TWI639023B - a method of applying an anti-reflective coating to an optical surface of a mold, a mold having an optical surface transferable to an anti-reflective coating of the lens, and an optical lens manufactured - Google Patents

Abstract

This invention relates to a method of applying an anti-reflective coating to an optical surface of a mold. In one embodiment, the method comprises the steps of: providing a lens mold having an optical surface; forming a layer of superhydrophobic material on the optical surface, wherein the superhydrophobic material contains a quantity of arms decane, the amount being a relative percentage of the superhydrophobic material; forming an antireflective coating layered structure on the superhydrophobic material layer; and forming a coupling layer deposited in a single layer thickness on the antireflective coating layer structure, the forming system This is accomplished by a vapor deposition or a dip coating or spin coating using a solution of a coupling agent in an aprotic solvent under aprotic conditions.

Description

a method of applying an anti-reflective coating to an optical surface of a mold, a mold having an optical surface transferable to an anti-reflective coating of the lens, and an optical lens manufactured thereby [Cross-application for related applications]

This application is filed on April 15, 2011, to the patent application entitled "ANTI-REFLECTIVE LENSES AND METHODS FOR MANUFACTURING THE SAME" by Kai C. Su, Leslie F. Stebbins, Bill Mantch and Eugene C. Letter. Partial application for 13/088, 199. The disclosure of the above-identified application in the application is hereby incorporated by reference in its entirety.

This application is also filed on October 10, 2012 by Kai C. Su, Leslie F. Stebbins, Bill Mantch and Eugene C. Letter, entitled "ANTI-REFLECTIVE LENSES AND METHODS FOR MANUFACTURING THE SAME" Part of the continuation of application No. 13/648,642. The disclosure of the above-identified application in the application is hereby incorporated by reference in its entirety.

Some references are cited and discussed in the description of the present invention, which may include patents, patent applications, and various publications. The citation and/or discussion of such references is provided to clarify the description of the invention and is not to be construed as a "prior art" of the invention described herein. All references cited and discussed in this specification are hereby incorporated by reference in their entirety in their entirety herein in The manner of citation is incorporated into the general.

The present invention relates generally to an optical surface, and more particularly to an antireflective lens and method of making the same.

Antireflective lenses are typically formed by placing an antireflective coating on a plastic ophthalmic lens. An anti-reflective (AR) coating is applied to the surface of the ophthalmic lens and other optical devices to reduce reflection. Especially for ophthalmic lenses, reducing reflections not only looks better, but more importantly, it is better to use because it produces less glare by eliminating multiple reflections, working at night or computer monitors. This is especially true when this is the case. Less glare means that the wearer often finds that his eyes are not very tired, especially at the end of the day. The AR coating also allows more light to pass through the lens, thereby increasing contrast and thus increasing visual acuity.

The field of cast plastic ophthalmic lenses involves introducing a lens forming material between two molds and then polymerizing the lens forming material into a solid. A liquid plastic formulation, such as a CR39 monomer, is injected into a chamber formed by the front and back molds having an internally polished mold surface for the machined face of the lens. The plastic is cured in the mold and the mold is then separated to produce a finished ophthalmic lens that meets the selected prescription. The lens is then ground around the edge to fit into the selected frame. The coating can be applied to the inside of the processing lens or the front or back mold so that it will bond to the lens when cured.

Some optometrists provide on-site eyewear services. Several companies have developed methods for casting lenses in the office. However, because AR coatings must be applied via vacuum vapor deposition, current methods of applying AR coatings to spectacles still require shipping the spectacles to different facilities. Of course, this means extra time and cost. Therefore, there is a need for a method of fabricating glasses with AR coatings on site.

One type of AR coating for ophthalmic lenses is to alternately stack high refractive index materials and low refractive index materials. The most commonly used low refractive index material is ceria; zirconium dioxide and/or titanium dioxide is commonly used as a high refractive index material.

One problem with AR coatings, especially when applied to plastic ophthalmic lenses, is adhesion. The AR coating is typically applied via vacuum deposition. It is well known that the adhesion of vacuum deposited coatings to their substrates is generally problematic. Organic plastic lens materials and inorganic AR materials do not easily adhere to each other, resulting in peeling or scratching. Therefore, there is a need for a novel method of applying an AR coating to a plastic lens with greater adhesion.

It should be noted that several patents disclose the use of decane to bind an inorganic matrix to an organic matrix. No. 5,733,483 to Soane et al. discloses the use of a coupling layer to bond an AR multilayer made of yttria with an acrylate-containing lens. The coupling agent has a decyloxy head and an acrylate tail. An example of a decane used therein is methacryloxypropyltrimethoxydecane.

No. 4,615,947 to Goosens discloses an acrylic compound which is mixed with an organopolyoxane to increase the adhesion of the organodecane hard coat to the thermoplastic substrate. U.S. Patent No. 5,025,049 to Takarada et al. also discloses a primer which increases the adhesion of an organic polyoxyalkylene layer to a thermoplastic substrate. The primer is a mixture of an organic copolymer comprising an alkoxyquinone alkylated monomer and other ingredients.

Other patents discuss the use of decane to combine an organic matrix with another organic matrix. U.S. Patent No. 6,150,430 to Walters et al. discloses the use of organofunctional decane to improve the adhesion of an organic polymeric layer to an organic polymeric substrate.

A plastic lens having an AR coating and/or a hard coat layer is disclosed in U.S. Patent No. 5,096,626 to the name of U.S. Pat. This patent discusses prior art The method has poor adhesion and indicates that it achieves excellent adhesion by forming a lens using a set of molds, wherein the AR coating is first applied to a mold and then the lens unit is poured between the molds And carry out the polymerization. A decane coupling agent such as methacryloxypropyltrimethoxydecane may be included in the hard coat layer/AR coating solution, which may contain colloidal cerium oxide, colloidal cerium oxide or colloidal titanium dioxide.

U.S. Patent No. 6,986,857 to Klemm et al. discloses a method of assembling a lens using a topcoat, an AR coating, an anti-scratch coating, an impact primer, and a lens substrate. Klemm the solution and the poor topcoat adhesion of the AR coating is a problem of a first coating layer AR coating layer (comprising a stack of four layers) as two _sub-layer SiO. Another thin layer of SiO _{2 was} applied between the AR stack and the scratch resistant coating to improve the adhesion between the two.

The above references generally use sol-gel chemical reactions and require high heat ( 80 ° C). However, heating to a high temperature is not suitable for casting and curing the lens with a plastic mold because the optical surface of the mold will be deformed.

Therefore, there is a need in the art for solving the aforementioned shortcomings and deficiencies that have not yet been solved.

In one aspect, the invention relates to a method of applying an anti-reflective (AR) coating to a plastic substrate such as a plastic ophthalmic lens, wherein the AR coating exhibits good adhesion to the substrate, wherein the method eliminates initial SiO ₂ or The MgF ₂ layer and the release agent layer. Superhydrophobic materials can now be applied directly to the surface of the mold.

In one embodiment, the method comprises the steps of: providing a lens mold having an optical surface; forming a superhydrophobic material on the optical surface a layer formed by heating a hot boat in contact with one or more crucibles containing a superhydrophobic material to a temperature between about 200 ° C and about 500 ° C, wherein the superhydrophobic material contains a certain amount a double-armed decane, the amount being a relative percentage of the superhydrophobic material; forming an AR coating layered structure on the superhydrophobic material layer; and forming a coupling agent deposited on the AR coating layer structure in a single layer thickness The formation is carried out under aprotic conditions using vapor deposition or by dip coating or spin coating using a solution of a coupling agent in an aprotic solvent. In one embodiment, the hot boat is heated by a low voltage high amperage current. In another embodiment, the hot boat is heated by an electron beam. In other embodiments, a combination of heating methods is used. In some embodiments, the crucible in contact with the hot boat contains ceramic or metal pellets that are adsorbed with a superhydrophobic material.

In one embodiment, the amount of the arms decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material.

In one embodiment, the dual-arm decane comprises bis(trimethoxydecylpropyl)amine.

In one embodiment, the coupler layer is formed from a composition comprising a cyclic azanonane wherein the coupler layer is formed from N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane . In another embodiment, the coupler layer is formed from a composition comprising dual-arm decane.

In one embodiment, the step of forming an AR coating layer structure on the layer further comprises the step of forming a first material having a first refractive index and a thickness of about 5 to 100 nm on the superhydrophobic material layer. a second layer of a second material having a second refractive index higher than the first refractive index and having a thickness of about 40 to 50 nm is formed on the first layer; the first refractive index is formed on the second layer and the thickness is a third layer of a first material of about 10 to 20 nm; a fourth layer of a second material having a second refractive index and a thickness of about 50 to 70 nm formed on the third layer; and a first refraction formed on the fourth layer a fifth layer of a first material having a thickness of about 25 to 40 nm; a sixth layer having a second material having a second refractive index and a thickness of about 10 to 25 nm on the fifth layer; and a sixth layer A seventh layer having a first refractive index and a first material having a thickness of about 5 to 15 nm is formed, wherein the first material having the first refractive index is SiO ₂ and the second material having the second refractive index is ZrO ₂ . In one embodiment, each SiO ₂ layer is deposited using ion assist or without ion assist.

In one embodiment, the method further includes the step of forming a SiO ₂ layer between the AR coating layer structure and the superhydrophobic material layer.

In another aspect, the invention is directed to a mold having an optical surface that can be transferred to an AR coating of a lens. In one embodiment, the mold has a superhydrophobic formation on the optical surface by heating a hot boat in contact with one or more crucibles containing the superhydrophobic material to a temperature between about 200 ° C and about 500 ° C. a layer of a material, wherein the superhydrophobic material contains a certain amount of double-arm decane, the amount being a relative percentage of the superhydrophobic material; an AR coating layered structure formed on the superhydrophobic material layer; A coupler layer deposited on the antireflective coating layer structure by a vapor deposition or a solution of a coupling agent in an aprotic solvent by dip coating or spin coating under proton conditions.

In one embodiment, the mold further includes a SiO ₂ layer formed between the AR coating layered structure and the superhydrophobic material layer.

In one embodiment, the amount of the arms decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material.

In one embodiment, the AR coating layered structure comprises a first layer of a first material having a first index of refraction and a thickness of between about 5 and 100 nm formed on the layer of superhydrophobic material; on the first layer a second layer formed of a second material having a second refractive index higher than the first refractive index and having a thickness of about 40 to 50 nm; having a first refractive index formed on the second layer and having a thickness of about 10 to a third layer of a first material of 20 nm; a fourth layer of a second material having a second refractive index and having a thickness of about 50 to 70 nm formed on the third layer; and having a first layer formed on the fourth layer a fifth layer of a first material having a refractive index and a thickness of about 25 to 40 nm; a sixth layer of a second material having a second refractive index and having a thickness of about 10 to 25 nm formed on the fifth layer; A seventh layer of the first material having a first refractive index and a thickness of about 5 to 15 nm formed on the six layers. In one embodiment, the first material having a first index of refraction is SiO ₂ and the second material having a second index of refraction is ZrO ₂ . In one embodiment, each SiO ₂ layer is deposited using ion assist or without ion assist.

In one embodiment, the dual-arm decane comprises bis(trimethoxydecylpropyl)amine.

In one embodiment, the coupler layer is formed from a composition comprising a cyclic azanonane. In one embodiment, the coupler layer is formed from N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane.

In another aspect, the invention is directed to an optical lens made from a mold having an optical surface. In one embodiment, the optical lens has a lens body having an optical surface; a hard coating on the optical surface of the lens body; and an AR coating. The AR coating comprises a layer of superhydrophobic material formed by heating a hot boat in contact with one or more crucibles containing a superhydrophobic material to a temperature between about 200 ° C and about 500 ° C on the optical surface of the mold. Wherein the superhydrophobic material contains a quantity of double-armed decane, the amount being a relative percentage of the superhydrophobic material; an anti-reflective coating formed on the superhydrophobic material layer a layered structure; and a coupler layer deposited on the antireflective coating layer structure in a single layer thickness. The hard coat layer is in substantial contact with the coupler layer of the anti-reflective coating.

In one embodiment, the AR coating layered structure comprises a first layer of a first material having a first index of refraction and a thickness of between about 5 and 100 nm formed on the layer of superhydrophobic material; Forming a second layer of a second material having a second refractive index higher than the first refractive index and having a thickness of about 40 to 50 nm; forming the first refractive index on the second layer and having a thickness of about 10 to 20 nm a third layer of the first material; a fourth layer of a second material having a second refractive index and a thickness of about 50 to 70 nm formed on the third layer; and a first refraction formed on the fourth layer a fifth layer of a first material having a thickness of about 25 to 40 nm; a sixth layer of a second material having a second refractive index and having a thickness of about 10 to 25 nm formed on the fifth layer; and A seventh layer of the first material having a first refractive index and a thickness of about 5 to 15 nm formed on the layer. In one embodiment, the first material having a first index of refraction is SiO ₂ and the second material having a second index of refraction is ZrO ₂ . In one embodiment, each SiO ₂ layer is deposited using ion assist or without ion assist.

In one embodiment, the amount of the arms decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material.

In one embodiment, the dual-arm decane comprises bis(trimethoxydecylpropyl)amine.

In one embodiment, the coupler layer is formed from a composition comprising a cyclic azanonane. In one embodiment, the coupler layer is formed from N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane.

In one embodiment, the optical lens further comprises an SiO ₂ layer formed between the AR coating layer structure and the superhydrophobic material layer.

In another aspect, the invention is directed to a method of applying an AR coating to an optical surface of a mold. In one embodiment, the method comprises the steps of: providing a lens mold having an optical surface; forming a layer of superhydrophobic material on the optical surface, wherein the superhydrophobic material contains a quantity of arms decane, the amount being super a relative percentage of the hydrophobic material; forming an AR coating layered structure on the superhydrophobic material layer; and forming a coupling layer deposited on the AR coating layer structure in a single layer thickness, the formation being in the aprotic This is accomplished by dip coating or spin coating using a vapor deposition or a solution using a coupling agent in an aprotic solvent. In one embodiment, the amount of the arms decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material.

In one embodiment, the step of forming an AR coating layered structure on the layer further comprises the steps of: forming a first layer of a first material having a first index of refraction on the layer of superhydrophobic material; Forming a second layer of a second material having a second index of refraction; forming a third layer of a first material having a first index of refraction on the second layer; forming a second material having a second index of refraction on the third layer a fourth layer; a fifth layer of a first material having a first refractive index formed on the fourth layer; a sixth layer of a second material having a second refractive index formed on the fifth layer; and a sixth layer A seventh layer of a first material having a first refractive index is formed thereon. In one embodiment, the first index of refraction and the second index of refraction satisfy a ratio of H/L > 1, wherein L and H are values of the first and second indices of refraction, respectively. In one embodiment, the first material having a first index of refraction is SiO ₂ and the second material having a second index of refraction is ZrO ₂ .

In one embodiment, the coupler layer is formed from a composition comprising a cyclic azanonane.

In one embodiment, a superhydrophobic material is formed on the optical surface The step of layering comprises heating a hot boat in contact with one or more crucibles containing a superhydrophobic material. In one embodiment, the heating step comprises heating the hot boat to a temperature between about 200 ° C and about 500 ° C.

In yet another aspect, the present invention is directed to a mold having an optical surface that can be transferred to an AR coating of a lens. In one embodiment, the mold has a layer of superhydrophobic material formed on the optical surface, wherein the superhydrophobic material contains a quantity of double-armed decane, the amount being a relative percentage of the superhydrophobic material; An AR coating layered structure formed on a layer of a material; and a solution of a coupling agent in an aprotic solvent using a vapor deposition or a dip coating or spin coating under aprotic conditions in the AR coating layer A layer of coupler deposited in a single layer thickness. In one embodiment, the amount of the arms decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material.

In one embodiment, the superhydrophobic material layer is formed on the optical surface by heating a hot boat in contact with one or more crucibles containing a superhydrophobic material at a temperature, wherein the temperature is between about 200 ° C and about 500. Between °C.

In one embodiment, the AR coating layered structure comprises a first layer of a first material having a first index of refraction formed on the layer of superhydrophobic material; a second index of refraction formed on the first layer a second layer of the second material; a third layer of the first material having the first refractive index formed on the second layer; and a second material having the second refractive index formed on the third layer a fourth layer; a fifth layer of a first material having a first refractive index formed on the fourth layer; a sixth layer of a second material having a second refractive index formed on the fifth layer; and A seventh layer of the first material having a first refractive index formed on the six layers. In one embodiment, the first index of refraction and the second index of refraction satisfy a ratio of H/L > 1, wherein L and H are values of the first and second indices of refraction, respectively. In one embodiment, the first material having a first index of refraction is SiO ₂ and the second material having a second index of refraction is ZrO ₂ .

In one embodiment, the coupler layer is formed from a composition comprising a cyclic azanonane.

In one aspect, the invention relates to an optical lens made from a mold having an optical surface. In one embodiment, the optical lens has a lens body having an optical surface; a hard coating on the optical surface of the lens body; and an AR coating. The AR coating comprises a layer of superhydrophobic material formed on the optical surface of the mold, wherein the superhydrophobic material contains a quantity of double-arm decane, the amount being a relative percentage of the superhydrophobic material; and the superhydrophobic material An anti-reflective coating layered structure formed on the layer; and a coupler layer deposited on the anti-reflective coating layer structure in a single layer thickness. The hard coat layer is in substantial contact with the coupler layer of the anti-reflective coating.

In one embodiment, a layer of superhydrophobic material is formed on the optical surface of the lens mold by heating a heated boat in contact with one or more crucibles containing a superhydrophobic material at a temperature. In one embodiment, the temperature is between about 200 ° C and about 500 ° C.

In one embodiment, the amount of the arms decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material.

In one embodiment, the AR coating layered structure comprises a first layer of a first material having a first index of refraction formed on the layer of superhydrophobic material; a second index of refraction formed on the first layer a second layer of the second material; a third layer of the first material having the first refractive index formed on the second layer; and a second material having the second refractive index formed on the third layer a fourth layer; a fifth layer of a first material having a first refractive index formed on the fourth layer; a sixth layer of a second material having a second refractive index formed on the fifth layer; and A seventh layer of the first material having a first refractive index formed on the six layers. In one embodiment, the first index of refraction and the second index of refraction satisfy a ratio of H/L > 1, wherein L and H are values of the first and second indices of refraction, respectively. In one embodiment, the first material having a first index of refraction is SiO ₂ and the second material having a second index of refraction is ZrO ₂ .

In one embodiment, the coupler layer is formed from a composition comprising a cyclic azanonane.

These and other aspects of the present invention will be apparent from the following description of the preferred embodiments of the invention. Changes and modifications.

402‧‧‧Mold

404‧‧‧Optical surface

406‧‧‧Superhydrophobic material layer

410‧‧‧SiO ₂ layer

411‧‧‧Anti-reflective coating layered structure

412‧‧‧SiO ₂ layer / first layer

414‧‧‧ZrO _2nd floor / second floor

416‧‧‧SiO ₂ layer / third layer

418‧‧‧ZrO _2nd /4th Floor

420‧‧‧SiO ₂ layer / 5th floor

422‧‧‧ZrO ₂ /6th Floor

424‧‧‧SiO ₂ / seventh

426‧‧‧ coupling layer

502‧‧‧Mold

504‧‧‧Optical surface

506‧‧‧Superhydrophobic material layer

510‧‧‧SiO ₂ layer

511‧‧‧Anti-reflective coating layered structure

512‧‧‧SiO ₂ layer / first layer

514‧‧‧ZrO ₂ /Second

516‧‧‧SiO ₂ / third layer

518‧‧‧ZrO _2nd /4th floor

520‧‧‧SiO ₂ / 5th floor

522‧‧‧ZrO ₂ /6th Floor

524‧‧‧SiO ₂ / seventh

526‧‧‧ coupling layer

One or more embodiments of the present invention are described with reference to the accompanying drawings, and, Wherever possible, the same reference numerals are in the

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic illustration of a coupling agent related chemical reaction used in the manufacture of antireflective coated lenses of the prior art.

2 shows a schematic diagram of a coupling-related chemical reaction for making an anti-reflective coated lens in accordance with one embodiment of the present invention.

Figure 3 shows a schematic representation of the temperature dependence of the AR coating and the resulting lens on the coating of the superhydrophobic layer in accordance with an embodiment of the present invention.

4 shows a schematic diagram of the preparation of an anti-reflective coated lens mold in accordance with one embodiment of the present invention.

Figure 5 shows an anti-reflective coated lens in accordance with one embodiment of the present invention. Schematic diagram of mold preparation.

The invention is described in the following with reference to the accompanying drawings, in which, FIG. However, the invention may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Similar component symbols throughout the specification refer to similar components.

The terms used in the specification generally have their ordinary meaning in the art, within the scope of the invention, and in the specific content of each term. Certain terms used to describe the invention are discussed below or elsewhere in this specification to provide additional guidance to the practitioner regarding the description of the invention. For convenience, certain terms may be highlighted in this specification, for example, in italics and/or quotation marks. The use of highlighting has no effect on the terminology and meaning of the term; in the same content, regardless of whether the term is prominent, its scope and meaning are the same. It should be noted that the same features or circumstances may be expressed in more than one manner. Thus, any one or more of the terms discussed herein may be described using alternative terms and synonyms, and no matter whether the terms are described or discussed in detail herein, the use of alternative terms and synonyms does not have any particular meaning. Certain terms are provided synonymously, and the use of one or more synonyms does not exclude the use of other synonyms. The use of any of the examples in this specification, including examples of any of the terms discussed herein, is merely illustrative and is not intended to limit the scope and meaning of the invention or any exemplified term. As such, the invention is not limited to the various embodiments presented in this specification.

It should be noted that when one component is called "on another component" In this case, the intervening elements may be present directly on or between other components. Conversely, when an element is referred to as "directly on the other element," the intervening element is absent. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

It will be understood that, although the terms "first", "second", "third", etc. may be used in the specification to describe various elements, components, regions, layers and/or sections, such elements, components, and regions , layers and/or sections are not limited by these terms. The terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed hereinafter may be referred to as a second element, component, region, layer or section, without departing from the disclosure.

The terminology used in the description is for the purpose of describing particular embodiments, and is not intended to limit the invention. The singular forms "a", "the" and "the" are intended to include the plural. It will be further understood that the terms "comprises/comprising" or "includes/including" or "has/having" when used in this specification means that the features, regions, integers, steps, The operation, the components, and/or the components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, components, components and/or groups thereof.

In addition, relative terms such as "lower" or "bottom", "upper" or "top" and "left" and "right" may be used herein to describe the relationship of one element to another. It will be understood that the relative terms are intended to encompass different orientations of the device in addition to the orientations described in the drawings. For example, if the device in one figure is turned over, it is described as being on the "lower" side of the other components. The components above will be oriented on the "upper" side of the other components. Therefore, the exemplary term "lower" can encompass the "lower" and "upper" orientations, depending on the particular orientation of the drawings. Similarly, if the device in one of the figures is turned over, the element described as "below the other elements" or "under the other elements" will be oriented "above the other elements." Thus, the exemplified terms "below" or "under" can encompass the <RTIgt;

Unless otherwise defined, all terms (including technical and scientific terms) used in the specification have the same meaning meaning meaning It should be further understood that terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the relevant art and the teachings of the present invention, and should not be construed in the sense of idealization or over-formalization. Explain, unless explicitly defined as such herein.

As used in this specification, "about", "about" or "substantially" shall generally mean within 20%, preferably within 10% and more preferably within 5% of a given value or range. The quantities given herein are approximate quantities, meaning that the term "about", "about" or "roughly" can be inferred if not explicitly stated.

As used in this specification, the terms "comprise/comprising", "include/including", "carry/carrying", "having (has/have/having)", "containing (contain/) ""involved/involving" and the like should be understood to be open, that is, meant to include (but not limited to).

Overview of the invention

Embodiments of the present invention will be described below with reference to the accompanying drawings in FIGS. 1-5. In accordance with the purpose of the present invention, as embodied and broadly described herein, The present invention relates to an eyeglass lens for coating AR, a mold, a composition and a method for manufacturing an AR lens.

Incorporated in its entirety by reference herein, the origin of U.S. Application No. 13 / 088,199 in the previous application requires the removal agent layer (standard hydrophobic layer) and a SiO is between the hydrophobic material and the mold ₂ or MgF ₂ layers.

However, according to various embodiments of the present invention, the initial SiO ₂ or MgF ₂ layer and the release agent layer can be eliminated by controlling the temperature at which the superhydrophobic material is applied. Superhydrophobic materials can be applied directly to the mold surface. The superhydrophobic material used in the examples of the specification is, but not limited to, Daikin Optool DSX. It should be noted that other superhydrophobic materials may also be utilized to practice the invention.

In one embodiment, the superhydrophobic material is coated at less than 540 ° C (as measured on a hot boat). A preferred temperature range is from about 250 to 500 °C.

The superhydrophobic layer may have any thickness from 20 nm to 100 nm, preferably 40 nm.

According to embodiments of the invention, there is still a need for arms to stabilize the superhydrophobic layer. The arms and superhydrophobic material are placed in the pellets and coated together. In one embodiment, the amount of the arms that are mixed with the superhydrophobic material must be between 0.01 g and 0.1 g per pill in the Satis 1200 chamber. Use two pills in a single run. The preferred weight of the arms (for a 40 nm superhydrophobic layer) was 0.04 g per pill.

Both arms decane are commercially available from Gelest, Inc. Preferably, the arms decane may be a bis(trimethoxydecylpropyl)amine having the formula:

In one embodiment, the superhydrophobic material contains from about 1.7% to about 8.3 weight percent of the cobine in terms of the superhydrophobic material.

The superhydrophobic layer on the mold is not a release agent layer. The superhydrophobic layer transfers the lens to and becomes part of the lens during lens casting and curing.

After the superhydrophobic coating, an anti-reflective (AR) coating is applied. The AR coating is a layered structure (4 to 7 layers or even 7 or more layers) having a multilayer dielectric material coated by vacuum deposition such that the last layer is ion-assisted SiO ₂ . Preferably, the AR coating is a layered structure having a plurality of layers of three or more dielectric materials having alternating high and low refractive indices.

A layer of decane coupling agent is applied to the AR coated mold to promote adhesion of the hard coat layer. The coupler layer must be coated under aprotic conditions. This can be done using methods commonly used in the lens industry today (such as spin coating, spray coating, dip coating, vacuum coating). The coupler layer was applied at room temperature. The decane coupling agent can be a double-arm decane. Alternatively, the decane coupling agent is a cyclic azanonane. Separately, the decane from the cyclic azanonane will bind to the AR coating and the functional groups will bond to the organic hardcoat.

The next coating applied to the mold is a scratch resistant (hard) coating. The hard coat layer can be applied by conventional methods in the lens industry, including spin coating, spray coating or dip coating, followed by curing.

The exemplary process illustrated above can be applied over the different optical surfaces of the optical mold assembly containing the front and back molds. After the coating is applied to the front and back molds, the mold is assembled with a gasket to form an optical mold assembly. The chamber of the assembly is then filled with the lens material formulation and cured. After curing is complete, the lens is removed from the assembly. Transferring all of the coating to the lens allows the lens to be coated with a superhydrophobic, anti-reflective, and scratch resistant coating. Can also use this process to create partial Light and light color lenses.

Thus, in one aspect, more particularly, the present invention relates to a method of making a AR coated plastic substrate having good AR coating adhesion. In one embodiment, the plastic substrate is a plastic eyeglass lens.

In another aspect, the invention is directed to a method of fabricating an AR coated plastic spectacle lens in situ.

The AR coating is typically applied to the lens surface to reduce reflection. Typically, the AR coating is made of a plurality of layers of high refractive index and low refractive index materials such as ZrO ₂ and SiO ₂ . One problem with inorganic ruthenium oxide AR coatings is that they are not easily adhered to plastic organic lenses. The present invention successfully solves this problem by using a coupling layer, inter alia, between the inorganic cerium oxide AR coating and the lens. In one embodiment of the invention, the coupling layer is formed using a cyclic azanonane. In another embodiment, the coupling layer is formed using double-armed decane.

In general, a method of forming an ophthalmic lens having an AR coating thereon includes the steps of preparing first and second molds in which the optical surfaces face each other. In a preferred embodiment, a mold and a gasket are used, such as those described in U.S. Patent No. 7,114,696, which is incorporated herein in its entirety by reference. Various desired coatings are applied to the interior of one or both molds. A mold having a coating thereon is placed in a gasket assembly that provides spacing between the molds. The liquid monomer is placed in the compartment and cured to give the lens.

The mold may be formed of any suitable material that is capable of withstanding the processing temperatures used below and that provides the surface of the type desired for the optical component.

In one embodiment of the invention, as a first step, the coating is applied directly to the optical surface of the plastic mold by electron beam deposition. After the first coating, a second coating can be applied, after which the multilayer AR coating is applied in the reverse order. In one embodiment of the invention, the AR coating is a multilayer structure having alternating layers of two different materials (low refractive index material and low refractive index material). In a preferred embodiment of the present invention, the AR coating is a multilayer structure having seven alternating layers formed of two different materials (high refractive index material and low refractive index material) having a ratio H/L>1, wherein L and H are the values of the first and second refractive indices, respectively. The material which is considered to be suitable for the practice of the present invention is a low refractive index material cerium oxide as a high refractive index material zirconium dioxide (referred to as "ZrO ₂ ") and a refractive index of about 1.46.

In one embodiment of the present invention, by a vacuum deposition coating layers such that the first and the last layer are silicon dioxide (SiO _2).

After the AR coating is applied, the coupler layer or film is applied by vapor deposition. When the coupling agent is a cyclic azanonane, it will bind to the surface hydroxyl groups on the ceria layer, opening the ring and creating organic molecules on the surface. This can be carried out under vacuum at room temperature and does not require water as a catalyst.

Next, an anti-scratch (hard) coating is applied. The hard coat layer can be applied as a stretch of the AR coating process by vacuum deposition or by a more conventional spin coating, spray coating or dip coating method, after the coating is applied.

After applying the various coatings to the mold, the front and back molds are assembled. The chamber of the assembly is then filled with a lens material formulation that is then cured and bonded to the hard coat to remove the lens from the assembly after curing is complete. Transferring all of the coating to the lens allows the lens to be coated with a superhydrophobic, anti-reflective, and scratch resistant coating.

Cyclic azanonesane is commercially available from Gelest, Inc. The formula includes azaindole heterocyclopentane having the formula:

Wherein R ¹ and R ^{2 are} independently selected from the group consisting of branched and straight-chain, substituted and unsubstituted alkyl, alkenyl and alkoxy groups, and wherein R ³ is selected from the group consisting of: substituted And unsubstituted saturated and unsaturated, branched and linear aliphatic hydrocarbon groups; substituted and unsubstituted branched and linear aralkyl groups; substituted and unsubstituted aryl groups; and hydrogen. The cyclic azanonane also includes a diazepine ring compound having the formula:

Wherein R ³ is selected from the group consisting of substituted and unsubstituted saturated and unsaturated, branched and straight-chain aliphatic hydrocarbon groups; substituted and unsubstituted branched and linear aralkyl groups; And an unsubstituted aryl group; and hydrogen; and wherein R ⁴ and R ^{5 are} independently selected from the group consisting of substituted and unsubstituted branched chains and linear alkyl groups and alkoxy groups.

Preferred superhydrophobic compounds are Optool DSX available from Daikin. This hydrophobic compound is free of additives typically included in commercial superhydrophobic formulations to increase the adhesion of superhydrophobic materials to plastic lenses.

More specifically, these and other aspects of the invention are described below.

Embodiments and examples of the invention

Without limiting the scope of the invention, the following is given Other illustrative embodiments of the inventive embodiments and their associated results. It should be noted that for the convenience of the reader, the title or subtitle may be used in the examples, which should in no way limit the scope of the invention. In addition, some of the theories are proposed and disclosed herein; however, regardless of their correctness or error, they should not limit the scope of the invention as long as it is practiced in accordance with the present invention without regard to any particular theory or The invention can be.

Example 1: Cyclic azanonane

The invention can be practiced using various types of cyclic azadecanes, including:

(a) SIB 1932.4 or N-n-butyl-aza-2,2-dimethoxyfluorene heterocyclopentane, C ₉ H ₂₁ NO ₂ Si, having the formula:

(b) SID 3543.0 or 2,2-dimethoxy-1,6-diaza-2-indenyloctane, C ₇ H ₁₈ N ₂ O ₂ Si, having the formula:

(c) SIA0592.0 or N-aminoethyl-aza-2,2,4-trimethylfluorene heterocyclopentane, C ₈ H ₂₁ NSi, having the formula:

(d) SIA0380.0 or N-allyl-aza-2,2-dimethoxyfluorene heterocyclopentane, C ₈ H ₁₇ NO ₂ Si, having the formula:

Example 2: Coating bonding test

This example demonstrates various tests for the combination of coatings produced in accordance with various embodiments of the present invention.

Cross hatch test. In the cross hatch test, a series of 10 lines spaced 1 mm apart was cut into the coating with a blade. A second series of 10 lines spaced 1 mm apart from the first and at an interval of 1 mm were cut into the coating. A piece of cellophane tape is then applied to the cross hatch pattern and quickly pulled away from the coating.

Crack test. In the crack test, the lens was removed from the mold and then annealed at 80 ° C for 20 minutes. The lenses were quickly transferred to room temperature water and cracks were examined. If no cracks appear, the AR/coupler system is acceptable.

Boiling brine test. In the boiling brine test, the lens was first contained in 4.5% NaCl and 0.8% NaH ₂ PO ₄ . Immerse in a boiling salt solution of 2H ₂ O for two minutes. Next, the lenses were quickly transferred to deionized water at room temperature (18-24 ° C). The AR/coupler system is acceptable if no cracks or delamination are noted in the coating.

Example 3: Preparation and coating of superhydrophobic layer

In this example, a method of making a superhydrophobic layer is provided, particularly in accordance with various embodiments of the present invention.

A layer of superhydrophobic material having a thickness of about 40 nm was deposited on the mold using a steel boat. The two copper-evaporated superhydrophobic materials, also known as copper "liners" containing steel wool, each contain 0.04 g of coke hexane and an excess of superhydrophobic material. As shown in the examples below, the quality of the AR coating and the resulting lens is substantially dependent on the temperature of the steel boat that coats the superhydrophobic layer. All temperature measurements were obtained by recording the temperature of the steel boat during deposition.

Example ( A ): Raise the temperature of the steel boat to 1350 degrees Fahrenheit (about 730 degrees Celsius). Therefore, a light pulse-like mark can be seen in the AR coating. Cracks appeared on the resulting lens.

Example ( B ): Raise the temperature of the steel boat to 1200 degrees Fahrenheit (about 650 degrees Celsius). No pulse-like marks were visible, but cracks appeared on the resulting lenses. In addition, the lens did not pass the contact angle test.

Example ( C ): Raise the temperature of the steel boat to 1000 degrees Fahrenheit (about 540 degrees Celsius). Cracks still appear on the lens and the lens does not pass the contact angle test.

Example ( D ): Raise the temperature of the steel boat to 900 degrees Fahrenheit (about 480 degrees Celsius). The lens has no cracks and the contact angle is improved.

Example ( E ): Raise the temperature of the steel boat to 700 degrees Fahrenheit (about 370 degrees Celsius). The lens has no cracks and a good contact angle.

Example ( F ): Raise the temperature of the steel boat to 500 degrees Fahrenheit (about 260 degrees Celsius). The contact angle was acceptable but not as good as the results in Example 5. It is also more difficult to separate the mold and the lens after casting. No cracks appear.

Example ( G ): When the temperature of the boat rises to 400 degrees Fahrenheit (about 200 degrees Celsius), the coater cannot continuously detect the growth of the superhydrophobic layer on the mold.

Figure 3 shows the dependence of the AR coating and the resulting lens on the temperature of the steel boat coated with the superhydrophobic layer. According to the invention, a preferred temperature range is from about 200 to 500 degrees Celsius.

Example 4: Preparation of AR coating applied to disposable mold

In this example, a method of applying an AR coating to a disposable mold is provided, particularly in accordance with yet another embodiment of the present invention. It should be noted that in this example, the SiO ₂ layer is formed or deposited with or without ion assist.

Referring now to Figure 4, the following process is performed using a standard box coater and electron beam for evaporation in combination with a mold 402 having an optical surface 404. These processes are carried out using well-known vacuum practices.

program:

(1) Cleaning the optical surface 404 of the mold 402. In one embodiment of the invention, the surface of the mold is plasma cleaned for about 2 minutes.

(2) Forming a superhydrophobic material layer 406 having a thickness of about 30 to 40 nm on the optical surface 404, wherein the superhydrophobic material contains from about 1.7% by weight to about 8.3% by weight of the cobine. In one embodiment, the superhydrophobic material comprises Within one or more of the contact with the metal plate or boat. In certain embodiments, the superhydrophobic material is vacuum evaporated from one or more crucibles while the metal boat is heated to a temperature between about 200 ° C and about 500 ° C. In some embodiments, the crucible is a copper material and the boat is a stainless steel material.

(3) An SiO ₂ layer 410 deposited on the layer 406 without using ion assist and having a thickness of about 5 to 40 nm is formed.

(4) A SiO ₂ layer 412 deposited using ion assisted deposition and having a thickness of about 5 to 100 nm is formed on the layer 410.

(5) A ZrO ₂ layer 414 having a thickness of about 40 to 50 nm is formed on the layer 412.

(6) A SiO ₂ layer 416 deposited on the layer 414 without using ion assist and having a thickness of about 10 to 20 nm is formed.

(7) A ZrO ₂ layer 418 having a thickness of about 50 to 70 nm is formed on the layer 416.

(8) An SiO ₂ layer 420 deposited on the layer 418 without using ion assist and having a thickness of about 25 to 40 nm is formed.

(9) A ZrO ₂ layer 422 having a thickness of about 10 to 25 nm is formed on the layer 420.

(10) A SiO ₂ layer 424 deposited using ion assisted deposition and having a thickness of about 5 to 15 nm is formed on the layer 422.

(11) A single layer of thick coupler layer 426 deposited using dip or vapor deposition is formed over layer 424.

It should be noted that in this embodiment, the superhydrophobic material layer 406 contains from about 1.7% to about 8.3 weight percent of the cobine in terms of the superhydrophobic material such that the AR coating can be stable. An example of the concentration of the arms hemane in the superhydrophobic material is from about 0.01 g to 0.05 g of cob hexane per 0.6 g of superhydrophobic material. If no very small arms decane is used or used in the superhydrophobic material, the AR coating cracks and separates from the mold. In addition, the SiO ₂ layer 410 acts as a protective seal for the AR layered structure 411 and as a natural bonding surface or "linker" between the AR layered structure 411 and the superhydrophobic material layer 406. Likewise, the SiO ₂ layer 424 provides a natural bonding surface or "linker" between the AR layer structure 411 and the coupler layer 426. It should be noted that although both layer 410 and layer 412 are formed of SiO ₂ , they are formed by different processes such that they adhere to each other but function differently.

Example 5: Preparation of AR coating applied to disposable mold

In this example, a method of applying an AR coating to a disposable mold is provided, particularly in accordance with another embodiment of the present invention. It should be noted that in this example, the SiO ₂ layer is formed or deposited with or without ion assist.

Referring now to Figure 5, the following process is performed using a standard box coater and electron beam for evaporation in combination with a mold 502 having an optical surface 504. These processes are carried out using well-known vacuum practices.

program:

(1) Cleaning the optical surface 504 of the mold 502. In one embodiment of the invention, the surface of the mold is plasma cleaned for about 2 minutes.

(2) A superhydrophobic material layer 506 having a thickness of about 30 to 40 nm is formed on the optical surface 504, wherein the superhydrophobic material contains from about 1.7% by weight to about 8.3% by weight of the superhydrophobic material. In one embodiment, the superhydrophobic material is contained within one or more of the crucibles in contact with the metal sheet or boat. In certain embodiments, the superhydrophobic material is vacuum evaporated from one or more crucibles while the metal boat is heated to a temperature between about 200 ° C and about 500 ° C. In some In the embodiment, the crucible is a copper material containing steel wool and the boat is a stainless steel material.

(3) A SiO ₂ layer 510 deposited on the layer 506 without using ion assist and having a thickness of about 5 to 40 nm is formed.

(4) A SiO ₂ layer 512 deposited using ions assisted and having a thickness of about 5 to 100 nm is formed on the layer 510.

(5) A ZrO ₂ layer 514 having a thickness of about 40 to 50 nm is formed on the layer 512.

(6) A SiO ₂ layer 516 deposited on the layer 514 without using ion assist and having a thickness of about 10 to 20 nm is formed.

(7) A ZrO ₂ layer 518 having a thickness of about 50 to 70 nm is formed on the layer 516.

(8) A SiO ₂ layer 520 deposited on the layer 518 without using ion assist and having a thickness of about 25 to 40 nm is formed.

(9) A ZrO ₂ layer 522 having a thickness of about 10 to 25 nm is formed on the layer 520.

(10) A SiO ₂ layer 524 deposited using ion assisted deposition and having a thickness of about 5 to 15 nm is formed on layer 522.

(11) A single layer thick coupler layer 526 deposited using vapor deposition is formed over layer 524.

Example 6: Preparation and coating of coupling agents

In Examples 4 and 5, the present invention was practiced, inter alia, by applying a layer of a coupling agent applied to an AR coated mold to promote adhesion of the hard coat layer.

In material-wise, the coupling agent is a functional decane wherein decane is bonded to the AR coating and the functional groups are combined with the organic hardcoat. According to one embodiment of the invention, the cyclic azanonane is particularly well suited for this coating because the device forms a decane bond via a ring opening reaction at room temperature. This results in a single layer having functional groups that are easily attached to the hard coat layer to form a strong AR hard coat bond. Xianxin, the first and only discovery of the present invention in the industry, used cyclic azadecane as a coupling agent in the optical lens forming process. In another embodiment, the functional decane is a double-arm decane. For the examples as shown in Figures 4 and 5, bis(trimethoxydecylpropyl)amine was used as the decane couple in the case where SiO _{2 was} used as the first material having the first refractive index. Mixtures to create a strong AR hardcoat bond and achieve in-situ AR lens formation.

In terms of procedural, the coupling agent must be coated under aprotic conditions and can be carried out using a number of methods commonly practiced in the lens industry today, such as spin coating, spray coating, dip coating, and vacuum coating. Three specific examples of coupling agent coating are provided below.

A. Vacuum coating - program:

(1) placing the optical mold in one of the front mold and the rear mold in a vacuum chamber, wherein the corresponding optical surface of the mold is coated according to one of the various embodiments of the present invention as shown in Examples 4 and 5. A mold of cloth AR, the vacuum chamber is evacuated to produce an aprotic environment having a predetermined pressure, wherein the coupling agent will vaporize as the coupling agent is introduced into the chamber.

(2) Introducing the coupling agent into the sealed chamber and coating it and reacting with each AR coating for a minimum of 10 minutes.

(3) The chamber is evacuated to an initial (pre-coupler) predetermined pressure to remove excess coupling agent.

(4) The vacuum is released and the optical mold assembly is removed from the chamber. Thereafter, a hard coat layer can be applied.

B. Dip coating - - program:

(1) A solution of a coupling agent in an aprotic solvent (minimum 0.05%). Examples of aprotic solvents include toluene, benzene, petroleum ether or other hydrocarbon solvents.

(2) The AR coated mold prepared according to one of the various embodiments of the present invention as shown in Examples 4 and 5 was exposed to a solution (or treated with a solution) for a minimum of 5 minutes at room temperature.

(3) The treated mold is removed from the solution and washed with ethanol or a similar solvent.

(4) The mold is then air dried and then a hard coat layer can be applied.

C. Spin coating - program:

(1) A solution of a coupling agent in an aprotic solvent (minimum 0.05%). Examples of aprotic solvents include toluene, benzene, petroleum ether, Isopar L or other hydrocarbon solvents.

(2) The solution is placed in a spin coating system in which a pump or pressure chamber is used to spray the solution onto a rapidly rotating shaft.

(3) An AR-coated mold prepared according to one of the various embodiments of the present invention as shown in Examples 4 and 5 was placed in a rotating shaft. The coupling agent solution is applied while rotating the mold to produce a uniform coating.

(4) The rotating shaft was removed from the treated mold and dried under IR heating. A hard coat layer can then be applied.

Example 7: Procedure for manufacturing lenses for coating AR

This example demonstrates a method or procedure for making an AR coated lens in accordance with one embodiment of the present invention.

According to one embodiment of the invention as shown in one of Examples 4 and 5, the corresponding optical surfaces of the front and rear molds of the optical mold assembly are AR coated. Subsequent to the formation of N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane on the AR surface (424, 524) using a dip coating process as described in Example 6 above. A coupling layer of N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane (426, 526). A solution of 0.05% coupling agent in petroleum ether was prepared. The optical surface was immersed in the solution for 5 minutes at room temperature. It was then washed with ethanol, allowed to air dry, and immediately subjected to a hard coating using a spin coating process. The hard coat, AR and superhydrophobic coating are transferred from the mold to the lens during casting.

In one aspect, the invention relates to a method of applying an anti-reflective coating to an optical surface of a mold. In various embodiments of the invention as shown in Figures 4 and 5, such methods have the steps of providing a lens mold 402 or 502 having an optical surface 404 or 504; forming a thickness on the optical surface 404 or 504 A superhydrophobic material layer 406 or 506 of about 20 to 100 nm, wherein the superhydrophobic material contains from about 1.7% to about 8.3% by weight of the superhydrophobic material of the cochleon; forming an anti-hydrophobic layer 406 or 506 A reflective coating layer structure 411 or 511; and a coupling agent layer 426 or 526 having a single layer thickness deposited using dip coating, spin coating or vapor deposition on the anti-reflective coating layer structure 411 or 511.

In one embodiment, the superhydrophobic material is contained within one or more of the crucibles in contact with the metal sheet or boat. In certain embodiments, the superhydrophobic material is vacuum evaporated from one or more crucibles while the metal boat is heated to a temperature between about 200 ° C and about 500 ° C. In some embodiments, the crucible is a copper material and the boat is a stainless steel material.

The step of forming the anti-reflective coating layer structure 411 or 511 on the layer 406 or 506 can be carried out by: (1) forming a first refractive index on the superhydrophobic layer 406 or 506 and having a thickness of about 5 to 100 nm. a first layer 412, 512 or 612 of a first material; (2) forming a second layer 414 or 514 of a second material having a second index of refraction and having a thickness of between about 40 and 50 nm on the first layer 412 or 512; 3) forming a third layer 416 or 516 having a first refractive index and a first material having a thickness of about 10 to 20 nm on the second layer 414 or 514; (4) forming a second layer on the third layer 416 or 516 a fourth layer 418 or 518 of a second material having a refractive index and a thickness of about 50 to 70 nm; (5) forming a first material having a first refractive index and a thickness of about 25 to 40 nm on the fourth layer 418 or 518 a fifth layer 420 or 520; (6) forming a sixth layer 422 or 522 having a second refractive index and a second material having a thickness of about 10 to 25 nm on the fifth layer 420 or 520; and (7) at the sixth A seventh layer 424 or 524 of a first material having a first index of refraction and a thickness of between about 5 and 15 nm is formed on layer 422 or 522.

In one embodiment, the first refractive index and the second refractive index satisfy a ratio of H/L > 1, wherein L and H are first and second refractive index values, respectively. In other words, the second refractive index value is greater than the first refractive index value.

In one embodiment, the first material having the first index of refraction comprises SiO ₂ and the second material having the second index of refraction comprises ZrO ₂ .

In practicing the invention in accordance with the methods described above, each SiO ₂ layer is deposited using ion assist or without ion assist.

In the embodiment shown in Figures 4 and 5, the steps of forming the anti-reflective coating layer structure 411 or 511 on the superhydrophobic layer 406 or 506 are performed on the superhydrophobic layers 406, 506. The step of depositing SiO ₂ layers 410, 510 having a thickness of 5 to 40 nm without ion assisting results in the formation of SiO ₂ layers 410, 510 between the superhydrophobic layers 506, 606 and the first layers 412, 512.

In one embodiment, the arms decane can be bis(trimethoxydecylpropyl)amine.

In one embodiment, the coupler layer is formed from a composition comprising a cyclic azanonane. In a particular embodiment, the coupler layer is formed from N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane. In another embodiment, the coupler layer is formed from a composition comprising dual-arm decane.

In another aspect, the invention is directed to a mold having an optical surface having an anti-reflective coating that can be transferred to an optical surface of the lens. In various embodiments as shown in Figures 4 and 5, such a mold has a superhydrophobic material layer 406 or 506 deposited on the optical surface 404 or 504 of the mold 402 or 502 having a thickness of about 20 to 100 nm. Wherein the superhydrophobic material contains from about 1.7% to about 8.3% by weight of the superhydrophobic material of the cobine. In one embodiment, the superhydrophobic material is contained within one or more of the crucibles in contact with the metal sheet or boat. In certain embodiments, the superhydrophobic material is vacuum evaporated from one or more crucibles while the metal boat is heated to a temperature between about 200 ° C and about 500 ° C. In some embodiments, the crucible is a copper material and the boat is a stainless steel material.

The mold also has an anti-reflective coating layer structure 411 or 511 deposited on the superhydrophobic layer 406 or 506; and deposited on the anti-reflective coating layer structure 411 or 511 by dip coating or vapor deposition deposition and having A single layer thickness coupler layer 426 or 526.

As shown in Figures 4 and 5, the anti-reflective coating layered structure 411 or 511 has: (1) a first layer 412 or 512 of a first material having a first refractive index and a thickness of about 5 to 100 nm deposited on the superhydrophobic layer 406 or 506; (2) deposited on the first layer 412 or 512 a second layer 414 or 514 having a second refractive index and a second material having a thickness of about 40 to 50 nm; (3) having a first refractive index deposited on the second layer 414 or 514 and having a thickness of about 10 to 20 nm a third layer 416 or 516 of the first material; (4) a fourth layer 418 or 518 of a second material having a second index of refraction and having a thickness of about 50 to 70 nm deposited on the third layer 416 or 516; 5) a fifth layer 420 or 520 deposited on the fourth layer 418 or 518 having a first refractive index and a first material having a thickness of about 25 to 40 nm; (6) deposited on the fifth layer 420 or 520 a sixth layer 422 or 522 of a second material having a second refractive index and a thickness of about 10 to 25 nm; and (7) a first refractive index deposited on the sixth layer 422 or 522 and having a thickness of about 5 to 15 nm The seventh layer 424 or 524 of the first material.

The first refractive index and the second refractive index satisfy a ratio of H/L > 1, wherein L and H are first and second refractive index values, respectively. In other words, the second refractive index value is greater than the first refractive index value.

In one embodiment, the first material having the first index of refraction comprises SiO ₂ and the second material having the second index of refraction comprises ZrO ₂ .

Each SiO ₂ layer in the antireflective coating layered structure is deposited using ion assist or without ion assist.

Alternatively, in various embodiments as shown in Figures 4 and 5, SiO ₂ layers 410, 510 having a thickness of 5 to 40 nm are deposited on layers 406, 506 without ion assistance such that layers 406, 506 are Layers 410, 510 are formed between layers 412, 512.

The double-armed decane may be bis(trimethoxydecylpropyl)amine.

The coupling agent layer is formed from a composition comprising functional decane. In some embodiments, the functional decane comprises a double-arm decane. In other embodiments, the functional decane comprises a cyclic azanonane. In various embodiments as shown in Figures 4 and 5, the coupler layer is formed from N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane.

In another aspect, the invention is directed to an optical lens. An optical lens has a lens body having an optical surface and an anti-reflective coating formed on the optical surface, wherein in various embodiments as shown in Figures 4 and 5, the anti-reflective coating has an optical deposition on the mold 402 or 502 The super-hydrophobic material layer 406 or 506 having a thickness on the surface 404 or 504 of about 20 to 100 nm, wherein the superhydrophobic material contains from about 1.7% to about 8.3% by weight of the superhydrophobic material of the cobine. In one embodiment, the superhydrophobic material is contained within one or more of the crucibles in contact with the metal sheet or boat. In certain embodiments, the superhydrophobic material is vacuum evaporated from one or more crucibles while the metal boat is heated to a temperature between about 200 ° C and about 500 ° C. In some embodiments, the crucible is a copper material and the boat is a stainless steel material.

The antireflective coating also has an antireflective coating layered structure 411 or 511 deposited on the superhydrophobic layer 406 or 506; and deposited on the antireflective coating layered structure 411 or 511 and coupled to the optical surface of the lens body A coupler layer 426 or 526 deposited using vapor deposition and having a single layer thickness.

The anti-reflective coating layered structure 411 or 511 is formed by: (1) a first layer 412 of a first material having a first refractive index and a thickness of about 5 to 100 nm deposited on the superhydrophobic layer 406 or 506 or 512; (2) having a second refractive index and thickness deposited on the first layer 412 or 512 a second layer 414 or 514 of a second material of about 40 to 50 nm; (3) a third layer of the first material having a first refractive index and a thickness of about 10 to 20 nm deposited on the second layer 414 or 514 416 or 516; (4) a fourth layer 418 or 518 of a second material having a second index of refraction and having a thickness of about 50 to 70 nm deposited on the third layer 416 or 516; (5) deposited on the fourth layer 418 Or a fifth layer 420 or 520 of a first material having a first refractive index and a thickness of about 25 to 40 nm; or (6) having a second refractive index deposited on the fifth layer 420 or 520 and having a thickness of about a sixth layer 422 or 522 of a second material of 10 to 25 nm; and (7) a first refractive index deposited on the sixth layer 422 or 522 and in contact with the coupling agent layer 426 or 526 and having a thickness of about 5 to 15 nm The seventh layer 424 or 524 of the first material.

The first refractive index and the second refractive index satisfy a ratio of H/L > 1, wherein L and H are first and second refractive index values, respectively. In other words, the second refractive index value is greater than the first refractive index value.

In one embodiment, the first material having the first index of refraction comprises SiO ₂ and the second material having the second index of refraction comprises ZrO ₂ .

Each SiO ₂ layer in the antireflective coating layered structure is deposited using ion assist or without ion assist.

Alternatively, in various embodiments as shown in Figures 4 and 5, SiO ₂ layers 410, 510 having a thickness of 5 to 40 nm are deposited on layers 406, 506 without ion assistance such that layers 406, 506 are Layers 410, 510 are formed between the first layers 412, 512.

The double-armed decane may be bis(trimethoxydecylpropyl)amine.

The coupling agent layer is formed from a composition comprising a cyclic azanonane. in In various embodiments as shown in Figures 4 and 5, the coupler layer is formed from N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane.

In another aspect, the invention is directed to a coupling agent useful in the manufacture of lenses. In one embodiment, the coupling agent comprises both arms decane. In one embodiment, the coupling agent comprises a cyclic azanonane. In a particular embodiment, the cyclic azanonane comprises N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane. It should be noted that, in use, a cyclic azanonane and a double-arm decane are applied in a solvent. For the examples as shown in Figures 4 and 5, wherein SiO _{2 is} used as the first material having the first refractive index, using N-n-butyl-aza-2,2-dimethoxy-oxime The heterocyclic pentane acts as a coupling agent to allow surface-bound ring-opening reactions as shown in Figure 2 without the need for water or heat, resulting in better bonding and on-site AR lens formation. This is better than the process shown in Figure 1 which requires especially high heat.

It is further noted that in practicing the present invention, the steps of the various embodiments given above may be performed as intended or in a different order.

In another aspect, the invention is directed to an optical lens. In one embodiment, the optical lens has a lens body having an optical surface, a hard coating on the optical surface of the lens body, and an anti-reflective coating on the optical surface.

The above description of the exemplary embodiments of the present invention is provided for the purpose of illustration and description, and is not intended to In view of the above disclosure, various modifications and changes may be made to the embodiments.

The selection and description of the embodiments are intended to explain the principles of the invention and its application in the application of the invention. The invention and the various embodiments are utilized by various modifications and modifications in the particular application. Alternate embodiments will be apparent to those skilled in the art from this disclosure, without departing from the scope of the invention. Therefore, the scope of the invention is defined by the scope of the appended claims, and not by the foregoing description and the exemplary embodiments described herein.

Claims (47)

A method of applying an anti-reflective coating to an optical surface of a mold, comprising the steps of: (a) providing a lens mold having an optical surface; (b) forming a layer of superhydrophobic material on the optical surface, the forming By heating a hot boat in contact with one or more crucibles containing the superhydrophobic material to a temperature between about 200 ° C and about 500 ° C, wherein the superhydrophobic material contains a certain amount of arms decane The amount is the relative percentage of the superhydrophobic material; (c) forming an anti-reflective coating layered structure on the superhydrophobic material layer; and (d) forming a single layer on the anti-reflective coating layer structure A layer thickness deposited coupler layer is formed by a vapor deposition or a dip coating or spin coating using a solution of a coupling agent in an aprotic solvent under aprotic conditions. The method of claim 1, wherein the amount of the double-arm decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material. The method of claim 1, wherein the step of forming an anti-reflective coating layer structure on the layer further comprises the steps of: (a) forming a first refractive index on the superhydrophobic material layer and a first layer of a first material having a thickness of about 5 to 100 nm; (b) forming a second material having a second refractive index higher than the first refractive index and having a thickness of about 40 to 50 nm on the first layer a second layer; (c) forming a third layer of the first material having the first refractive index and having a thickness of about 10 to 20 nm on the second layer; (d) forming the third layer on the third layer Birefringence and thickness of about 50 a fourth layer of the second material up to 70 nm; (e) forming a fifth layer of the first material having the first index of refraction and having a thickness of about 25 to 40 nm on the fourth layer; (f) Forming a sixth layer of the second material having the second refractive index and having a thickness of about 10 to 25 nm on the fifth layer; and (g) forming the first refractive index on the sixth layer and having a thickness of about 5 Up to 15 nm of the seventh layer of the first material. The method of claim 3, wherein the first material having the first refractive index is SiO ₂ and the second material having the second refractive index is ZrO ₂ . The method of claim 4, wherein each SiO ₂ layer is deposited using ion assist or without ion assist. The method of claim 1, wherein the two-arm decane comprises bis(trimethoxydecylpropyl)amine. The method of claim 1, wherein the coupling agent layer is formed from a composition comprising a cyclic azanonane or a double-arm decane. The method of claim 7, wherein the coupling agent layer is formed of N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane. The method of claim 1, further comprising the step of forming a SiO ₂ layer between the anti-reflective coating layer structure and the superhydrophobic material layer. A mold having an optical surface that is transferable to an antireflective coating of a lens, comprising: (a) a layer of superhydrophobic material formed on the optical surface, the formation being formed by one or more The hot contact of the superhydrophobic material The boat is heated to a temperature between about 200 ° C and about 500 ° C, wherein the superhydrophobic material contains a quantity of cob hexane, the amount being the relative percentage of the superhydrophobic material; (b) the superhydrophobic An anti-reflective coating layered structure formed on the layer of the material; and (c) a coupler layer deposited on the layer of the anti-reflective coating layer in a single layer thickness, the formation being used under aprotic conditions The phase deposition is carried out by dip coating or spin coating using a solution of a coupling agent in an aprotic solvent, the coupling agent layer being formed from a composition comprising a cyclic azanonane or a double-arm decane. The mold of claim 10, wherein the amount of the double-arm decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material. The mold of claim 10, wherein the anti-reflective coating layer structure comprises: (a) a first refractive index formed on the superhydrophobic material layer and a thickness of about 5 to 100 nm a first layer of a first material; (b) a second layer of a second material having a second index of refraction greater than the first index of refraction and having a thickness of between about 40 and 50 nm formed on the first layer; c) a third layer of the first material having the first refractive index and having a thickness of about 10 to 20 nm formed on the second layer; (d) having the second layer formed on the third layer a fourth layer of the second material having a refractive index and a thickness of about 50 to 70 nm; (e) a first material formed on the fourth layer having the first refractive index and having a thickness of about 25 to 40 nm a fifth layer; (f) having the second refractive index formed on the fifth layer and having a thickness of about a sixth layer of the second material of 10 to 25 nm; and (g) a seventh layer of the first material having the first refractive index and having a thickness of about 5 to 15 nm formed on the sixth layer. The mold of claim 12, wherein the first material having the first refractive index is SiO ₂ and the second material having the second refractive index is ZrO ₂ . The mold of claim 13, wherein each SiO ₂ layer is deposited using ion assist or without ion assist. The mold of claim 10, wherein the double-arm decane comprises bis(trimethoxydecylpropyl)amine. The mold of claim 10, wherein the coupling agent layer is formed of N-n-butyl-aza-2,2-dimethoxy-hydrazine heterocyclopentane. The mold of claim 10, further comprising an SiO ₂ layer formed between the anti-reflective coating layer structure and the superhydrophobic material layer. An optical lens manufactured from a mold having an optical surface, comprising: a lens body having an optical surface; a hard coat layer coated on the optical surface of the lens body; and an anti-reflective coating comprising: (a) a superhydrophobic material layer formed on the optical surface of the mold by heating a hot boat in contact with one or more crucibles containing the superhydrophobic material to about 200 ° C and about 500 ° C Between temperatures, wherein the superhydrophobic material contains a quantity of double-arm decane, the amount being the relative percentage of the superhydrophobic material; (b) the anti-reflective coating formed on the superhydrophobic material layer Layered knot And (c) a coupler layer deposited on the anti-reflective coating layer structure in a single layer thickness, wherein the hard coat layer is substantially in contact with the coupler layer of the anti-reflective coating layer, the coupler layer It is formed from a composition comprising a cyclic azanonane or a double-arm decane. The optical lens of claim 18, wherein the amount of the double-arm decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material. The optical lens of claim 18, wherein the anti-reflective coating layer structure comprises: (a) a first refractive index formed on the superhydrophobic material layer and a thickness of about 5 to 100 nm a first layer of the first material; (b) a second layer formed on the first layer having a second refractive index higher than the first refractive index and having a thickness of about 40 to 50 nm; (c) a third layer of the first material having the first refractive index and having a thickness of about 10 to 20 nm formed on the second layer; (d) having the first layer formed on the third layer a fourth layer of the second material having a second refractive index and a thickness of about 50 to 70 nm; (e) the first material having the first refractive index and having a thickness of about 25 to 40 nm formed on the fourth layer a fifth layer; (f) a sixth layer of the second material having the second refractive index and having a thickness of about 10 to 25 nm formed on the fifth layer; and (g) on the sixth layer And forming a seventh layer of the first material having the first refractive index and having a thickness of about 5 to 15 nm in contact with the coupler layer. The optical lens of claim 20, wherein the first material having the first refractive index is SiO ₂ and the second material having the second refractive index is ZrO ₂ . The optical lens of claim 21, wherein each SiO ₂ layer is deposited using ion assist or without ion assist. The optical lens of claim 18, wherein the double-arm decane comprises bis(trimethoxydecylpropyl)amine. The optical lens of claim 18, wherein the coupling agent layer is formed of N-n-butyl-aza-2,2-dimethoxy-fluorene heterocyclopentane. The optical lens of claim 18, further comprising an SiO ₂ layer formed between the anti-reflective coating layer structure and the superhydrophobic material layer. A method of applying an anti-reflective coating to an optical surface of a mold, comprising the steps of: (a) providing a lens mold having an optical surface; (b) forming a superhydrophobic material layer on the optical surface, wherein The superhydrophobic material contains a quantity of double-armed decane, the amount being the relative percentage of the superhydrophobic material; (c) forming an anti-reflective coating layered structure on the superhydrophobic material layer; and (d) a layer of a coupling agent deposited in a single layer thickness on the anti-reflective coating layer structure, which is subjected to dip coating under aprotic conditions using vapor deposition or by using a solution of a coupling agent in an aprotic solvent or Spin coating to achieve. The method of claim 26, wherein the amount of the arms decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material. The method of claim 26, wherein the method is formed on the layer The step of the anti-reflective coating layer structure further comprises the steps of: (a) forming a first layer of a first material having a first refractive index on the superhydrophobic material layer; and (b) forming a first layer on the first layer a second layer of a second material having a second index of refraction; (c) forming a third layer of the first material having the first index of refraction on the second layer; (d) forming on the third layer a fourth layer of the second material having the second refractive index; (e) forming a fifth layer of the first material having the first refractive index on the fourth layer; (f) in the fifth layer Forming a sixth layer of the second material having the second refractive index; and (g) forming a seventh layer of the first material having the first refractive index on the sixth layer. The method of claim 28, wherein the first refractive index and the second refractive index satisfy a ratio of H/L > 1, wherein L and H are the first refractive index and the second refractive index, respectively. The value. The method of claim 29, wherein the first material having the first refractive index is SiO ₂ and the second material having the second refractive index is ZrO ₂ . The method of claim 26, wherein the coupler layer is formed from a composition comprising a cyclic azanonane or a double-arm decane. The method of claim 26, wherein the step of forming the superhydrophobic material layer on the optical surface comprises heating and one or more There is a hot boat in contact with the superhydrophobic material. The method of claim 32, wherein the heating step comprises heating the hot boat to a temperature between about 200 ° C and about 500 ° C. A mold having an optical surface that is transferable to an antireflective coating of a lens, comprising: (a) a layer of superhydrophobic material formed on the optical surface, wherein the superhydrophobic material contains a quantity of arms a decane, the amount being a relative percentage of the superhydrophobic material; (b) an antireflective coating layered structure formed on the superhydrophobic material layer; and (c) on the antireflective coating layer structure a coupler layer deposited in a single layer thickness, which is achieved by a vapor deposition or a dip coating or spin coating using a solution of a coupling agent in an aprotic solvent under aprotic conditions, the coupling layer It is formed from a composition comprising a cyclic azanonane or a double-arm decane. The mold of claim 34, wherein the amount of the double-arm decane is from about 1.7 wt% to 8.3% wt% of the superhydrophobic material. The mold of claim 34, wherein the anti-reflective coating layer structure comprises: (a) a first layer of a first material having a first refractive index formed on the superhydrophobic material layer (b) a second layer of a second material having a second refractive index formed on the first layer; (c) the first material having the first refractive index formed on the second layer The third floor; (d) a fourth layer of the second material having the second refractive index formed on the third layer; (e) the first layer having the first refractive index formed on the fourth layer a fifth layer of material; (f) a sixth layer of the second material having the second refractive index formed on the fifth layer; and (g) formed on the sixth layer a seventh layer of the first material having a refractive index. The mold of claim 36, wherein the first refractive index and the second refractive index satisfy a ratio of H/L > 1, wherein L and H are the first refractive index and the second refractive index, respectively. The value. The mold of claim 37, wherein the first material having the first refractive index is SiO ₂ and the second material having the second refractive index is ZrO ₂ . The mold of claim 34, wherein the superhydrophobic material layer is formed on the optical surface by heating at a temperature to contact one or more crucibles containing the superhydrophobic material. The hot boat is realized. The mold of claim 39, wherein the temperature is between about 200 ° C and about 500 ° C. An optical lens manufactured from a mold having an optical surface, comprising: a lens body having an optical surface; a hard coat layer coated on the optical surface of the lens body; and an anti-reflective coating comprising: (a) a layer of superhydrophobic material formed on the optical surface of the mold, Wherein the superhydrophobic material contains a quantity of the double-armed decane, the amount being the relative percentage of the superhydrophobic material; (b) the anti-reflective coating layered structure formed on the superhydrophobic material layer; c) a coupler layer deposited on the antireflective coating layer structure in a single layer thickness, wherein the hard coat layer is substantially in contact with the coupler layer of the antireflective coating, the coupler layer comprising a ring A combination of azaxane or a double arm decane is formed. The optical lens of claim 41, wherein the amount of the double-arm decane is from about 1.7 wt% to 8.3% by weight of the superhydrophobic material. The optical lens of claim 41, wherein the anti-reflective coating layer structure comprises: (a) a first material having a first refractive index formed on the superhydrophobic material layer a layer; (b) a second layer of a second material having a second index of refraction formed on the first layer; (c) the first layer having the first index of refraction formed on the second layer a third layer of material; (d) a fourth layer of the second material having the second refractive index formed on the third layer; (e) having the first layer formed on the fourth layer a fifth layer of the first material having a refractive index L and a thickness of about 25 to 40 nm; (f) a sixth layer of the second material having the second refractive index formed on the fifth layer; (g) a seventh layer of the first material having the first refractive index formed on the sixth layer and in contact with the coupler layer. The optical lens of claim 43, wherein the first refractive index and the second refractive index satisfy a ratio of H/L >1, wherein L and H are the first refractive index and the second refractive index, respectively The value of the rate. The optical lens of claim 44, wherein the first material having the first refractive index is SiO ₂ and the second material having the second refractive index is ZrO ₂ . The optical lens of claim 41, wherein the superhydrophobic material layer is formed on the optical surface of the mold by heating at one temperature and one or more containing the superhydrophobicity The material is contacted by the hot boat to achieve. The optical lens of claim 46, wherein the temperature is between about 200 ° C and about 500 ° C.