COATED FILM FOR APPLYING TO LIGHT TRANSMITTING ARTICLES
This invention relates to light transmitting articles. More specifically this
invention relates to coatings for light transmitting articles.
This invention relates particularly to coatings for optical lenses such as
ophthalmic lenses and it will be convenient to hereinafter describe the invention
with reference to this example application. It is to be understood however that
the invention is capable of broader application. Merely by way of example, the
invention might also find application in lenses for disposable cameras,
binoculars and transparent covers for picture frames.
Spectacle or ophthalmic lenses are generally manufactured in two basic
forms, namely stock lenses and semifinished lenses. Stock lenses are
moulded with their front and rear surfaces polished and only require peripheral
edging in a prescription laboratory before being fitted to a frame. By contrast the concave rear surfaces of semi-finished lenses still require surfacing and
polishing when they leave the manufacturing site. Because the surfacing of the
rear surface is dependent upon a wearer's prescription it can only be done in a
prescription laboratory.
Spectacle lenses are made from glass and from plastic. Plastic lenses
have been known for some time and are increasingly being preferred to glass
lenses for spectacles. Plastic lenses are lighter than glass lenses and can be
made thinner than glass lenses.
Plastic lenses are typically coated with at least one, and typically three to
seven coatings to improve their durability and performance. The coatings
which are frequently applied to plastic lenses are firstly a hard coat to increase
the abrasion resistance of the softer underlying plastic lens substrate, and
secondly an AR coat or coating (anti-reflection coating) to reduce unwanted
reflection of light. Other coatings which may also be applied to the lens are a
primer coat to improve the fracture resistance of an AR coated lens and a coating of lubricious material for easing cleaning of the lens. Where the term
"multi-coat" is used in the specification it is intended to describe coatings of this
general nature.
Plastic lenses may also be coated with other optically effective coatings
including sunlens coatings, mirror coatings, photochromic coatings and tint
coatings.
A hard coat generally comprises an inorganic compound linked to an
organic matrix for the purpose of increasing the abrasion resistance of the
softer, underlying lens body. The hard coating is typically 1 to 10 micron thick.
Hard coats are typically applied by liquid application techniques such as
roller coating, dipping or spinning of liquids. However hard coats may also be
applied by vacuum deposition techniques such as Plasma Polymerisation (PP)
or Plasma Enhanced Chemical Vapour Deposition (PECVD).
An AR coating, as described above, reduces unwanted reflection of light
and thereby enables the wearer to see and be seen more clearly. Typically a
high quality AR coating reduces the natural (photopic) reflectance of glass or
plastic from 4% to 8% per surface to well under 0.5% per surface. Some
known AR coatings comprise three to five layers of metal or semi-metal oxides,
such TiO2 and SiO2, arranged in the form of an interference stack. The design
of the interference stack is well known to those skilled in the art of vacuum deposition of optical multi-layer thin films. The thickness of the layers in the
multi-layer stack typically ranges from 10 nanometres to several hundred
nanometres. The thickness and uniformity of the layers in the stack must be
carefully controlled. It is well recognised that AR coatings of this general type are quite brittle and are not resilient.
AR coatings are typically deposited in high technology vacuum
deposition systems employing electron beam (e-beam) evaporation and in
some cases ion assisted deposition (IAD). The application of AR coatings to
plastic lenses by vacuum deposition techniques is fraught with difficulties.
Often problems are encountered in getting the AR coat to satisfactorily adhere
to the lens substrate. One problem is the limitation on the temperature to which
the plastic substrate may be heated during deposition. Another problem is that
vacuum deposition requires a pristine lens substrate surface. Any dirt or
imperfection on the surface of the lens will detract from the coating, and may
make it commercially unacceptable. A further problem is that vacuum
deposition apparatus is very expensive and requires highly skilled personnel if it
is to be operated effectively.
Primer coatings may be applied to AR coated lenses to improve the fracture resistance thereof. The primer coating, which typically is made of
polyurethane, is applied between the surface of the lens and the hard coating to
stop cracks propagating from the brittle AR coating into the lens.
A lubricious or easyclean coating typically comprises a very thin layer of
lubricious organic film which is applied to the outermost coating on the lens to
facilitate cleaning of the lens. The lubricious coating might also be provided
with hydrophobic and/or anti-static properties.
As described above, the concave rear surface of a semi-finished lens
cannot undergo final surfacing and polishing at the point of manufacture
because this is done in a prescription laboratory according to the wearer's
prescription. These final coatings either have to be applied to the lens in the
prescription laboratory or else they have to be forwarded from the prescription
laboratory to a central processing facility for the coatings.
The problems of vacuum deposition of AR coatings described above are
exacerbated in a prescription laboratory. The pristine conditions required for
satisfactory AR coating by vacuum deposition are often difficult to obtain within
prescription laboratories. Further the high cost of apparatus and skilled
operating personnel may be more difficult to justify in a prescription laboratory
which may process only five to ten pairs of semi-finished lenses per day.
An additional problem encountered in applying an AR coating to a lens in
a prescription laboratory is that different lenses from a variety of manufacturers
often need to be coated at about the same time. However the lenses of
different manufacturers are made of different materials and require different
coatings. There is no standard hard coat and AR coat which can be applied to
all finished lenses. It is generally difficult to efficaciously coat lenses made of different materials using the same piece of equipment.
At the same time, it is not commercially attractive to send a semifinished
lens, once it has been surfaced and polished according to a wearer's
prescription, to a centralised coating facility. Prescription laboratories require the ability to finish and fit lenses quickly and efficiently thereby providing the
customer with a quick turnaround time, eg less than 24 hours. It would
therefore be advantageous if a way of applying an optically effective coat,
particularly an AR coat, speedily and simply to a lens in a prescription
laboratory could be devised.
It is therefore an object of this invention to provide a coat or coating for a
lens which can be speedily and simply applied to a lens in a prescription
laboratory.
According to a first aspect of this invention there is provided a film for
applying to a light transmitting article including:
a film substrate; and
an optically effective coat applied to the film substrate for improving the
optical properties of a light transmitting article to which the film is applied.
Typically the film substrate is a thin polymeric film. In order for the film to
be capable of conforming closely to both concave and convex lens surfaces it
would have to be flexible and extensible, eg it would need to be sufficiently
durable to withstand stretching during lamination. It would also need to be able
to withstand wear and tear in use.
Advantageously the film substrate is polyethylene terephthalate (PET).
PET is sold by Du Pont in Australia under the trademark MYLAR. PET can withstand temperatures well in excess of 100°C which may permit sol-gel and
nanotechnology approaches to optical thin film deposition to be used. PET has
the additional advantage that its glass transition temperature of approximately
67°C allows the film substrate to be deformed by the application of moderate
heat and thus conform to a convex or concave lens surface.
Alternatively the film substrate may be cellulose acetyl butyrate (CAB).
The optically effective coat may be an AR coat for reducing unwanted
reflection of a light source.
Preferably the AR coat comprises an organic based multi-layer coat.
Each layer may comprise nanometric particles of inorganics in an organic
matrix which permits some degree of stretch formation, eg a polysiloxane
compound. Preferably the AR coat comprises a layer containing titanium
compounds sandwiched between two layers containing polysiloxanes which are
substantially titanium-free. Typically the titanium containing layers contain up to 10 weight per cent titanium dioxide.
It is particularly preferred that the layer of the AR coat proximate to the
film substrate contains polysiloxane resins, colloidal silica, organic dicarboxylic
acid and surfactants.
Particularly suitable AR coats are described in United States patents
5,104,692 and 5,173,368 assigned to Pilkington Visioncare Holdings Ine, the
entire contents of which are incorporated herein by reference. The two and
three layer AR coats disclosed in those patents are very suitable. The two and
three layer designs disclosed in the above patents can be extended to four or
five layer designs, or even designs having a greater number of layers.
At the same time however it is to be clearly understood that coatings
other than those described in the above referenced US Patents may be also be
used.
Naturally the AR coat would have to be capable of withstanding the
compressive and tensile forces encountered when the film was conformed to a
lens surface during lamination, ie it would need to be both flexible and
extensible. Conventional vacuum deposited AR coats which comprise ceramic
coatings such as SiO2, TiO2, Nb2O5, AI2O3, SiN, and other metal and semi-
metal oxides and nitrides, are brittle and will crack or craze if attempts are
made to stretch and deform them. A polysiloxane multilayer AR coat is much
more flexible than a conventional ceramic AR coat applied by vacuum
deposition.
The extensibility of the materials described in US Patents 5,104,692 and 5,173,368 above can be further enhanced by the addition of a suitable flexibility
enhancing agent such as dimethylsiloxane. The flexibility enhancing agent may
comprise up to 10% by weight of the coating.
Altematively the optically effective coat may confer the effect of a
sunlens, a tinted lens, a mirror coated lens, or any combination of these effects.
The film may further include a hard coat sandwiched between the film
substrate and the optically effective coat, eg AR coat.
Advantageously the hard coat comprises an inorganic compound linked
to an organic matrix, eg a polysiloxane.
Optionally the film may include a lubricious organic coating applied to the optically effective coat to facilitate easy cleaning of the article. Further
optionally the film may include a primer coat of polyurethane positioned
between the film substrate and the AR coat.
The optically effective coat may be applied by liquid film application
techniques and the hard coat may also be applied by liquid film application
techniques. Suitable techniques inlude curtain flow coating, dip coating, roller
coating and spin coating. The lubricious organic coating may also be applied
by liquid film application techniques.
Naturally liquid coating techniques are substantially less complicated
than the vacuum deposition techniques which have traditionally been used to
deposit AR coats. Liquid film application techniques are also substantially
cheaper than vacuum deposition techniques and accordingly there is a strong
cost incentive to apply the coatings in this fashion. Liquid film application
techniques would be vastly more difficult to use on the variably curved surfaces
of lenses than on thin flat film.
Alternatively, the optically effective coat and the hardcoat may be
deposited by vacuum deposition techniques, eg e-beam evaporation (with or
without IAD), PP and PECVD. The vacuum applied hard coat and optically effective coat may be rendered extensible without cracking by the inclusion of
organic compounds in both coatings. These organic compounds include
monomeric vapours of the type used to create organic hardcoats by means of
plasma polymerisation, eg siloxanes, alkyl- and alkoxysilanes. The lubricious
organic coating may also be applied using these techniques.
Finally the optically effective coat, eg the AR coat would typically be
designed such that it underwent minimal change in residual reflectance colour
or other optical property when the thickness of each layer was reduced at a
given point on the lens as a result of stretching the coated film to conform to the
lens shape. The design necessary to obtain residual reflectance colour stability
for AR coats would be well known to those skilled in the art of optical multi-layer
thin film design and will not be described in further detail here.
According to a second aspect of this invention there is provided a light
transmitting article including an article substrate, and a film applied to the article
substrate, the film including a film substrate and an optically effective coat
applied to the film substrate.
The film may include any one or more of the preferred features
described above with respect to the first aspect of the invention.
Typically the light transmitting article is an ophthalmic lens having front
and rear surfaces.
Typically the film is applied to at least the rear surface of the lens.
Optionally the film may be applied to both the front and rear surfaces of the lens.
Advantageously the film is adhered to the lens by means of a UV curable
adhesive. Adhesives having acrylate functionality are particularly preferred.
According to a third aspect of this invention there is provided apparatus
for laminating a film to an ophthalmic lens, including means for drawing the film
tautly across a flat or substantially convex surface of the lens such that it conformingly engages the surface of the lens.
Advantageously the means for drawing the film across the surface of the
lens comprises a pair of laminating rings.
Advantageously the apparatus also includes a film deforming member
for urging the film into conforming engagement with a substantially concave
surface of the lens.
In one embodiment, the film deforming member includes a bladder
having a flexible wall for urging the film into conforming engagement with the
surface of the lens when the bladder is filled with fluid under pressure.
Preferably the apparatus further includes a UV source for irradiating a
UV curable adhesive with UV radiation so as to adhere the film to the lens.
Optionally the apparatus also includes means for placing a drop of
adhesive substantially centrally on a surface of the lens.
Apparatus in accordance with this invention for laminating a film in
accordance with this invention to a lens may come in a variety of forms. It will
be convenient to hereinafter describe in detail an example embodiment of the
film and an example embodiment of the apparatus with reference to the
accompanying drawings. It is to be understood however that the specific
nature of this embodiment does not supersede the generality of the proceeding
statements. In the drawings:
Figs 1 and 2 are schematic sectional front views of apparatus being used
to apply a multi-coated film to a convex surface of a lens;
Fig 3 is a three-dimensional view of the apparatus, film and lens of Fig 2;
and
Figs 4 and 5 are schematic sectional front views of apparatus being used
to apply a multi-coated film to a concave surface of a lens.
Figs 1 to 3 show inter alia a film 1 and an ophthalmic lens 2.
The film 1 comprises a film substrate which is coated with a hardcoat, an
optically effective coat which is an AR coat, and a lubricious coat. The
substrate is typically made of PET which is sold under the trade mark MYLAR
by Du Pont in Australia. Special optically clear and homogeneous grades of
PET are known and are preferable for this application. The hard coat typically
comprises a polysiloxane compound. The AR coat is typically a three layer
coating composition containing a middle layer of titanium compound
sandwiched between two layers containing polysiloxane compound.
Particularly suitable AR coatings of this type are disclosed in United States
patent 5,173,368 which is assigned to Pilkington Visioncare Holdings Limited.
The lubricious coating facilitates easy cleaning of the lens. The various
coatings applied to the substrate which are collectively referred to as a "multi-
coat" are not shown in the drawings.
The coatings are typically applied to the film substrate by liquid
application techniques. Roll coating is particularly preferred for the application
of these coatings to the film substrate. The film is typically produced in sheets
or rolls and then distributed to the sites at which it is laminated to the lenses, eg
prescription laboratories.
The ophthalmic lens has a convex front surface 3 and a concave rear
surface 4 as is typical for these lenses. The rear surface is surfaced, and
possibly also polished, according to the wearer's prescription in the prescription
laboratory and once this has been done the lens is ready to have the film
laminated thereto.
An appropriately configured piece of film is cut from the roll and
stretched tautly across the surface 3 of the lens 2 spaced from the surface 3.
The film 1 is held in this position by being clamped between a pair of circular
laminating rings 5, one ring 5 being mounted over each major surface of the
film 1. The rings 5 are connected to each other by screws forming a ring
assembly, although any other fastening means could equally be used.
Typically the rings 5 are made of metal although other suitable materials may
also be used.
A drop of adhesive 6 is disposed between the film 1 and the lens 2 for
adhering the film 1 to the lens 2 when it is drawn across the lens. The drop of
adhesive 6 is typically positioned over the centre of the surface 3 of the lens 2
and remains there due to surface tension. The drawing shows the drop spaced
from the surface 3 for the purposes of clarity of illustration only.
While other types of glue may be used, the glue used in the illustrated
embodiment, is of the type which is cured by UV radiation. Adhesives with
acrylate functionality are particularly suitable. UV radiation is provided by a UV
light source 7. The light source 7 is positioned above the lens 2 such that the film 1 is positioned in between the source 7 and the lens 2. The structure and
functioning of the UV source 7 would be well known to persons skilled in the art
and will not be described in further detail here.
As indicated above, other glues may also be used. For example, a so-
called super glue, or isocyanate glue may also be used. Isocyanate glues cure
anaerobically when oxygen is excluded from the atmosphere surrounding the
glue and certain minimum dimensions for the layer of glue are met.
The use of an adhesive to adhere the film to the lens overcomes many of the problems encountered in the prior art vacuum deposition techniques.
The bonding of the film to the lenses is efficacious and is not prone to
delamination provided the surfaces of the thin polymeric film and the lens are
appropriately pretreated. Further the fact that the film and the substrate may be
made of different materials for different lens materials does not substantially
affect the laminating procedure. While different films will be used for different
lenses, the laminating procedure will be essentially the same for each. Further
the lens surface does not have to be cleaned and dried to the exacting
standards required for commercially acceptable vacuum deposition.
The film 1 may be heated above its glass transition temperature to aid
deformation and therefore conformance with the convex lens surface by hot air.
It must be understood however that heating equipment for blowing hot air has
not been illustrated in the drawings.
The film 1 is laminated to the lens 2 by moving the rings 5 downwardly
over the surface 3 of the lens 2 so that the film 1 is drawn tautly across the lens
2. Fig 2 illustrates the relative positioning of the components at this stage of
the laminating process. By drawing the film 1 tautly across the surface 3, the
glue 6 is spread evenly over the surface 3. When all air has been excluded
from the film-lens interface, the glue 6 is irradiated with UV light from the UV
light source 7.
Figs 4 and 5 show the lamination of a film 1 to a concave rear surface 4
of a lens 2. While this lamination process is more complex than that illustrated
in Figs 1 and 2, many of the components of the apparatus are the same. The
same reference numerals shall be used to refer to the same components,
unless otherwise specified.
In Fig 4, the concave surface 4 of the lens 2, rather than the surface 3 is
closely spaced from the film 1 which is again clamped between a pair of circular
laminating rings 5.
There is an additional component for which there is no equivalent in Figs
1 and 2, namely a film deforming member 8. The member 8 comprises a
bladder housing a flexible, fluid impermeable, polymeric membrane 10 and a
rigid planar base element 11. The bladder may be filled with air, water, silicone
or other suitable UV transparent fluid which may be heated above the glass
transition temperatures of the film (eg above about 67°C for PET). Both the
membrane 10 and the base element 11 are UV transparent. The membrane 10
is clamped onto one surface of a circular ring 12, which is similar in construction
to one of the rings 5 while the base element 11 is mounted to an opposed
surface of the ring 12. The membrane 10, base element 11 , and ring 12,
together form an inflatable bag which can be inflated by pumping fluid through
an fluid inlet port 13 having an appropriate valve means.
As in Figs 1 and 2, a drop of glue 6 is positioned on the surface 4,
substantially centrally relative thereto. Fig 4 shows the drop spaced from the
surface 4 for the purpose of clarity of illustration only.
The manner in which the film 1 is laminated to the surface 4 of the lens 2
is quite different to that in the Fig 1 and 2 embodiments. Instead of rings 5 being moved towards the lens 2, the bag is inflated such that the membrane 10
urges the film 1 outwardly into conforming engagement with the surface 4 of the
lens 2. Fig 5 shows the components substantially in this position although the
membrane 10 is shown spaced a small distance away from the film 1 for clarity only. As in Fig 1 , this action spreads the glue evenly across the surface of the
lens 2. Once all air is excluded from the film-lens interface, the glue is
irradiated with UV light from the source 7. When the glue has cured, the
finished lens complete with multi-coat applied thereto can be removed.
Thus a film can be speedily and easily applied in a prescription
laboratory by inexperienced personnel using the laminating apparatus
illustrated in Figs 4 and 5. A multi-coat might also be applied to the convex
surface 3 of the lens.
An advantage of a preferred embodiment of this invention, is that a lens
can be coated simply and speedily with an AR coat and a hardcoat at a
prescription laboratory which does not have sophisticated vacuum deposition
equipment. Small prescription laboratories will be able to simply and speedily
apply multi-coats to spectacle lenses using only inexpensive laminating
equipment of the type already available in many prescription laboratories for laminating lens components together.
A further advantage of a preferred embodiment of this invention is that
the AR coat is more securely adhered to the lens than with the vacuum deposition processes. This is particularly important in a prescription laboratory
where lenses made from different materials need to be provided with a multi-
coat. Using the existing processes, difficulties are often encountered in
obtaining satisfactory adhesion of the multi-coat to the different lens materials.
A further advantage is that the surface of the lens to which the film is to be
laminated would not have to be as scrupulously clean and free of moisture as
would be the case were the known vacuum deposition techniques to be used.
A further advantage of a preferred embodiment of this invention is that it
may obviate the need to polish a lens after surfacing thereof Current state of
the art surfacing machines are able to produce surfaces which have a fine surface finish. It is quite possible that such surfaces will not need polishing
prior to laminating with the film of this invention to produce a multi-coated lens.
It has long been recognised that it would be desirable to eliminate the step of
polishing a lens. Several attempts have been made to introduce so-called "cut
and coat" technology which directly coats the rear concave surface of the lens,
after surfacing, with a hard coat for covering over the surface texture and
blemishes. However, such attempts have not so far proved satisfactory.
A yet further advantage of a preferred embodiment of the invention, is
that it is technically easier and therefore less expensive to apply a multi-coat to
a flat, horizontal, continuous roll of film than it is to apply such a multi-coat to
discrete lenses, particularly the curved surfaces thereof. There are substantial
handling difficulties and thereby substantial costs associated with sending individual lenses through a plurality of coating processes. Further, the yields of
each coating process are typically only 90%-95% when coating individual
lenses, and would be substantially higher when coating continuous film.
Further it is possible to use liquid film application processes such as roll coating
to coat the film instead of difficult vacuum deposition processes. These liquid
application processes could not easily be used to coat lenses.
It is to be understood that various alterations, modifications, and/or
additions may be introduced into the constructions and arrangements of parts
previously described without departing from the ambit of the invention disclosed
herein.