Ophthalmic Lens Comprising a Multilayered Interferential Coating and Manufacturing Method Thereof
20200041697 · 2020-02-06
Inventors
Cpc classification
G02B5/0858
PHYSICS
G02B1/16
PHYSICS
G02C7/10
PHYSICS
G02B5/0816
PHYSICS
International classification
G02C7/10
PHYSICS
Abstract
This invention relates to an ophthalmic lens comprising a multilayered interferential coating and to a manufacturing method thereof.
The ophthalmic lens comprises: an organic substrate having a front main face and a rear main face, and a multilayered interferential coating (30) which is coated on at least one of the front main face and the rear main face,
According to the invention, the multilayered interferential coating (30) comprises at least one graphene layer (2) which has a uniform thickness of between 0.1 nm to 1 nm.
Claims
1. An ophthalmic lens comprising: an organic substrate having a front main face and a rear main face; and a multilayered interferential coating which is coated on at least one of the front main face and the rear main face; wherein the multilayered interferential coating comprises at least one graphene layer which has a uniform thickness of between 0.1 nm to 1 nm.
2. The ophthalmic lens of claim 1, wherein the multilayered interferential coating forms a stack comprising inorganic dielectric thin layers and the at least one graphene layer.
3. The ophthalmic lens of claim 1, wherein the multilayered interferential coating comprises at least two said graphene layers.
4. The ophthalmic lens of claim 1, wherein the multilayered interferential coating forms a stack comprising an alternation of: at least one high refractive layered unit of refraction index greater than 1.55; and at least one layer selected from a low refractive layer of refraction index lower than 1.55 and a metallic layer.
5. The ophthalmic lens of claim 4, wherein the at least one high refractive layered unit comprises: the at least one graphene layer; and an underlying encapsulating layer over which the at least one graphene layer continuously extends.
6. The ophthalmic lens of claim 5, further comprising an overlying encapsulating layer beneath which the at least one graphene layer continuously extends.
7. The ophthalmic lens of claim 5, wherein each of the underlying encapsulating layer and the overlying encapsulating layer is based of boron nitride.
8. The ophthalmic lens of claim 7, wherein each of the underlying encapsulating layer and the overlying encapsulating layer is based of hexagonal boron nitride.
9. The ophthalmic lens of claim 5, wherein the at least one high refractive layered unit comprises the underlying encapsulating layer and the overlying encapsulating layer sandwiching a said graphene layer, the multilayered interferential coating successively comprising, in a direction moving away from the organic substrate, at least one unitary assembly of: one said high refractive layered unit; and one said low refractive layer which covers the said high refractive layered unit; and the multilayered interferential coating has a said high refractive layered unit as a bottom layer and one said low refractive layer as a top layer, and comprising a number of said unitary assembly(ies) ranging from 1 to 8.
10. The ophthalmic lens of claim 9, wherein the one said low refractive layer is based on SiO2 and has a thickness of between 10 nm and 180 nm, the multilayered interferential coating comprising a number of said unitary assembly(ies) ranging from 1 to 5.
11. The ophthalmic lens of claim 9, wherein the multilayered interferential coating forms a visible antireflection coating and/or an infrared reflective coating for a spectacle lens.
12. The ophthalmic lens of claim 11, wherein the multilayered interferential coating forms a visible antireflection coating having a mean light reflection factor in the visible region R.sub.v lower than or equal to 1.1% for an angle of incidence of 15.
13. The ophthalmic lens of claim 12, wherein the multilayered interferential coating forms a visible antireflection coating having a mean light reflection factor in the visible region R.sub.v lower than or equal to 1.02% for an angle of incidence of 15.
14. The ophthalmic lens of claim 11, wherein the multilayered interferential coating forms an infrared reflective coating having an IR reflection factor R.sub.IR measured across 780-2000 nm greater than or equal to 30%, measured at an angle of incidence of 15.
15. The ophthalmic lens of claim 14, wherein the multilayered interferential coating forms an infrared reflective coating having an IR reflection factor RIR measured across 780-2000 nm greater than or equal to 40%, measured at an angle of incidence of 15.
16. The ophthalmic lens of claim 5, wherein the multilayered interferential coating successively comprises, in a direction moving away from the organic substrate: as a bottom layer, one lower said high refractive layered unit which comprises the underlying encapsulating layer and the overlying encapsulating layer sandwiching a said graphene layer; one said layer selected from a low refractive layer and a metallic layer which covers the said lower high refractive layered unit; and as a top layer, one said graphene layer extending over one said underlying encapsulating layer to form an upper said high refractive layered unit which is devoid of a said overlying encapsulating layer; the number of said graphene layers in the multilayered interferential coating ranging from 1 to 8.
17. The ophthalmic lens of claim 16, wherein: said lower high refractive layered unit has a thickness of between 20 nm and 70 nm; the one said layer selected from a low refractive layer and a metallic layer which covers the said lower high refractive layered unit is: a SiO.sub.2 layer having a thickness of between 120 nm and 170 nm; or a metallic layer having a thickness of between 5 nm and 15 nm; and the upper said high refractive layered unit which is devoid of a said overlying encapsulating layer has a thickness of between 40 nm and 60 nm.
18. The ophthalmic lens of claim 16, wherein the multilayered interferential coating forms: (i) where said layer which covers the said lower high refractive layered unit is a low refractive SiO.sub.2 layer, a visible reflective coating forming a mirror front surface of a spectacle lens; and (ii) where said layer which covers the said lower high refractive layered unit is a metallic layer selected from silver, gold and copper, a visible antireflection coating and/or an infrared reflective coating.
19. The ophthalmic lens of claim 18, wherein in case (i) the spectacle lens is a solar spectacle lens.
20. The ophthalmic lens of claim 18, wherein in case (i) the multilayered interferential coating forms a visible reflecting coating having a mean light reflection factor in the visible region R.sub.v greater than or equal to 20% for an angle of incidence of 15.
21. The ophthalmic lens of claim 20, wherein in case (i) the multilayered interferential coating forms the visible reflecting coating having a mean light reflection factor in the visible region Rv greater than or equal to 30% for an angle of incidence of 15.
22. The ophthalmic lens of claim 18, wherein in case (ii) the multilayered interferential coating forms: a visible antireflection coating having a mean light reflection factor in the visible region R.sub.v lower than or equal to 1% for an angle of incidence of 15; and an infrared reflective coating having an IR reflection factor R.sub.IR measured across 780-2000 nm greater than or equal to 30%, measured at an angle of incidence of 15.
23. The ophthalmic lens of claim 22, wherein the visible antireflection coating has a mean light reflection factor in the visible region Rv lower than or equal to 0.8% for an angle of incidence of 15.
24. The ophthalmic lens of claim 22, wherein the infrared reflective coating has an IR reflection factor RIR measured across 780-2000 nm greater than or equal to 35%, measured at an angle of incidence of 15.
25. The ophthalmic lens of claim 22, wherein in case (ii) the multilayered interferential coating forms: the visible antireflection coating having a mean light reflection factor in the visible region R.sub.v lower than or equal to 0.8% for an angle of incidence of 15; and the infrared reflective coating having an IR reflection factor RIR measured across 780-2000 nm greater than or equal to 35%, measured at an angle of incidence of 15.
26. The ophthalmic lens of claim 5, wherein the at least one high refractive layered unit comprises: the at least one graphene layer; and the underlying encapsulating layer has a thickness of between 5 nm and 85 nm; wherein said at least one high refractive layered unit has a thickness of between 10 nm to 120 nm.
27. The ophthalmic lens of claim 26, wherein the overlying encapsulating layer has a thickness of less than 80 nm.
28. A method for manufacturing an ophthalmic lens comprising: obtaining an organic substrate having a front main face and a rear main face; and depositing by chemical vapor deposition a multilayered interferential coating on at least one of the front main face and the rear main face, the multilayered interferential coating comprising at least one graphene layer which has a uniform thickness of between 0.1 nm to 1 nm.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0080] The present invention will be described in more detail by referring to the appended drawings, wherein:
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DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS
[0093] The terms comprise (and any grammatical variation thereof, such as comprises and comprising), have (and any grammatical variation thereof, such as has and having), contain (and any grammatical variation thereof, such as contains and containing), and include (and any grammatical variation thereof, such as includes and including) are open-ended linking verbs. They are used to specify the presence of stated features, integers, steps or components or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps or components or groups thereof. As a result, a method, or a step in a method, that comprises, has, contains, or includes one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements.
[0094] Unless otherwise indicated, all numbers or expressions referring to quantities of ingredients, ranges, reaction conditions, etc. used herein are to be understood as modified in all instances by the term about.
[0095] Also unless otherwise indicated, the indication of an interval of values from X to Y or between X to Y, according to the present invention, means as including the values of X and Y.
[0096] In the present application, when an ophthalmic lens comprises one or more coatings onto the surface thereof, the expression to deposit a layer or a coating onto the lens is intended to mean that a layer or a coating is deposited onto the external (exposed) surface of the outer coating of the lens, that is to say its coating that is the most distant from the substrate.
[0097] A coating, that is said to be on a substrate or deposited onto a substrate is defined as a coating, which (i) is positioned above the substrate, (ii) is not necessarily in contact with the substrate, that is to say one or more intermediate coatings may be arranged between the substrate and the coating in question, and (iii) does not necessarily completely cover the substrate.
[0098] In a preferred embodiment, the coating on a substrate or deposited onto a substrate is in direct contact with this substrate.
[0099] When a layer 1 is lying under a layer 2, it is intended to mean that layer 2 is more distant from the substrate than layer 1.
[0100] As used herein, the rear (or the inner) face of the substrate is intended to mean the face which, when using the lens, is the nearest from the wearer's eye. It is generally a concave face. On the contrary, the front face of the substrate, is the face which, when using the lens, is the most distant from the wearer's eye. It is generally a convex face.
[0101] The ophthalmic lens prepared according to the present invention may be a transparent ophthalmic lens or a lens blank thereof. The lens may be coated on its convex main side (front side), concave main side (back side), or both sides according to the invention.
[0102] Thermoplastic materials usable for the organic substrate may be selected from, for instance: polyamides; polyimide; polysulfones; polycarbonates and copolymers thereof; poly(ethylene terephtalate) and polymethylmethacrylate (PMMA).
[0103] As used herein, a polycarbonate (PC) is intended to mean either homopolycarbonates or copolycarbonates and block copolycarbonates.
[0104] Thermoset materials usable for the substrate may be selected from, for instance: cycloolefin copolymers such as ethylene/norbornene or ethylene/cyclopentadiene copolymers; homo- and copolymers of allyl carbonates of linear or branched aliphatic or aromatic polyols, such as homopolymers of diethylene glycol bis(allyl carbonate) (CR 39); homo- and copolymers of (meth)acrylic acid and esters thereof, which may be derived from bisphenol A; polymer and copolymer of thio(meth)acrylic acid and esters thereof, polymer and copolymer of allyl esters which may be derived from Bisphenol A or phtalic acids and allyl aromatics such as styrene, polymer and copolymer of urethane and thiourethane, polymer and copolymer of epoxy, and polymer and copolymer of sulphide, disulfide and episulfide, and combinations thereof.
[0105] Homopolymers of diethylene glycol bis(allyl carbonate) (CR 39), allylic and (meth)acrylic copolymers, having a refractive index between 1.54 and 1.58, are preferred.
[0106] As used herein, a (co)polymer is intended to mean a copolymer or a polymer. As used herein, a (meth)acrylate is intended to mean an acrylate or a methacrylate.
[0107] Particularly recommended substrates include those substrates obtained through (co)polymerization of the diethyleneglycol bis-allyl-carbonate, marketed, for example, under the trade name CR-39 by the PPG Industries company (ORMA lenses, ESSILOR), or polythiourethanes/polysulfides, marketed for instance under MR series by Mitsui, or allylic and (meth)acrylic copolymers, having a refractive index between 1.54 and 1.58.
[0108] Prior to depositing the multilayered interferential coating onto the optionally coated substrate, for example with an abrasion-resistant layer and/or a scratch-resistant coating or with a sub-layer, the surface of said optionally coated substrate is usually submitted to a physical or chemical surface activating treatment, so as to reinforce the adhesion of the antireflective coating. Such pre-treatment is generally conducted under vacuum. It may be a bombardment with energetic and/or reactive species, for example with an ion beam (Ion Pre-Cleaning or IPC) or with an electron beam, a corona discharge treatment, an ion spallation treatment, an ultraviolet treatment or a plasma-mediated treatment under vacuum, generally using an oxygen or an argon plasma. It may also be an acid or basic treatment and/or a solvent-based treatment (water, hydrogen peroxide or any organic solvent).
[0109] The multilayered interferential coating may be deposited onto a sub-layer, which then does not belong to the multilayered interferential coating.
[0110] Because of its relatively high thickness, the sub-layer does not generally take part to the antireflective optical activity, especially when it has a refractive index close to that of the underlying coating (which is generally the anti-abrasion and anti-scratch coating) or to that of the substrate, if the sub-layer is directly deposited onto the substrate.
[0111] The sub-layer should have a thickness that is sufficient for promoting the abrasion resistance of the antireflective coating, but preferably not to such an extent that a light absorption could be caused, which, depending on the sub-layer nature, could significantly reduce the relative transmission factor .sub.v. Its thickness is generally lower than 300 nm, more preferably lower than 200 nm, and is generally higher than 90 nm, more preferably higher than 100 nm.
[0112] The sub-layer preferably comprises a SiO.sub.2-based layer, this layer comprising preferably at least 80% by weight of silica, more preferably at least 90% by weight of silica, relative to the layer total weight, and even more preferably consists in a silica layer. The thickness of such silica-based layer is generally lower than 300 nm, more preferably lower than 200 nm, and is generally higher than 90 nm, more preferably higher than 100 nm.
[0113] The ophthalmic lens of the invention may contain an additional antistatic layer (i.e. in addition to a graphene layer), so as not to retain and/or develop a substantial static charge, by incorporating at least one charge dissipating conductive layer into the stack present on the surface of the lens.
[0114] The ability for a glass to evacuate a static charge obtained after rubbing with a piece of cloth or using any other procedure to generate a static charge (charge applied by corona . . . ) may be quantified by measuring the time it takes for said charge to dissipate. Thus, antistatic glasses have a discharge time of about a few hundred milliseconds, preferably 500 ms or less, whereas it is of about several tens of seconds for a static glass. In the present application, discharge times are measured according to the method exposed in the French application FR 2 943 798.
[0115] As used herein, an electrically conductive layer or an antistatic layer is intended to mean a layer which, due to its presence on the surface of a non-antistatic substrate (i.e. having a discharge time higher than 500 ms), enables to have a discharge time of 500 ms or less after a static charge has been applied onto the surface thereof.
[0116] The electrically conductive layer may be located on various places in the stack, generally in or in contact with the antireflective coating, provided the anti-reflective properties thereof are not affected. It is preferably located between two layers of the antireflective coating, and/or is adjacent to a layer with a high refractive index of such antireflective coating. Preferably, the electrically conductive layer is located immediately under a layer with a low refractive index of the antireflective coating, most preferably is the penultimate layer of the antireflective coating by being located immediately under the silica-based outer layer of the antireflective coating.
[0117] The low refractive layers (e.g. SiO.sub.2 layers) are preferably deposited by chemical vapor deposition, under vacuum, according to any of the following methods: i) by optionally ion-beam assisted, evaporation; ii) by ion-beam sputtering; iii) by cathode sputtering; iv) by plasma-assisted chemical vapor deposition. These various methods are described in the following references Thin Film Processes and Thin Film Processes II, Vossen & Kern, Ed., Academic Press, 1978 and 1991, respectively. A particularly recommended method is the evaporation under vacuum.
[0118] Generally, the front and/or rear main face of the substrate onto which an antireflective coating will be deposited is coated with an impact-resistant primer layer, with an anti-abrasion and/or anti-scratch coating, or with an impact-resistant primer layer coated with an anti-abrasion and/or anti-scratch coating.
[0119] The anti-abrasion and/or scratch-resistant coatings are preferably hard coatings based on poly(meth)acrylates or silanes, generally comprising one or more mineral fillers intended to increase the hardness and/or the refractive index of the coating once cured.
[0120] Hard anti-abrasion and/or scratch-resistant coatings are preferably prepared from compositions comprising at least one alkoxysilane and/or a hydrolyzate thereof, obtained for example through hydrolysis with a hydrochloric acid solution and optionally condensation and/or curing catalysts.
[0121] The anti-abrasion and/or scratch-resistant coating composition may be deposited onto the main face of the substrate by dip- or spin-coating. It is then cured by a suitable method (preferably using heat or ultraviolet radiation).
[0122] The thickness of the anti-abrasion and/or scratch-resistant coating does generally vary from 2 to 10 m, preferably from 3 to 5 m.
[0123] Prior to depositing the abrasion-resistant coating and/or the scratch-resistant coating, it is possible to apply onto the substrate a primer coating to improve the impact resistance and/or the adhesion of the subsequent layers in the final product. This coating may be any impact-resistant primer layer traditionally used for articles in a transparent polymer material, such as ophthalmic lenses.
[0124] An ophthalmic lens according to the invention may also comprise coatings formed on the multilayered interferential coating and capable of modifying the surface properties thereof, such as hydrophobic and/or oleophobic coatings (antifouling top coat). These coatings are preferably deposited onto the outer layer of the multilayered interferential coating, in particular when the outer layer of the multilayered interferential coating is silica based. As a rule, their thickness is lower than or equal to 10 nm, does preferably range from 1 to 10 nm, more preferably from 1 to 5 nm.
[0125] Instead of the hydrophobic coating, a hydrophilic coating may be used which provides antifog properties, or an antifog precursor coating which provides antifog properties when associated with a surfactant. Examples of such antifog precursor coatings are described in the patent application WO 2011/080472.
[0126] An ophthalmic lens of the invention may be a spectacle lens such as a polarized lens, a photochromic lens or a solar lens, which may be tinted or not, be corrective, or not.
[0127] This ophthalmic lens may be inserted in spectacle frames or in a head mounted device. Non limiting examples of head mounted devices include immersive and non-immersive devices, in particular see-through devices and see-around devices. Head mounted devices may be either augmented reality devices or virtual reality devices.
[0128] The front face and/or the rear face of the substrate of the lens may be successively coated with an impact-resistant primer layer, an abrasion-resistant layer and/or a scratch-resistant layer, said multilayered interferential coating of the invention, and with a hydrophobic and/or oleophobic coating.
[0129] The following examples illustrate the present invention in a more detailed, but non-limiting manner.
Examples
[0130] Graphene was used for the following simulations in the form of a single monolayer sheet 2 sandwiched in boron nitride (BN) layers 3 and 4 (see
[0131] The optical properties of graphene (refractive index and absorption coefficient, both as functions of wavelength) were extrapolated from tabulated graphite properties.
[0132] A graphene monolayer 2 having a thickness of 2 was put in sandwich between BN layers 3 and 4. For the simulations, we have considered the 280-2000 nm domain which is relevant regarding applications in UV, visible and IR ranges. To our knowledge, no optical index of single graphene sheet is mentioned in the literature. We therefore used the optical index of graphite for the simulations. The BN material displays an optical index very close to those of transparent high index materials like ZrO.sub.2. In terms of optical properties, the high refractive layered units 1 and 1 of
[0133] During the optimization carried out by the applicant, the thicknesses of the BN layers 3 and 4 were variables, and different kind of multilayered interferential coatings 10, 20, 30, 40, 50 according to the invention were designed in
[0134] The lenses where prepared with an organic lens substrate ORMA (obtained by polymerizing a diethylene glycol bis(allyl carbonate), typically CR39) having a 65 mm diameter, a refractive index in the range of around 1.5, and a power of 2.00 diopters. The multilayered interferential coating according to invention was deposited on front face. A multilayered interferential coating corresponding to example 1 of WO2012076714 was deposited on rear face.
[0135] The mean light reflection factor, noted R.sub.v, is such as defined in the ISO 13666:1998 Standard, and measured in accordance with the ISO 8980-4, i.e. this is the weighted spectral reflection average over the whole visible spectrum between 380 and 780 nm. R.sub.v was measured for an angle of incidence of 15 on front face.
[0136] The relative light transmission factor in the visible spectrum, noted T.sub.v, is such as defined in the standard NF EN 1836 and relates to an average in the 380-780 nm wavelength range that is weighted according to the sensitivity of the eye at each wavelength of the range and measured under D65 illumination conditions (daylight).
[0137] The IR reflection factor R.sub.IR was measured across 780-2000 nm at an angle of incidence of 15.
[0138] The colorimetric coefficients of the lenses refer to reflected light on front face, in the international colorimetric system CIE L*a*b* and are calculated between 280 and 780 nm, taking the standard illuminant D 65 and the observer into account (angle of 10). The observer is a standard observer as defined in the international colorimetric system CIE L*a*b*.
[0139] 1) The high refractive layered unit 1 of
[0140] 1.1) The multilayered interferential coating 10 of
[0143] The optical performances of coating 10 were as indicated below:
TABLE-US-00001 R.sub.v = 0.55% T.sub.v = 97.3% C* = 41 h = 305
[0144] 1.2) The multilayered interferential coating 20 of
[0147] The optical performances of coating 20 were as indicated below:
TABLE-US-00002 R.sub.v = 0.98% T.sub.v = 95.9% C* = 11 h = 135
[0148] 1.3) The multilayered interferential coating 30 of
[0151] The optical performances of coating 30 were as indicated below:
TABLE-US-00003 R.sub.v = 1.02% T.sub.v = 94.5% R.sub.IR (780-1400 nm) 40%
[0152] 2) The high refractive layered unit 1 of
[0153] 2.1) The multilayered interferential coating 40 of
[0157] The optical performances of coating 40 were as indicated below:
TABLE-US-00004 R.sub.v = 32% T.sub.v = 67% C* = 14 h = 135
[0158] In this configuration a flash deposition of an SiO.sub.2 layer with a thickness below 5 nm could be additionally performed in order to allow a subsequent deposition of a fluorinated coating surmounting the interferential coating 40 to impart easy cleaning properties to the ophthalmic lens.
[0159] 2.2) The multilayered interferential coating 50 of
[0163] The optical performances of coating 50 were as indicated below:
TABLE-US-00005 R.sub.v = 0.8% T.sub.v = 92.5% R.sub.IR (780-2000 nm) 35%
[0164] In this configuration a flash deposition of an SiO.sub.2 layer with a thickness below 5 nm could be additionally performed in order to allow a subsequent deposition of a fluorinated coating surmounting the interferential coating 40 to impart easy cleaning properties to the ophthalmic lens.