CA2631367A1 - A method for coating an ophthalmic lens within an injection molding machine - Google Patents

A method for coating an ophthalmic lens within an injection molding machine Download PDF

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Publication number
CA2631367A1
CA2631367A1 CA002631367A CA2631367A CA2631367A1 CA 2631367 A1 CA2631367 A1 CA 2631367A1 CA 002631367 A CA002631367 A CA 002631367A CA 2631367 A CA2631367 A CA 2631367A CA 2631367 A1 CA2631367 A1 CA 2631367A1
Authority
CA
Canada
Prior art keywords
coating
lens
coatings
clamp force
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002631367A
Other languages
French (fr)
Other versions
CA2631367C (en
Inventor
Xu Chen
Matthew James Lockwood
Hsinjin Yang
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EssilorLuxottica SA
Original Assignee
Essilor International(Compagnie Generale D'optique)
Xu Chen
Matthew James Lockwood
Hsinjin Yang
Essilor International
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Essilor International(Compagnie Generale D'optique), Xu Chen, Matthew James Lockwood, Hsinjin Yang, Essilor International filed Critical Essilor International(Compagnie Generale D'optique)
Publication of CA2631367A1 publication Critical patent/CA2631367A1/en
Application granted granted Critical
Publication of CA2631367C publication Critical patent/CA2631367C/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00865—Applying coatings; tinting; colouring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1679—Making multilayered or multicoloured articles applying surface layers onto injection-moulded substrates inside the mould cavity, e.g. in-mould coating [IMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/0048—Moulds for lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00865—Applying coatings; tinting; colouring
    • B29D11/00894—Applying coatings; tinting; colouring colouring or tinting
    • B29D11/00903—Applying coatings; tinting; colouring colouring or tinting on the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C2045/0079—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping applying a coating or covering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/32—Moulds having several axially spaced mould cavities, i.e. for making several separated articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0026—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0016—Lenses
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
    • Y10S425/808—Lens mold

Abstract

A method for in-mold coating of an injection molded thermoplastic lens that resides in an injection molding machine oriented to a horizontal parting line(116). An optical lens(<1,<2) is initially formed by injecting molten thermoplastic resin into an edge-gated lens-forming cavity held closed under a primary clamp force. The mold (10, 12) is opened at a time when the lens is rigid enough to retain its shape. An unpressurized full metered charge of coating (6Of) is applied onto the center of the lens. The coating is co-molded by ramping up the clamp force from zero to a secondary clamp force less than the primary clamp force to compress the coating into a uniformly thick, fringe-free layer.

Claims (31)

1. A method for optically coating an injection molded thermoplastic lens (L1, L2) that resides in an injection molding machine oriented to a horizontal parting line (16), comprising the steps of:
injecting (102) molten thermoplastic resin into an edge-gated lens-forming cavity held closed under a primary clamp force;

opening (106) the mold (10, 12) at a time when the lens is rigid enough to retain its shape;
depositing (108) an unpressurized full metered charge of coating (60e, 60f) onto the center of the lens (L1, L2); and co-molding (110, 112) the coating by ramping up the clamp force from zero to a secondary clamp force not greater than the primary clamp force to compress the coating into a uniformly thick, fringe-free layer.
2. The method of claim 1, wherein the co-molding step (110, 112) includes reclamping (110) the open mold (10, 12) to the same cavity volume to spread the coating (60e, 60f) radially-outwardly to a lens periphery within a surficial zone.
3. The method of claim 2, wherein during said reclamping step (110), the coating (60e, 60f) is spread in the absence back pressure.
4. The method of any of claims 1 to 3, wherein the co-molding step (110, 112) includes co-molding the coating (60e, 60f) to exactly replicate the part-forming surface without deforming the lens (L1, L2).
5. The method of any of claims 1 to 4, wherein said depositing step (108) comprises applying a liquid coating (60e, 60f) in an open-air state that thermally cures from the heat of the solidifying lens (L1, L2) and the mold (10, 12) and forms an optically transparent coating.
6. The method of any of claims 1 to 5, wherein the mold (10, 12) opens and closes vertically.
7. The method of any of claims 1 to 6, wherein the primary clamp force is over 100 tons.
8. The method of any of claims 1 to 7, wherein the primary clamp force is about 150 tons.
9. The method of any of claims 1 to 8, wherein the secondary clamp force is less than the primary clamp force, and preferentially in the range from about 10% to about 90 % of the primary clamp force.
10. The method of any of claims 1 to 8, wherein the secondary clamp force is equal to the primary clamp force.
11. The method according to any of claims 1 to 10, wherein the full metered charge of coating (60e, 60f) is between 0.1 ml and 5.0 ml.
12. The method according to any of claims 1 to 11, wherein the full metered charge of coating (60e, 60f) is between 0.1 nil and 0.8 ml, and preferentially between 0.2 ml and 0.5 ml.
13. The method according to any of claims 1 to 12, wherein the thermoplastic resin is selected from the group consisting of polymethyl(meth)acrylate, polycarbonate, polycarbonate/polyester blends, polyamide, polyester, cyclic olefin copolymers, polyurethane, polysulfone, polystyrene, polypentane and combinations thereof.
14. The method according to claim 13, wherein thermoplastic is a polycarbonate derivative.
15. The method according to claim 5, wherein the liquid coating (60e, 60f) includes one or more (meth)acrylate compounds, an initiator, and a metal salt.
16. The method according to claim 15, wherein the liquid coating (60e, 60f) includes at least one hexafunctional acrylate compound, at least one difunctional acrylate compound, and at least one monofunctional acrylate compound.
17. The method according to any of claims 15 or 16, wherein the initiator is selected from alkyl aralkyl peracide compounds.
18. The method according to any of claims 15 to 17, wherein the metal salt is Cobalt naphthenate.
19. The method according to claim 5, wherein the liquid coating (60e, 60f) sufficiently cures at the molding temperature of the substrate lens.
20. The method according to any of claims 1 to 19, wherein said co-molding step (110, 112) includes curing the coating (60e, 60f) for about 20 seconds to 5 minutes.
21. The method according to any of claims 1 to 20, wherein said co-molding step (110, 112) includes curing the coating (60e, 60f) for about 20 seconds to 1 minute.
22. The method of any of claims 1 to 21, wherein the edge-gated lens-forming cavity is one of an afocal lens forming cavity, a unifocal lens forming cavity, a bifocal straight-top lens forming cavity, a trifocal straight-top lens forming cavity, and a progressive lens forming cavity.
23. The method of any of claims 1 to 22, wherein following said co-molding step (110, 112), the method further including the step of :

ejecting (116) the lens from the mold after the coating has cured and the lens is capable of withstanding ejection forces without deforming.
24. The method of any of claims 1 to 23, wherein following said co-molding step (110, 112), the method additionally including the step (120, 112) of:

further opening (106) the mold at a time when the lens is rigid enough to retain its shape;
further depositing (108) an unpressurized full metered charge of further coating onto the center of the lens; and further co-molding (110, 112) the coating by ramping up the clamp force from zero to a secondary clamp force to compress the further coating into a further uniformly thick, fringe-free layer.
25. The method of claim 24, wherein the further deposited coating is the same as said deposited coating (60e, 60f).
26. The method of any of claims 24 or 25, wherein the deposited coating (60e, 60f) is selected from the group consisting of photochromic coatings, anti-fog coatings, anti-static coatings, anti-scratch coatings, protective coatings, anti-reflective coatings, imbibable coatings, clear coatings, cosmetically tinted coatings and anti-smudge coatings.
27. The method of claim 24, wherein the further deposited coating is different from said deposited coating (60e, 60f).
28. The method of claim 27, wherein the further deposited coating has a different optical function from said deposited coating to produce an in-mold multifunctional coated lens (LI, L2).
29. The method of claim 28, wherein the deposited coating (60e, 60f) and the further deposited coating are independently selected from the group consisting of photochromic coatings, anti-fog coatings, anti-static coatings, anti-scratch coatings, protective coatings, anti-reflective coatings, imbibable coatings, clear coatings, cosmetically tinted coatings and anti-smudge coatings.
30. The method of any of claims 24 to 29, wherein said steps of further opening (106), further depositing (108) and further co-molding (110, 112) are repeated for the application of a third or higher layer of coatings.
31. A thermoplastic ophthalmic lens manufactured by the process of any of claims 1 to 30.
CA2631367A 2005-12-21 2006-12-21 A method for coating an ophthalmic lens within an injection molding machine Active CA2631367C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US11/313,590 2005-12-21
US11/313,590 US7833442B2 (en) 2005-12-21 2005-12-21 Method for coating an ophthalmic lens within an injection molding machine
PCT/IB2006/004146 WO2007085910A2 (en) 2005-12-21 2006-12-21 A method for coating an ophthalmic lens within an injection molding machine

Publications (2)

Publication Number Publication Date
CA2631367A1 true CA2631367A1 (en) 2007-08-02
CA2631367C CA2631367C (en) 2012-07-10

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA2631367A Active CA2631367C (en) 2005-12-21 2006-12-21 A method for coating an ophthalmic lens within an injection molding machine

Country Status (9)

Country Link
US (2) US7833442B2 (en)
EP (1) EP1963085B1 (en)
CN (1) CN101321616B (en)
AT (1) ATE480391T1 (en)
AU (1) AU2006336869B2 (en)
BR (1) BRPI0620111B8 (en)
CA (1) CA2631367C (en)
DE (1) DE602006016857D1 (en)
WO (1) WO2007085910A2 (en)

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Also Published As

Publication number Publication date
US7833442B2 (en) 2010-11-16
US20090124721A1 (en) 2009-05-14
BRPI0620111B1 (en) 2017-11-14
WO2007085910A3 (en) 2007-11-29
WO2007085910A2 (en) 2007-08-02
AU2006336869B2 (en) 2010-07-01
AU2006336869A1 (en) 2007-08-02
US20070138665A1 (en) 2007-06-21
US7850879B2 (en) 2010-12-14
EP1963085A2 (en) 2008-09-03
DE602006016857D1 (en) 2010-10-21
BRPI0620111A2 (en) 2013-01-15
ATE480391T1 (en) 2010-09-15
CN101321616B (en) 2011-10-12
EP1963085B1 (en) 2010-09-08
CN101321616A (en) 2008-12-10
BRPI0620111B8 (en) 2018-06-12
CA2631367C (en) 2012-07-10

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