SPECTACLE LENS WITH ANTIBACTERIAL AND/OR ANTIVIRAL PROPERTIES AND METHOD FOR MANUFACTURING THE SAME

Abstract

A spectacle lens has on at least one surface thereof at least two coatings modified to exhibit an antibacterial effect and/or an antiviral effect. A method of making such a spectacle lens includes dispersing at least one biocidal component in a solvent and/or dissolving at least one biocidal component in a solvent, the dispersed at least one biocidal component and the dissolved at least one biocidal component being different from each other.

Claims

1. A spectacle lens comprising: a spectacle lens substrate; and at least one antibacterial and/or antiviral coating, wherein the at least one antibacterial and/or antiviral coating is at least an outermost coating of the spectacle lens on the front surface thereof and/or at least the outermost coating of the spectacle lens on the back surface thereof, which is at least one selected from the group consisting of a clean coat layer, an anti-fog coating, and an antireflective coating modified to contain at least one biocidal component, wherein the spectacle lens includes on at least one surface thereof at least two coatings modified to exhibit an antibacterial effect and/or an antiviral effect.

2. The spectacle lens according to claim 1, wherein the at least two modified coatings are directly adjacent to each other, one of the at least two modified coatings being the outermost coating thereof.

3. The spectacle lens according to claim 1, wherein the at least two modified coatings each comprises at least one biocidal component, the at least one biocidal component of each modified coating being identical to or different from the at least one biocidal component of the other modified coating.

4. The spectacle lens according to claim 1, wherein the at least one biocidal component is selected from at least one of the group consisting of at least one biocidal inorganic metal, at least one biocidal inorganic metal oxide, at least one biocidal inorganic metal hydroxide, at least one biocidal inorganic metal oxide hydrate, and at least one biocidal inorganic metal sulfide.

5. The spectacle lens according to claim 4, wherein the at least one biocidal inorganic metal, the at least one biocidal inorganic metal oxide, the at least one biocidal inorganic metal hydroxide, the at least one biocidal inorganic metal oxide hydrate, and the at least one biocidal inorganic metal sulfide each is composed of or comprises silver, copper, titanium, zinc, and/or iron.

6-7. (canceled)

8. A method for manufacturing a spectacle lens containing a spectacle lens substrate and at least one antibacterial and/or antiviral coating, the method comprising the following steps: providing a spectacle lens substrate having an uncoated or precoated front surface and an uncoated or precoated back surface, wherein the method further comprises: depositing under vacuum on at least one of the uncoated or precoated surfaces at least one clean coat component resulting at least one clean coat layer or at least one anti-fog component resulting in at least one anti-fog coating; dispersing at least one biocidal component in at least one solvent and/or dissolving at least one biocidal component in at least one solvent, the dispersed at least one biocidal component and the dissolved at least one biocidal component being different from each other; modifying the at least one clean coat layer with the at least one biocidal component by diffusion of the at least one biocidal component into the at least one clean coat layer, the at least one biocidal component diffusing either completely or partially into the at least one clean coat layer, resulting in the at least one antibacterial and/or antiviral coating based on at least one modified clean coat layer; or modifying the at least one anti-fog coating with the at least one biocidal component by diffusion of the at least one biocidal component into the at least one anti-fog coating, the at least one biocidal component diffusing either completely or partially into the at least one anti-fog coating, resulting in the at least one antibacterial and/or antiviral coating based on at least one modified anti-fog coating.

9. The method according to claim 8, wherein the at least one biocidal component is selected from at least one of the group consisting of at least one metal, at least one metal oxide, at least one metal hydroxide, at least one metal oxide hydrate, at least one metal salt and at least one metal sulfide.

10-13. (canceled)

14. The method according to claim 8, wherein the method comprises the additional step: applying by vacuum deposition at least one clean coat layer adjacent to and on top of the at least one modified clean coat layer.

15. The method according to claim 14, wherein the at least one clean coat layer covers the underneath directly adjacent modified clean coat layer completely or partially.

16-20. (canceled)

Description

[0193] The following examples are non-limiting for the scope of the disclosure:

I SPECTACLE LENS ACCORDING TO THE EXAMPLES AND COMPARATIVE EXAMPLES

Comparative Example 1

[0194] An uncoated Zeiss CR39 plano flat sheet lens substrate based on polyallyldiglycol carbonate was firstly coated by the dip method with composition according to example 2 of EP 2 578 649 A1 and then vacuum deposited with a five layers antireflective coating that the material of each layer is SiO.sub.2, CrO.sub.2, SiO.sub.2, CrO.sub.2, SiO.sub.2 respectively. The layer thicknesses were 30 nm, 30 nm, 20 nm, 60 nm and 90 nm. Afterwards, the spectacle lens was further coated a hydrophobic clean coat layer with a thickness of 5 nm of the hydrophobic material Cotec 900 from COTECH GmbH.

Example 1

[0195] An uncoated Zeiss CR39 plano flat sheet lens substrate based on polyallyldiglycol carbonate was firstly coated by the dip method with composition according to example 2 of EP 2 578 649 A1 then vacuum deposited with a five layers antireflective coating that the material of each layer is SiO.sub.2, CrO.sub.2, SiO.sub.2, CrO.sub.2, SiO.sub.2 respectively. The layer thicknesses were 30 nm, 30 nm, 20 nm, 60 nm and 90 nm. An antibacterial and/or antiviral coating based on clean coat layer was further deposited on this surface: the biocidal compound was deposited by thermal evaporation and the clean coat component was deposited by electron beam evaporation and ion-beam assistance with purged 30 sccm O.sub.2in chamber. This antibacterial and/or antiviral coating consists of 20% by weight of the biocidal component Ag.sub.2O and 80% by weight of the clean coat component and exhibits a total thickness of 5 nm.

Example 2

[0196] An uncoated Zeiss CR39 plano flat sheet lens substrate based on polyallyldiglycol carbonate was firstly coated by the dip method with composition according to example 2 of EP 2 578 649 A1 then vacuum deposited with a same antireflective coating as in example 1. An antibacterial and/or antiviral coating based on clean coat layer was further deposited on this surface: the biocidal compound was deposited by thermal evaporation and the clean coat component was deposited by electron beam evaporation and ion-beam assistance with purged 30 sccm O.sub.2 in chamber. This antibacterial and/or antiviral coating consists of 20% by weight of the biocidal component CuO and 80% by weight of the clean coat component and exhibits a total thickness of 5 nm.

Example 3

[0197] A plano flat sheet lens that prepared by the process according to comparative example 1 was fixed on a lens chuck with one side facing up. A cotton cloth fully soaked with 0.1 mol/L AgNO.sub.3 water solution was used to manually wipe on the lens for 200 cycles. The obtained lens was further dried in a curing oven for 30 min at 50° C.

Example 4

[0198] A plano flat sheet lens that prepared by the process according to comparative example 1 was fixed on a lens chuck with one side facing up. A cotton cloth fully soaked with 0.5 mol/L AgNO3 water solution was used to manually wipe on the lens for 200 cycles. The obtained lens was further dried in a curing oven for 30 min at 50° C.

Example 5

[0199] An uncoated Zeiss CR39 plano flat sheet lens substrate based on polyallyldiglycol carbonate was firstly coated by the dip method with a hardening silicone film and then vacuum deposited with a same antireflection coating as examplel. An antibacterial and/or antiviral coating based on clean coat component was further applied on the top surface by dip coating. The resin for the dip coating process is prepared by adding 0.05 g 0.1 mol/L AgNO.sub.3 ethanol solution in 100 g Cotec Duralon from COTECH GmbH. The obtained lens was further dried in a curing oven for 3 hrs at 50° C.

II CHARACTERIZATION OF THE SPECTACLE LENSES ACCORDING TO THE EXAMPLES AND COMPARATIVE EXAMPLES

IIa Determination of Contact Angle

[0200] The water contact angle of the spectacle lenses according to the examples and comparative was measured with an OCA20 contact angle meter from Dataphysics; deionized water was used as liquid. Droplet size 2 μL.

IIb Antibacterial and/or Antiviral Effect

[0201] The antibacterial effect of the spectacle lenses of the examples and comparative example has been assessed according to the following procedure: [0202] Spectacle lens sample preparation: the spectacle lenses according to the examples and the comparative examples were firstly sterilized by a dry-heat sterilizer at 170° C. for 60 mins and then further sterilized in an autoclave at 121° C. for 15 mins. The control samples were made of medical grade polyethylene and sterilized using the same procedure. [0203] Bacterial preparation and test inoculum: the selected bacteria were transferred from the stock culture to the slant culture medium and incubated for 24 hrs at 35° C., afterwards, this culture is further transferred to a fresh slant culture medium for another 24 hrs at 35° C. Further, the bacterial culture is countered to obtain the desired concentration. [0204] Inoculation and incubation: certain volume of test inoculum was added to the test sample surface for incubation [0205] Recovery of bacteria: after 24 hr, the bacteria was recovered from the test sample surface and counted. The antibacterial activity and bacterial reduction ratio was calculated according to equation: [0206] Reduction ratio=(C.sub.t−T.sub.t)/C.sub.t
where [0207] C.sub.t=number of viable bacterial recovered from untreated test specimen (control sample) after 24 hr and [0208] T.sub.t=number of viable bacterial recovered from treated test specimen (lens sample) after 24 hr, [0209] Antibacterial activity=U.sub.t−A.sub.t
where [0210] U.sub.t=the average of the common logarithm of the number of viable bacterial recovered from untreated test specimen (control sample) after 24 hrs [0211] A.sub.t=the average of the common logarithm of the number of viable bacterial recovered from treated test specimen (lens sample) after 24 hrs.

[0212] For assessing the antiviral effect of the spectacle lenses of the examples and comparative example, the following procedure has been applied: [0213] Spectacle lens sample preparation: the spectacle lenses according to the examples and comparative examples were sterilized by a solution of 70% alcohol/30% water and ready as “test sample”
Control: the control was to ensure the virus activity when it was not treated with the test samples. In the control a 1 ml plastic vial made of medical grade polyethylene that was sterilized using the same procedure as the lens samples, [0214] Virus preparation: the selected virus was diluted with the maintenance medium (DMEM: Dulbecco's Modified Eagle Medium) contains 10% FBS (Fetal Bovine Serum) to obtain a virus suspension of 1000 PFU (Plaque forming units). [0215] Cell preparation and growth: the selected host cell was planked onto a six well plastic plate and 1 ml of DMEM growth medium contains 10% FBS was added for cell growth. The growth period took 12 to 16 hrs. Afterwards, the growth medium was removed and 500 μl of maintenance medium was added. [0216] Treatment and recovery of virus: for test samples, 100 μl of virus suspension was added to the spectacle lens surface for treatment of 24 hrs. Afterwards, the suspension was recovered from the spectacle lens surface and added to the six wells plastic plate. The spectacle lens was further washed for 3 times with 50 μl maintenance medium to fully recover the virus. For the control, 100 μl of virus suspension was added to the plastic vial for 24 hrs. Afterwards, the suspension was recovered from the vial and added to the six wells plastic plate. The vial was further washed for 3 times with 50 μl maintenance medium to fully recover the virus. [0217] Cell infection: the recovered virus stays in the six wells plastic plate for an infection of 24 hrs. [0218] Determine cell infection rate: the cell in the six wells plastic plate was collected and put under a flow cytometry to determine the cell infection rate. [0219] The virus viability was obtained by the calculating infection rate normalize to the control (control =100%).

[0220] The spectacle lenses according to the examples and the comparative examples has been assessed with respect to the bacteria or viruses as shown in table 2 below.

TABLE-US-00002 TABLE 2 Antibacterial Antibacterial Virus Example/ Clean Water reduction ratio - activity - viability - Comparative Biocidal Coat Contact staphylococcus staphylococcus Herpes example component material Angle aureus aureus virus Comparative — Cotec 117° 41.3% 0.2 90% example 1 900 Example 1 Ag.sub.2O Cotec 115° >99.9% 6.2 <1% Co- 900 deposition Example 2 CuO Cotec 112° >99.9% 5.6 20% Co- 900 deposition Example 3 0.1 mol/L Cotec 116° >99.9% 5.6  5% Diffusion AgNO.sub.3 in 900 water Example 4 0.5 mol/L Cotec 117° >99.9% 5.6 4.2%  Diffusion AgNO.sub.3 in 900 water Example 5 0.1 mol/L Cotec 115° >99.9% 5.6 10% Dip coating AgNO.sub.3 in Duralon ethanol

[0221] 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.

[0222] 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.

[0223] 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.