustrations of various treated functional elements.

For example, fig. 2A depicts a functional element 250 comprising a single thermoplastic film 246. The unitary thermoplastic film 246 can include a primer coating 202 on the concave surface 244 of the functional element 250. The at least one thermoplastic film 246 may be one of a PC film, a TAC film, and a PA film, among others.

Fig. 2B depicts a functional element 250 comprising a thermoplastic film 246 and a functional film 248. The functional element 250 can include a primer coating 202 on the concave surface 244 of the thermoplastic film 246 of the functional element 250. The at least one thermoplastic film 246 may be one of a PC film, a TAC film, and a PA film, among others. The functional film 248 may be one of a polyvinyl alcohol (PVA) film, a Thermoplastic Polyurethane (TPU) film, and a polyether block amide (PEBA) film, among others. In an example, the at least one thermoplastic film 246 and/or the functional film 248 can include a resin that includes an optical filter that imparts visual properties and optical functionality on the functional element 250. The functional elements 250 may be PVA/PC functional elements, PVA/TAC functional elements or PVA/PA functional elements, among others. In another example, the dye is a photochromic dye within the functional film 247, and the functional film 247 is any of a PEBA film or a TPU film. The functional elements 250 derived therefrom may be TPU/PC functional elements, TPU/TAC functional elements, PEBA/TAC functional elements, TPU/PA functional elements or PEBA/PA functional elements, among others. After the functional film 248 is laminated with the at least one thermoplastic film 246, the functional element 250 may have a thickness between 0.5 μm and 500 μm.

Fig. 2C depicts a functional element 250 comprising a first thermoplastic film 246', a functional film 248, and a second thermoplastic film 246 ". The functional element 250 may include a primer coating 202 on the concave surface 244 of the first thermoplastic film 246' of the functional element 250 or on the convex surface 243 of the second thermoplastic film 246 "of the functional element 250. In an example, the functional element 250 can include a primer coating 202 on both the concave surface 244 of the first thermoplastic film 246' of the functional element 250 and the convex surface 243 of the second thermoplastic film 246 "of the functional element 250. The first thermoplastic film 246' and/or the second thermoplastic film 246 "can be one of, among others, PC film, TAC film, and PA film. The functional film 248 may be one of a polyvinyl alcohol (PVA) film, a Thermoplastic Polyurethane (TPU) film, and a polyether block amide (PEBA) film, among others. In an example, one or more of the first thermoplastic film 246', the functional film 248, and the second thermoplastic film 246 "can include a resin that includes an optical filter that imparts visual properties and optical functionality on the functional element 250. The functional elements 250 may be PC/PVA/PC functional elements, TAC/PVA/TAC functional elements or PA/PVA/PA functional elements, among others. In another example, the dye is a photochromic dye within the functional film 248, and the functional film 248 is either a PEBA film or a TPU film. The functional elements 250 derived therefrom may be PC/TPU/PC functional elements, TAC/TPU/TAC functional elements, TAC/PEBA/TAC functional elements, PA/TPU/PA functional elements or PA/PEBA/PA functional elements, among others. After the functional film 248 is laminated with the first and second thermoplastic films 246', 246 ", the functional element 250 may have a thickness between 0.5 μm and 500 μm.

Turning now to fig. 3A and 3B and as depicted in fig. 1, a casting mold may include one or more voids depending on the lens substrate design of an ophthalmic lens. Fig. 3A and 3B depict a method of making an ophthalmic lens in view of the one or more voids and according to an exemplary embodiment of the present disclosure. It may be appreciated that the functional elements described above with reference to fig. 2A through 2C may each be an embodiment of the flow diagrams of fig. 3A and 3B.

Referring to fig. 3A, a method 300 is a high level generalized flow chart for preparing an ophthalmic lens having a functional element adhered to one or more lens substrates, wherein adhesion is promoted by treating one or more surfaces of the functional element.

In step 305 of method 300 and in view of fig. 1, a functional element having a convex surface and a concave surface may be provided.

In a sub-process 310 of the method 300, one or more of the convex and concave surfaces of the functional element may be processed. The treatment may include applying a primer to one or more of the convex and concave surfaces of the functional element. The sub-process 310 of the method 300 will be described in further detail with reference to FIG. 4B and subsequent figures.

In a sub-process 320 of the method 300, the treated functional element may be adhered to one or more lens substrates. Adhering may include forming one or more lens substrates from the lens substrate precursor within the one or more voids of the casting mold, as shown in fig. 1.

In adhering the treated functional element to one or more lens substrates, and referring now to fig. 3B, in a sub-process 320 of the method 300, the treated functional element may be adhered to one or more lens substrates. At step 321 of sub-process 320, the treated functional element may be disposed within a casting mold according to the desired design of the ophthalmic lens. For example, the processed functional elements may be arranged such that one or more voids are left behind. At step 322 of sub-process 320, one or more voids may be filled with a lens substrate precursor (or monomer). The lens substrate precursor can be an uncured thermoset polymer, such asA lens substrate precursor. After injecting the lens substrate precursor into the one or more voids of the casting mold, the lens substrate precursor may be allowed to cure to a desired hardness before removing the ophthalmic lens from the casting mold at step 323 of sub-process 320. It will be appreciated that the sub-process 310 of the method 300 is consistent for each of the remaining embodiments of the present disclosure, and as such, the description with reference to the following figures will be omitted for the sake of brevity.

Referring now to fig. 4A, a description of an exemplary embodiment of the present disclosure is provided wherein a functional element comprising a first thermoplastic film, a functional film, and a second thermoplastic film is adhered to a unitary lens substrate on one surface of the functional element.

At step 405 of method 400, a functional element having a convex surface and a concave surface may be provided.

In a sub-process 410 of the method 400, a convex or concave surface of the functional element may be processed. The treatment may include applying a primer to the convex or concave surface of the functional element. The sub-process 410 of the method 400 will be described in further detail with reference to fig. 4B.

In a sub-process 420 of the method 400, the treated functional element may be adhered to a lens substrate in a manner similar to that of fig. 3B. Adhering may include forming a lens substrate from a lens substrate precursor within the void of a casting mold and contacting it with a surface of a functional element, as shown in fig. 1.

Referring now to FIG. 4B, a sub-process 410 of the method 400 describes the treatment of a convex or concave surface of a functional element. At step 411 of the sub-process 410, a primer coating may be applied to the convex or concave surface of the functional element.

In embodiments, the primer coating may be one of a variety of primers that provide strong adhesion between the functional element and the lens substrate. The primer can be formulated to include a component that promotes bonding with the functional element and the lens substrate. While conventional primers rely on relatively weak primer-primer and primer-substrate electrostatic forces to adhere, the primers of the present disclosure can bond to the surface to which they are applied. The end result of the primer is increased tack strength and durability.

According to embodiments, the primer disclosed herein is particularly useful for adhering functional elements comprising PC films to foundryIs effective on lens substrates. The primer can be designed to provide a degree of penetration into the surface of the PC film or other element layer of the functional element. The PC film penetration qualities of the primer promote its adhesion.

In embodiments, a primer as disclosed herein may comprise at least one first reactive monomer, at least one second reactive monomer, and at least one photoactivatable catalyst. In an embodiment, the primer further comprises a solvent. The at least one first reactive monomer may be a mixture of at least one acrylic monomer selected from the group consisting of monoacrylate monomers and diacrylate monomers and at least one acrylate monomer selected from the group consisting of triacrylate monomers to hexaacrylate monomers. In an example, the reactive group of the at least one second reactive monomer may be an epoxy group. The at least one second reactive monomer may be an epoxy monomer selected from glycidyl ethers of polyhydric alkanols. The at least one photoactivatable catalyst may be a photoactivatable catalyst. The light may be UV light. The at least one photoactivatable catalyst may be a cationic catalyst and may be selected from the group consisting of aromatic onium salts and iron arene salt complexes. In embodiments, the primer may further comprise a free radical photoinitiator as a component of the photoactivatable catalyst. The radical photoinitiator may be one selected from the group consisting of benzophenone and acetophenone.

In an example, the at least one first reactive monomer can be at least one monomer capable of reacting with a lens substrate monomer or lens substrate precursor. The at least one monomer may be included in an amount between 0.25 wt.% and 75 wt.%, preferably between 10 wt.% and 50 wt.%, based on the total weight of the at least one second reactive monomer and the at least one monomer present in the composition. In an embodiment, the at least one monomer may be a mixture of acrylate monomers.

According to an embodiment, the at least one second reactive monomer may have a molecular weight between about 50 and 1,000. The at least one second reactive monomer may be included in an amount between 1 wt.% and 90 wt.%, preferably between 50 wt.% and 90 wt.%, based on the total weight of the at least one second reactive monomer and the at least one first reactive monomer. In an embodiment, the at least one second reactive monomer may be a mixture of an epoxy resin and a cycloaliphatic epoxy resin. In embodiments, the at least one second reactive monomer may be an alkoxysilane such as allyltrimethoxysilane, allyltriethoxysilane, allyl methacrylate, and vinyltrimethoxysilane.

According to an embodiment, the at least photoactivatable catalyst may be comprised in an amount of between 0.1 and 10 wt.%, preferably between 0.1 and 3 wt.%. In embodiments, the at least one photoactivatable catalyst may be a mixture of a cationic photoinitiator and a free radical photoinitiator.

In embodiments, the primer may comprise a curable composition. Of course, the curing process may cause chemical reactions that alter certain components of the primer component. In some embodiments, the primer component functional groups can be selected to interact with the functional elements and react with the lens substrate to which they will adhere. In this manner, primer compositions as disclosed herein can be designed and tailored to provide adhesion to specific functional elements and/or lens substrate target materials.

In some embodiments, a solvent may be used to dissolve the primer component. When present, the solvent may be included in an amount between 20 wt.% and 99 wt.%. In examples, the solvent is an alcohol such as methanol, ethanol, n-propanol, and isopropanol, among others. In another example, the solvent may be one of a ketone, an acetate solvent, acetone, methyl ethyl ketone, ethyl acetate, cyclopentanone, and cyclohexanone, and any combination thereof.

According to embodiments, the at least one first reactive monomer may exhibit the same chemical functionality as the lens substrate monomer. The at least one first reactive monomer helps ensure compatibility of the primer composition with the polymerized lens substrate monomer (also referred to herein as a lens substrate precursor) when the at least one first reactive monomer exhibits the same chemical functionality as the lens substrate monomer. In some embodiments, the at least one first reactive monomer has a different chemical functionality than the polymerized monomer of the lens substrate. Further, the at least one first reactive monomer may have a different chemical functionality than the lens substrate monomer, but may still be capable of reacting with the polymerized lens substrate monomer. In this case, the at least one first reactive monomer is selected to include the same reactive functional group as the lens substrate monomer. For example, the lens substrate monomer can consist essentially of allyl diglycol carbonate (i.e.,) And at least one first reactive monomer may be diallyl ether. Although both the lens substrate monomer and the at least one first reactive monomer are different compounds, they may react with each other through their reactive functional groups. In some aspects, the at least one first reactive monomer comprises a reactive group functionality of 1 or greater, preferably at least 2. Increasing the reactive functionality increases the potential for reaction with at least one first reactive monomerThe type of functional group (b). In an example, the at least one first reactive monomer may include one or more reactive groups selected from the group consisting of: allyl, vinyl, acrylic, thiol, isocyanate, epoxy, and amine.

In some embodiments, at least one second reactive monomer has a reactive functionality of 1 or greater, preferably 2. Increasing the reactive functionality increases the amount and type of functional groups that can react with the at least one second reactive monomer. In some embodiments, the at least one second reactive monomer is an epoxy monomer. In some embodiments, the at least one second reactive monomer is a functional, (meth) acrylate-based resin.

In some embodiments, the functional element is a polarizing element. The polarizing element may include at least one thermoplastic film and a PVA film as a polarizing layer. The at least one thermoplastic film may be PC. In some embodiments, the ophthalmic lens substrate monomer may be allyl diglycol carbonate. The at least one first reactive monomer of the primer can react with the lens substrate monomer to provide chemical bonds that form the basis for strong adhesion between the functional element and the lens substrate.

According to embodiments, the primer may be applied to the PC-based functional element by flow coating, spin coating, gravure coating, slot die coating, or other means known to those skilled in the art. For example, the primer may be applied by a drop down plate method using a meyer rod (Mayer rod), where the meyer rod is wound with wire MR #3.5, the diameter of the wire determining how the thickness of the primer is applied. In some aspects, wherein a solvent is included, the applied primer can be dried at a predetermined temperature ranging, for example, from about 40 ℃ to about 80 ℃, for a predetermined time, for example, between about 15 seconds and about 2 minutes, in order to remove the solvent from the primer composition. If employed, other drying conditions known to those skilled in the art may be employed to remove the solvent. According to embodiments, after application onto the functional element, the applied primer may be allowed to dry completely or partially.

Table 1 and table 2 provide exemplary compositions of the primers described herein. It will be appreciated that these values should be considered approximate in view of the composition ranges described hereinbefore.

TABLE 1

TABLE 2

Components	The composition%
		Second reactive monomer	56.1
A first reactive monomer	18.5
		Solvent(s)	25.1
Photoactivatable catalysts (cationic)	0.3

The applied primer may be exposed to an amount of UV light or an increase in temperature sufficient to activate the photoactivatable catalyst and initiate curing of the applied primer.

In an embodiment, at step 412 of sub-process 410, functionality may be enabled by exposure to electromagnetic radiationThe primed surface of the element is at least partially cured. The electromagnetic radiation may be UV light, infrared light or visible light, among others. In an example, the electromagnetic radiation is UV light provided by a heirlich special light source (Heraeus eclegight) F300S with H + bulbs. The power, energy, and exposure time may be selected to optimize curing. Typical non-limiting curing conditions include about 7 feet per minute (UVA about 1500 mJ/cm)²About 1200mW/cm²) To about 21 feet per minute (500 mJ/cm)²，1100mW/cm²)。

At step 413 of sub-process 410, the UV curable primer on the surface of the functional element may be further cured by exposure to heat. In an example, the heat may be applied by an infrared oven. For example, an infrared oven may be heated to 500 ° F and the UV cured primer on the surface of the functional element may be exposed to heat for a predetermined time. For example, the predetermined time may be, for example, between 5 seconds and 60 seconds, preferably about 30 seconds. Of course, it is to be appreciated that the temperature and predetermined time for heating the UV cured primer on the surface of the functional element may be based on the desired hardness. In some applications, less than 100% cured primer may be required to promote adhesion.

In view of the flow diagrams of fig. 4A and 4B, fig. 5A provides an exemplary illustration of a method 400 in which adhesion between a functional element 550 and a lens substrate 506 is illustrated, the functional element 550 comprising a first thermoplastic film, a functional film, and a second thermoplastic film. In an embodiment, it may be desirable to produce an ophthalmic lens 501 having a lens substrate 506 only on the concave surface 544 of the functional element 550. Thus, the primer 502 can be applied as a treated surface of the functional element 550 onto the concave surface 544 of the functional element 550. As depicted in fig. 4A, the functional element 550 may be arranged within the casting mold such that the convex surface 543 of the functional element 550 is in contact with the concave insert of the casting mold and a void exists between the treated surface of the functional element 550 and the convex casting insert of the casting mold. After introduction and at least partial curing of the lens substrate precursor, the treated surface of the functional element 550 and the adhered lens substrate 506 can be removed from the casting mold as described in fig. 3B. According to need, ophthalmicThe lens 501 may include a lens substrate 506 on the concave surface 544 of the functional element 550. In an example, the lens substrate 506 can be a thermoset lens substrate, such as

In view of the flow diagrams of fig. 4A and 4B, fig. 5B provides an exemplary illustration of the method 400, wherein adhesion between the functional element 550 and the lens substrate 506 is shown, the functional element 550 comprising a first thermoplastic film, a functional film, and a second thermoplastic film. In an embodiment, it may be desirable to produce an ophthalmic lens 501 having a lens substrate 506 only on the convex surface 543 of the functional element 550. Thus, the primer 502 can be applied as a treated surface of the functional element 550 onto the convex surface 543 of the functional element 550. As depicted in fig. 4A, the functional element 550 may be disposed within the casting mold such that the concave surface 544 of the functional element 550 is in contact with the male insert of the casting mold and a void exists between the treated surface of the functional element 550 and the female cavity insert of the casting mold. After introduction and at least partial curing of the lens substrate precursor, the treated surface of the functional element 550 and the adhered lens substrate 506 can be removed from the casting mold as described in fig. 3B. The ophthalmic lens 501 may include a lens substrate 506 on the convex surface 543 of the functional element 550, as desired. In an example, the lens substrate 506 can be a thermoset lens substrate, such as

Referring now to fig. 6A, a description of an exemplary embodiment of the present disclosure is provided wherein a functional element comprising a first thermoplastic film, a functional film, and a second thermoplastic film is adhered to a lens substrate on both surfaces of the functional element.

At step 625 of method 600, a functional element having a convex surface and a concave surface may be provided.

In a sub-process 630 of the method 600, the convex and concave surfaces of the functional element may be processed. The treatment may include applying a primer to the convex and concave surfaces of the functional element. The sub-process 630 of the method 600 will be described in further detail with reference to fig. 6B.

In sub-process 635 of method 600, the treated functional element can be adhered to a lens substrate in a manner similar to that of FIG. 3B. Adhering may include forming a lens substrate from a lens substrate precursor within the void of a casting mold, as shown in fig. 1.

Referring now to FIG. 6B, a sub-process 630 of method 600 describes the processing of the convex and concave surfaces of the functional element.

At step 631 of sub-process 630, a primer may be applied to the convex and concave surfaces of the functional element.

According to an embodiment, the primer may be one of a variety of primers that provide strong adhesion between the functional element and the surface of the lens substrate. The primer can be formulated to include a component that promotes bonding with the functional element and the lens substrate. While conventional primers rely on relatively weak primer-primer and primer-substrate electrostatic forces to adhere, the primers of the present disclosure can bond to the surface to which they are applied. The end result of the primer is increased tack strength and durability.

According to embodiments, the primer disclosed herein is particularly useful for adhering functional elements comprising PC films to foundryIs effective on lens substrates. The primer can be designed to provide a degree of penetration into the surface of the PC film or other element layer of the functional element. The PC film penetration qualities of the primer promote its adhesion.

In embodiments, a primer as disclosed herein may comprise at least one first reactive monomer, at least one second reactive monomer, and at least one photoactivatable catalyst. In an embodiment, the primer further comprises a solvent. The at least one first reactive monomer may be a mixture of at least one acrylic monomer selected from the group consisting of monoacrylate monomers and diacrylate monomers and at least one acrylate monomer selected from the group consisting of triacrylate monomers to hexaacrylate monomers. In an example, the reactive group of the at least one second reactive monomer may be an epoxy group. The at least one second reactive monomer may be an epoxy monomer selected from glycidyl ethers of polyhydric alkanols. The at least one photoactivatable catalyst may be a photoactivatable catalyst. In an example, the photoactivating agent may be electromagnetic radiation, such as UV light, visible light, or infrared light, among others. The at least one photoactivatable catalyst may be a cationic catalyst and may be selected from the group consisting of aromatic onium salts and iron arene salt complexes. In embodiments, the primer may further comprise a free radical photoinitiator as a component of the photoactivatable catalyst. The radical photoinitiator may be one selected from the group consisting of benzophenone and acetophenone.

In an example, the at least one first reactive monomer can be at least one monomer capable of reacting with the lens substrate monomer. The at least one monomer may be included in an amount between 0.25 wt.% and 75 wt.%, preferably between 10 wt.% and 50 wt.%, based on the total weight of the at least one second reactive monomer and the at least one monomer present in the composition. In an embodiment, the at least one monomer may be a mixture of acrylate monomers.

According to an embodiment, the at least one second reactive monomer may have a molecular weight between about 5 and about 1,000. The at least one second reactive monomer may be included in an amount between 1 wt.% and 90 wt.%, preferably between 50 wt.% and 90 wt.%, based on the total weight of the at least one second reactive monomer and the at least one first reactive monomer. In an embodiment, the at least one second reactive monomer may be a mixture of an epoxy resin and a cycloaliphatic epoxy resin. In embodiments, the at least one reactive monomer may be an alkoxysilane such as allyltrimethoxysilane, allyltriethoxysilane, allyl methacrylate, and vinyltrimethoxysilane.

According to an embodiment, the at least photoactivatable catalyst may be comprised in an amount of between 0.1 and 10 wt.%, preferably between 0.1 and 3 wt.%. In embodiments, the at least one photoactivatable catalyst may be a mixture of a cationic photoinitiator and a free radical photoinitiator.

In embodiments, the primer may comprise a curable composition. Of course, the curing process may cause chemical reactions that alter certain components of the primer component. In some embodiments, the primer component functional groups can be selected to interact with the functional elements and react with the lens substrate to which they will adhere. In this manner, primer compositions as disclosed herein can be designed and tailored to provide adhesion to specific functional elements and/or lens substrate target materials.

In some embodiments, a solvent may be used to dissolve the primer component. When present, the solvent may be included in an amount between 20 wt.% and 99 wt.%. In examples, the solvent is an alcohol such as methanol, ethanol, n-propanol, and isopropanol, among others. In another example, the solvent can be a ketone, an acetate solvent, acetone, methyl ethyl ketone, ethyl acetate, cyclopentanone, and cyclohexanone, and any combination thereof.

According to embodiments, the at least one first reactive monomer may have the same chemical functionality as the lens substrate monomer. When the at least one first reactive monomer has the same chemical functionality as the lens substrate monomer, the at least one first reactive monomer assists in ensuring compatibility of the primer composition with the polymerized lens substrate monomer (also referred to herein as lens substrate precursor). In some embodiments, the at least one first reactive monomer has a different chemical functionality than the lens substrate monomer. The at least one first reactive monomer may have a different chemical functionality than the lens substrate monomer, but may still be capable of reacting with the lens substrate monomer. In this case, the at least one first reactive monomer is selected to include the same reactive functional group as the lens substrate monomer. For example, the lens substrate monomer can consist essentially of allyl diglycol carbonate (i.e.,) And at least one first reactive monomer may be diallyl ether. Although the lens substrate monomer and the at least one first reactive monomer are different compounds, they may react with each other through their reactive functional groups. In thatIn some aspects, the at least one first reactive monomer comprises a reactive group functionality of 1 or greater, preferably at least 2. Increasing the reactive functionality increases the types of functional groups that can react with the at least one first reactive monomer. The at least one first reactive monomer may include one or more reactive groups selected from the group consisting of: allyl, vinyl, acrylic, thiol, isocyanate, epoxy, and amine.

In some embodiments, at least one second reactive monomer has a reactive functionality of 1 or greater, preferably 2. Increasing the reactive functionality increases the amount and type of functional groups that can react with the at least one second reactive monomer. In some embodiments, the at least one second reactive monomer is an epoxy monomer. In some embodiments, the at least one second reactive monomer is a functional, (meth) acrylate-based resin.

In some embodiments, the functional element is a polarizing element. The polarizing element may include at least one thermoplastic film and a PVA film as a polarizing layer. The at least one thermoplastic film may be PC. In some embodiments, the ophthalmic lens substrate monomer may be allyl diglycol carbonate. The at least one first reactive monomer of the primer can react with the lens substrate monomer to provide chemical bonds that form the basis for strong adhesion between the functional element and the lens substrate.

According to embodiments, the primer may be applied to the PC-based functional element by flow coating, spin coating, gravure coating, slot die coating, or other means known to those skilled in the art. For example, the primer may be applied by a drop down plate method using a meyer rod (Mayer rod), where the meyer rod is wound with wire MR #3.5, the diameter of the wire determining how the thickness of the primer is applied. In some aspects, and when a solvent is included in the primer, the applied primer may be dried at a predetermined temperature, for example, between about 40 ℃ and about 80 ℃, for a predetermined time, for example, between about 15 seconds and about 2 minutes, in order to remove the solvent from the primer composition. When a solvent is present in the primer, other drying conditions known to those skilled in the art can be employed to remove the solvent. According to embodiments, after application onto the functional element, the applied primer may be allowed to dry completely or partially.

Exemplary compositions of the primer are described above with reference to tables 1 and 2.

The applied primer may be exposed to UV light or an increase in temperature in an amount sufficient to activate the photoactivatable catalyst and initiate the curing process. Thus, in an embodiment, at step 632 of sub-process 630, the primed surface of the functional element may be at least partially cured by exposure to electromagnetic radiation. The electromagnetic radiation may be UV light, infrared light or visible light, among others. In an example, the electromagnetic radiation is UV light provided by a heirlich special light source (Heraeus eclegight) F300S with H + bulbs. The power, energy, and exposure time may be selected to optimize curing. Typical non-limiting curing conditions include about 7 feet per minute (UVA about 1500 mJ/cm)²About 1200mW/cm²) To about 21 feet per minute (500 mJ/cm)²，1100mW/cm²)。

At step 633 of sub-process 630, the UV cured primer on the concave and convex surfaces of the functional element may be further cured by exposure to heat. In an example, the heat may be applied by an infrared oven. For example, an infrared oven may be heated to 500 ° F and the UV cured primer on the concave and convex surfaces of the functional element may be exposed to heat for a predetermined time. For example, the predetermined time may be between 5 seconds and 60 seconds, preferably about 30 seconds. Of course, it will be appreciated that the temperature and predetermined time for heating the UV cured primer on the concave and convex surfaces of the functional element may be based on the desired hardness. In some applications, less than 100% cured primer may be required to promote adhesion.

In view of the flow diagrams of fig. 6A and 6B, fig. 7 provides an exemplary illustration of a method 600 in which adhesion between a functional element 750 and a lens substrate 706 is illustrated, the functional element 750 comprising a first thermoplastic film, a functional film, and a second thermoplastic film. In an embodiment, it may be desirable to produce an ophthalmic lens 701 having a lens substrate 706 on a concave surface 744 of a functional element 750 and a convex surface 743 of the functional element 750. Thus, the primer 702 may be applied as a treated surface of the functional element 750 onto the concave surface 744 of the functional element 750 and the convex surface 743 of the functional element 750.

As depicted in fig. 6A, the functional element 750 may be disposed within the casting mold such that a first predetermined distance is maintained between the convex surface 743 of the functional element 750 and the concave cavity insert of the casting mold, and a second predetermined distance is maintained between the concave surface 744 of the functional element 750 and the convex cavity insert of the casting mold. In this way, a void of the casting mold may exist within a space defined by the first predetermined distance and the second predetermined distance, to which the treated surface of the functional element 750 is exposed. After the lens substrate precursor is introduced into the void and at least partially cured, the treated surface of the functional element 750 adhered to the lens substrate 706 can be removed from the casting mold as described in fig. 3B. As desired, the ophthalmic lens 701 may include a convex lens base 707 on the convex surface 743 of the functional element 750 and a concave lens base 708 on the concave surface 744 of the functional element 750 as lens bases. In an example, the convex lens substrate 707 and the concave lens substrate 708 can be a thermoset lens substrate, such as

As part of the present disclosure, the following includes specific examples. These examples are for illustrative purposes only and are not intended to limit the present invention. Indeed, these examples may not be exemplary embodiments of the present disclosure, but are intended to provide examples of comparisons between non-limiting examples of the present disclosure and other practices in the art. One of ordinary skill in the art will readily recognize that parameters may be changed or modified to produce substantially the same results.

Examples of the invention

For each of the following examples, the base primer composition is first described.

Reference base composition #1 (epoxy acrylate primer)

The reference base primer composition, defined as base composition #1, was formulated and composed of acrylate monomers and acrylates as at least one first reactive monomer, epoxy resins and acrylate monomers as at least one second reactive monomer, and cationic and free radical photoinitiators as at least one photoinitiator, as shown in table 3.

TABLE 3

Component (catalog)	Component (group)	(wt.%) of the composition
			UVR-6110	Cycloaliphatic epoxy resins	55.8
Erisys GE-30	Epoxy resin	18.8
			SR-399	Acrylate monomer	16.6
SR-339	Acrylic esters	8.21
			UVI-6976	Cationic photoinitiators	0.40
DAROCUR 1173	Free radical photoinitiators	0.20

In the example, UVR-6110 is 3, 4-epoxycyclohexylmethyl-3, 4-epoxycyclohexylcarboxylate with a reactive group functionality of 2, Erisys GE-30 is trimethylolpropane triglycidyl ether liquid epoxy resin with a reactive group functionality of 3, SR-399 is dipentaerythritol pentaacrylate with a reactive group functionality of 5, SR-339 is 2-phenoxyethyl acrylate with a reactive group functionality of 1, UVI-6976 is < 60% mixed triarylsulfonium hexafluoroantimonate in propylene carbonate, and Darocur 1173 is 2-hydroxy-2-methyl-1-phenyl-propan-1-one.

Example 1

Primer 1 of example 1 comprised reference base composition #1(90 wt.%) and allyl methacrylate (10 wt.%). The primer 1 is applied to both surfaces of a flat functional element which is then thermoformed to the desired curvature in order to produce an ophthalmic lens having a concave lens substrate and a convex lens substrate adhered to the functional element. Thus, the primer 1 is first applied to the first planar surface of the functional element and UV cured to tack-free, as shown in fig. 6B. The functional element with the treated first planar surface is then applied as a primer on the second planar surface of the functional element and cured, as described above. A primer was applied to each of the first planar surface of the functional element and the second planar surface of the functional element by a pull-down plate method using a #3.5 meyer bar. As described above, the disc of functional elements is die cut and thermoformed to 4 base curvatures before being positioned in the semi-finished lens casting unit. One or more voids are maintained on either side of the functional element. Then used as a lens base precursor containing about 3% isopropyl peroxydicarbonate (IPP)The monomer fills the casting mold. Will be filledThe casting mold is cured to the desired hardness and the SF lens is surface treated to-6.00 diopters or-8.00 diopters.

Example 2

Primer 2 of example 2 contained reference base composition #1(90 wt.%) and allyltrimethoxysilane (10 wt.%). The primer 2 is applied to both surfaces of a flat functional element which is then thermoformed to the desired curvature in order to produce an ophthalmic lens having a concave lens substrate and a convex lens substrate adhered to the functional element. Thus, the primer 2 is first applied to the first planar surface of the functional element and UV cured to tack-free, as shown in fig. 6B. The functional element with the treated first planar surface is then applied as a primer on the second planar surface of the functional element and cured, as described above. A primer was applied to each of the first planar surface of the functional element and the second planar surface of the functional element by a pull-down plate method using a #3.5 meyer bar. As described above, the disc of functional elements is die cut and thermoformed to 4 base curvatures before being positioned in the semi-finished lens casting unit. One or more voids are maintained on either side of the functional element. Thermosetting with about 3% IPP for subsequent use as a lens substrate precursorThe monomer fills the casting mold. The filled casting mold was cured to the desired hardness and the SF lens surface treated to-6.00 diopters or-8.00 diopters.

Example 3

Primer 3 of example 3 contained reference base composition #1(90 wt.%) and allyltriethoxysilane (10 wt.%). The primer 3 is applied to both surfaces of a flat functional element which is then thermoformed to the desired curvature in order to produce an ophthalmic lens having a concave lens substrate and a convex lens substrate adhered to the functional element. Thus, the primer 3 is first applied to the first flat surface of the functional element and UV cured to tack-free, as shown in fig. 6B. The functional element with the treated first flat surface is then applied as a primer to the second flat of the functional element, as described aboveFlat surface and cured. A primer was applied to each of the first planar surface of the functional element and the second planar surface of the functional element by a pull-down plate method using a #3.5 meyer bar. As described above, the disc of functional elements is die cut and thermoformed to 4 base curvatures before being positioned in the semi-finished lens casting unit. One or more voids are maintained on either side of the functional element. Thermosetting with about 3% IPP for subsequent use as a lens substrate precursorThe monomer fills the casting mold. The filled casting mold was cured to the desired hardness and the SF lens surface treated to-6.00 diopters or-8.00 diopters.

Example 4

Primer 4 of example 4 contained reference base composition #1(86 wt.%) and vinyltrimethoxysilane (14 wt.%). The primer 4 is applied to both surfaces of a flat functional element which is then thermoformed to the desired curvature in order to produce an ophthalmic lens having a concave lens substrate and a convex lens substrate adhered to the functional element. Thus, the primer 4 is first applied to the first planar surface of the functional element and UV cured to tack-free, as shown in fig. 6B. The functional element with the treated first planar surface is then applied as a primer on the second planar surface of the functional element and cured, as described above. A primer was applied to each of the first planar surface of the functional element and the second planar surface of the functional element by a pull-down plate method using a #3.5 meyer bar. As described above, the disc of functional elements is die cut and thermoformed to 4 base curvatures before being positioned in the semi-finished lens casting unit. One or more voids are maintained on either side of the functional element. Thermosetting with about 3% IPP for subsequent use as a lens substrate precursorThe monomer fills the casting mold. The filled casting mold was cured to the desired hardness and the SF lens surface treated to-6.00 diopters or-8.00 diopters.

After removal from the casting mold and surface treatment, little to no haze and minimal demolding or delamination were observed in the semi-finished lenses containing the internally positioned functional elements treated with any of examples 1 to 4. The results for these lenses are shown in table 4.

TABLE 4

Obviously, many modifications and variations are possible in light of the above teaching. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.

Embodiments of the present disclosure may also be described in parentheses below.

(1) An ophthalmic lens, comprising: at least one polymeric lens substrate comprising at least one thermosetting monomer; a functional component comprising at least one thermoplastic layer, a surface of the at least one thermoplastic layer facing the polymeric lens substrate; and a primer coating deposited onto the surface of the at least one thermoplastic film facing the polymeric lens substrate.

(2) The ophthalmic lens of (1), wherein the functional component comprises at least one dye selected from the group consisting of: photochromic dyes, dichroic dyes, blue light cut dyes, infrared cut dyes, ultraviolet cut dyes, selective wavelength cut dyes, color enhancement dyes, polarizing dyes, and filter dyes.

(3) The ophthalmic lens of (1) or (2), wherein the functional layer comprises the photochromic dye as the at least one dye and is one of a polyether block amide functional layer or a thermoplastic polyurethane functional layer.

(4) The ophthalmic lens of (1) or (2), wherein the functional component comprises a functional layer comprising the polarizing dye as the at least one dye and being a polyvinyl alcohol functional layer.

(5) The ophthalmic lens according to any one of (1), (2) and (4), wherein the at least one thermoplastic film of the functional component is two thermoplastic films and the polyvinyl alcohol functional layer is disposed between the two thermoplastic films, each of the two thermoplastic films being a thermoplastic film selected from the group consisting of a polycarbonate film, a triacetyl cellulose film and a polyamide film.

(6) The ophthalmic lens of any one of (1) to (5), wherein the at least one polymeric lens substrate is adhered to the convex surface of the functional component.

(7) The ophthalmic lens of any one of (1) to (6), wherein the at least one polymeric lens substrate is adhered to the concave surface of the functional component.

(8) The ophthalmic lens according to any one of (1) to (7), wherein at least one thermoplastic film of the functional component is a polycarbonate film.

(9) The ophthalmic lens of any one of (1) to (8), wherein the primer coating layer comprises at least one first reactive monomer, at least one second reactive monomer, and at least one photoactive catalyst.

(10) The ophthalmic lens of any one of (1) to (9), wherein the at least one photoactive catalyst is reactive to ultraviolet light.

(11) The ophthalmic lens of any one of (1) to (10), wherein the at least one second reactive monomer of the primer coating is an alkoxysilane.

(12) The ophthalmic lens of any one of (1) to (11), wherein the at least one second reactive monomer of the primer coating comprises a reactive group selected from the group consisting of: allyl, vinyl, acrylic, thiol, isocyanate, epoxy, and amine.

(13) The ophthalmic lens according to any one of (1) to (12), wherein the reactive group is an epoxy group.

(14) The ophthalmic lens of any one of (1) to (13), wherein the at least one photoactive catalyst comprises a cationic photoinitiator and a free-radical photoinitiator.

(15) The ophthalmic lens of any one of (1) to (14), wherein the at least one first reactive monomer of the primer coating is an acrylic monomer or a mixture of acrylic monomers.

Accordingly, the foregoing discussion discloses and describes merely exemplary embodiments of the present invention. As will be understood by those skilled in the art, the present disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, as well as other claims. The present disclosure, including any readily discernible variants of the teachings herein, define, in part, the scope of the foregoing claim terminology such that no inventive subject matter is dedicated to the public.