Primer for ophthalmic lenses

Abstract

An ophthalmic lens is disclosed that includes a substrate-agnostic adhesive primer for bonding a functional element to a lens substrate. In particular, the ophthalmic lens includes at least one polymeric lens substrate comprising at least one thermoset monomer, a functional component comprising at least one thermoplastic layer having a surface facing the polymeric lens substrate, and a primer coating deposited onto the surface of the at least one thermoplastic film facing the polymeric lens substrate.

Description

BACKGROUND TECHNICAL FIELD

[0002] The present disclosure relates to the field of ophthalmic lenses, including ophthalmic lenses containing functional elements for eyeglasses and sunglasses.

[0003] DESCRIPTION OF THE RELATED ART

[0004] Additional functionality, such as filtering or optical functionality, can be integrated into ophthalmic lenses by incorporating functional elements, such as films, wafers, or laminates.

[0005] One of the problems associated with integrating thermoplastic-based functional elements into ophthalmic thermoset lenses is the compatibility of the thermoplastic functional element with the lens casting material or surrounding lens substrate. The functional element should not be damaged by the lens casting material and should have good adhesion. Compatibility issues can arise during the manufacturing process, during the finishing process, or during use. During the manufacturing process, some degree of connectivity with the casting monomer is highly desirable. Strong adhesive bonding can help, for example, to improve part output and efficiency. During the finishing process, some degree of connectivity with the casting resin is highly desirable. Lens finishing processing steps include lens blocking, framing, back curve generation, back curve refinement and polishing, lens edging, and deblocking. These processing steps can impart high levels of stress to the lens and can cause delamination of the functional element. There is a need to provide ophthalmic lenses with good adhesion and optical transparency to the customer.

[0006] Current casting Polarized lenses are manufactured using a fragile polyvinyl alcohol (PVA) polarizing film with a thickness of about 30 pm. These thin polarizing films are susceptible to damage during handling. For example, during the production of polarized lenses, many manual handling steps are required, which increases the likelihood of damage.

[0007] To this end, the PVA film can be laminated in a more durable film, such as triacetyl cellulose (TAC). A primer is applied to the polarizing laminate to obtain good adhesion in the casting lens, resulting in a more robust TAC / PVA / TAC polarizing element that improves handling durability compared to a single layer of PVA film. However, current industry primers can damage the optical quality of the polycarbonate (PC) polarizing laminate when used with a polycarbonate / PVA / polycarbonate laminate and do not provide sufficient adhesion and can fog the laminate, hindering the manufacturing process. Despite the advances made in the field of polarizing film adhesive primers, there is a need to provide primers that provide improved adhesion and function well during manufacturing and finishing and across various lens substrates. Such primers would enable the production of robust functional elements that can be universally applied to ophthalmic lenses.

[0008] The foregoing "Background" description is for the purpose of generally presenting the context of the disclosure. The work of the inventors, to the extent the inventors' work is described in this background section as well as aspects of the description that can not otherwise qualify as prior art at the time of SUMMARY

[0009] The present disclosure relates to an ophthalmic lens.

[0010] According to embodiments, the present disclosure further relates to an ophthalmic lens comprising at least one polymeric lens substrate comprising at least one thermosetting monomer, a functional component comprising at least one thermoplastic layer, a surface of the at least one thermoplastic layer facing the polymeric lens substrate, and a primer coating deposited onto the surface of the at least one thermoplastic film facing the polymeric lens substrate. In embodiments, the primer coating comprises at least one first reactive monomer, at least one second reactive monomer, and at least one photoactive catalyst.

[0011] The foregoing paragraph is provided by way of general introduction, and is not intended to limit the scope of the following claims. The described embodiments and further advantages will best be understood by reference to the following detailed description taken in conjunction with the accompanying drawings, in which: BRIEF DESCRIPTION OF DRAWINGS

[0012] A more complete appreciation of the present disclosure and its many attendant advantages will be readily understood by reference to the following detailed description, taken in conjunction with the accompanying drawings, in which:

[0013] Figure 1 is a cross-sectional schematic view of a casting unit according to an exemplary embodiment of the present disclosure;

[0014] Figure 2A is a schematic representation of a treated functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

[0015] Figure 2B is a schematic representation of a treated functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

[0016] Figure 2C is a schematic representation of a treated functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

[0017] Figure 3A is a flowchart of a method of a functional element of an ophthalmic lens according to an exemplary embodiment of the present disclosure;

[0018] Figure 3Bis a flowchart of a sub-process of a method of functional elements of an ophthalmic lens according to example embodiments of the present disclosure;

[0019] Figure 4A is a flowchart of a sub-process of a method of functional elements of an ophthalmic lens according to example embodiments of the present disclosure;

[0020] Figure 4B is a flowchart of a sub-process of a method of functional elements of an ophthalmic lens according to example embodiments of the present disclosure;

[0021] Figure 5A is a flowchart of a sub-process of a method of functional elements of an ophthalmic lens according to example embodiments of the present disclosure;

[0022] Figure 5B is a flowchart of a sub-process of a method of functional elements of an ophthalmic lens according to example embodiments of the present disclosure;

[0023] Figure 6A is a flowchart of a sub-process of a method of functional elements of an ophthalmic lens according to example embodiments of the present disclosure;

[0024] Figure 6B is a flowchart of a sub-process of a method of functional elements of an ophthalmic lens according to example embodiments of the present disclosure; and

[0025] Figure 7 is a flowchart of a sub-process of a method of functional elements of an ophthalmic lens according to example embodiments of the present disclosure. DETAILED DESCRIPTION

[0026] The terms "a" or "an", as used herein, are defined as one or more than one. The term "plurality", as used herein, is defined as two or more than two. The term "another", as used herein, is defined as at least a second or more. The terms "including" and / or "having", as used herein, are defined as "comprising" (i.e., open language). The mere

[0027] The terms "about" and "approximately" are defined as close to as is understood by those skilled in the art. In one non-limiting embodiment, these terms are defined as within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0028] The term "laminate" or "laminated lens" or variations of these terms, when used in the claims and / or specification, refer to similar structures.

[0029] The term "substantially" and variations thereof, are defined to include a range of 10%, 5%, 1%, or 0.5%.

[0030] The terms "inhibit" or "reduce" or "prevent" or "avoid" or any variations of these terms, when used in the claims and / or specification, include any measurable decrease or complete inhibition to achieve a desired result.

[0031] The term "effective", when used in the specification and / or claims, means adequate to achieve a desired, intended, or expected result.

[0032] The methods of the present disclosure can "comprise", "consist essentially of", or "consist of" the particular ingredients, components, compositions, etc. disclosed throughout the present specification.

[0033] The terms "primer" and "primer coating" can be used interchangeably in the specification and / or claims, but are intended to express the same or similar materials.

[0034] The terms "functional component" and "functional element" can be used interchangeably in the specification and / or claims, but are intended to express the same or similar materials. The terms "functional component" or "functional element" can be used as a high-level term to refer to each of (1) a thermoplastic layer, (2) a thermoplastic layer and a functional layer, and (3) a thermoplastic layer, a functional layer, and a thermoplastic layer, as appropriate for a given embodiment.

[0035] The present disclosure relates to an ophthalmic lens characterized by a primer independent of the lens substrate for adhering a functional element to one or more lens substrates, wherein the functional element can be one of a film, a wafer, or a laminate.

[0036] This is particularly important because certain optical functions of filter systems and functional elements established in polycarbonate (PC) lens substrates (such as color enhancement, polarization, blue light filtering, near infrared filtering, photochromic properties, and myopic defocus, among others) are not readily usable with thermoset lens substrates. For example, functional elements including polycarbonate films can be damaged by the thermoset lens substrate precursor during casting, resulting in reduced adhesion and optically eroded and hazy ophthalmic lenses. Accordingly, it will be appreciated that a significant amount of development time is required to design a solution for a filter that is compatible with the surrounding monomer host or lens substrate precursor. Moreover, because thermoset lens substrates are prevalent in lens production, it is of great interest to have a technical solution for the innovation of functional elements manufactured for PC lens substrates that can be readily implemented in thermoset lens substrates.

[0037] The introduction of functional elements having filter and / or optical functions into a lens substrate requires consideration of the compatibility between the functional element and the surrounding host or lens substrate to achieve the desired performance. To this end, one approach incorporates a functional element within a lens substrate by placing the functional element within a casting mold prior to the addition of the lens substrate precursor. As an alternative to placing functional elements of triacetyl cellulose and polyvinyl alcohol within a casting cavity, which can be considered a lens substrate specific solution, thermoplastic functional elements including PC films can be placed within a casting cavity prior to the addition of the lens substrate precursor with the intent of providing a universally applicable PC-based functional element that can be applied in a variety of lens substrate systems. However, although the adhesion between the PC-based functional element and the lens substrate can be sufficient, because the lens substrate precursor is of monomers, the PC-based functional element also degrades from contact with the lens substrate precursor. Degradation can result in haze and lack of visual clarity, among other things.

[0038] Accordingly, example embodiments of the present disclosure describe a primer that provides protection to a functional element and promotes adhesion between the functional element and a thermoset lens substrate (via the thermoset lens substrate precursor). For example, the primer can include a primer based on ultraviolet (UV) curable epoxy and acrylate.

[0039] According to embodiments, the primer can be applied to one or more surfaces of a PC-based functional element and adhered to a corresponding one or more thermoset lens substrates or one or more thermoset monomers.

[0040] According to embodiments, the present disclosure describes a process for a PC-based functional element that prepares and protects a surface of the PC-based functional element for contact with a thermoset lens substrate precursor.

[0041] ​The ophthalmic lenses of the present disclosure provide benefits including (1) consistent and uniform light filtering performance across a variety of lens base materials (e.g., thermoplastic lens base materials, thermoset lens base materials), and (2) reduced manufacturing complexity in handling multiple types of functional elements and different lens base materials by using a single, generally compatible functional element design.

[0042] Turning now to the drawings, Figure 1 A cross-sectional schematic of a functional element 150 within a casting mold 140 is provided. The functional element 150 can include a resin that includes a filter that imparts visual properties and optical functionality on the functional element 150. For example, the dye can be one of a photochromic dye, a dichroic dye, a blue light cutoff dye, an infrared cutoff dye, a UV cutoff dye, a selective wavelength cutoff dye, a color enhancing dye, or combinations thereof, among others. The thickness of the functional element 150 can be between 0.5 pm and 500 pm. In embodiments, the functional element 150 can include at least one thermoplastic film or at least one thermoplastic layer. The at least one thermoplastic film can be one of a PC film, a triacetyl cellulose (TAC) film, and a polyamide (PA) film, among others. In embodiments, the casting mold 140 is substantially cylindrical.

[0043] In embodiments, the casting mold 140 includes a gasket 145 and a first casting insert 141 and a second casting insert 142. At least one void can be defined between the first casting insert 141 and the second casting insert 142. During casting, the at least one void can be filled with a lens base material monomer. In an example, a desired ophthalmic lens can include a functional element having a lens base material on any surface of the functional element. This example reflects Figure 1 a schematic of. In this example, the at least one void can be a first void 148 and a second void 149, and the lens base material monomer can fill the first void 148 and the second void 149 in order to produce the desired ophthalmic lens, the curvature of the lens base material being defined by the curvature of the first casting insert 141 and the curvature of the second casting insert 142. In another example, a desired ophthalmic lens can include a functional element having a lens base material on only a single surface of the functional element. In this example, the functional element can abut either of the first casting insert 141 or the second casting insert 142, and the at least one void can be either of the first void 148 or the second void 149. The lens base material monomer can fill either the first void 148 or the second void 149 in order to produce the desired ophthalmic lens, and the curvature of the lens base material can be defined by either the first casting insert 141 or the second casting insert 142.

[0044] In embodiments, the lens base monomer can be a thermoset polyurethane, allyl diglycol carbonate, polythiourethane, cyclophosphazene polymer, epoxy resin, poly(meth)acrylate, polythiomethacrylate, or combinations thereof. The lens base of the ophthalmic lens can be a thermoset lens base.

[0045] In embodiments, the curvature of the first casting insert 141 and the curvature of the second casting insert 142 can determine the lens power of the ophthalmic lens. For a semi-finished (SF) lens, the curvature along the convex side of the SF lens is fixed, and the curvature along the concave side of the SF lens can be modified after casting by, for example, grinding and polishing.

[0046] In embodiments, and prior to being placed in the casting mold 140 and integrated with the ophthalmic lens, the functional element 150 can be a flat functional element, and can be thermoformed into the spherical dome shape of the thermoformed functional element 150 via, for example, a thermoforming machine. During thermoforming, the flat functional element can be placed onto a heated thermoforming insert, and a vacuum force can be applied to secure the flat functional element to the thermoforming insert. By adjusting the temperature of the heat applied and the force of the vacuum applied, the flat functional element can be formed into the curved shape of the thermoforming insert to produce the thermoformed functional element 150.

[0047] In embodiments, thermoforming the flat functional element can produce a curved structure and define the curvature of either or both surfaces of the functional element.

[0048] According to embodiments, Figure 1 The functional element 150 can be treated with a primer coating on at least one surface of the functional element 150, as described above, in order to improve adhesion between the functional element 150 and the lens base monomer.

[0049] While the following figures will describe methods of applying a primer coating, Figures 2A to 2C Illustrations of various treated functional elements are presented.

[0050] For example, Figure 2A A functional element 250 including a single thermoplastic film 246 is described. The single thermoplastic film 246 can include a primer coating 202 on the concave surface 244 of the functional element 250. The at least one thermoplastic film 246 can be one of a PC film, a TAC film, and a PA film, among others.

[0051] Figure 2BA functional element 250 is described that includes a thermoplastic film 246 and a functional film 248. The functional element 250 can include a primer coating 202 on the concave surface 244 of the thermoplastic film 246 of the functional element 250. The at least one thermoplastic film 246 can be one of a PC film, a TAC film, and a PA film among others. The functional film 248 can be one of a polyvinyl alcohol (PVA) film, a thermoplastic polyurethane (TPU) film, and a polyether block amide (PEBA) film among others. In an example, the at least one thermoplastic film 246 and / or the functional film 248 can include a resin that includes a filter that imparts visual properties and optical functionality on the functional element 250. The functional element 250 can be a PVA / PC functional element, a PVA / TAC functional element, or a PVA / PA functional element among others. In another example, the dye is a photochromic dye within the functional film 247, and the functional film 247 is either a PEBA film or a TPU film. The resulting functional element 250 from there can be a TPU / PC functional element, a TPU / TAC functional element, a PEBA / TAC functional element, a TPU / PA functional element, or a PEBA / PA functional element among others. The functional element 250 can have a thickness between 0.5 pm and 500 pm after the functional film 248 is laminated with the at least one thermoplastic film 246.

[0052] Figure 2CA functional element 250 is described that includes a first thermoplastic film 246’, a functional film 248, and a second thermoplastic film 246”. The functional element 250 can include a primer coating 202 on the concave surface 244 of the first thermoplastic film 246’ of the functional element 250 or on the convex surface 243 of the second thermoplastic film 246” of the functional element 250. In an example, the functional element 250 can include a primer coating 202 on both the concave surface 244 of the first thermoplastic film 246’ of the functional element 250 and the convex surface 243 of the second thermoplastic film 246” of the functional element 250. The first thermoplastic film 246’ and / or the second thermoplastic film 246” can be one of a PC film, a TAC film, and a PA film among others. The functional film 248 can be one of a polyvinyl alcohol (PVA) film, a thermoplastic polyurethane (TPU) film, and a polyether block amide (PEBA) film among others. In an example, one or more of the first thermoplastic film 246’, the functional film 248, and the second thermoplastic film 246” can include a resin that includes a filter that imparts visual properties and optical functionality on the functional element 250. The functional element 250 can be a PC / PVA / PC functional element, a TAC / PVA / TAC functional element, or a PA / PVA / PA functional element among others. In another example, the dye is a photochromic dye within the functional film 248, and the functional film 248 is either a PEBA film or a TPU film. The resulting functional element 250 from this can be a PC / TPU / PC functional element, a TAC / TPU / TAC functional element, a TAC / PEBA / TAC functional element, a PA / TPU / PA functional element, or a PA / PEBA / PA functional element among others. After the functional film 248 is laminated with the first thermoplastic film 246’ and the second thermoplastic film 246”, the functional element 250 can have a thickness between 0.5 pm and 500 pm.

[0053] Turning now Figure 3A and Figure 3B and as Figure 1 described, the cast mold can include one or more voids depending on the lens base material design of the ophthalmic lens. Figure 3A and Figure 3B A method of making an ophthalmic lens taking into account the one or more voids and according to exemplary embodiments of the present disclosure is described. It can be appreciated that the functional elements described above with reference to Figures 2A to 2C may each be Figure 3A and Figure 3B implementations of the flowcharts described above.

[0054] With reference to Figure 3A , the method 300 is a high-level generalized flowchart for making an ophthalmic lens having a functional element adhered to one or more lens base materials, where adhesion is facilitated by treating one or more surfaces of the functional element.

[0055] In step 305 of method 300 and with reference to Figure 1 , a functional element having a convex surface and a concave surface can be provided.

[0056] In sub-process 310 of method 300, one or more of the convex surface and the concave surface of the functional element can be treated. The treatment can include applying a primer to one or more of the convex surface and the concave surface of the functional element. Sub-process 310 of method 300 will be described in further detail with reference to Figure 4B and the subsequent figures.

[0057] In sub-process 320 of method 300, the treated functional element can be adhered to one or more lens base materials. The adhering can include forming one or more lens base materials from a lens base material precursor within one or more voids of a casting mold, as Figure 1 shown.

[0058] In adhering the treated functional element to one or more lens base materials, and with reference now to Figure 3B , in sub-process 320 of method 300, the treated functional element can be adhered to one or more lens base materials. In step 321 of sub-process 320, the treated functional element can be arranged within a casting mold according to a desired design of an ophthalmic lens. For example, the treated functional element can be arranged such that one or more voids are left. In step 322 of sub-process 320, the one or more voids can be filled with a lens base material precursor (or monomer). The lens base material precursor can be an uncured thermoset polymer, such as a lens base material precursor. After injecting the lens base material precursor into the one or more voids of the casting mold, in step 323 of sub-process 320, the lens base material precursor can be allowed to cure to a desired hardness before the ophthalmic lens is removed from the casting mold. It can be appreciated that sub-process 310 of method 300 is consistent for each of the remaining embodiments of the present disclosure, and as such, the description with reference to the subsequent figures will be omitted for brevity.

[0059] Reference is now made to Figure 4A , a description of example embodiments of the present disclosure is provided in which a functional element comprising a first thermoplastic film, a functional film, and a second thermoplastic film is adhered to a single lens base material on one surface of the functional element.

[0060] In step 405 of method 400, a functional element having a convex surface and a concave surface can be provided.

[0061] In sub-process 410 of method 400, the convex surface or the concave surface of the functional element can be treated. The treatment can include applying a primer to the convex surface or the concave surface of the functional element. The description of sub-process 410 of method 400 will be described in further detail with reference toFigure 4B Sub-process 410 of method 400 is now described in further detail.

[0062] In sub-process 420 of method 400, the treated functional element can be adhered to the lens substrate in a manner similar to that described in Figure 3B Figure 1

[0063] Referring now to Figure 4B , sub-process 410 of method 400 describes the treatment of the convex or concave surface of the functional element. In step 411 of sub-process 410, a primer coating can be applied to the convex or concave surface of the functional element.

[0064] In embodiments, the primer coating can be one of a variety of primers that provide strong adhesion between the functional element and the lens substrate. The primer can be formulated to include components that promote bonding with the functional element and the lens substrate. While conventional primers rely on relatively weak primer-primer and primer-substrate electrostatic forces for adhesion, the primers of the present disclosure can bond with the surfaces to which they are applied. The end result of the primer is enhanced adhesion strength and durability.

[0065] According to embodiments, the primers disclosed herein are particularly effective for adhering functional elements including PC films to cast lens substrates. The primers can be designed to provide a degree of penetration into the surface of the PC film or other element layer of the functional element. The PC film penetration quality of the primer promotes its adhesion.

[0066] In embodiments, the primers as disclosed herein can include at least one first reactive monomer, at least one second reactive monomer, and at least one photoactivatable catalyst. In embodiments, the primer further includes a solvent. The at least one first reactive monomer can be a mixture of at least one acrylic monomer selected from the group consisting of monoacrylate monomers and diacrylate monomers and at least one acrylate monomer selected from the group consisting of triacrylate monomers to hexaacrylate monomers. In examples, the reactive group of the at least one second reactive monomer can be an epoxy group. The at least one second reactive monomer can be an epoxy monomer selected from glycidyl ethers of polyhydric alkanols. The at least one photoactivatable catalyst can be a photoactivated catalyst. The light can be UV light. The at least one photoactivatable catalyst can be a cationic catalyst and can be selected from the group consisting of aromatic onium salts and iron arene salt complexes. In embodiments, the primer can further include a free radical photoinitiator as a component of the photoactivatable catalyst. The free radical photoinitiator can be one free radical photoinitiator selected from the group consisting of benzophenone and acetophenone.

[0067] ​​In an example, the at least one first reactive monomer can be at least one monomer capable of reacting with the lens substrate monomer or lens substrate precursor. The at least one monomer can be included in an amount between 0.25 wt.% and 75 wt.%, preferably between 10 wt.% and 50 wt.%, based on the total weight of the at least one second reactive monomer and the at least one monomer present in the composition. In an embodiment, the at least one monomer can be a mixture of acrylate monomers.

[0068] According to an embodiment, the at least one second reactive monomer can have a molecular weight between about 50 and 1,000. The at least one second reactive monomer can be included in an amount between 1 wt.% and 90 wt.%, preferably between 50 wt.% and 90 wt.%, based on the total weight of the at least one second reactive monomer and the at least one first reactive monomer. In an embodiment, the at least one second reactive monomer can be a mixture of epoxy resins and cycloaliphatic epoxy resins. In an embodiment, the at least one second reactive monomer can be an alkoxysilane such as allyltrimethoxysilane, allyltriethoxysilane, allyl methacrylate, and vinyltrimethoxysilane.

[0069] According to an embodiment, the at least photoactivatable catalyst can be included in an amount between 0.1 wt.% and 10 wt.%, preferably between 0.1 wt.% and 3 wt.%. In an embodiment, the at least one photoactivatable catalyst can be a mixture of cationic photoinitiators and free radical photoinitiators.

[0070] In an embodiment, the primer can include a curable composition. Of course, the curing process can cause chemical reactions that change certain components in the primer components. In some embodiments, the primer component functionalities can be selected so as to interact with the functional elements and react with the lens substrate to which they will adhere. In this way, the primer compositions as disclosed herein can be designed and tailored to provide adhesion to specific functional elements and / or lens substrate target materials.

[0071] In some embodiments, a solvent can be used to dissolve the primer components. When present, the solvent can be included in an amount between 20 wt.% and 99 wt.%. In an example, the solvent is an alcohol such as methanol, ethanol, n-propanol, and isopropanol, among others. In another example, the solvent can be one of a ketone, an acetate solvent, acetone, methyl ethyl ketone, ethyl acetate, cyclopentanone, and cyclohexanone, and any combination thereof.

[0072] According to embodiments, the at least one first reactive monomer can exhibit the same chemical functionality as the lens substrate monomer. When the at least one first reactive monomer exhibits the same chemical functionality as the lens substrate monomer, the at least one first reactive monomer assists in ensuring the priming composition's compatibility with the polymeric lens substrate monomer (also referred to herein as a lens substrate precursor). In some embodiments, the at least one first reactive monomer has a different chemical functionality than the lens substrate polymeric monomer. Further, the at least one first reactive monomer can have a different chemical functionality than the lens substrate monomer, but can still be capable of reacting with the polymeric lens substrate monomer. In this case, the at least one first reactive monomer is selected to include the same reactive functional group as the lens substrate monomer. For example, the lens substrate monomer can consist primarily of allyl diglycol carbonate (i.e., ) and the at least one first reactive monomer can be diallyl ether. Although the lens substrate monomer and the at least one first reactive monomer are different compounds, they can react with each other through their reactive functional groups. In some aspects, the at least one first reactive monomer includes a reactive group functionality of 1 or greater, preferably at least 2. Increasing the reactive functionality increases the types of functional groups that can react with the at least one first reactive monomer. In an example, the at least one first reactive monomer can include one or more reactive groups selected from the group consisting of allyl, vinyl, acrylic, thiol, isocyanate, epoxy, and amine.

[0073] In some embodiments, the at least one second reactive monomer has a reactive functionality of 1 or greater, preferably 2. Increasing the reactive functionality increases the amount and types of functional groups that can react with the at least one second reactive monomer. In some embodiments, the at least one second reactive monomer is an epoxy monomer. In some embodiments, the at least one second reactive monomer is a functional, (meth)acrylate-based resin.

[0074] In some embodiments, the functional element is a polarizing element. The polarizing element can include at least one thermoplastic film and a PVA film as a polarizing layer. The at least one thermoplastic film can be PC. In some embodiments, the ophthalmic lens substrate monomer can be allyl diglycol carbonate. The at least one first reactive monomer of the primer can react with the lens substrate monomer to provide chemical bonds that form the basis of the strong adhesion between the functional element and the lens substrate.

[0075] According to embodiments, the primer can be applied to the PC-based functional element by flow coating, spin coating, gravure coating, slot-die extrusion coating, or other means known to those skilled in the art. For example, the primer can be applied by a down-draw plate method using a Mayer rod, where the Mayer rod is a wire MR #3.5, the diameter of the wire determining how thick the primer is applied. In aspects where solvent is included, the applied primer can be dried at a predetermined temperature ranging, for example, from about 40 °C to about 80 °C for a predetermined time, for example, between about 15 seconds and about 2 minutes, in order to remove the solvent from the primer composition. If employed, other drying conditions known to those skilled in the art can be employed to remove the solvent. According to embodiments, after application to the functional element, the applied primer can be allowed to dry completely or partially.

[0076] Tables 1 and 2 provide exemplary compositions of the primers described herein. It can be appreciated that these values should be considered approximate in view of the composition ranges described previously.

[0077] Table 1

[0078]

[0079]

[0080] Table 2

[0081] Component % of composition Second reactive monomer 56.1 First reactive monomer 18.5 Solvent 25.1 Photoactivatable catalyst (cationic) 0.3

[0082] The applied primer can be exposed to an amount of UV light or temperature increase sufficient to activate the photoactivatable catalyst and initiate curing of the applied primer.

[0083] In embodiments, at step 412 of sub-process 410, the coated surface of the functional element can be at least partially cured by exposure to electromagnetic radiation. The electromagnetic radiation can be UV light, infrared light, or visible light, among others. In an example, the electromagnetic radiation is UV light provided by a Heraeus oblelight F300S with H+ bulbs. The power, energy, and exposure time can be selected to optimize curing. Typical non-limiting curing conditions include about 7 feet / minute (UVA about 1500 mJ / cm 2 , about 1200 mW / cm 2 ) to about 21 feet / minute (500 mJ / cm 2 , 1100 mW / cm 2 ).

[0084] In step 413 of subprocess 410, the UV-curable primer on the surface of the functional element can be further cured by exposure to heat. In this example, the heat can be applied using an infrared oven. For example, the infrared oven can be heated to 500°F, and the UV-curable primer on the surface of the functional element can be exposed to heat for a predetermined time. For example, the predetermined time can be, for instance, between 5 and 60 seconds, preferably about 30 seconds. Of course, it will be understood that the temperature and predetermined time used to heat the UV-curable primer on the surface of the functional element can be based on the desired hardness. In some applications, a primer that is not 100% cured may be required to promote adhesion.

[0085] Considering Figure 4A and Figure 4B Flowchart Figure 5A An exemplary illustration of method 400 is provided, illustrating the adhesion between a functional element 550 and a lens substrate 506, the functional element 550 including a first thermoplastic film, a functional film, and a second thermoplastic film. In embodiments, it may be desirable to produce an ophthalmic lens 501 having the lens substrate 506 only on the concave surface 544 of the functional element 550. Therefore, a primer 502 may be applied as a treated surface of the functional element 550 to the concave surface 544 of the functional element 550. Figure 4A As described above, the functional element 550 can be arranged within a casting mold such that the convex surface 543 of the functional element 550 contacts the concave insert of the casting mold, and a gap exists between the treated surface of the functional element 550 and the convex casting insert of the casting mold. After the introduction and at least partial curing of the lens substrate precursor, as... Figure 3B The treated surface of the functional element 550 and the adhered lens substrate 506 can be removed from the casting mold. If necessary, the ophthalmic lens 501 may include the lens substrate 506 on the concave surface 544 of the functional element 550. In this example, the lens substrate 506 may be a thermosetting lens substrate, such as...

[0086] Considering Figure 4A and Figure 4B Flowchart, Figure 5B An exemplary illustration of method 400 is provided, illustrating the adhesion between a functional element 550 and a lens substrate 506, the functional element 550 including a first thermoplastic film, a functional film, and a second thermoplastic film. In embodiments, it may be desirable to produce an ophthalmic lens 501 having the lens substrate 506 only on the convex surface 543 of the functional element 550. Therefore, a primer 502 may be applied as a treated surface of the functional element 550 to the convex surface 543 of the functional element 550. Figure 4AAs described above, the functional element 550 can be disposed within the casting mold such that the concave surface 544 of the functional element 550 is in contact with the convex insert of the casting mold and a gap exists between the treated surface of the functional element 550 and the concave cavity insert of the casting mold. After introduction and at least partial solidification of the lens base precursor, as Figure 3B described above, the treated surface of the functional element 550 and the adhered lens base 506 can be removed from the casting mold. The ophthalmic lens 501 can include the lens base 506 on the convex surface 543 of the functional element 550 as desired. In examples, the lens base 506 can be a thermoset lens base, such as

[0087] Referring now to Figure 6A , a description of example embodiments of the disclosure is provided in which a functional element comprising a first thermoplastic film, a functional film, and a second thermoplastic film is adhered to a lens base on both surfaces of the functional element.

[0088] At step 625 of the method 600, a functional element having a convex surface and a concave surface can be provided.

[0089] At sub-process 630 of the method 600, the convex surface and the concave surface of the functional element can be treated. The treatment can include applying a primer to the convex surface and the concave surface of the functional element. Sub-process 630 of the method 600 will be described in further detail with reference to Figure 6B .

[0090] At sub-process 635 of the method 600, the treated functional element can be adhered to a lens base in a manner similar to Figure 3B . Figure 1

[0091] Referring now to Figure 6B , sub-process 630 of the method 600 describes the treatment of the convex surface and the concave surface of the functional element.

[0092] At step 631 of sub-process 630, a primer can be applied to the convex surface and the concave surface of the functional element.

[0093] According to embodiments, the primer can be one of a variety of primers that provide strong adhesion between the functional element and the surface of the lens base. The primer can be formulated to include components that promote bonding with the functional element and the lens base. While conventional primers rely on relatively weak primer-primer and primer-base electrostatic forces for adhesion, the primers of the present disclosure can bond with the surfaces to which they are applied. The end result of the primer is enhanced adhesion strength and durability.

[0094] ​According to embodiments, the primers disclosed herein are particularly effective for adhering functional elements including PC films to cast lenses. The primer can be designed to provide a degree of penetration into the surface of the PC film or other element layer of the functional element. The PC film penetration quality of the primer facilitates its adhesion.

[0095] In embodiments, the primer as disclosed herein can include at least one first reactive monomer, at least one second reactive monomer, and at least one photoactivatable catalyst. In embodiments, the primer further includes a solvent. The at least one first reactive monomer can be a mixture of at least one acrylic monomer selected from the group consisting of monoacrylate monomers and diacrylate monomers and at least one acrylate monomer selected from the group consisting of triacrylate monomers to hexaacrylate monomers. In examples, the reactive group of the at least one second reactive monomer can be an epoxy group. The at least one second reactive monomer can be an epoxy monomer selected from glycidyl ethers of polyhydric alkanols. The at least one photoactivatable catalyst can be a photoactivated catalyst. In examples, the photoactivator can be electromagnetic radiation such as UV light, visible light, or infrared light among others. The at least one photoactivatable catalyst can be a cationic catalyst and can be selected from the group consisting of aromatic onium salts and iron arene salt complexes. In embodiments, the primer can further include a free radical photoinitiator as a component of the photoactivatable catalyst. The free radical photoinitiator can be one free radical photoinitiator selected from the group consisting of benzophenone and phenone.

[0096] In examples, the at least one first reactive monomer can be at least one monomer capable of reacting with the lens substrate monomer. The at least one monomer can be included in an amount between 0.25 wt.% and 75 wt.%, preferably between 10 wt.% and 50 wt.%, based on the total weight of the at least one second reactive monomer and the at least one monomer present in the composition. In embodiments, the at least one monomer can be a mixture of acrylate monomers.

[0097] According to embodiments, the at least one second reactive monomer can have a molecular weight between about 5 and about 1,000. The at least one second reactive monomer can be included in an amount between 1 wt.% and 90 wt.%, preferably between 50 wt.% and 90 wt.%, based on the total weight of the at least one second reactive monomer and the at least one first reactive monomer. In embodiments, the at least one second reactive monomer can be a mixture of epoxy resins and cycloaliphatic epoxy resins. In embodiments, the at least one reactive monomer can be an alkoxysilane such as allyltrimethoxysilane, allyltriethoxysilane, allyl methacrylate, and vinyltrimethoxysilane.

[0098] According to embodiments, the at least photoactivatable catalyst can be included in an amount between 0.1 wt.% and 10 wt.%, preferably between 0.1 wt.% and 3 wt.%. In embodiments, the at least one photoactivatable catalyst can be a mixture of cationic photoinitiators and free radical photoinitiators.

[0099] In embodiments, the primer can include a curable composition. Of course, the curing process can cause chemical reactions that alter certain components in the primer components. In some embodiments, the primer components functional groups can be selected so as to interact with the functional elements and react with the lens substrate to which they will adhere. In this way, the primer compositions as disclosed herein can be designed and tailored to provide adhesion to specific functional elements and / or lens substrate target materials.

[0100] In some embodiments, a solvent can be used to dissolve the primer components. When present, the solvent can be included in an amount between 20 wt.% and 99 wt.%. In an example, the solvent is an alcohol such as methanol, ethanol, n-propanol, and isopropanol, among others. In another example, the solvent can be a ketone, an acetate solvent, acetone, methyl ethyl ketone, ethyl acetate, cyclopentanone, and cyclohexanone, among any combination thereof.

[0101] According to embodiments, the at least one first reactive monomer can have the same chemical functionality as the lens substrate monomers. When the at least one first reactive monomer has the same chemical functionality as the lens substrate monomers, the at least one first reactive monomer assists in ensuring the compatibility of the primer composition with the polymeric lens substrate monomers (also referred to herein as lens substrate precursors). In some embodiments, the at least one first reactive monomer has a different chemical functionality than the lens substrate monomers. The at least one first reactive monomer can have a different chemical functionality than the lens substrate monomers, but can still be able to react with the lens substrate monomers. In this case, the at least one first reactive monomer is selected to include the same reactive functional groups as the lens substrate monomers. For example, the lens substrate monomers can consist primarily of allyl diglycol carbonate (i.e., ) and the at least one first reactive monomer can be a diallyl ether. Although the lens substrate monomers and the at least one first reactive monomer are different compounds, they can react with each other through their reactive functional groups. In some aspects, the at least one first reactive monomer includes a reactive group functionality of 1 or greater, preferably at least 2. Increasing the reactive functionality increases the types of functional groups that can react with the at least one first reactive monomer. The at least one first reactive monomer can include one or more reactive groups selected from the group consisting of allyl, vinyl, acrylic, thiol, isocyanate, epoxy, and amine.

[0102] In some embodiments, the at least one second reactive monomer has a reactivity functionality of 1 or greater, preferably 2. Increasing the reactivity functionality increases the amount and type of functional groups that can react with the at least one second reactive monomer. In some embodiments, the at least one second reactive monomer is an epoxy monomer. In some embodiments, the at least one second reactive monomer is a functional, (meth)acrylate-based resin.

[0103] In some embodiments, the functional element is a polarizing element. The polarizing element can include at least one thermoplastic film and a PVA film as a polarizing layer. The at least one thermoplastic film can be PC. In some embodiments, the ophthalmic lens base material monomer can be allyl diglycol carbonate. The at least one first reactive monomer of the primer can react with the lens base material monomer to provide chemical bonds that form the basis of strong adhesion between the functional element and the lens base material.

[0104] According to embodiments, the primer can be applied to the PC-based functional element by flow coating, spin coating, gravure coating, slot-die extrusion coating, or other means known to those skilled in the art. For example, the primer can be applied by a down-draw plate method using a Mayer rod, where the Mayer rod is a wire MR #3.5, the diameter of the wire determining how thick the primer is applied. In some aspects, and when a solvent is included within the primer, the applied primer can be dried at a predetermined temperature, for example, between about 40°C and about 80°C, for a predetermined time, for example, between about 15 seconds and about 2 minutes, in order to remove the solvent from the primer composition. Other drying conditions known to those skilled in the art can be employed to remove the solvent when present in the primer. According to embodiments, after being applied to the functional element, the applied primer can be allowed to dry completely or partially.

[0105] Exemplary compositions of the primer are described above with reference to Tables 1 and 2.

[0106] The applied primer can be exposed to an amount of UV light or temperature increase sufficient to activate the photoactivatable catalyst and initiate the curing process. Thus, in embodiments, at step 632 of sub-process 630, the coated surface of the functional element can be at least partially cured by exposure to electromagnetic radiation. The electromagnetic radiation can be UV light, infrared light, or visible light, among others. In an example, the electromagnetic radiation is UV light provided by a Heraeus oblelight F300S with H+ bulbs. The power, energy, and exposure time can be selected to optimize the curing. Typical non-limiting curing conditions include about 7 feet / minute (UVA about 1500 mJ / cm 2 , about 1200 mW / cm 2 ) to about 21 feet / minute (500 mJ / cm 2, 1100 mW / cm 2 ).

[0107] At step 633 of sub-process 630, the UV-cured primer on the concave surface and the convex surface of the functional element can be further cured by exposure to heat. In an example, the heat can be applied by an infrared oven. For example, the infrared oven can be heated to 500 °F and the UV-cured primer on the concave surface and the convex surface of the functional element can be exposed to the heat for a predetermined time. For example, the predetermined time can be between 5 seconds and 60 seconds, preferably about 30 seconds. Of course, it can be appreciated that the temperature and the predetermined time for heating the UV-cured primer on the concave surface and the convex surface of the functional element can be based on the desired hardness. In certain applications, less than 100% cured primer can be desired in order to facilitate adhesion.

[0108] With reference to Figure 6A and Figure 6B flowcharts, Figure 7 an exemplary illustration of method 600 is provided in which adhesion between a functional element 750 and a lens substrate 706 is shown, the functional element 750 including a first thermoplastic film, a functional film, and a second thermoplastic film. In an embodiment, it can be desirable to produce an ophthalmic lens 701 having the lens substrate 706 on both the concave surface 744 of the functional element 750 and the convex surface 743 of the functional element 750. Accordingly, a primer 702 can be applied to both the concave surface 744 of the functional element 750 and the convex surface 743 of the functional element 750 as the treated surface of the functional element 750.

[0109] As described in Figure 6A , the functional element 750 can be arranged within a casting mold such that the convex surface 743 of the functional element 750 is maintained at a first predetermined distance from a concave cavity insert of the casting mold and the concave surface 744 of the functional element 750 is maintained at a second predetermined distance from a convex cavity insert of the casting mold. In this manner, a void of the casting mold can exist within the space defined by the first predetermined distance and the second predetermined distance to which the treated surface of the functional element 750 is exposed. After the lens substrate precursor is introduced into the void and at least partially cured, as described in Figure 3B , the treated surface of the functional element 750 adhered to the lens substrate 706 can be removed from the casting mold. As desired, the ophthalmic lens 701 can include a convex lens substrate 707 on the convex surface 743 of the functional element 750 and a concave lens substrate 708 on the concave surface 744 of the functional element 750 as the lens substrate. In an example, the convex lens substrate 707 and the concave lens substrate 708 can be thermoset lens substrates, such as

[0110] As part of the disclosure, specific examples are included below. These examples are for illustrative purposes only and are not intended to limit the application. In fact, these examples can not be example embodiments of the disclosure, but are intended to provide examples of non-limiting examples of the disclosure and contrast between other practices in the art. Those of ordinary skill in the art will readily recognize that parameters can be varied or modified to produce substantially equivalent results.

[0111] Example

[0112] For each of the examples that follow, the base primer composition is first described.

[0113] Reference Base Primer Composition Defined as Base Composition #1

[0114] The reference base primer composition defined as Base Composition #1 is formulated and composed of acrylate monomers as at least one first reactive monomer and acrylate, epoxy resin and acrylate monomers as at least one second reactive monomer, and cationic photoinitiator and free radical photoinitiator as at least one photoinitiator, as shown in Table 3.

[0115] Table 3

[0116] Component (Catalogue) Component (Family) % of composition (wt. %) UVR-6110 Cycloaliphatic epoxy resin 55.8 Erisys GE-30 Epoxy resin 18.8 SR-399 Acrylate monomer 16.6 SR-339 Acrylate 8.21 UVl-6976 Cationic photoinitiator 0.40 DAROCUR 1173 Radical photoinitiator 0.20

[0117] In the examples, UVR-6110 is 3,4-epoxycyclohexylmethyl-3,4- epoxycyclohexylcarboxylate with a reactive group functionality of 2, Erisys GE-30 is trimethylolpropane triglycidyl ether liquid epoxy resin with a reactive group functionality of 3, SR-399 is dipentaerythritol pentaacrylate with a reactive group functionality of 5, SR-339 is 2-phenoxyethyl acrylate with a reactive group functionality of 1, UVI-6976 is triaryl sulfonium hexafluoroantimonate in propylene carbonate < 60%, and Darocur 1173 is 2-hydroxy-2-methyl-l-phenyl-propan-l-one.

[0118] Example 1

[0119] Primer 1 of Example 1 comprises the reference base composition #1 (90 wt.%) and allyl methacrylate (10 wt.%). Primer 1 is applied to both surfaces of a flat functional element which is then thermoformed to a desired curvature in order to produce an ophthalmic lens having a concave lens substrate and a convex lens substrate adhered to the functional element. Thus, primer 1 is first applied to a first flat surface of the functional element and UV cured to tack free, as Figure 6BExample 1 The monomer fills the casting mold. The filled casting mold is cured to the desired hardness and the SF lens surface is treated to -6.00 diopters or -8.00 diopters.

[0120] Example 2

[0121] Primer 2 of Example 2 comprises Reference Base Composition #1 (90 wt.%) and allyltrimethoxysilane (10 wt.%). Primer 2 is applied to both surfaces of a flat functional element that is then thermoformed to the desired curvature in order to produce an ophthalmic lens having a concave lens base and a convex lens base adhered to the functional element. Thus, primer 2 is first applied to the first flat surface of the functional element and UV cured to tack free as shown. Figure 6B The monomer fills the casting mold. The filled casting mold is cured to the desired hardness and the SF lens surface is treated to -6.00 diopters or -8.00 diopters. The monomer fills the casting mold. The filled casting mold is cured to the desired hardness and the SF lens surface is treated to -6.00 diopters or -8.00 diopters.

[0122] Example 3

[0123] Primer 3 of Example 3 comprises Reference Base Composition #1 (90 wt.%) and allyltriethoxysilane (10 wt.%). Primer 3 is applied to both surfaces of a flat functional element that is then thermoformed to the desired curvature in order to produce an ophthalmic lens having a concave lens base and a convex lens base adhered to the functional element. Thus, primer 3 is first applied to the first flat surface of the functional element and UV cured to tack free as shown. Figure 6BThe functional element with the treated first planar surface is then coated as a primer on the second planar surface of the functional element and cured. The primer is applied to each of the first planar surface of the functional element and the second planar surface of the functional element by using a draw down plate method with a #3.5 Meyer bar. The discs of the functional element are die cut and thermoformed to a 4 base curvature before being positioned in the semi-finished lens casting cell. One or more voids are maintained on either side of the functional element. The thermoset resin containing about 3% IPP as a lens substrate precursor is then cast onto the functional element. The cast lens is cured to the desired hardness and the SF lens surface is treated to -6.00 diopters or -8.00 diopters. The monomer fills the casting mold. The filled casting mold is cured to the desired hardness and the SF lens surface is treated to -6.00 diopters or -8.00 diopters.

[0124] Example 4

[0125] Primer 4 of Example 4 comprises Reference Base Composition #1 (86 wt.%) and vinyltrimethoxysilane (14 wt.%). Primer 4 is applied to both surfaces of a planar functional element which is then thermoformed to a desired curvature in order to produce an ophthalmic lens having a concave lens substrate and a convex lens substrate adhered to the functional element. Thus, primer 4 is first applied to the first planar surface of the functional element and UV cured to non-tacky, as described above. Primer 4 is then applied to the second planar surface of the functional element and UV cured to non-tacky. The discs of the functional element are die cut and thermoformed to a 4 base curvature before being positioned in the semi-finished lens casting cell. One or more voids are maintained on either side of the functional element. The thermoset resin containing about 3% IPP as a lens substrate precursor is then cast onto the functional element. The cast lens is cured to the desired hardness and the SF lens surface is treated to -6.00 diopters or -8.00 diopters. Figure 6B The functional element with the treated first planar surface is then coated as a primer on the second planar surface of the functional element and cured. The primer is applied to each of the first planar surface of the functional element and the second planar surface of the functional element by using a draw down plate method with a #3.5 Meyer bar. The discs of the functional element are die cut and thermoformed to a 4 base curvature before being positioned in the semi-finished lens casting cell. One or more voids are maintained on either side of the functional element. The thermoset resin containing about 3% IPP as a lens substrate precursor is then cast onto the functional element. The cast lens is cured to the desired hardness and the SF lens surface is treated to -6.00 diopters or -8.00 diopters. The monomer fills the casting mold. The filled casting mold is cured to the desired hardness and the SF lens surface is treated to -6.00 diopters or -8.00 diopters.

[0126] After removal from the casting mold and surface treatment, little to no haze and little to no delamination or delamination was observed in the semi-finished lenses containing internally positioned functional elements treated with any of Examples 1-4. The results of these lenses are shown in Table 4.

[0127] Table 4

[0128]

[0129]

[0130] Obviously, many modifications and changes are possible in light of the above teaching. Therefore, it is to be understood that the application can be practiced otherwise than as specifically described herein within the scope of the appended claims.

[0131] Embodiments of the present disclosure can also be as described in the following brackets.

[0132] (1) An ophthalmic lens comprising: at least one polymeric lens substrate comprising at least one thermoset monomer; a functional component comprising at least one thermoplastic layer having a surface facing the polymeric lens substrate; and a primer coating deposited onto the surface of the at least one thermoplastic film facing the polymeric lens substrate.

[0133] (2) The ophthalmic lens of (1), wherein the functional component comprises at least one dye selected from the group consisting of: a photochromic dye, a dichroic dye, a blue light cutoff dye, an infrared cutoff dye, an ultraviolet cutoff dye, a selective wavelength cutoff dye, a color enhancing dye, a polarizing dye, and a filtering dye.

[0134] (3) The ophthalmic lens of (1) or (2), wherein the functional layer comprises the photochromic dye as the at least one dye and is one of a polyether block amide functional layer or a thermoplastic polyurethane functional layer.

[0135] (4) The ophthalmic lens of (1) or (2), wherein the functional component comprises a functional layer comprising the polarizing dye as the at least one dye and is a polyvinyl alcohol functional layer.

[0136] (5) The ophthalmic lens of any one of (1), (2), and (4), wherein the at least one thermoplastic film of the functional component is two thermoplastic films and the polyvinyl alcohol functional layer is disposed between the two thermoplastic films, each of the two thermoplastic films is a thermoplastic film selected from the group consisting of a polycarbonate film, a triacetyl cellulose film, and a polyamide film.

[0137] (6) The ophthalmic lens of any one of (1) to (5), wherein the at least one polymeric lens substrate is adhered to a convex surface of the functional component.

[0138] (7) The ophthalmic lens of any one of (1) to (6), wherein the at least one polymeric lens substrate is adhered to a concave surface of the functional component.

[0139] (8) The ophthalmic lens of any one of (1) to (7), wherein the at least one thermoplastic film of the functional component is a polycarbonate film.

[0140] (9) The ophthalmic lens of any one of (1) to (8), wherein the primer coating comprises at least one first reactive monomer, at least one second reactive monomer, and at least one photoactive catalyst.

[0141] (10) The ophthalmic lens of any one of (1) to (9), wherein the at least one photoactive catalyst is reactive to ultraviolet light.

[0142] (11) The ophthalmic lens of any one of (1) to (10), wherein the at least one second reactive monomer of the primer coating is an alkoxysilane.

[0143] (12) The ophthalmic lens of any one of (1) to (11), wherein the at least one second reactive monomer of the primer coating comprises a reactive group selected from the group consisting of allyl, vinyl, acrylic, thiol, isocyanate, epoxy, and amine.

[0144] (13) The ophthalmic lens of any one of (1) to (12), wherein the reactive group is epoxy.

[0145] (14) The ophthalmic lens of any one of (1) to (13), wherein the at least one photoactive catalyst comprises a cationic photoinitiator and a free radical photoinitiator.

[0146] (15) The ophthalmic lens of any one of (1) to (14), wherein the at least one first reactive monomer of the primer coating is an acrylic monomer or a mixture of acrylic monomers.

[0147] Thus, the foregoing discussion discloses and describes only exemplary embodiments of the present application. As will be understood by those skilled in the art, the present application can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present application is intended to be illustrative, but not limiting of the scope of the application or other claims. The disclosure, including any readily discernible variants of the teachings herein, defines and enables the scope of the foregoing claims to the fullest extent feasible. No subject matter is to be construed as being outside the scope and spirit of the claims, unless such subject matter is expressly recited in the claims.

Claims

1. An ophthalmic lens comprising: at least one polymeric lens substrate comprising at least one thermosetting monomer; a functional component comprising at least one thermoplastic layer, a surface of the at least one thermoplastic layer facing the polymeric lens substrate; and a primer coating deposited onto the surface of the at least one thermoplastic film facing the polymeric lens substrate, wherein, the primer coating comprises at least one first reactive monomer, at least one second reactive monomer, and at least one photoactive catalyst, wherein the at least one second reactive monomer of the primer coating is an alkoxysilane, and the at least one photoactive catalyst comprises a cationic photoinitiator and a free radical photoinitiator. the functional component comprises at least one dye selected from the group consisting of a photochromic dye, a dichroic dye, a blue light cutoff dye, an infrared cutoff dye, an ultraviolet cutoff dye, a selective wavelength cutoff dye, a color enhancing dye, a polarizing dye, and a filtering dye.

2. The ophthalmic lens of claim 1, wherein, the functional component comprises a functional layer having the photochromic dye as the at least one dye and is one of a polyether block amide functional layer or a thermoplastic polyurethane functional layer.

3. The ophthalmic lens of claim 2, wherein, the functional component comprises a functional layer having the polarizing dye as the at least one dye and is a polyvinyl alcohol functional layer.

4. The ophthalmic lens of claim 2, wherein, 5. The ophthalmic lens of claim 4, wherein, the at least one thermoplastic film of the functional component is two thermoplastic films and the polyvinyl alcohol functional layer is disposed between the two thermoplastic films, each of the two thermoplastic films is selected from the group consisting of a polycarbonate film, a triacetyl cellulose film, and a polyamide film. the at least one polymeric lens substrate is adhered to a convex surface of the functional component.

6. The ophthalmic lens of claim 1, wherein, the at least one polymeric lens substrate is adhered to a concave surface of the functional component.

7. The ophthalmic lens of claim 1, wherein, the at least one thermoplastic film of the functional component is a polycarbonate film.

8. The ophthalmic lens of claim 1, wherein, the at least one photoactive catalyst is reactive to ultraviolet light.

9. The ophthalmic lens of claim 1, wherein, the at least one first reactive monomer of the primer coating is an acrylic monomer or a mixture of acrylic monomers.

10. The ophthalmic lens of claim 1, wherein, ​

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