Spectacle lens comprising at least one ultrathin lens and process for production thereof

Abstract

A spectacle lens includes proceeding from a front face on the object side of the spectacle lens to an opposite reverse face of the spectacle lens, at least components A, B, and C. The component A includes an ultrathin lens, the component B includes at least one of a polymeric material or a mineral glass, and the component C includes at least one of a functional layer or an ultrathin lens. The spectacle lens has no damage after impact of a steel ball with a diameter of 15.87 mm and a weight of 16.36 g from a height of 1.27 m.

Claims

1. A process for producing a spectacle lens including, proceeding from a front face on the object side of the spectacle lens to an opposite reverse face of the spectacle lens, at least components A, B, and C, wherein the component A and the component C include an ultrathin lens, wherein the component B includes at least one of a polymeric material or a mineral glass, wherein the ultrathin lens has an average thickness within a range of from 90 m to 210 m, wherein the spectacle lens has a middle thickness within a range of from 0.34 mm to 2.22 mm, and wherein the spectacle lens has no damage after impact of a steel ball of a size of 15.87 mm and a weight of 16.36 g from a height of 1.27 m, the process comprising: providing the ultrathin lens of the component A as a formed ultrathin lens; providing the ultrathin lens of the component C; flame treating an edge region of the formed ultrathin lens of the component A and the ultrathin lens of the component C; providing a finished spectacle lens of the component B including the at least one of the polymeric material or the mineral glass; optionally, forming a functional layer on at least one of the front face or the reverse face of the component B; bonding the reverse face of the component A to the front face of the component B and bonding the reverse face of the component B to the front face of the ultrathin lens of the component C; and edging the spectacle lens including the components A, B, and C, wherein the ultrathin lens of the component A and the ultrathin lens of the component C are based on a glass composition, wherein the glass composition of the component A is identical or different from the glass composition of the component C, and wherein the finished spectacle lens of the component B is a monofocal spectacle lens, a multifocal spectacle lens, a bifocal spectacle lens, a trifocal spectacle lens, a varifocal spectacle lens, or a degressive spectacle lens.

2. The process for producing the spectacle lens as claimed in claim 1, further comprising at least one of: providing the ultrathin lens of the component C as the formed ultrathin lens; coating a reverse face of the ultrathin lens of the component A with the functional layer; coating a front face of the ultrathin lens of the component C with the functional layer; coating the front face of the finished spectacle lens with the functional layer and the reverse face of the finished spectacle lens with the functional layer; bonding the coated reverse face of the component A to the coated front face of the component B and bonding the coated reverse face to the coated front face of the ultrathin lens of component C; and coating the front face of the ultrathin lens of the component A with the functional layer and coating the reverse face of the ultrathin lens of the component C with the functional layer.

3. The process as claimed in claim 1, wherein the components A, B, and C are bonded with an adhesive, by a thermal treatment, or by contact bonding.

4. The process as claimed in claim 1, wherein the components A, B, and C are bonded to one another with an adhesive based on an amine-catalyzed thiol hardening of an epoxy resin at a temperature within a range of from 20 C. to 80 C.

5. The process as claimed in claim 1, wherein the ultrathin lens has an average thickness within a range of from 90 m to 120 m.

6. The process as claimed in claim 2, wherein the reverse face of the ultrathin lens of the component A is coated with at least one functional layer, and wherein the at least one functional layer is selected from the group consisting of a coloring layer, a photochromic layer, a polarizing layer, or a reflection layer.

7. The process as claimed in claim 1, wherein at least one of the front face of the ultrathin lens of the component A or the reverse face of the ultrathin lens of the component C is coated with at least one functional layer, and wherein the at least one functional layer is selected from the group consisting of an antireflection layer, an electrically conductive layer, a semiconductive layer, an antifog layer, and a clean-coat layer.

8. The process as claimed in claim 1, further comprising: providing the ultrathin lens of component A and the ultrathin lens of component C as the formed ultrathin lens.

9. The process as claimed in claim 1, wherein a surface topography of the components A, B, and C is in each case selected from the group consisting of planar, spherical, aspherical, toric, and atoric, wherein the surface topography of a respective front face and a respective reverse face of the components A and C is a same, wherein the surface topography of the component A is the same as or different than the surface topography of the component C, and wherein the surface topography of the component A is the same as or different than the surface topography of the front face of the component B, and the surface topography of the component C is the same as or different than the surface topography of the reverse face of the component B.

10. A process for producing a spectacle lens including, proceeding from a front face on the object side of the spectacle lens to an opposite reverse face of the spectacle lens, at least components A, B, and C, wherein the component A includes an ultrathin lens, wherein the component B includes at least one of a polymeric material or a mineral glass, and wherein the component C includes a functional layer, wherein the ultrathin lens has an average thickness within a range of from 90 m to 210 m, wherein the spectacle lens has a middle thickness within a range of from 0.34 mm to 2.22 mm, and wherein the spectacle lens has no damage after impact of a steel ball of a size of 15.87 mm and a weight of 16.36 g from a height of 1.27 m, the process comprising: providing the ultrathin lens of the component A as a formed ultrathin lens; flame treating an edge region of the ultrathin lens of the component A; providing a finished spectacle lens of the component B including the at least one of the polymeric material or the mineral glass; optionally, forming a functional layer on the front face of the component B; bonding the reverse face of the component A to the front face of the component B and coating the reverse face of the component B with the functional layer of the component C; and edging the spectacle lens including the components A, B, and C, wherein the ultrathin lens of the component A is based on a glass composition, and wherein the finished spectacle lens of the component B is a monofocal spectacle lens, a multifocal spectacle lens, a bifocal spectacle lens, a trifocal spectacle lens, a varifocal spectacle lens, or a degressive spectacle lens.

11. The process for producing the spectacle lens as claimed in claim 10, further comprising at least one of: coating a reverse face of the ultrathin lens of the component A with a functional layer; coating the front face of the finished spectacle lens with the functional layer and the reverse face of the finished spectacle lens with the functional layer; and bonding the coated reverse face of the component A to the coated front face of the component B.

12. The process as claimed in claim 10, wherein the functional layer of the component C is selected from the group consisting of a coloring layer, a photochromic layer, a polarizing layer, or a reflection layer.

13. The process as claimed in claim 10, wherein the ultrathin lens has an average thickness within a range of from 90 m to 120 m.

14. The process as claimed in claim 10, wherein the reverse face of the ultrathin lens of the component A is coated with at least one functional layer, and wherein the at least one functional layer is selected from the group consisting of a coloring layer, a photochromic layer, a polarizing layer, or a reflection layer.

15. The process as claimed in claim 10, wherein the front face of the ultrathin lens of the component A is coated with at least one functional layer, and wherein the at least one functional layer is selected from the group consisting of an antireflection layer, an electrically conductive layer, a semiconductive layer, an antifog layer, and a clean-coat layer.

16. The process as claimed in claim 10, wherein a surface topography of the components A and B is in each case selected from the group consisting of planar, spherical, aspherical, toric, and atoric, wherein the surface topography of the reverse face of the component A is the same as the surface topography of the front face of the component B, and the surface topography of the front face of the component A is the same as or different than the surface topography of the reverse face of the component B.

17. The process as claimed in claim 10, wherein the components A and B are bonded with an adhesive, by a thermal treatment, or by contact bonding.

18. The process as claimed in claim 10, wherein the components A and B are bonded to one another with an adhesive based on an amine-catalyzed thiol hardening of an epoxy resin at a temperature within a range of from 20 C. to 80 C.

19. A process for producing a spectacle lens including, proceeding from a front face on the object side of the spectacle lens to an opposite reverse face of the spectacle lens, at least components A, B, and C, wherein the component A and the component C include an ultrathin lens, wherein the component B includes at least one of a polymeric material or a mineral glass, wherein the ultrathin lens has an average thickness within a range of from 90 m to 210 m, wherein the spectacle lens has a middle thickness within a range of from 0.34 mm to 2.22 mm, and wherein the spectacle lens has no damage after impact of a steel ball of a size of 15.87 mm and a weight of 16.36 g from a height of 1.27 m, the process comprising: providing the ultrathin lens of the component A and the ultrathin lens of the component C; flame treating an edge region of the ultrathin lens of the component A and the ultrathin lens of the component C; providing a finished spectacle lens of the component B including the at least one of the polymeric material or the mineral glass; optionally, forming a functional layer on at least one of the front face or the reverse face of the component B; bonding the reverse face of the component A to the front face of the component B and bonding the reverse face of the component B to the front face of the ultrathin lens of the component C; removing a portion of the edge region of the ultrathin lens of the component A and the ultrathin lens of the component C; and edging the spectacle lens including the components A, B, and C, wherein the ultrathin lens of the component A and the ultrathin lens of the component C are based on a glass composition, wherein the glass composition of the component A is identical or different from the glass composition of the component C, and wherein the finished spectacle lens of the component B is a monofocal spectacle lens, a multifocal spectacle lens, a bifocal spectacle lens, a trifocal spectacle lens, a varifocal spectacle lens, or a degressive spectacle lens.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The disclosure will now be described with reference to the drawings wherein:

(2) FIG. 1 shows possible exemplary embodiments of coatings of the spectacle lens of the disclosure; and

(3) FIG. 2 shows possible surface topographies of the spectacle lens of the disclosure.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

(4) There follows a detailed elucidation of the disclosure by some examples, but these do not restrict the disclosure.

I Production of the Spectacle Lenses of the Disclosure

Examples 1 to 11

(5) i) A semifinished spectacle lens based on polyallyldiglycol carbonate (CR 39, from PPG Industries, Inc.) having a front-face curvature of 123.50 mm was adjusted to an optical strength of 2.00 dpt by means of abrasive processing on the reverse face R.sub.B of the semifinished spectacle lens. 500 L of the adhesive according to example 2 of WO 2015/121341 A1 were applied to the middle of the front face and then the ultrathin lens formed by means of a ceramic mold (ultrathin lens prior to forming: D 263 T eco, from Schott AG) having a radius of curvature of 123.50 mm was pressed on manually with the aid of a centering machine, such that the adhesive was distributed uniformly between the convex front face V.sub.B of the spectacle lens and the concave reverse face R.sub.B of the ultrathin lens. To cure the adhesive, the spectacle lens comprising components A and B was cured with a Hnle UV-LED source at 25 C. for 40 sec.

(6) TABLE-US-00003 Middle thickness of Average thickness of Example spectacle lens [mm] ultrathin lens [m] 1 2.39 210 2 2.22 100 3 1.84 100 4 1.66 100 5 1.58 100 6 1.13 100 7 1.00 100 8 0.70 100 9 0.59 100 10 0.47 100 11 0.41 100

Examples 12 to 14

(7) A semifinished spectacle lens based on polyallyldiglycol carbonate (CR 39, from PPG Industries, Inc.) having a front-face curvature of 123.50 mm was adjusted to an optical strength of 2.00 dpt by means of abrasive processing on the reverse face R.sub.B of the semifinished spectacle lens. A hard lacquer layer according to example 2 of EP 2 578 649 A1 was applied on the reverse face R.sub.B via spin-coating, which was cured at 120 C. for three hours. 500 L of the adhesive according to example 2 of WO 2015/121341 A1 were applied to the middle of the front face and then the ultrathin lens formed by means of a ceramic mold (ultrathin lens prior to forming: D 263 T eco, from Schott AG) having a radius of curvature of 123.50 mm was pressed on manually with the aid of a centering machine, such that the adhesive was distributed uniformly between the convex front face V.sub.B of the spectacle lens and the concave reverse face R.sub.B of the ultrathin lens. To cure the adhesive, the spectacle lens comprising components A and B was cured with a Hnle UV-LED source at 25 C. for 40 sec.

(8) TABLE-US-00004 Middle thickness of Average thickness of Example the spectacle lens [mm] ultrathin lens [m] 12 1.73 210 13 1.54 210 14 1.28 210

Examples 15 to 16

(9) A semifinished spectacle lens based on polyallyldiglycol carbonate (CR 39, from PPG Industries, Inc.) having a front-face curvature of 123.50 mm was adjusted to an optical strength of 2.00 dpt by means of abrasive processing on the reverse face R.sub.B of the semifinished spectacle lens. Thereafter, a hard lacquer layer according to example 2 of EP 2 578 649 A1 is applied to the spectacle lens by a dipping method, and is cured at 120 C. for three hours. The reverse face was subjected to vapor deposition of an antireflection layer (DuraVision Platinum, from ZEISS) and then of the clean-coat layer (AFP 3000+, from Cotec GmbH), each by means of a PVD method. 500 L of the adhesive according to example 2 of WO 2015/121341 A1 were applied to the middle of the front face and then the ultrathin lens formed by means of a ceramic mold (ultrathin lens prior to forming: D 263 T eco, from Schott AG) having a radius of curvature of 123.50 mm was pressed on manually with the aid of a centering machine, such that the adhesive was distributed uniformly between the convex front face V.sub.B of the spectacle lens and the concave reverse face R.sub.B of the ultrathin lens. To cure the adhesive, the spectacle lens comprising components A and B was cured with a Hnle UV-LED source at 25 C. for 40 sec. The front face was subjected to vapor deposition of an antireflection layer (DuraVision Platinum, from ZEISS) and then of the clean-coat layer (AFP 3000+, from Cotec GmbH), each by means of a PVD method.

(10) TABLE-US-00005 Middle thickness of Average thickness of Example the spectacle lens [mm] ultrathin lens [m] 15 1.97 210 16 1.65 210

Examples 17 and 18

(11) A semifinished spectacle lens based on polyallyldiglycol carbonate (CR 39, from PPG Industries, Inc.) having a front-face curvature of 123.50 mm was adjusted to an optical strength of 2.00 dpt by means of abrasive processing on the reverse face R.sub.B of the semifinished spectacle lens. Thereafter, a hard lacquer layer according to example 2 of EP 2 578 649 A1 was applied to the spectacle lens by a dipping method, and cured at 120 C. for three hours. The reverse face was subjected to vapor deposition of an antireflection layer (DuraVision Platinum, from ZEISS) and then of the clean-coat layer (AFP 3000+, from Cotec GmbH), each by means of a PVD method. 500 L of the adhesive according to example 2 of WO 2015/121341 A1 were applied to the middle of the front face and then the ultrathin lens formed by means of a ceramic mold (ultrathin lens prior to forming: D 263 T eco, from Schott AG) having a radius of curvature of 123.50 mm was pressed on manually with the aid of a centering machine, such that the adhesive was distributed uniformly between the convex front face V.sub.B of the spectacle lens and the concave reverse face R.sub.B of the ultrathin lens. To cure the adhesive, the spectacle lens comprising components A and B was cured with a Hnle UV-LED source at 25 C. for 40 sec.

(12) TABLE-US-00006 Middle thickness of Average thickness of Example the spectacle lens [mm] ultrathin lens [m] 17 2.02 210 18 1.66 210

Comparative Examples 1 to 3

(13) A semifinished spectacle lens based on polyallyldiglycol carbonate (CR 39, from PPG Industries, Inc.) having a front-face curvature of 123.50 mm was adjusted to an optical strength of 2.00 dpt by means of abrasive processing on the reverse face R.sub.B of the semifinished spectacle lens. Thereafter, a hard lacquer layer according to example 2 of EP 2 578 649 A1 was applied to the spectacle lens by a dipping method, and cured at 120 C. for three hours. The front and reverse faces were subjected to vapor deposition of an antireflection layer (DuraVision Platinum, from ZEISS) and then of the clean-coat layer (AFP 3000+, from Cotec GmbH), each by means of a PVD method.

(14) TABLE-US-00007 Middle thickness of Comparative example the spectacle lens [mm] 1 1.55 2 1.64

(15) II Characterization of the Spectacle Lenses of the Disclosure and of the Spectacle Lenses from the Comparative Examples

(16) IIa Ball Drop Test According to 21CFR801.410

(17) The spectacle lenses according to the disclosure of examples 1 to 18 passed the ball drop test without difficulty. They showed no signs at all of damage to the surface. By contrast, the spectacle lenses from comparative examples passed the ball drop test but each showed a star-shaped crack as error profile.

(18) IIb Reduction in the Weight of the Spectacle Lenses of the Disclosure

(19) As well as the thickness of a lens, weight is also of major importance to the user. Wearing comfort in particular is promoted by a minimum weight. It should be noted that D 263 T eco glass from Schott AG has a density of 2.51 g/cm.sup.3 and is thus much heavier than polymer substrates based on polyallyldiglycol carbonate (density=1.32 g/cm.sup.3). The polymer substrate thus weighs just 52.6% of the mineral glass. To compensate for this additional weight, it is crucial to reduce the middle thickness of the polymer substrate.

(20) For the planar ultrathin lens made of D 263 T eco from Schott AG with a diameter of 70 mm and a thickness of 100 m, this results in a weight of 965.5 mg; 210 m results in 2027.5 mg. Given a layer thickness of 100 m for the adhesive (density 1.32 g/cm.sup.3), the combination of ultrathin lens and adhesive results in a weight of 1342.5 mg (ultrathin lens thickness 100 m) or 2174.9 mg (ultrathin lens thickness 210 m). There is a corresponding savings potential in the polymer for various reductions in thickness according to the following Table:

(21) TABLE-US-00008 Polymer substrate: Spectacle lens comprising components A (ultrathin lens), polyallyldiglycol carbonate adhesives, B (polyallyldiglycol carbonate) Reduction in mg difference in total weight mg difference in total weight thickness Weight saving of hybrid dome [100 m] + of hybrid dome [210 m] + [mm] [mg] adhesive [100 m] adhesive [100 m] 0.1 507.74 834.7 1667.2 0.3 1523.21 180.7 651.7 0.4 2030.95 688.5 144.0 0.5 2538.69 1196.2 363.7 0.6 3046.43 1704.0 871.5 0.7 3554.17 2211.7 1379.2 0.8 4061.90 2719.4 1887.0 0.9 4569.64 3227.2 2394.7

(22) It follows from these calculations that a polymer substrate thinner by 0.3 mm (100 m ultrathin lens) or 0.5 mm (210 m ultrathin lens) leads to a finished spectacle lens which is lighter overall. Given current minimum thicknesses in the region of 2 mm for polyallyldiglycol carbonate-based spectacle lenses, the hybrid lenses, with the passing of the FDA ball drop test down to middle thickness 0.41 mm, offers distinct potential for reduction in the weight of a spectacle lens. Examples 5 to 11 and 14 meet this condition.

(23) The foregoing description of the exemplary embodiments of the disclosure illustrates and describes the present invention. Additionally, the disclosure shows and describes only the exemplary embodiments but, as mentioned above, it is to be understood that the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the concept as expressed herein, commensurate with the above teachings and/or the skill or knowledge of the relevant art.

(24) The term comprising (and its grammatical variations) as used herein is used in the inclusive sense of having or including and not in the exclusive sense of consisting only of. The terms a and the as used herein are understood to encompass the plural as well as the singular.

(25) All publications, patents and patent applications cited in this specification are herein incorporated by reference, and for any and all purposes, as if each individual publication, patent or patent application were specifically and individually indicated to be incorporated by reference. In the case of inconsistencies, the present disclosure will prevail.