U.S. patent application number 13/126367 was filed with the patent office on 2011-10-06 for bi-layer adhesive for lens lamination.
Invention is credited to Arnaud Glacet, Peiqi Jiang, Bruce Keegan.
Application Number | 20110242657 13/126367 |
Document ID | / |
Family ID | 41445670 |
Filed Date | 2011-10-06 |
United States Patent
Application |
20110242657 |
Kind Code |
A1 |
Glacet; Arnaud ; et
al. |
October 6, 2011 |
BI-LAYER ADHESIVE FOR LENS LAMINATION
Abstract
A method for laminating a film on to an optical article and a
bi-layer adhesive for use in the method. The bi-layer adhesive
includes a latex adhesive layer or a specific silane adhesive and
an HMA layer sequentially disposed on the film and dried to form a
solid layer of uniform thinness throughout to provide optical
quality. Various types of films may be employed to provide an
optical function. Following optional pre-treatment steps, the
adhesives are coated on to the film. An optical hot press technique
is used to deliver heat and pressure over a short period of time to
form a functionally-enhanced optical article with high adhesive
strength.
Inventors: |
Glacet; Arnaud; (Clearwater,
FL) ; Jiang; Peiqi; (Tarpon Springs, FL) ;
Keegan; Bruce; (Seminole, FL) |
Family ID: |
41445670 |
Appl. No.: |
13/126367 |
Filed: |
November 2, 2009 |
PCT Filed: |
November 2, 2009 |
PCT NO: |
PCT/US2009/062959 |
371 Date: |
June 13, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12264376 |
Nov 4, 2008 |
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13126367 |
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Current U.S.
Class: |
359/492.01 ;
156/272.6; 156/275.5; 156/327; 156/329; 156/331.7; 216/34; 359/642;
428/336; 428/343; 428/355EN; 428/355N |
Current CPC
Class: |
Y10T 428/2878 20150115;
Y10T 428/28 20150115; Y10T 156/1002 20150115; G02B 5/3041 20130101;
G02B 1/041 20130101; Y10T 428/31551 20150401; C09J 175/04 20130101;
Y10T 428/2896 20150115; Y10T 428/265 20150115; B29D 11/0073
20130101; C09J 119/02 20130101 |
Class at
Publication: |
359/492.01 ;
428/343; 428/355.EN; 428/336; 428/355.N; 359/642; 156/329; 156/327;
156/272.6; 216/34; 156/331.7; 156/275.5 |
International
Class: |
G02B 1/08 20060101
G02B001/08; B32B 7/12 20060101 B32B007/12; B32B 3/00 20060101
B32B003/00; G02B 1/10 20060101 G02B001/10; B32B 37/02 20060101
B32B037/02; B32B 37/06 20060101 B32B037/06; B32B 37/12 20060101
B32B037/12; B32B 38/10 20060101 B32B038/10; B32B 37/14 20060101
B32B037/14 |
Claims
1. A functionalized optical element comprising: an optical base
element; and a functionalized layered structure incorporating at
least one functional layer which is glued directly to the optical
base element to form a functionalized optical element, wherein the
optical element further includes a bi-layer adhesive structure
which comprises a layer of latex adhesive or
gamma-aminopropyltriethoxysilane adhesive disposed on a surface of
said functionalized layered structure and a layer of hot melt
adhesive (HMA) disposed between the latex layer or the
gamma-aminopropyltriethoxysilane layer and the optical base element
to form a bi-layer adhesive that permanently retains the
functionalized layered structure on the optical base element while
maintaining optical quality.
2. The functionalized optical element of claim 1, wherein said
latex adhesive layer comprises a material selected from the group
consisting of an acrylic latex, a (meth)acrylic latex, a
polyurethane latex, a core/shell latex, and combinations
thereof.
3. The functionalized optical element of claim 2, wherein said
latex layer comprises a dry, solid layer of between 0.5 microns and
10 microns thick with a uniform thickness throughout to provide
optical quality.
4. The functionalized optical element of claim 2, wherein said
latex layer comprises a dry, solid layer of between 1.0 microns and
5.0 microns thick with a uniform thickness varying by less than 0.5
microns throughout to provide optical quality
5. The functionalized optical element of claim 1, wherein said hot
melt adhesive layer includes one or more of a UV curable HMA, a UV
curable monomer, a thermal curable HMA, and a thermal curable
monomer.
6. The functionalized optical element of claim 1, wherein said hot
melt adhesive layer includes one or more of a polymer HMA,
thermoplastic polymer HMA, and a colloid.
7. The functionalized optical element of claim 1, wherein said hot
melt adhesive layer includes a heat-activatable polyurethane
adhesive.
8. The functionalized optical element of claim 7, wherein the HMA
layer comprises a dry, solid layer between 1.0 microns and 20
microns with a uniform thickness throughout to provide optical
quality.
9. The functionalized optical element of claim 8, wherein the HMA
layer comprises a dry, solid layer between 1.5 microns and 10
microns with a uniform thickness varying by less than 0.5 microns
throughout to provide optical quality.
10. The functionalized optical element of claim 1, wherein the
functionalized layered structure includes one or more layers
selected from the group consisting of: an optical function layer;
an optical structured layer; a Fresnel lens structure; a polarizing
layer; a photochromic layer; a hard coat layer; a top coat layer;
an anti-fog layer; an anti-smudge layer; an anti-reflective layer;
and an antistatic layer.
11. The functionalized optical element of claim 1, wherein the
functionalized layered structure includes one of a polarizing film,
a TAC/PVA/TAC polarizing film and a PET polarizing film.
12. The functionalized optical element of claim 1, wherein the
optical base element is a thermoplastic optical base element
selected from the group consisting of a finished lens, a
semi-finished lens, a PAL lens, an afocal lens, a plano lens, a
unifocal lens, and a multifocal lens.
13. The functionalized optical element of claim 1, wherein the
optical base element is a thermoset optical base element selected
from the group consisting of a finished lens, a semi-finished lens,
a PAL lens, an afocal lens, a plano lens, a unifocal lens and a
multifocal lens.
14. The functionalized optical element of claim 1, wherein the
optical base element is a polycarbonate lens, and wherein the
functionalized layered structure includes a polarizing film and
wherein the latex adhesive is a polyurethane latex adhesive, and
wherein the HMA is a heat-activatable polyurethane adhesive which
collectively form a laminated polarized ophthalmic lens.
15. The functionalized optical element of claim 1, wherein the
optical base element is a high refractive index lens comprising a
polyurethane polymer formed from polyisocyanate and polythiol, and
wherein the functionalized layered structure includes a polarizing
film and wherein the latex adhesive is a polyurethane adhesive, and
wherein the HMA is a heat-activatable polyurethane adhesive, which
collectively form a laminated polarized ophthalmic lens.
16. A method for manufacturing a functionalized optical element
comprising the following steps: providing (10) an optical base
element; providing (10) a functionalized layered structure that
includes at least one functional layer; first coating (16a) a layer
of latex adhesive or a layer of gamma-aminopropyltriethoxysilane
adhesive onto one surface of said functionalized layered structure;
second coating (18a) a layer of hot-melt adhesive onto the dried
latex adhesive layer or the dried gamma-aminopropyltriethoxysilane
adhesive layer to form a uniformly thin bi-layer adhesive lamina of
optical quality; and hot pressing (20) the functionalized layered
structure against the optical base element with the second HMA
coating layer in contact with a surface of the optical base element
to form a functionalized optical element with high adhesive
strength.
17. The method of claim 16, wherein the optical base element has a
base curve, and prior to said first coating step, the method
further includes the step of: thermoforming the functionalized
layered structure to a curve that is close to the base curve.
18. The method of claim 16, wherein prior to said first coating
step, the method further includes the step of: surface treating
(13) the functionalized layered structure with a corona discharge
and/or a caustic treatment.
19. The method of claim 16, wherein said first coating step
comprises spin coating a liquid polyurethane latex adhesive to a
final dry thickness of between 0.5 microns and 10 microns.
20. The method of claim 16, wherein said second coating step
comprises spin coating a liquid polyurethane HMA to a final dry
thickness of between 1 micron and 20 microns.
21. The method of claim 16, further including the following step:
exposing the functionalized optical element to UV radiation.
22. The method of claim 16, wherein said first coating step
comprises spin coating a liquid polyurethane latex adhesive to a
final dry thickness of between 1.0 microns and 5.0 microns; and
wherein said second coating step comprises spin coating a liquid
polyurethane HMA to a final dry thickness of between 1.5 microns
and 10 microns to provide a bi-layer adhesive lamina at optical
quality with a uniform thickness varying by less than 0.5 microns
across the surface.
23. The method of claim 22, wherein the functionalized layered
structure includes one or more layers selected from the group
consisting of: an optical function layer; an optical structured
layer; a Fresnel lens structure; a polarizing layer; a photochromic
layer; a hard coat layer; a top coat layer; an anti-fog layer; an
anti-smudge layer; an anti-reflective layer; and an anti-static
layer.
24. The method of claim 22, wherein the functionalized layered
structure includes a polarizing film.
25. The method of claim 22, wherein the optical base element is a
thermoplastic optical base element selected from the group
consisting of a finished lens, a semi-finished lens, a PAL lens, an
afocal lens, a plano lens, a unifocal lens, and a multifocal
lens.
26. The method of claim 22, wherein the optical base element is a
thermoset optical base element selected from the group consisting
of a finished lens, a semi-finished lens, a PAL lens, an afocal
lens, a plano lens, a unifocal lens, and a multifocal lens.
27. The method of claim 22, wherein the optical base element is a
polycarbonate lens, and wherein the functionalized layered
structure includes a polarizing film which collectively form a
laminated polarized ophthalmic lens.
28. The method of claim 22, wherein the optical base element is a
high refractive index lens comprising a polyurethane based polymer
formed from polyisocyanate and polythiol, and wherein the
functionalized layered structure includes a polarizing film which
collectively form a laminated polarized ophthalmic lens.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a method for laminating a
functionalized layered structure to an optical base element with a
bi-layer adhesive and the resulting functionalized optical
element.
[0003] 2. The Prior Art
[0004] Various films and coatings are combined with optical
elements to enhance their performance. Adhesion between polarized
films and plastic lenses has been a long standing problem within
the industry. The selection of one adhesive always represents a
compromise between ease of use, mechanical integrity and optical
quality.
[0005] One approach is detailed in WO2006/082105 which employs a
latex glue in a film transfer process. In EP 1868798 an HMA glue
for a film transfer process is described. In WO2002/096521 a
polarized film is laminated with a pressure sensitive adhesive. In
a mechanical approach described in US2007/0195262, a complex
support is used to warp the film during lamination to improve
adhesion.
[0006] However, the techniques previously disclosed have a number
of drawbacks, mainly due to low adhesion or low mechanical
performance. Attempts to cure these defects have marginally
improved adhesion strength with a loss of optical quality.
Accordingly, there is a need to provide a method of adhesive
application which compensates for the different material properties
of the film and lens surface to provide high adhesive strength in a
basic lamination process.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the present invention to
improve both the mechanical and optical properties of laminated
functionalized optical elements.
[0008] It is a further object to present two different adhesives
and methods for applying same to provide a bi-layer adhesive that
can be readily employed in a variety of optical hot press
methods.
[0009] It is another object to apply the different adhesives in
such a manner as to form a uniformly thin layer at optical
quality.
[0010] These and other objects according to the invention are
achieved by a functionalized optical element that includes an
optical base element and a functionalized layered structure
incorporating at least one functional layer which is glued directly
to the optical base element to form a functionalized optical
element. A bi-layer adhesive structure is disposed between the
optical base element and the functionalized layered support. The
bi-layer adhesive structure includes a layer of latex adhesive
disposed on a surface of said functionalized layered structure and
a layer of hot melt adhesive disposed between the latex layer and
the optical base element to form a bi-layer adhesive that
permanently retains the functionalized layered structure on the
optical base element while maintaining optical quality. The
bi-layer adhesive structure may be includes a layer of a specific
silane adhesive, more particularly a gamma
aminopropyltriethoxysilane disposed on a surface of said
functionalized layered structure and a layer of hot melt adhesive
disposed between the silane adhesive layer and the optical element
to form a bi-layer adhesive that permanently retains the
functionalized layered structure on the optical base element while
maintaining also optical quality.
[0011] The latex adhesive layer comprises a material selected from
the group consisting of an acrylic latex, a (meth)acrylic latex, a
polyurethane latex, a core/shell latex, and combinations thereof.
The latex layer comprises a dry, solid layer of between 0.5 microns
and 10 microns thick with a uniform thickness throughout to provide
optical quality. In a preferred embodiment the latex layer is
between 1.0 microns and 5.0 microns thick with a uniform thickness
varying by less than 0.5 microns throughout to provide optical
quality.
[0012] The hot melt adhesive layer includes one or more of a UV
curable HMA, a UV curable monomer. a thermal curable HMA, and a
thermal curable monomer, a polymer HMA, a thermoplastic polymer
HMA, and a colloid. In a preferred embodiment, the HMA is a
heat-activatable polyurethane adhesive. The HMA layer comprises a
dry, solid layer between 1.0 microns and 20 microns with a uniform
thickness throughout to provide optical quality. In a preferred
embodiment the HMA layer is between 1.5 microns and 10 microns with
a uniform thickness varying by less than 0.5 microns throughout to
provide optical quality.
[0013] Various types of functionalized layered structure includes
one or more layers selected from the group consisting of: an
optical function layer; an optical structured layer; a Fresnel lens
structure; a polarizing layer; a photochromic layer; a hard coat
layer; a top coat layer; an anti-fog layer; an anti-smudge layer;
an anti-reflective layer; and an anti-static layer. In a preferred
embodiment, the functionalized layered structure includes one of a
polarizing film. a PET polarizing film. Polarizing film comprises
notably a PVA layer sandwiched between two identical or different
layers of material selected from cellulose triacetate (TAC),
cellulose acetate butyrate (CAB), polycarbonate (PC) and
polyurethane (PU). As example of polarizing film, TAC/PVA/TAC
represents one of the more common types.
[0014] The optical base element is a thermoplastic or thermoset
optical base element selected from the group consisting of a
finished lens, a semi-finished lens, a PAL lens, an afocal lens, a
plano lens, a unifocal lens, and a multifocal lens.
[0015] A preferred ensemble is an optical base element comprising a
polycarbonate lens, and wherein the functionalized layered
structure includes a polarizing film and wherein the latex adhesive
is a polyurethane latex adhesive, and wherein the HMA is a
heat-activatable polyurethane adhesive, which collectively form a
laminated polarized ophthalmic lens.
[0016] Another preferred ensemble is an optical base element
comprising a high refractive index lens comprising a polyurethane
polymer formed from polyisocyanate and polythiol, and wherein the
functionalized layered structure includes a polarizing film and
wherein the latex adhesive is a polyurethane adhesive, and wherein
the HMA is a heat-activatable polyurethane adhesive, which
collectively form a laminated polarized ophthalmic lens.
[0017] Another aspect of the invention includes a method for
manufacturing a functionalized optical element comprising the
following steps. An optical base element and a functionalized
layered structure that includes at least one functional layer is
provided. A layer of latex adhesive is firstly coated onto one
surface of said functionalized layered structure. A layer of
hot-melt adhesive is secondly coated onto the dried latex adhesive
layer to form a uniformly thin bi-layer adhesive lamina of optical
quality. The functionalized layered structure is hot pressed
against the optical base element with the second HMA coating layer
in contact with a surface of the optical base element to form a
functionalized optical element with high adhesive strength.
[0018] The functionalized layered structure is thermoformed to a
curve that is close to the base curve of the optical base element,
prior to lamination. An additional pre-treatment step may include
surface treating the functionalized layered structure with a corona
discharge and/or a chemical treatment like a caustic treatment.
Depending on the material of the optical base element, an optional
pre-treatment step may also be carried out on the optical base
element. Such pre-treatment could also be a UV or plasma
treatment.
[0019] The first coating step comprises spin coating a liquid
polyurethane latex adhesive to a final dry thickness of between 0.5
microns and 10 microns. The second coating step comprises spin
coating a liquid polyurethane HMA to a final dry thickness of
between 1 micron and 20 microns. The laminated functionalized
optical element may be exposed to heat and UV radiation. It is
important to mention that the quality of adhesion is very dependent
on how bi-adhesive layer is formed. Then the inventors should
undersigned that coating the bi-adhesive layer onto the
functionalized layer then hot-pressed it to the optical base
element provide a high adhesion. On the contrary when a bi-adhesive
layer is applied to the optical base element which is then
hot-pressed onto the functionalized layer, the adhesion is very
poor.
[0020] In a preferred embodiment, the first coating step comprises
spin coating a liquid polyurethane latex adhesive to a final dry
thickness of between 1.0 microns and 5.0 microns; and wherein said
second coating step comprises spin coating a liquid heat activable
polyurethane adhesive HMA to a final dry thickness of between 1.5
microns and 10 microns to provide a bi-layer adhesive lamina at
optical quality with a uniform thickness varying by less than 0.5
microns across the surface. In a preferred embodiment, the optical
base element is a polycarbonate lens, and wherein the
functionalized layered structure includes a polarizing film which
collectively form a laminated polarized ophthalmic lens.
BRIEF DESCRIPTION OF THE DRAWING
[0021] The advantages, nature, and various additional features of
the invention will appear more fully upon consideration of the
illustrative embodiments now to be described in detail in
connection with accompanying drawing:
[0022] FIG. 1 is a flowchart showing various steps according to an
embodiment of the lamination method according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] In the manufacture and customization of optical elements,
the properties of the optical base element are frequently enhanced
by laminating a functionalized layered structure onto a surface of
the optical base element. Within the category of adhesive based
lamination methods, various techniques have been proposed which
include a single layer of thermal curable glue, UV curable glue,
hot melt adhesives (HMA) or pressure sensitive adhesives (PSA). All
of the prior art techniques have either optical or mechanical
performance issues due to un-even thickness of the glue layer, a
lack of good adhesion or low mechanical properties of the adhesive
layer.
[0024] The principle of this invention is to use a bi-layer
adhesive that is applied to the functionalized layered structure in
stages before laminating to the lens. The first adhesive layer is
latex which can bond strongly to the functionalized layered
structure. A specific silane adhesive, gamma
aminopropyltriethoxysilane, may be used as first adhesive layer in
the place of latex adhesive. The second adhesive layer is a hot
melt adhesive (HMA) which can bond strongly to the lens. By using
the combination of these two layers, the functionalized layered
structure can be strongly bonded to the lens by a variety of
methods in a very short time. The latex and HMA layers can be
applied to the functionalized layered support in liquid form, for
example, via spin coating or dip coating, to obtain a very thin,
and uniformly thick adhesive layer of optical quality. To improve
the adhesion between the latex and the functionalized layered
support, optional pre-treatment steps can be performed, such as
corona or caustic treatment. The functionalized layered support may
be thermoformed to a shape close to the base curve of the optical
base element. In addition, the surface of the functionalized
layered support may be subjected to a corona discharge treatment or
a chemical treatment more specifically a caustic treatment. Such
pre-treatment may also be applied to the optical base element.
[0025] The bi-layer adhesive is useful in laminating to optical
base elements made from plastic which could be thermoplastic or
thermoset material. The base elements could be made from any
suitable optical thermoset material including polyurethanes, CR-39.
and high index polyurethanes, for example 1.67. An exemplary list
of plastics includes polycarbonate. polyamide, polyimide,
polysulfone, copolymers of polyethyleneterephthalate and
polycarbonate, polyolefine, homopolymers and copolymers of
diethylene glycol bis(allylcarbonate), homopolymers and copolymers
of (meth)acrylic monomers, homopolymers and copolymers of
thio(meth)acrylic monomers, homopolymers and copolymers of
urethane, homopolymers and copolymers of thiourethane, epoxy
homopolymers and copolymers, and episulfure homopolymers and
copolymers. In a preferred embodiment the optical base element
comprises an injection molded thermoplastic lens, for example,
polycarbonate, or as thermoset material high refractive index 1.67
material comprising a polyurethane polymer formed from
polyisocyanate and polythiol.
[0026] The bi-layer adhesive is useful in laminating to either the
convex or the concave side of optical base elements, for example,
ophthalmic lenses. The lenses may be sunglasses, plano lenses,
visors, or prescription (Rx) lenses. Such lenses may include
finished lenses (F), semi-finished lenses (SF), progressive
addition lenses (PAL), multifocal lenses, unifocal lenses and
afocal lenses. The optical base element may be clear, tinted or
dyed.
[0027] The functionalized layered support may comprise a film or
coating that contributes an optical or performance function to the
optical base element. In addition, the functionalized layered
support may comprise a multi-functional film or coating that
contributes at least one optical function, at least one performance
function, or combinations thereof. Examples of optical functions
include polarizing and photochromically enabling optical elements.
Such functions are realized by polarized films, microstructured
films as described for example in WO2006/013250, photochromic films
and photochromic coatings. Polarizing materials are commercially
available as polyethyleneterephthalate film (PET) or
polyvinylacetate film (PVA) encapsuled either by two cellulosed
films of two major types--cellulose triacetate (TAC) films and
cellulose acetate butyrate (CAB) films--or polycarbonate or
polyurethane films. Other functionalized layer films could be PET
which bears an antireflective coating, hard coat, or any other
top-coat, such as an antistatic coating, anti-fog or anti-smudge
coating, and a polarized coating or layers. In a preferred
embodiment of the invention, a polarizing film is adhered to an
optical base element to provide a polarized lens.
[0028] Examples of performance functions include hard coating,
impact resistant, anti-fog, anti-static, anti-smudge and
anti-reflective. Such functions are realized in the form of hard
multi-coat (HMC) films which have several layers capped by a top
coat film.
[0029] The functionalized layered element will have one surface
designated for contact with the optical base element. Following any
optional pre-treatment steps, this contact surface will receive a
layer of latex adhesive, applied so as to achieve optical quality
and good bond to the functionalized layered element. The various
application processes shall be described in greater detail below.
The application step involves drying the latex layer so that a
thin, solid layer of latex remains. The dried latex layer shall be
of sufficient purity to display color, transmission and clarity at
a level consistent with optical quality ophthalmic lenses. In
addition, the latex layer shall possess a uniform thickness across
its surface. Uniform thickness refers to a layer which has a
consistent thickness that varies by less than 0.01 microns to 0.5
microns. According to the invention, the latex layer shall be
applied to a thickness of between about 0.5 and about 10 microns.
In a preferred embodiment, the latex layer shall have a thickness
of between 1.0 microns to 5.0 microns. For layers about 0.5 microns
thick, the variation in thickness should be less than 0.1 microns.
For layers about 5.0 microns thick, the variation in thickness
should be less than 0.5 micron.
[0030] Latex materials meeting such requirements that may be used
in the invention include polyurethane latex, acrylic latex, and
core/shell latex. For example, (meth)acrylic such as acrylic
latexes commercialized under the name Acrylic latex A-639 by
Zeneca, polyurethane latexes such as the latexes commercialized
under the names NV-213, W-240 and W-234 by Baxenden, or a
polyurethane latex based on this commercialized product.
Preferably, polyurethane latexes are utilized in the practice of
the invention and more particularly such latexes as described in
U.S. Pat. No. 5,316,791. Other preferred latexes are core/shell
latexes such as those described in U.S. Pat. No. 6,503,631 and U.S.
Pat. No. 6,489,028. Other preferred latexes are
alkyl(meth)acrylates such as butylacrylate or
butyl(meth)acrylate.
[0031] The latex materials may optionally be blended with additives
to adjust the rheological. mechanical or optical properties
thereof. For example, a coupling agent may be added to the latex
material to promote adhesion to the functionalized layered support
as described in U.S. Pat. No. 6,562,466. The latex material may
include a cosmetic or photochromic dye or color dye or functional
materials, such as anti-static materials, for example, as described
in EP 1161512, U.S. Pat. No. 6,770,710 and U.S. Pat. No.
6,740,699.
[0032] As mentioned hereinbefore, in place of latex, it is possible
to use as adhesive a specific silane derivative which is
represented by gamma aminopropyltriethoxysilane. This compound is
notably commercialized by Momentive Performance Material under the
name Silquest A-1100. In the present invention, A-1100 solution was
made by adding 6.25% of A-1100 by volume to deionized water, such
solution being spin-coated on the functionalized layer.
[0033] Second HMA Layer. After the latex layer is dry. solid and
stable, a hot melt adhesive (HMA) material is applied over the
latex layer, in a manner to achieve optical quality. The various
application processes shall be described in greater detail below.
The application step involves drying the HMA so that a thin, solid
layer of HMA remains. The dried HMA layer shall be of sufficient
purity to display color, transmission and clarity at a level
consistent with optical quality ophthalmic lenses. In addition, the
HMA layer shall possess a uniform thickness across its surface.
Uniform thickness refers to a layer which has a consistent
thickness that varies by less than 0.1 microns to 0.5 microns.
According to the invention, the HMA layer shall be applied to a
thickness of between about 1.0 and about 30 microns. in a preferred
embodiment, the latex layer shall have a thickness of between 1.5
microns to 15 microns. For layers about 1.5 microns thick, the
variation in thickness should be less than 0.5 microns. For layers
about 10.0 microns thick, the variation in thickness should be less
than 1.0 micron.
[0034] HMA materials meeting such requirements that may be used in
the invention include polyurethane based heat-activatable adhesive
materials. These materials are characterized as aqueous anionic
dispersions of high molecular weight polyurethane. One type that
kind of HMA is commercially available from Bayer are referred to as
Dispercoll.RTM. U 42 and KA-8758. Bond Polymers International LLC
commercialized also two waterborne polyurethane dispersions which
are usable in the present invention: Bondthane.RTM. UD-104 and
Bondthane.RTM. UD-108. The HMA materials may optionally be blended
with additives to adjust the rheological, mechanical or optical
properties thereof. For example, additives, such as water or
colloid silica or surfactant, can be added to the HMA formulation
to facilitate crosslinking to improve the hardness and durability.
A suitable colloid could be LUDOX.RTM. SM-30 colloidal silica, 30
wt. % suspension in H2O. The percentage of colloid in HMA could be
in the range of 1-20 wt % and with a preferred range of 2-10 wt %.
The HMA materials in this invention can also be any known polymer
for formulating a hot melt adhesive, but is preferably a
thermoplastic polymer. Thus, HMA polymer can be chosen amongst
polyolefins, polyamides, polyurethanes, polyurethane/ureas,
polyvinypyrrolidones, polyesters, polyesteramides, poly(oxazolines)
and poly(meth)acrylic systems. Suitable polyolefines are disclosed
in particular U.S. Pat. No. 5,128,388. Preferred polyolefines are
block thermoplastic elastomers such as block elastomers comprising
polystyrene blocks, polybutadiene blocks, polyisoprene blocks or
ethylene-butylene copolymer blocks. Besides, any kinds of
UV/thermal curable HMA or HMA blend with UV/thermal curable
monomers adhesive layers can be used in this invention as a second
adhesive layer.
[0035] The bi-layer adhesive according to the invention comprises
dry latex adhesive layer disposed between a functionalized layered
structure and a dry polyurethane HMA layer. Under various processes
that provide heat, pressure and time, the bi-layer adhesive
operates to adhere the functionalized layered structure to an
optical base element. The bi-layer adhesive comprises a uniformly
thin layer at optical quality. We refer to this construct as a
lamina, meaning an ultra thin layer composed of two different
adhesives with uniform thickness thereby providing optical quality.
The bi-layer adhesive provides a unique combination of materials
that address disparate material properties between the
functionalized layered structure and the optical base element. The
latex layer typically exhibits good adhesion to the functionalized
layered support, or to the optical base element in one surface
alone during wet coating and to dry stage. However, it has poor
adhesive to lens when re-activated by heating and pressure after
drying on the TAC film. The HMA layer, in contrast, has variable
adhesive strength to lens when re-activated after drying. But it
does not have a good adhesion as the latex layer to the film during
wet and dry stage. More particularly, the HMA has limited adhesive
strength to the surface of the functionalized layered structure.
Surprisingly, it was discovered that treating the functionalized
layered structure with a latex adhesive or specific silane layer,
the HMA would now have high adhesive strength on both the lens and
the functional film. Accordingly, the combination of the latex
layer and the HMA layer overcomes the problems associated with
adhering different materials together to provide a functionalized
optical element with both optical quality and high mechanical
strength.
[0036] As can be seen in the flowchart of FIG. 1, there are shown
various steps for the manufacturing of a functionalized optical
element. While one optional pre-processing step is shown, there may
be two or more pre-processing steps involved in a particular
embodiment of the invention. Likewise, other steps may be
introduced at various stages and the claimed method is intended to
cover those in a non-limiting fashion.
[0037] In step 10, there is provided a functionalized layered
structure. The functionalized layered structure may have more than
one layer. The functionalized layered support can include a
combination of functional layers and non-functional layers. The
types and categories of functional layers are described above in a
non-limiting exemplary listing. An optical base element is also
provided. The types and categories of optical base elements are
described above in a non-limiting exemplary listing.
[0038] In step 13, optional pre-processing steps may be employed.
The functionalized layered structure may be pre-processed to
improve the adhesion of the latex adhesive thereto. For example,
the facing surface may be exposed to a corona discharge treatment
or caustic treatment. Alternatively, or in addition, the
functionalized layered structure may be thermoformed to a curve
that is similar to the base curve of the facing surface of the
optical base element. If thermoforming is employed, the
functionalized layered support will be thermoformed to a curve
within about 1 diopter of the base curve of the optical base
element. Both thermoforming and an adhesion improvement step may be
carried out, in any order.
[0039] Step 16 encompasses a latex adhesive application step to
deposit the latex material onto the functionalized layered
structure. Prior to application, an optional blending step 15 may
be provided. The latex material may be combined with an additive to
enhance rheological, mechanical or optical properties. For example,
a coupling agent may be blended with the latex material in order to
promote adhesion with the functionalized layered structure. A
cosmetic dye or photochromic dye or a color dye may be blended with
the latex material. Two or more compatible additives may be
employed.
[0040] In step 16a, the latex adhesive is applied in a liquid form
to the facing surface of the functionalized layered structure. The
latex is then dried 16b to form a uniformly thin, solid layer at
optical quality. The latex adhesive may be deposited by various
application methods known within the optics industry to provide
thin even coating layers, for example, spin coating or dip coating.
The wet latex layer is subjected to a drying step 16b, which may
include the introduction of heat. Drying may take place within a
controlled atmosphere involving clean, dry air.
[0041] Step 18 encompasses an HMA application step to deposit an
HMA material onto the dried latex layer. In step 18a, the HMA is
applied in a liquid form to the facing surface of the
functionalized layered structure, on top of the latex layer. The
HMA is then dried 18b to form a uniformly thin, solid layer at
optical quality. The HMA may be deposited by various application
methods known within the optics industry to provide thin even
coating layers, for example, spin coating or dip coating. The wet
HMA layer is subjected to a drying step 18b, which may include the
introduction of heat. Drying may take place within a controlled
atmosphere involving clean, dry air.
[0042] The dried bi-adhesive layer is then placed in contact with
the facing surface of the optical base element, and subjected to a
lamination step 20. Generally, lamination involves a combination of
pressure and heat applied over a short period of time. It may also
include exposing the hot pressed ensemble to UV radiation, to cure
a UV curable adhesive, if present. Various systems and processes
are known within the optics industry to provide a precise and
uniform amount of pressure across optical surfaces. An exemplary
listing of lamination systems that may be employed with the
invention include the following. So-called "hot press" or "hot-air"
systems may be used for lamination. An accumulator device having a
lens support may be set-up to apply pressure, with the set-up then
placed into an oven. An FST (Front Side Transfer) process may be
used, as described in EP 1917136. An BST (Back Side Transfer)
process may be used, as described in WO2003/004255. Other HMC film
lamination systems may be used. A process, as described in
WO2006/105999, may be used with the addition of heat. Injection
molded lenses can be laminated in-mold, by placing the
functionalized layered structure into the open mold opposite of
where the lens is retained, and then closing the mold to apply heat
and pressure. We define Post Injection Press Coating (PIPC) (as
described in WO2007/085910) as an in-mold lamination system
utilizing the heat and pressure from an injection mold to laminate
a film onto a just molded lens. A basic laminating process would
involve applying pressure greater than 10 psi, heating to at least
60 degrees C., and holding for at least about 2 to 5 minutes. Any
one of these parameters could be adjusted higher or lower depending
on the overall process conditions and the total amount of energy
being introduced into the lamination.
[0043] The resulting functionalized optical element has good
mechanical properties as gauged by high adhesive strength of the
functionalized layered support to the optical base element. Samples
of the resulting functionalized optical element are able to
withstand conventional lens processing and demanding adhesion tests
without delaminating. To conduct such adhesion tests, known as the
peel force test, a 25.4 mm wide band is cut in the laminated film.
The lens is solidly attached to a platform. A force is applied at
90 degrees to peel the band of film from the lens. The peeling
speed is 2.54 mm/min. The force required to maintain the peeling
speed is recorded. The resulting functionalized optical element has
good optical properties due to the selection of adhesives and their
precise application methods. Several examples of the inventive
method will be presented below along with comparative examples
which demonstrate the inventions utility.
Examples 1 & 2
[0044] Adhesion comparison test on TAC/PVA/TAC film between a
urethane latex based on W-234 from Baxenden and HMA-U42: TAC film
was corona treated firstly, then the films were spin coated with
either the urethane latex solution or U42 in the spin conditions of
450-500 rpm for 3-5 seconds and 1000-1500 rpm for 8-10 seconds and
then dried at 60 degrees C. for 10-30 min. After drying and
cooling, the adhesion behavior on TAC film was measured by classic
crosshatch tape method as shown in the following Table 1. The
result showed that Latex has better adhesion score than HMA on a
TAC film.
TABLE-US-00001 TABLE 1 Adhesive test on TAC polarized film
Crosshatch Tape Ex. Adhesives Film Treatment Coating adhesion score
Ex. 1 Latex TAC Corona Spin and dry 0 Ex. 2 HMA/U42 TAC Corona Spin
and dry 5 * Crosshatch tape score 0 means perfect adhesion between
Latex and TAC film and 5 means adhesion failure between U42 and
TAC.
Example 3
[0045] A TAC polarized film (TAC/PVA/TAC) from Onbitt company was
first thermoformed to a curve close to the front side of a
polycarbonate lens. The convex side of the TAC film is subjected to
a corona discharge using Tantec equipment. A urethane latex
adhesive based on W-234 from Baxenden is spin coated onto the
treated film surface, and set to dry for 30 minutes at 60 degrees
C. Next, an HMA solution of Dispercoll.RTM. U 42 is spin coated on
top of the dried latex layer, and set to dry for 10 minutes at 60
degrees C. The dried bi-adhesive layer was then set against a
polycarbonate lens, utilizing an accumulator device having a lens
support and an inflatable silicon membrane. The pressure was slowly
increased to 30 psi to achieve full contact across the entire
surfaces of the film and lens. The accumulator set-up was place in
an oven at 80 degrees C. for 30 minutes.
[0046] After lamination the polarized optical element exhibited
very strong adhesion between the film and the lens. No delamination
occurred even after severe Rx surfacing, polishing and edging. The
adhesion force between the laminated film and lens was measured by
Instron equipment, wherein the 90 degree pull test resulted in a
1.01 N/mm measurement with a pull speed of 2.45 mm/minutes. In the
peel test a force of 22.5 N was recorded to peel the film at 2.54
mm/min.
Comparative Example A
[0047] Example 3 was repeated except the TAC film was only coated
with a single layer of latex adhesive. The resulting functionalized
optical element displayed poor adhesion between the film and the
lens. The film could be easily peeled off from the lens by hand.
The adhesion was too low to be recorded in the peel test.
Comparative Example B
Example 3 was repeated except the TAC film was only coated with a
single layer of HMA of U42. In the peel test a force of 11.5 N was
recorded to peel the film at 2.54 mm/min. This correlates to 50% of
the adhesion force demonstrated in Example 1.
Example 4
[0048] Example 3 was repeated except the lamination step was
conducted by using a small hot press device with a pressure of 26
psi and heating at 90 degrees C. for 5 minutes. The resulting
functionalized optical element had the same good adhesion between
the functionalized layered structure and the optical base element.
In the peel test a force of 20N was recorded to peel the film at
2.54 mm/min.
Example 5
[0049] Example 4 was repeated except the lamination step was
conducted by an post-injection press coating process (PIPC) right
after a lens was injection molded. The mold was opened, with the
lens being retained on one side. The polarized film was loaded into
the other side, against the empty molding insert. The mold was
re-clamped at considerable pressure whereby the residual mold heat
allowed lamination to be completed within 1 to 2 minutes. In this
in-mold lamination process, the molding pressure was about 7 ton
and the temperature was set 140 C. The resulting functionalized
optical element had the same good adhesion between the
functionalized layered structure and the optical base element. In
the peel test a force of 65N was recorded to peel the film at 2.54
mm/min. The increase is attributed to a more intimate bonding
resulting from the very higher temperature and pressure of the
injection mold.
Example 6
[0050] Example 4 was repeated except the Polar TAC film was
replaced by a clear optical glade PET film and the lens was Essilor
high index polyurethane lens materials (Thin & Light 1.6). The
obtained lens has very good adhesion between polyurethane lens and
the PET film and the adhesion peel force is about 31N at 2.54
mm/min speed. The lens did not show any de-lamination between film
and lens during edging and polish process.
Example 7
[0051] A bi-layer adhesive (a urethane latex based on W-234 from
Baxenden and KA8758 of Dispercoll) can also be used to adhere a top
coat and AR & HC coating layers onto the backside of the lens
materials. Firstly, the top coat and AR & HC coating layers
were reversely coated on a polycarbonate carrier (7.0 base curve)
which is described in the U.S. Pat. No. 6,562,466. Then a bi-layer
adhesive was coated as described in Ex. 1. After that, the coated
carrier was laminated onto a -2.00 Orma lens with the back curve of
6.5 under lamination conditions of 30 psi balloon pressure and 80
degrees C. for 4 minutes. After cool down, the carrier was removed
to get a top/AR and HC coating layer transferred to the backside of
the Orma lens. The adhesive between coating layers and lens is very
good with adhesion score of 0 according to the Essilor standard
crosshatch tape test.
Comparative Example C
[0052] Same example as Ex. 7 was repeated except no latex adhesive
layer was used between HMC and Top/AR/HC layer. The obtained lens
showed a good coating layer transferred but did not have a good
adhesion score (score 5) according to the Essilor Standard
crosshatch tape test, which is considered as a coating adhesion
failure.
Comparative Example D
[0053] Same example as Ex. 7 was repeated except no HMA adhesive
layer was used. The obtained lens did not show a good coating
transfer and the adhesion score was 5 according to the Essilor
Standard crosshatch tape test, which is considered as a coating
adhesion failure.
Example 8
[0054] Example 7 was repeated except the pure KA-8758 HMA solution
was replaced by a colloid contained KA-8758 HMA, which is made by a
mixture of KA-8758 solution (93 wt %) and the LUDOX.RTM. SM-30
colloidal silica, 30 wt. % suspension in H2O (7 wt %). The obtained
lens has same good adhesion between lens substrate and the AR &
HC layer as Ex. 7. It has also very good transparency. The most
interesting result by adding silica colloid is that the hardness of
the HMA has been improved so that the surface of the lens is much
harder compared to Example 7. Therefore, the lens would not be
easily scratched by a finger nail.
Examples 9 to 11
Example of TAC Film Treatment
[0055] For different grade or different supplier's polar TAC film,
and for high refractive index polyurethane material for optical
base element, a caustic pretreatment was found every efficient to
bring a good adhesion as shown in the following Examples 9 to 11
and Table 2. The conditions and latex used in such examples are
same than example 3.
TABLE-US-00002 TABLE 2 Pre-treatment test of Sumitomo film for
better adhesion in film lamination Pre-treatment before Polar
adhesive Adhesive Lamination Peel Examples TAC film applied layers
Lens process Force Example Sumitomo Corona Latex + 1.67 5 min at 4N
9 U42 index 90 C. and (=very material 25 PSI poor) Example Sumitomo
IPA Latex + 1.67 5 min at Very 10 U42 index 90 C. and pool material
25 PSI Example Sumitomo 10% NaOH Latex + 1.67 5 min at 18N 11
solution for 2 U42 index 90 C. and (good) min at 50 C. material 25
PSI
[0056] As a result, an effective method of caustic wash by 10% of
NaOH solution was found very good in this bi-adhesive system for
1.67 film lamination product. For further better and consistent
adhesion, the lens could also be caustic washed as the film.
[0057] Example of using specific silane adhesive A-1100 to replace
latex as first adhesive layer: the example 11 was repeated by using
A-1100 to replace the first adhesive layer. A better adhesion force
of 24N was obtained. The laminated lens has no delamination during
coating post-treatment and Rx surfacing.
Example with Different HMA Family:
[0058] The example 11 was repeated by using different HMA material
of UD104 which is from another HMA supplier of Bond Polymer
International Inc. A better adhesion force was obtained with UD104.
In this experiment, all the lens and functionalized layer were
caustic washed. The conditions and latex used in such examples are
same than example 3, and the results are shown in Table 3.
TABLE-US-00003 TABLE 3 Adhesion Test with Different HMA
Functionalized layer TAC film TAC film TAC film First layer latex
latex latex Second layer Bayer U42C U42/UD104 Bond Polymer
(50%/50%) UD104 HMA supplier Bayer Corp Bond Polymer Inc Bond
Polymer Inc Lens Materials 1.67 1.67 1.67 Peel force by 18-20 N
25-30 N 30-35 N Instron Peel by Hand Hard Harder Harder
[0059] The preceding description and examples have proposed
adhesive materials and methods for manufacturing functionally
enhanced optical articles. Various types of films and coatings have
been discussed which can be readily laminated onto optical base
elements. The invention is useful in laminating sandwiched
polarizing films onto ophthalmic lenses. The films and coatings are
generally referred to as functionalized layered structures, which
may undergo pre-treatment steps prior to adhesive application. The
adhesive comprises a bi-layer adhesive structure that includes two
different types of adhesive. A latex adhesive layer is disposed on
the surface of the functionalized layered structure, and a HMA is
disposed between the latex adhesive layer and the optical base
element. The adhesive layers comprise a dry, solid layer of uniform
thinness throughout to provide optical quality. Various dyes or
other additive may be included in the adhesive formulations.
[0060] In one embodiment of the method, the functionalized layered
support may be subject to corona discharge surface treatment and/or
thermoforming. The adhesive layers are individually coated on to
the functionalized layered support and allowed to dry, thereby
forming a uniformly thin bi-layer adhesive lamina of optical
quality. Spin-coating is advantageously employed as a coating
technique. Various hot press techniques for optical applications
may be used to deliver heat and pressure over a short period of
time to laminate the functionalized layered structure to the
optical base element to form a functionalized optical element with
high adhesive strength.
[0061] Having described preferred embodiments for lens
manufacturing, materials used therein for adhesives and films and
methods for processing same (which are intended to be illustrative
and not limiting), it is noted that modifications and variations
can be made by persons skilled in the an in light of the above
teachings. It is therefore to be understood that changes may be
made in the particular embodiments of the invention disclosed which
are within the scope and spirit of the invention as outlined by the
appended claims.
* * * * *