Method for manufacturing an ophthalmic lens

Abstract

A method for manufacturing an ophthalmic lens is disclosed, the ophthalmic lens comprising a lens substrate and at least one coating, wherein the method comprises at least the following steps: providing a lens substrate comprising an uncoated or pre-coated front surface and an uncoated or pre-coated back surface; partially or completely covering at least one of the surfaces of the lens substrate with at least one coating composition; drying and / or pre-curing the at least one coating composition; contacting the surface of the at least one coating composition with at least one mechanical device; curing and / or hardening the at least one coating composition and obtaining an ophthalmic lens comprising a lens substrate and at least one coating, the surface morphology of the at least one coating being modified by the at least one mechanical device.

Description

[0001] The invention relates to a method for producing an ophthalmic lens.

[0002] According to Brien A. Holden et al., Global Vision Impairment Due to Uncorrected Presbyopia, Arch Ophthalmol. 2008; 126(12): 1731-1739, uncorrected distance refractive error is the most common cause of visual impairment. In Universal eye health: a global action plan 2014-2019, World Health Organization 2013, WHO estimated that 285 million people had visual impairment in 2010. CSYLam et al., Defocus Incorporated Multiple Segments (DIMS) spectacle lenses slow myopia progression: a 2-year randomised clinical trial, Br J Ophthalmol 2019; 0: 1–6, tested multiple positive optical defocus (DIMS) spectacle lenses (also disclosed, for example, in US 2017 / 0131567 A1, US 2019 / 0212580 A1 or US 2020 / 0159044 A1, which should be mandatory myopic defocus) in a study with children. DIMS spectacle lenses were shown to slow myopia progression and axial length growth in myopic children.

[0003] US 2017 / 0131567 A1 discloses an eyeglass, which includes a first refractive area having a first refractive power based on a prescription for correcting abnormal refraction of an eye and a second refractive area having a function of focusing an image at a position other than the retina of the eye to suppress the progress of abnormal refraction of the eye. The second refractive area is formed into a plurality of independent island-shaped areas.

[0004] US 2019 / 0212580 A1 discloses an eyeglass, which includes a first refraction area and a second refraction area as disclosed in US 2017 / 013167 A1. According to US 2019 / 0212580 A1, the second refraction area is dispersedly arranged as a plurality of mutually separated areas, each of which is surrounded by the first refraction area.

[0005] US 2020 / 0159044 A1 discloses a first spectacle lens, which includes a first refractive area having a refractive power based on a prescription for correcting myopia and a second refractive area having a refractive power different from the first refractive power. Each of the second refractive areas is formed into a convex shape extending from the object side surface of the spectacle lens. Each of the second refractive areas has a greater curvature than the object side surface of the first refractive area. The second refractive area includes a plurality of refractive areas having a plurality of refractive powers different from each other. US 2020 / 0159044 A1 further discloses a second spectacle lens, which includes a first refractive area based on a prescription for correcting myopia and a second refractive area having a refractive power different from the first refractive power. The second refractive area of ​​the second spectacle lens is non-concentrically formed into a plurality of island-shaped areas, and the refractive power of the second refractive area is 2.00D to 5.00D greater than the first refractive power of the first refractive area. US 2020 / 0159044 A1 further discloses a third eyeglass, which includes a first refractive area having a first refractive power based on a prescription for correcting abnormal eye refraction and a second refractive area having a refractive power different from the first refractive power. The second refractive area of ​​the third eyeglass is non-concentrically formed into a plurality of island-shaped areas, which are arranged to form a hexagon inscribed in a circle with a predetermined radius.

[0006] US 2015 / 0160477 A1 discloses a multi-element lens for controlling defocus and eye diopter, which divides the lens into a lens area corresponding to the central visual field of the eye and a convex lens area corresponding to the equatorial visual field of the eye. The multi-element lens includes a large unit convex lens that produces large defocus, a small unit concave lens that produces small defocus or focusing by combining on the large unit convex lens, or a small single lens that produces small defocus is provided separately on the large unit convex lens. The junction between the large unit concave lens and the small unit concave lens or the small single lens is a progressive focus structure or a step focus structure. US 2015 / 0160477 A1 also discloses a sub-unit concave lens or a middle single lens on the large unit convex lens, each combination produces middle defocus by combining with the lens of the large unit convex lens. The sub-unit concave lens or the middle single lens is arranged on the outer ring of the small unit concave lens or the small single lens and is annular.

[0007] WO 2018 / 026697 A1 discloses ophthalmic lenses for treating myopia. These lenses include a dot pattern distributed on each lens, the dot pattern including an array of dots spaced at a distance of 1 mm or less, each dot having a maximum size of 0.3 mm or less. The dots may be arranged on a square grid, a hexagonal grid, another grid, or in a semi-random or random pattern. The dots may be spaced at regular intervals, or the dot spacing may vary depending on the distance of the dots from the center of the lens. The dot pattern may include a clear aperture without dots having a maximum size greater than 1 mm, which is aligned with the visual axis of the wearer of the glasses. The clear aperture may be substantially circular or similar in shape. The dots may be protrusions or recesses on the surface of the corresponding lens. The protrusions may be formed of a transparent material. In order to make these protrusions, discrete portions of material are deposited on the lens surface corresponding to the dot pattern (e.g., by using an inkjet printer). The discrete portions provide protrusions after curing (e.g., using radiation). The dot pattern may reduce the image contrast of an object seen through the dot pattern by at least 30% compared to the image contrast of an object seen through the clear aperture. According to WO 2018 / 026697 A1, a pair of glasses is customized for a wearer, in particular so as to have lenses with an optical power that corrects the wearer's on-axis vision to 20 / 20 or better, the lenses comprising a dot pattern distributed on each lens, the dot pattern comprising an array of dots arranged such that, for at least a portion of the wearer's peripheral vision, the lenses correct the wearer's vision to 20 / 25 or better and reduce image contrast by at least 30% compared to the on-axis image contrast.

[0008] WO 2006 / 034652 A1 discloses a method for treating the progression of a refractive disorder in a human eye, in particular a method for counteracting the progression of myopia by strengthening myopic defocus and a method for counteracting the progression of hyperopia by strengthening hyperopic defocus. The method comprises generating a first image on the retina of a human eye, and generating a second image to produce defocus. Changing the defocus balance of the eye should affect the axial eye growth in the direction towards the normal refraction. This artificial movement can be introduced by a spectacle lens, preferably together with conventional correction, so that normal vision can be maintained. The spectacle lens can be a Fresnel lens or a center-peripheral multifocal lens comprising concentric optical zones with two or more optical powers.

[0009] WO 2010 / 075319 A2 discloses a therapeutic method for preventing, improving, or reversing an obstacle related to eye length. Therefore, in order to reduce the average spatial frequency of the image input to the retina of the eye to a value exceeding a threshold spatial frequency to inhibit further elongation of the eye, an artificial blur is caused in the patient's vision. In order to cause artificial blur, blur-inducing glasses can be used. Blurring glasses cause blurring by: small bumps or depressions in one or both surfaces of the lens, materials different from the lens material are included in the lens, higher levels of aberrations are included in the lens (including higher levels of aberrations that affect peripheral vision more), progressive negative correction is provided from the top of the lens to the bottom of the lens in one or both lenses, and coatings or films are applied to one or both surfaces of the lens. Reducing the density of bumps or depressions in the central area of ​​the lens, for example, helps to obtain relatively normal images of the portion of the scene that is axially aligned with the eye axis, while gradually blurring the portion of the scene that is not aligned with the optical axis. The amount of artificial blurring can be controlled by changing, for example, the density or size of the bumps or depressions.

[0010] WO 2019 / 166653 A1 discloses a lens element comprising a refractive area having a refractive power based on a human eye prescription and a plurality of at least three discontinuous optical elements, wherein at least one optical element has an aspherical optical function. At least one discontinuous optical element may be, for example, a multifocal refractive microlens made of a birefringent material, a diffractive lens, or have a shape configured to generate a caustic in front of the retina of the human eye.

[0011] WO 2019 / 16654A1 discloses a lens element, which includes a refractive area having a first refractive power based on a prescription for correcting abnormal refraction of a human eye, a second refractive power different from the first refractive power, and a plurality of at least three optical elements, wherein at least one optical element has an optical function of not focusing an image on the retina of the eye in order to slow down the progression of abnormal refraction of the eye. The difference between the first refractive power and the second refractive power may be greater than or equal to 0.5D.

[0012] WO 2019 / 166655 A1 discloses a lens element comprising a refractive area having a refractive power based on a human eye prescription and a plurality of at least three optical elements. The optical element is configured so that along at least one segment of the lens, the average sphere of the optical element increases from a point of the segment toward a peripheral portion of the segment. The optical element may be configured so that along at least one segment of the lens, the average cylinder of the optical element increases from a point of the segment toward a peripheral portion of the segment.

[0013] WO 2019 / 166657 A1 discloses a lens element comprising a prescription portion configured to provide a first optical power based on a wearer's prescription for correcting abnormal refraction of the wearer's eye to the wearer under standard wearing conditions and for foveal vision, and a plurality of at least three optical elements, wherein at least one optical element has an optical function of not focusing an image on the retina of the eye under standard wearing conditions and for peripheral vision so as to slow down the progression of abnormal refraction of the eye. At least one of the optical elements may have an optical function of focusing an image on a location other than the retina under standard wearing conditions and for peripheral vision.

[0014] WO 2019 / 166659 A1 discloses a lens element comprising a refractive zone having a refractive power based on a prescription of a wearer's eye, and a plurality of at least two continuous optical elements, wherein at least one optical element has an optical function of not focusing an image on the retina of the wearer's eye in order to slow down the progression of abnormal refraction of the eye. According to WO 2019 / 166659 A1, having a continuous optical element improves the aesthetics of the lens element and limits the degree of discontinuity of the lens element surface. At least two continuous optical elements may be independent.

[0015] WO 2019 / 206569 A1 discloses a lens element comprising a prescription portion configured to provide a wearer with a first optical function based on a wearer's prescription for correcting abnormal refraction of the wearer's eye under standard wearing conditions, and a plurality of continuous optical elements. Each optical element has a simultaneous bifocal optical function that simultaneously provides a second optical function under standard wearing conditions and a third optical function that does not focus an image on the retina of the eye under the standard wearing conditions in order to slow down the progression of abnormal refraction of the eye. According to WO 2019 / 206569A1, having a plurality of continuous optical elements that simultaneously provide the second and third optical functions allows easy configuration of a lens element that reduces the progression of abnormal refraction of the eye (such as myopia or hyperopia) by focusing part of the light on the wearer's retina and focusing part of the light in front of or behind the wearer's retina. In addition, the lens element allows selection of a portion of the light to be focused on the retina and a portion of the light not to be focused on the retina of the eye. WO 2019 / 026569 A1 also discloses a method for providing a lens element, the method comprising providing a lens component configured to provide a first refractive power based on a wearer's prescription for correcting abnormal refraction of the wearer's eye to a wearer under standard wearing conditions, providing an optical patch comprising a plurality of continuous optical elements and forming the lens element by placing the optical patch on one of the front surface or the back surface of the lens component. Alternatively, the method comprises casting the lens element and providing the optical patch comprising a plurality of continuous optical elements during casting.

[0016] EP 3 531 195 A1 discloses an ophthalmic lens comprising a nanostructured and / or microstructured coating. In order to obtain the nanostructured and / or microstructured coating, in a first step at least one surface of an uncoated or pre-coated lens substrate is covered with a layer of nanoparticles and / or microparticles, thereby masking the corresponding uncoated or pre-coated surface of the lens substrate. In a second step at least one coating is applied to the layer of nanoparticles and / or microparticles. Thus at least one coating covers the nanoparticles and / or microparticles and the corresponding uncoated or pre-coated surface of the lens substrate in the intermediate spaces between the nanoparticles and / or microparticles. In a third step the nanoparticles and / or microparticles are removed, and the nanostructured and / or microstructured coating remains on the corresponding uncoated or pre-coated surface of the lens substrate.

[0017] EP 2 682 807 A1 discloses a method for forming a mark on the surface of an ophthalmic lens by applying an additional transparent coating at the desired location of the coating, including a masking layer with openings at the desired location (both the masking layer and the openings will only be overcoated by the ophthalmic lens coating), or dyeing the lens substrate at the desired location. If an additional transparent coating is to be applied, a masking layer with openings is applied in a first step to the uncoated or precoated surface of the lens substrate to be marked. In a second step, a transparent coating is applied to the masking layer and through the openings of the masking layer to the respective uncoated or precoated surface. In a third step, the masking layer and the transparent coating on the masking layer are removed, so that the transparent coating remains on the respective uncoated or precoated surface. Thereafter, the transparent coating is overcoated with the coating of the ophthalmic lens, such as a multilayer anti-reflective coating, parts of a multilayer reflective coating and a water-repellent layer, so that a visible mark is produced. The mark can constitute a decorative pattern, logo, text that can be seen due to differences in light reflection, so that the wearer's field of vision is ensured without discomfort.

[0018] EP 3 339 940 A1 discloses a method for applying a coating to an uncoated or pre-coated surface of a lens substrate via a masking layer to ensure that, for example, a logo is visible due to the difference in refractive index of the coating applied with and without the masking layer.

[0019] WO 2007 / 066006 A2 discloses a method for transferring micro-sized patterns onto the surface of an optical article. Thus, a layer of transferable material is deposited on the surface of a stamp having recesses and protuberances constituting micro-reliefs, which correspond to the pattern to be transferred by contacting the stamp with a latex layer not yet dried and deposited on the surface of the optical article substrate. Depending on the pressure applied to the stamp, the layer of transferable material applied only to the protuberances or the layer of transferable material applied to the recesses and protuberances is transferred to the latex layer. After transfer, the stamp is removed.

[0020] US 2002 / 0158354 A1 discloses a method for preparing photochromic, UV / visible light absorbing and colored plastic lenses by using an activated light-curable lens forming composition. As an activating light source, an ultraviolet light source, an actinic light source, a visible light source and / or an infrared light source can be used. The lens forming material can include any suitable liquid monomer and any suitable photosensitive initiator. The lens curing unit includes a controller, which in particular determines the initial light dose required to cure the lens forming material in a pulse curing application, applies activating light of an intensity and duration sufficient to be equal to the determined light dose, and calculates the light dose required for the next application of activating light in the pulse curing application. A continuous activating light sequence can be used instead of a pulsed activating light curing sequence. In the case of a continuous activating light sequence, no equipment for generating light pulses is required, thereby reducing the cost of the lens curing device.

[0021] WO 97 / 39880A2 discloses forming an ophthalmic lens by placing a liquid polymerizable lens forming composition in a mold cavity, applying a plurality of high intensity light pulses to the lens forming composition, and curing the lens forming composition in a period of less than 30 minutes to form a substantially transparent ophthalmic lens. The pulses radiated from a flash light source (i.e., a flash lamp, such as a xenon light source) are preferably of sufficiently high intensity to induce a reaction in substantially all of the lens forming composition exposed to the pulses in the mold cavity. According to WO 97 / 39880A2, one advantage of applying pulsed light via a flash lamp is that, even when a higher intensity of light is applied, the total amount of light energy applied to cure the lens forming composition is reduced because the duration of the pulses is so short. According to WO 97 / 39880A2, another significant advantage is that relatively high quality semi-finished lens blanks and high magnification cast finished lenses can be produced without prematurely detaching from the mold cavity and without breaking. By interrupting or reducing the activation light at appropriate times during the cycle, the rate of heat generation and release can be controlled, and the occurrence of premature release can be reduced. According to WO 97 / 39880A2, it is possible to cure lens forming compositions comprising photoinitiators which absorb ultraviolet light in the wavelength range of 300 to 400 nm, and it is also possible for coating compositions each of which is curable when exposed to UV light and each of which comprises a photoinitiator to cure to form a substantially transparent combined coating.

[0022] WO 00 / 18569A2 discloses curing by placing a polymerizable lens forming composition in a mold / gasket assembly and continuously exposing the composition to pulsed activation light. A flash lamp (e.g., a xenon light source) can be used to emit activation light pulses. Tinted lenses, photochromic lenses, colorless lenses that absorb UV / light, and transparent lenses can be formed, the latter being formed by adding colorless, non-photochromic compounds that absorb UV / visible light to the lens forming composition. By adding UV / visible light absorbers to the lens forming composition, transparent lens compositions can be cured under stricter dosing requirements used in the curing of photochromic lens compositions. In addition, the transparent lenses formed can provide better protection against UV / visible light than transparent lenses formed in the absence of such compounds. In addition, WO 00 / 18569A2 discloses an in-mold method for forming a scratch-resistant coating or a tinted coating on a lens. Alternatively, the lens can be tinted, or a scratch-resistant coating can be applied to the lens after the lens is demolded. The scratch-resistant coating is then cured by applying activation light to this side of the lens. The lens forming compositions and coatings may contain a photoinitiator.

[0023] WO 2006 / 135390 A2 discloses coating compositions for curing ophthalmic lenses and coating compositions for uncoated ophthalmic lenses, each using an activating light pulse. Coatings such as hard coatings, anti-reflective coatings or photochromic coatings can be cured in an in-mold or in an out-of-mold process. Exemplarily, an ophthalmic lens is described that includes a hard coating and an anti-reflective coating manufactured by an in-mold process, wherein a mold with the coatings is exposed to a flash from a strobe light.

[0024] WO 01 / 94104A2 discloses the use of a UV-curable liquid composition for forming an anti-reflective coating on a visible light-transmitting ophthalmic lens. The anti-reflective coating can be formed in an in-mold or in an out-of-mold process. A hard coating composition can be applied before applying the anti-reflective coating. The UV light can be generated by a flash lamp. Light pulses can be used to affect the curing of the coating composition.

[0025] WO 03 / 078145A2 discloses an in-mold process for making coated ophthalmic lenses. Thus, before placing the lens forming composition in the mold cavity, the casting surface of the front mold member can be coated with one or more hard coatings. If two hard coatings are used, any defects (such as pinholes) in the first hard coating are covered by the second hard coating. The ophthalmic lens can be further coated with an anti-reflective coating in an in-mold process or in an out-of-mold process. Activation light including ultraviolet light, actinic light, visible light or infrared light can be applied to the coating composition to initiate curing of the coating composition. As an activation light source, a germicidal lamp, a mercury vapor lamp, a halide lamp and / or a strobe lamp can be used. By using a strobe lamp as an activation light source, less heat is generated between process runs, and the activation light dose can be controlled by controlling the intensity of the applied light, the frequency of the activation flashes, the duration of the activation flashes and / or the number of activation flashes. The lens forming material may include a photoinitiator that interacts with the activation light.

[0026] WO 00 / 56527A1 discloses lens forming compositions for preparing photochromic, UV / visible light absorbing colorless and colored plastic lenses by curing the lens forming composition with pulses of activating light in an in-mold process. The activating light capable of affecting a chemical change (e.g. causing polymerization to occur) may include ultraviolet light, actinic light, visible light, or infrared light. A flash lamp may be used to emit pulses of activating light to cure the lens forming material or to cure the lens coating. By placing a liquid coating in a mold and then curing it, a lens having a hard coating on the surface may be produced. The flash lamp may be a xenon light source. The relatively high intensity and short pulse duration of the xenon flash lamp may allow the lens forming composition to cure rapidly without applying significant radiant heat to the composition. The xenon flash lamp is used to apply multiple activating light pulses to the lens forming composition to cure it into an eyeglass lens in a period of less than 30 minutes. Due to the relatively high intensity that can be obtained with a xenon flash lamp, the lens forming composition may be allowed to penetrate and / or saturate more deeply, thereby allowing uniform curing of thicker lenses compared to conventional radiation-induced curing.

[0027] WO 99 / 06887A1 discloses an in-mold method for forming an ophthalmic lens by applying a plurality of activating light pulses to a lens forming composition. The pulses may be radiated from a flash lamp, such as a xenon light source. The flash lamp may also be used to cure the lens coating. WO 99 / 06887A1 further discloses an in-mold method for forming a scratch-resistant coating by placing a first coating composition in a mold member, distributing the first coating composition on a casting surface of the mold member, directing activating light at the mold member to cure at least a portion of the first coating composition, placing a second coating composition in the mold, the first coating composition and the second coating composition each comprising a photoinitiator, distributing the second coating composition on the first coating composition, directing activating light at the mold member to cure at least a portion of the second coating composition and forming a substantially transparent combined coating, assembling the mold member with the second mold member, placing a lens forming composition comprising a photoinitiator in a cavity and directing activating light at the mold to cure at least a portion of the lens forming material to form a coated ophthalmic lens. Alternatively, the ophthalmic lens may be demolded and then tinted, or a scratch resistant coating may be applied to the lens.The lens forming composition may contain activated light absorbing compounds, such as photochromic pigments, that inhibit the transmission of ultraviolet light to the eyes of a user wearing the ophthalmic lens.

[0028] US 2008 / 316558 A1 discloses a method of transferring a pattern onto the surface of an optical article by transferring a transferable material via a stamp.

[0029] EP20182515.5 discloses a method for drying and curing, sintering and / or hardening at least one coating precursor material by applying at least one single electromagnetic pulse. The at least one coating precursor material may include a hard coating precursor material in a hard coating. When compared with a conventional thermal curing process in which direct heat is applied, for example, in an oven, the total process duration required for drying and curing, sintering and / or hardening at least one coating precursor material is reduced. In addition, when the process parameters of the at least one single electromagnetic pulse are changed, the optical properties and / or mechanical properties are adjustable.

[0030] Based on the theory of creating a peripheral focus in front of or behind the retina to reduce or stop the stimulation of the retina of the eye that causes the eye to grow, several designs of eyeglasses have been proposed as described above. The stimulation originates from myopic or hyperopic defocus for peripheral vision, i.e., the focus is located behind or in front of the retina. When correcting the refraction of, for example, myopia with an eyeglass comprising a first refractive area and a second refractive area according to FIG. 1 of US 2017 / 013167 A1, in the foveal vision viewed through the hexagonal first refractive area with a refractive power based on the prescription for correcting the abnormal refraction of the eye, the light beam from infinity is refracted by the first refractive area, the cornea and other optical components of the eye to converge to a focus directly on the retina, actually on the fovea of ​​the eye. The object point at infinity forms a perfect image for the wearer of the eyeglass. Therefore, in the foveal vision, the eye should grow unchanged, subject to anatomical conditions that do not allow unchanged growth. In the peripheral vision viewed through one of the second refractive areas shown in FIG. 1 of US 2017 / 013167A1, the light beam from infinity is refracted by the second refractive area, the cornea, and other optical components of the eye to converge to a focus located in front of the eye retina. Therefore, in the peripheral vision where the focus is located in front of the eye retina, the eye should reduce the rate of eye growth or even stop it completely. However, the eye retina is not so uniformly curved that the light beam from infinity and refracted by any of the second refractive area, the cornea, and other optical components of the eye must converge to a focus located in front of the eye retina. In addition, the anatomical structure of the eye retina and the eye itself is formed or curved individually, and therefore is not the same for different people. Even the retina of a person's left eye and the retina of the right eye are not formed or curved in the same way. When the refraction of each eyeglass wearer is corrected with an eyeglass including the same defined first refractive area and the same defined second refractive area as in FIG. 1 of US 2017 / 013167 A1, the progression of myopia or hyperopia is uncontrollable. US 2017 / 013167 A1 does not mention a method for manufacturing a spectacle lens comprising a first refractive area and a second refractive area. For example, WO 2019 / 16653 A1, WO 2019 / 166654 A1, WO 2019 / 166655 A1, WO 2019 / 166657 A1 and WO 2019 / 166659 A1 propose different techniques for manufacturing the spectacle lenses described therein, such as direct surface treatment, molding, casting or injection, embossing, film forming, or photolithography.The use of molding processes for manufacturing ophthalmic lenses, such as those described in US 2017 / 013167 A1, WO 2019 / 16653 A1, WO 2019 / 166654 A1, WO 2019 / 166655 A1, WO 2019 / 166657 A1 or WO 2019 / 166659 A1, requires that each master mold has extremely high robustness and is able to obtain high quality of the corresponding optical surface. Molds made of glass will meet the aforementioned requirements, but are challenging and expensive to process. Using a molding process will require a different master mold to realize each optical surface with it, which is not suitable or at least not preferred in a high-throughput manufacturing process, for example for efficiency and cost reasons.

[0031] A very reliable method for producing any desired optical surface without the need for a mold is disclosed in EP19204745.4, published as EP 3812 142 A1. The method disclosed in EP19204745.4 even allows the production of final optical surfaces that are not obtainable by conventional grinding and polishing processes. The method disclosed herein is independent of the optical material to be used for the lens substrate. The method requires at least one coating that completely or at least partially covers the uncoated or pre-coated lens substrate, which at least one coating is modifiable when it is in contact or in contact with at least one medium. The modification of the at least one coating is preferably irreversible and has long-term stability. Compared to EP3 531 195 A1, for example, no additional coating is required to modify or adjust and / or produce any desired final optical surface. However, as described in EP19204745.4, when in contact with at least one medium capable of modifying the at least one coating, the time period for which the at least one coating is brought into contact is preferably in the range of 25 minutes to 30 hours, further preferably 30 minutes to 20 hours, more preferably 35 minutes to 15 hours and most preferably 40 minutes to 10 hours. The at least one coating may be brought into contact with the at least one medium at room temperature, i.e. at a temperature of 22°C ± 2°C, or at an elevated temperature comprising a temperature range of preferably 25°C to 80°C, further preferably 27°C to 55°C, more preferably 30°C to 50°C and most preferably 35°C to 45°C. The at least one coating may be brought into contact with the at least one medium when irradiated with xenon, preferably having a wavelength range of 280nm to 1200nm. The process conditions disclosed in EP19204745.4 and described above may be combined in any desired manner.

[0032] Departing from EP19204745.4, the problem of the present invention is to provide an alternative method for surface modification of ophthalmic lenses and thereby simultaneously speed up the time to obtain the ophthalmic lenses. Furthermore, the optical material of the lens substrate should not be restricted.

[0033] This problem has been solved by a method for producing an ophthalmic lens according to claim 1 and claim 12 .

[0034] The lens substrate is preferably based on an optical material, which is defined as a transparent material that can be manufactured into an optical component according to Section 3.3.1 of DIN EN ISO 13666:2019-12. The ophthalmic lens substrate can be made of: a mineral glass according to Section 3.3.1 of DIN EN ISO 13666:2019-12 and / or an organic hard resin (such as a thermosetting hard resin) according to Section 3.3.3 of DIN EN ISO 13666:2019-12; a thermoplastic hard resin according to Section 3.3.4 of DIN EN ISO 13666:2019-12; or a photochromic material according to Section 3.3.5 of DIN EN ISO 13666:2019-12.

[0035] Preferably, the ophthalmic lens substrate is based on at least one of the optical materials mentioned in the table below, particularly preferably on at least one of the organic hard resins.

[0036] Table: Examples of optical materials

[0037]

[0038] *Based on Sodium D line

[0039] In EP19204745.4, when in contact with at least one medium capable of modifying the at least one coating, the surface modification of the at least one coating that can be modified is preferably diffusion-controlled swelling of the at least one coating. It has been found that the modification of the surface modification, particularly the surface topography of the at least one coating, does not necessarily need to be a swelling process (as described in EP19204745.4) caused by at least one medium, preferably at least one acid, but is also possible by using the surface modification of at least one simple mechanical device. As in EP19204745.4, the at least one coating itself is modified without applying an additional coating. The at least one mechanical device should not be confused with, for example, a layer of nanoparticles and / or microparticles used for masking the coating in EP 3 531 195 A1, to which an additional coating must be applied to provide a structure of an additional coating based on the space between the nanoparticles and / or microparticles. In addition, the at least one mechanical device should not be confused with a transferable pattern by a stamp as disclosed in, for example, WO 2007 / 066006 A2.

[0040] In order to modify at least one coating by contact with at least one mechanical device, the at least one coating is applied to an uncoated or pre-coated surface of a lens substrate. Compared to conventional coating processes, the at least one coating applied is not cured and / or hardened, but preferably only dried and / or pre-cured. Drying and / or pre-curing preferably ensures that the at least one coating does not flow from the uncoated or pre-coated surface of the lens substrate to which it is applied. In addition, drying and / or pre-curing preferably ensures that the at least one coating is still modifiable when in contact with at least one mechanical device. Drying and / or pre-curing preferably increases the viscosity of the at least one coating without curing and / or hardening the at least one coating. The at least one mechanical device is preferably in contact with the surface of the at least one pre-cured coating. The contact is preferably achieved by touching the surface of the at least one pre-cured coating with the at least one mechanical device or by inserting the at least one mechanical device into the at least one pre-cured coating. After the at least one mechanical device is removed or pulled out of the at least one coating, a local change in the thickness of the at least one coating is observed. The at least one local change in the thickness of the coating is preferably observed as at least one microlens.

[0041] The at least one mechanical device is preferably only temporarily in contact with the at least one pre-cured or dried coating.

[0042] As at least one mechanical device, at least one contact head, an array of contact heads, a device comprising at least one contact head, at least one needle, an array of needles and / or a device comprising at least one needle can be used. Preferably, in an array of contact heads or in a device comprising at least two contact heads, each contact head is controllable or individually processable. Preferably, in an array of needles or in a device comprising at least two needles, each needle is controllable or individually processable. In an array of contact heads or in a device comprising at least two contact heads, each contact head can have the same form and the same size, or at least one of the contact heads can have a different form and / or a different size. In an array of needles or in a device comprising at least two needles, each of the needles can have the same form and the same size, or at least one of the needles can have a different form and / or a different size. In case a single contact head or a single needle (i.e. not an array or a device comprising at least two contact heads or at least two needles) should be used for the surface modification of the at least one coating, it should be mentioned that in this case at least two single contact heads or at least two single needles (e.g. having the same form and size or having different forms or sizes) are available.

[0043] Depending at least on the adjusted viscosity of the at least one precured coating, the removal speed or pull-out speed of the at least one mechanical device, the contact direction of the surface of the at least one precured coating with the at least one mechanical device, the direction in which the at least one mechanical device is inserted into the at least one precured coating, and / or the at least one mechanical device for surface modification of the at least one coating, a very wide variety of possible variations are provided for modifying the surface morphology of the at least one precured coating.

[0044] The modification of the surface topography of the at least one coating can produce at least one microlens with adjustable size and shape. The at least one microlens can show a 3D Gaussian shape, a 3D Gaussian shape with a flat top, a volcanic shape with a crater, or a complex shape or any mixed shape thereof. The shape of the at least one microlens can be symmetrical or asymmetrical. The at least one microlens preferably has a height in the range of preferably 1nm to 10μm, further preferably 2nm to 9μm, further preferably 3nm to 8μm, more preferably in the range of 4nm to 7μm and most preferably in the range of 5nm to 6μm. For surface modifications that produce complex shapes, the aforementioned ranges preferably apply to their maximum height. With regard to lateral extension, a width preferably in the range of 5μm to 20mm, further preferably 10μm to 10mm, further preferably 20μm to 5mm, more preferably 50μm to 4mm and most preferably 70μm to 3mm can be achieved by contacting the at least one coating with at least one mechanical device to modify the surface topography. The size is preferably determined by an optical profilometer based on white light interferometry.

[0045] With regard to the achievable surface power of the local surface modification producing the microlens or lenslet, a wide range is adjustable by the various modification possibilities described above. The surface power may be in the range of 0.2 diopters to 50 diopters, and preferably in the range of 0.25 diopters to 40 diopters, further preferably in the range of 0.3 diopters to 30 diopters, more preferably in the range of 0.4 diopters to 20 diopters and most preferably in the range of 0.5 diopters to 10 diopters. The surface power may be calculated as explained in EP19204745.4.

[0046] After the surface of the at least one precured coating has been modified by at least one mechanical device, the at least one coating is cured and / or hardened by a conventional curing process usually used for the corresponding at least one coating, for example by applying direct heat in an oven, or the at least one coating is cured and / or hardened by applying at least one electromagnetic pulse, for example using flash annealing or photonic curing methods. Regardless of the curing and / or hardening method used, the total process duration for obtaining the modified surface of the at least one coating is significantly reduced when compared to the method disclosed in EP19204745.4. However, the same or at least similar surface modification including at least one microlens can be achieved by contacting the precured surface of at least one coating with at least one mechanical device.

[0047] The use of a photonic curing method by applying at least one single electromagnetic pulse to the at least one modified surface has the advantage that the risk of unwanted or uncontrollable subsequent further modifications due to, for example, too low viscosity of the corresponding at least one pre-cured coating is minimized. The method is further compatible with temperature-sensitive lens substrates, i.e. temperature-sensitive lens substrates do not deteriorate even when reaching high temperatures for very short periods of time. Applying at least one single electromagnetic pulse to cure and / or harden the at least one pre-cured coating further has the advantage that the total process duration for curing and / or hardening is significantly reduced when compared to, for example, a thermal curing process or the method disclosed in EP19204745.4.

[0048] The at least one single electromagnetic pulse may be applied from at least one electromagnetic source selected from the group consisting of: at least one flash lamp (preferably at least one xenon flash lamp), at least one halogen lamp, at least one directed plasma arc, at least one laser, at least one microwave generator, at least one induction heater, at least one electron beam, at least one stroboscope and at least one mercury lamp. The at least one single electromagnetic pulse is preferably applied from at least one flash lamp. Preferably, the at least one flash lamp is a flash lamp filled with a gas selected from xenon, krypton and / or argon, preferably xenon. The at least one single electromagnetic pulse preferably has a wavelength in the range from 100nm to 1800nm, more preferably in the range from 150nm to 1300nm, most preferably in the range from 200nm to 1000nm. The at least one single electromagnetic pulse also preferably has a wavelength in the range from 350nm to 1000nm, more preferably in the range from 400nm to 800nm, most preferably in the range from 420nm to 700nm. The wavelength of the at least one single electromagnetic pulse applied from at least one of the aforementioned electromagnetic sources is preferably within these wavelength ranges. The at least one single electromagnetic pulse is applied to at least one of the surfaces of the eyeglass lens, namely (i) the front surface of the eyeglass lens, (i) the back surface of the eyeglass lens or (iii) the front and back surfaces of the eyeglass lens. In case (iii) when the at least one single electromagnetic pulse is to be applied to the front and back surfaces of the eyeglass lens, the position of one of the aforementioned electromagnetic sources can be alternated so that the at least one single electromagnetic pulse is applied directly to the front surface of the eyeglass lens or directly to the back surface of the eyeglass lens. Alternatively, in the aforementioned case (iii), at least two of the aforementioned electromagnetic sources are positioned so as to simultaneously or alternately apply the at least one single electromagnetic pulse directly to the front surface of the eyeglass lens and the at least one single electromagnetic pulse directly to the back surface of the eyeglass lens. In any case where at least two electromagnetic sources are used, the at least two electromagnetic sources can be of the same type or of different types.

[0049] "Single electromagnetic pulse" means light delivered by at least one of the above-mentioned electromagnetic sources and applied to at least one surface of the ophthalmic lens comprising at least one coating to be modified. At least one single electromagnetic pulse may be applied within one of the wavelength ranges defined above. The at least one single electromagnetic pulse preferably has a defined duration, i.e. a defined envelope. The envelope of the at least one single electromagnetic pulse is defined as the time period in which the at least one single electromagnetic pulse is applied to at least one surface of the ophthalmic lens comprising at least one coating to be modified. The envelope may be in the range from 50μs to 200ms, preferably in the range from 100μs to 150ms. Each single electromagnetic pulse may include at least two micropulses, each of the at least two micropulses having a defined duration within the envelope of each single electromagnetic pulse. The durations of the at least two micropulses within the envelope of a single electromagnetic pulse may be the same or different from each other. The percentage of the duration of all micropulses within the envelope of a single electromagnetic pulse is defined as the duty cycle of the single electromagnetic pulse. Furthermore, the at least one single electromagnetic pulse or at least one micropulse has a defined peak intensity. The peak intensity is defined as the rate at which light energy is applied per unit time to a unit area of ​​at least one coating layer, which is completely or at least partially covered by at least one medium, by a single electromagnetic pulse or a micropulse within a single electromagnetic pulse. The peak intensity is preferably in the range of 0.01 W / cm 2 Up to 200W / cm 2 In the range of 0.1 W / cm 2 Up to 150W / cm 2 In the range of 0.5 W / cm 2 Up to 100W / cm 2 range and most preferably from 1 W / cm 2 Up to 60W / cm 2The peak intensities of at least two micropulses within the envelope of a single electromagnetic pulse may be the same or different from each other. Preferably, the peak intensities of at least two micropulses within the envelope of a single electromagnetic pulse are the same as each other. The peak intensity between two consecutive micropulses within the envelope of a single electromagnetic pulse does not need to be zero, or does not need to be constant, or does not need to be equal. If necessary, each single electromagnetic pulse may be repeated to provide an electromagnetic pulse sequence. Within the electromagnetic pulse sequence, each single electromagnetic pulse may be repeated at least twice and up to 1000 times, preferably each single electromagnetic pulse is repeated between 2 and 100 times. Within the electromagnetic pulse sequence, the same single electromagnetic pulse is preferably repeated. Within the electromagnetic pulse sequence, the envelope of each single electromagnetic pulse may be the same or different from each other. Preferably, within the electromagnetic pulse sequence, the envelope of each single electromagnetic pulse is the same. Within the electromagnetic pulse sequence, each single electromagnetic pulse may include at least two micropulses, which may be the same or different from each other with respect to their peak intensity, duration and / or duty cycle. Preferably, within the sequence of electromagnetic pulses, each single electromagnetic pulse may include at least two micropulses, which are identical to each other with respect to their peak intensity, duration and / or duty cycle. Within the sequence of electromagnetic pulses comprising at least two single electromagnetic pulses, the at least two single electromagnetic pulses may be repeated at a repetition rate in the range of from 0.1 Hz to 5 Hz, preferably from 0.2 Hz to 4 Hz, further preferably from 0.3 Hz to 3.5 Hz and most preferably from 0.4 Hz to 2 Hz. The peak intensity of at least one single electromagnetic pulse within the envelope of at least one single electromagnetic pulse may be gradually reduced within the envelope and / or with each micropulse within the at least one single electromagnetic pulse. For example, this reduction may be due to the limitation of the charging capacitor of the electromagnetic source used to generate the at least one single electromagnetic pulse. The dose applied by at least one single electromagnetic pulse to the ophthalmic lens comprising at least one coating (the at least one coating is completely or at least partially covered by at least one medium) is the average intensity delivered with each single electromagnetic pulse over the total duration of the envelope, wherein each single electromagnetic pulse may or may not contain at least two micropulses each delivering a discrete amount of intensity. The dose applied by at least one single electromagnetic pulse may preferably be in the range of from 0.001 J / cm 2 Up to 50J / cm 2 , further preferably from 0.1 J / cm 2 Up to 30J / cm 2 , more preferably from 1 J / cm 2 Up to 20J / cm 2 And most preferably from 2.0 J / cm 2 Up to 15J / cm 2 In the range of 3 J / cm 2 Up to 8J / cm 2within the range.

[0050] The application of at least one single electromagnetic pulse includes the application of exactly one single electromagnetic pulse, which can be subdivided into at least two micropulses as described above. The application of at least one single electromagnetic pulse also includes the application of a single electromagnetic pulse, preferably at least two single electromagnetic pulses, and further preferably a plurality of single electromagnetic pulses, each of which can also be subdivided into at least two micropulses as explained above. Regardless of the exact number of single electromagnetic pulses, the explanation given above about at least one single electromagnetic pulse should apply.

[0051] The ophthalmic lens may comprise at least one coating modifiable when in contact with at least one mechanical device on the front surface (the surface of the lens intended to be mounted away from the eye according to section 3.2.13 of ISO 13666:2019(E)) and / or on the back surface (the surface of the lens intended to be mounted closer to the eye according to section 3.2.14 of ISO 13666:2019(E)). According to the definitions given previously, the terms front surface and back surface shall also apply to the lens substrate. Preferably, the ophthalmic lens comprises at least one coating modifiable when in contact with at least one mechanical device on its front surface. In case a photonic curing method is used for curing and / or hardening the modified surface, at least one single electromagnetic pulse may be applied to the front surface and / or back surface of the ophthalmic lens comprising at least one modifiable coating. Preferably, the at least one single electromagnetic pulse is applied to the front surface of the ophthalmic lens, which preferably comprises the at least one coating. However, in case the ophthalmic lens comprises at least one modifiable coating on its front and back surfaces, the at least one single electromagnetic pulse may still be applied to only one surface, for example only to the front surface. In this case, at least one coating, modified or unmodified, on the opposite surface (here the back surface of the ophthalmic lens) can be cured and / or hardened simultaneously and preferably at the same time by the at least one single electromagnetic pulse applied only to one surface (here the front surface). This simultaneous modification is believed to be based on the fact that energy is transferred from the at least one single electromagnetic pulse to both the front and back surfaces of the lens substrate due to slight differences in transparency of the lens substrate and the at least one modifiable coating. The transparency is preferably the transmittance at a given wavelength, which is preferably determined by using a UV VIS spectrophotometer, such as the UV VIS spectrophotometer Perkin Elmer 950S from Perkin Elmer. The portion of the light of the at least one single electromagnetic pulse that is not absorbed or only minimally absorbed by the at least one modifiable coating and / or the lens substrate is reflected at all possible interfaces, such as at the interface between the lens substrate and an adjacent coating and / or at the interface between the platform on which the ophthalmic lens is placed and an adjacent coating. The portion of the light of the at least one single electromagnetic pulse that is absorbed by, for example, the lens substrate is believed to be the cause of a brief transient heating of the lens substrate while not degrading the lens substrate. In addition, since the temperature is higher than the temperature of the at least one modifiable coating due to the brief transient heating of the lens substrate, the curing and / or hardening of the at least one coating on the opposite surface is believed to be based on an indirect effect caused by the applied at least one single electromagnetic pulse. Furthermore, the back reflection of the at least one single electromagnetic pulse from the platform on which the ophthalmic lens is placed is also believed to contribute to the curing and / or hardening of the at least one coating on the opposite surface to which the at least one single electromagnetic pulse was not directly applied.The combination of at least direct energy transfer from the at least one single electromagnetic pulse, indirect energy transfer from the heated lens substrate and indirect energy transfer from the platform is considered to be a reasonable explanation for the simultaneous curing and / or hardening of the at least one coating on the front and back surfaces of the ophthalmic lens by applying at least one single electromagnetic pulse to only one of the surfaces. Preferably, the total process duration is not or at least not significantly extended by applying the at least one single electromagnetic pulse to only one surface but curing and / or hardening the at least one coating on both surfaces simultaneously.

[0052] The total process duration, i.e. the total time required to cure and / or harden the at least one modified coating applied on at least one surface of an uncoated or pre-coated lens substrate by using at least one single electromagnetic pulse as described above, is preferably in the range of from 100 μs to 7 min, further preferably from 300 μs to 5 min, more preferably from 500 μs to 4 min and most preferably from 1 ms to 3 min. The total process duration for curing and / or hardening the at least one modified coating applied on at least one surface of an uncoated or pre-coated lens substrate by using a conventional thermal curing process (i.e. applying direct heat by an oven) can be up to three hours. Both variants of curing and / or hardening allow the surface modification of the at least one pre-cured coating in a reduced time compared to the method disclosed in EP19204745.4.

[0053] Modifying at least one pre-cured coating by contact with at least one mechanical device can produce a target optical surface that can be the same as the target optical surface obtainable by the method disclosed in EP19204745.4, but as mentioned above, the total process duration is much shorter than the contact time required in EP19204745.4 (although the pre-curing of the at least one coating, the surface modification produced by contact with at least one mechanical device and the additional curing and / or hardening are three steps to be performed).

[0054] The curing and / or hardening of the at least one coating can be carried out in a batch process or in a continuous process. A batch process can be carried out, for example, without displacement. A continuous process can be carried out, for example, with displacement. An example of a continuous process is by using a conveyor belt.

[0055] The surface modification of the at least precured coating is preferably irreversible after curing and / or hardening.

[0056] The at least one coating that can be modified upon contact with at least one mechanical device (preferably after drying and / or precuring) is preferably selected from at least one of the group consisting of: at least one primer coating, at least one hard coating, at least one photochromic coating and at least one coating based on a coating composition that can be used as a photochromic coating but does not contain at least one photochromic dye.

[0057] The at least one hard coating layer may be based on at least one of the hard coating compositions disclosed in US 2005 / 0171231 A1, US 2009 / 0189303 A1 or US 2002 / 0111390 A1. Alternatively, the at least one hard coating layer may be based on the anti-wear coating composition disclosed in WO 2007 / 070976 A1.

[0058] The at least one hard coating composition is preferably based on at least one hard coating composition disclosed in EP 2 578 649 A1, in particular in claim 1 of EP 2 578 649 A1. The at least one hard coating composition configured to produce at least one hard coating preferably comprises

[0059] A) a) at least one Si(OR 1 )(OR 2 )(OR 3 )(OR 4 ) silane derivatives, wherein R 1 , R 2 , R 3 and R 4 may be the same or different and are selected from alkyl, acyl, alkylene acyl, cycloalkyl, aryl or alkylene aryl, each of which may be optionally substituted, and / or

[0060] b) at least one hydrolysis product of the at least one silane derivative of formula (I), and / or

[0061] c) at least one condensation product of the at least one silane derivative of formula (I), and / or

[0062] d) any mixture of components a) to c);

[0063] B) a) at least one R 6 R 7 3-n Si(OR 5 ) n Silane derivatives, wherein R 5 is selected from alkyl, acyl, alkylene acyl, cycloalkyl, aryl or alkylene aryl, each of which may be optionally substituted, R 6 is an organic group containing at least one epoxy group, R 7is selected from alkyl, cycloalkyl, aryl or alkylenearyl, each of which may be optionally substituted, and n is 2 or 3; and / or

[0064] b) at least one hydrolysis product of the at least one silane derivative of formula (II), and / or

[0065] c) at least one condensation product of the at least one silane derivative of formula (II), and / or

[0066] Any mixture of components a) to c);

[0067] C) at least one colloidal inorganic oxide, hydroxide, oxide hydrate, fluoride and / or oxyfluoride;

[0068] D) at least one epoxy compound having at least two epoxy groups; and

[0069] E) at least one catalyst system comprising at least one Lewis acid and at least one thermolatent Lewis acid-base adduct.

[0070] The term "at least one hydrolysis product" of at least one silane derivative of the formula (I) or (II), respectively, means that the at least one silane derivative of the formula (I) or (II), respectively, has been at least partially hydrolyzed to form silanol groups.

[0071] The term "at least one condensation product" of at least one silane derivative of the formula (I) or formula (II), respectively, means that a certain degree of crosslinking has also occurred by condensation reaction of the silanol groups.

[0072] The at least one silane derivative of formula (I) may be selected from tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, tetraisopropoxysilane, tetrabutoxysilane, tetraisobutoxysilane, tetra(methoxyethoxy)silane, tetra(methoxypropoxy)silane, tetra(ethoxyethoxy)silane, tetra(methoxyethoxyethoxy)silane, trimethoxyethoxysilane, dimethoxydiethoxysilane or mixtures thereof.

[0073] The at least one silane derivative of formula (II) can be selected from 3-glycidoxymethyltrimethoxysilane, 3-glycidoxypropyltrihydroxysilane, 3-glycidoxypropyldimethylhydroxysilane, 3-glycidoxypropyldimethylethoxysilane, 3-glycidoxypropylmethyldiethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 3-glycidoxypropyldimethoxymethylsilane, 3-glycidoxypropyldiethoxymethylsilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane or mixtures thereof.

[0074] The at least one colloidal inorganic oxide may be selected from silicon dioxide, titanium dioxide, zirconium dioxide, tin dioxide, antimony oxide, aluminum oxide, silver oxide, copper oxide or mixtures thereof.

[0075] The average particle size of the at least one colloidal inorganic oxide, hydroxide, fluoride or oxyfluoride is preferably selected so that the transparency of the at least one hard coating is not affected. Preferably, the at least one colloidal inorganic oxide, hydroxide, oxide hydrate, fluoride and / or oxyfluoride has an average particle size in the range of from 2 nm to 150 nm, even more preferably from 2 nm to 70 nm. The average particle size is preferably determined by dynamic light scattering. The at least one colloidal inorganic oxide, hydroxide, oxide hydrate, fluoride or oxyfluoride helps to increase scratch resistance by incorporating into the existing network. Furthermore, the at least one colloidal inorganic oxide, hydroxide, oxide hydrate, fluoride or oxyfluoride is selected so that the refractive index of the at least one hard coating matches the refractive index of the uncoated ophthalmic lens substrate or with a pre-coating of the ophthalmic lens substrate.

[0076] The at least one epoxy compound having at least two epoxy groups is preferably a polyglycidyl ether compound, more preferably a diglycidyl ether or a triglycidyl ether compound. For example, as at least one epoxy compound (comprising at least two epoxy compounds), diglycidyl ether, ethylene glycol diglycidyl ether, propylene glycol diglycol glycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, trimethylolpropane triglycidyl ether, triglycidyl glycerol and / or trimethylolethane triglycidyl ether can be used in the coating composition. Preferably, the at least one epoxy compound includes trimethylolpropane triglycidyl ether, butanediol diglycidyl ether and / or 1,6-hexanediol diglycidyl ether.

[0077] The at least one catalyst system comprising at least one Lewis acid and at least one thermolatent Lewis acid-base adduct enables very uniform crosslinking and therefore also enables constant high strength over the entire layer thickness of at least one hard coating. The term "Lewis acid" relates to an electrophilic electron pair acceptor compound, the term "Lewis base" is understood to mean an electron pair donor compound. The at least one Lewis acid is preferably a Lewis acid that is catalytically active even at relatively low temperatures, for example at room temperature. The at least one Lewis acid can be selected from ammonium salts, metal salts (especially metal salts of metals from one of Group 1 (i.e., alkali metal salts), Group 2 (i.e., alkaline earth metal salts) or Group 13 (preferably Al or B) of the Periodic Table), halides of elements from Group 13 of the Periodic Table (especially AIX 3 or BX 3, wherein X is chlorine or fluorine), organic sulfonic acids and amine salts thereof, alkali metal salts or alkaline earth metal salts (e.g. alkali metal salts or alkaline earth metal salts of carboxylic acids), fluoride salts, organic tin compounds, or mixtures thereof. Preferred metal salts of metals from one of Groups 1, 2 and 13 of the Periodic Table of Elements are, for example, perchlorates or carboxylates. Preferred Lewis acids are, for example, ammonium perchlorate, magnesium perchlorate, sulfonic acids and salts thereof, such as trifluoromethanesulfonic acid and salts thereof.

[0078] The at least one Lewis acid-base adduct is understood to mean a compound which is catalytically active for the chemical reaction in question only at relatively high temperatures and remains essentially catalytically inactive at room temperature. The thermolatent catalyst compound is converted into the catalytically active state merely by supplying sufficient thermal energy.

[0079] The at least one silane derivative of formula (I) and / or the hydrolyzate of the silane derivative of at least one formula (I) and / or the condensation product of the silane derivative of at least one formula (I) are each based on the gross weight of the at least one hard coating composition, preferably present in the at least one hard coating composition in an amount of 5% by weight to 50% by weight, more preferably 6% by weight to 20% by weight. The amount given before is applicable to the at least one silane derivative of formula (I), the hydrolyzate of at least one formula (I), the condensation product of at least one formula (I) or any mixture thereof. The amount given before is also applicable to the mixture of the silane derivative of formula (I), the mixture of the hydrolyzate of the silane derivative of at least one formula (I), the mixture of the condensation product of the silane derivative of at least one formula (I) or any mixture thereof.

[0080] The at least one silane derivative of formula (II) and / or the hydrolyzate of the at least one silane derivative of formula (II) and / or the condensation product of the at least one silane derivative of formula (II) are each based on the gross weight of the at least one hard coating composition, preferably present in the at least one hard coating composition in an amount of 5% to 50% by weight, more preferably 6% to 20% by weight. The amount given before is applicable to the at least one silane derivative of formula (II), the hydrolyzate of the at least one formula (II), the condensation product of the at least one formula (II) or any mixture thereof. The amount given before is also applicable to the mixture of the silane derivative of formula (II), the mixture of the hydrolyzate of the silane derivative of at least one formula (II), the mixture of the condensation product of the silane derivative of at least one formula (II) or any mixture thereof.

[0081] The weight ratio of the at least one silane derivative of formula (I), the at least one hydrolysate of the silane derivative of formula (I) and / or the at least one condensation product of the silane derivative of formula (I) to the at least one silane derivative of formula (II), the at least one hydrolysate of the silane derivative of formula (II) and / or the at least one condensation product of the silane derivative of formula (II) is preferably in the range of from 95 / 5 to 5 / 95, more preferably in the range of from 70 / 30 to 30 / 70, and most preferably in the range of from 60 / 40 to 40 / 60.

[0082] The at least one colloidal inorganic oxide, hydroxide, fluoride and / or oxyfluoride are each based on the gross weight of the at least one hard coating composition, preferably present in the at least one hard coating composition in an amount of 5% to 50% by weight, more preferably 6% to 25% by weight. The aforementioned amount is applicable to a type of colloidal oxide, a type of hydroxide, a type of fluoride, a type of oxyfluoride, a mixture thereof, a mixture of different colloidal oxides, a mixture of different colloidal hydroxides, a mixture of different colloidal fluorides, a mixture of different colloidal oxyfluorides or a mixture thereof. The mixture of different colloidal oxides, hydroxides, fluorides or oxyfluorides can, for example, include one type of each with different particle sizes or different types of each with the same or different particle sizes.

[0083] The at least one epoxy compound having at least two epoxy groups is present in the at least one hard coating composition in an amount of preferably 0.1 wt % to 10 wt %, more preferably 0.5 wt % to 10 wt %, based on the total weight of the at least one hard coating composition, respectively. The amounts given above are applicable to mixtures of one type of epoxy compound or different types of epoxy compounds.

[0084] The at least one catalyst system is each preferably present in the at least one hard coating composition in an amount ranging from 0.01 wt % to 5 wt %, more preferably ranging from 0.1 wt % to 3 wt %, based on the total weight of the hard coating composition.

[0085] The weight ratio of the at least one Lewis acid to the at least one thermolatent Lewis acid-base adduct is preferably in the range from 20 / 1 to 1 / 2, more preferably from 5 / 1 to 2 / 1.

[0086] The hard coating composition further comprises at least one solvent, which comprises at least one alcohol, at least one ether, at least one ester or water. If the at least one solvent comprises two different solvents, the boiling point of the first solvent S1 and the boiling point of the second solvent S2 are S1 / S2≥1.2 or S1 / S2≤0.8. In addition, if the at least one solvent comprises two different solvents, the weight ratio of the first solvent to the second solvent is preferably in the range of from 5 to 0.01, more preferably in the range of from 2 to 0.2.

[0087] The water is preferably present in an amount of 2 wt % to 15 wt % based on the total weight of the hard coating composition.

[0088] The use of the above-mentioned coating composition comprising components (A) to (E) (i.e., at least one first silane derivative of formula (I), at least one hydrolysis product and / or at least one condensation product thereof, at least one second silane derivative of formula (II), at least one hydrolysis product and / or at least one condensation product thereof, at least one colloidal inorganic oxide, hydroxide, fluoride and / or oxyfluoride, at least one epoxide and at least one catalyst system) enables the production of at least one hard coating having very good adhesion strength, having high hardness; preferably having high scratch resistance and showing a low tendency to crack formation (despite the modification of the surface morphology having been accomplished by contact with at least one mechanical device). The at least one hard coating composition is preferably cured and / or hardened by applying direct heat or at least one single electromagnetic pulse, as described below.

[0089] As an alternative or in addition to the aforementioned at least one hard coating composition producing at least one hard coating, the edge surface of the edged lens, the front surface of the optionally uncoated or pre-coated ophthalmic lens substrate and the back surface of the optionally uncoated or pre-coated ophthalmic lens substrate each comprise at least one hard coating, preferably based on at least one hard coating composition comprising:

[0090] A) a) at least one R 1 R 2 3-n Si(OR 3 ) n Silane derivatives, wherein R 1 includes alkyl, cycloalkyl, acyl, aryl or heteroaryl, each of which may be substituted, R 2 is an organic residue containing an epoxy group, R 3 comprises alkyl, cycloalkyl, aryl or heteroaryl, each of which may be substituted, n=2 or 3, and / or

[0091] b) at least one hydrolysis product of the silane derivative of formula (III), and / or

[0092] c) at least one condensation product of a silane derivative of the formula (III), and / or

[0093] d) any mixture of components a) to c);

[0094] B) at least one colloidal inorganic oxide, hydroxide, oxide hydrate, fluoride and / or oxyfluoride;

[0095] C) at least one epoxy component comprising at least two epoxy groups; and

[0096] D) at least one catalyst system comprising at least one Lewis acid and at least one thermolatent Lewis base adduct.

[0097] The term "at least one hydrolysis product" of at least one silane derivative of the formula (III) means that the at least one silane derivative of the formula (III) has been at least partially hydrolyzed to form silanol groups.

[0098] The term "at least one condensation product" of at least one silane derivative of the formula (III) means that a certain degree of crosslinking has occurred by condensation reaction of the silanol groups.

[0099] The at least one silane derivative of formula (III) and / or the hydrolyzate of the at least one silane derivative of formula (III) and / or the at least one condensation product of the at least one silane derivative of formula (III) and / or any mixture thereof are each based on the gross weight of the at least one coating composition, preferably from 9 wt % to 81 wt %, further preferably from 13 wt % to 76 wt %, more preferably from 19 wt % and most preferably from 23 wt % to 66 wt % in the total amount in the range. The amount given above is applicable to the at least one silane derivative of formula (III), the hydrolyzate of the at least one formula (III), the condensation product of the at least one formula (III) or any mixture thereof. The amount given above is also applicable to a mixture of a silane derivative of formula (III), a mixture of a hydrolyzate of the at least one silane derivative of formula (III), a mixture of a condensation product of the at least one silane derivative of formula (III) or any mixture thereof.

[0100] The at least one colloidal inorganic oxide, hydroxide, oxide hydrate, fluoride and / or oxyfluoride are each based on the gross weight of the at least one hard coating composition, preferably from 3 wt % to 60 wt %, further preferably from 6 wt % to 58 wt %, more preferably from 9 wt % to 57 wt % and most preferably from 13 wt % to 55 wt % in the total amount in the range. The amount given before is applicable to a type of colloidal inorganic oxide, a type of colloidal inorganic hydroxide, a type of colloidal inorganic oxide hydrate, a type of colloidal inorganic fluoride, a type of colloidal inorganic fluoride and any mixture thereof. The amount given before is also applicable to a mixture of different colloidal inorganic oxides, a mixture of different colloidal inorganic hydroxides, a mixture of different colloidal inorganic oxide hydrates, a mixture of different colloidal inorganic fluorides, a mixture of different colloidal inorganic fluoride or any mixture thereof. The mixture mentioned can each include colloidal inorganic oxides, hydroxides, oxide hydrates, fluorides and / or oxyfluorides of different particle sizes or different types.

[0101] The at least one epoxy compound comprising at least two epoxy groups is present in the at least one hard coating composition in an amount preferably in the range of from 0.01 wt % to 14 wt %, further preferably from 0.07 wt % to 11 wt %, more preferably from 0.1 wt % to 6 wt % and most preferably from 0.2 wt % to 13 wt %, each based on the total weight of the at least one hard coating composition. The amounts given above apply to one type of epoxy compound as well as mixtures of different epoxy compounds.

[0102] The at least one catalyst system comprising at least one Lewis acid and at least one thermolatent Lewis base adduct is present in the at least one hard coating composition in an amount preferably ranging from 0.04 wt % to 4 wt %, further preferably from 0.1 wt % to 3 wt %, more preferably from 0.2 wt % to 2 wt % and most preferably from 0.3 wt % to 1 wt %, each based on the total weight of the at least one hard coating composition. The weight ratio of at least one Lewis acid to at least one thermolatent Lewis base adduct is preferably in the range of from 20:1 to 2:1, further preferably from 18:1 to 1:2, more preferably from 13:1 to 1:1 and most preferably from 6:1 to 1:1.

[0103] The at least one hard coating composition may comprise at least one organic solvent and / or water.The components of the at least one hard coating composition producing the at least one hard coating are used in amounts that add up to 100 wt %, based on the total weight of the at least one hard coating composition.

[0104] As at least one silane derivative of formula (III), for example, 3-glycidyloxymethyl-trimethoxysilane, 3-glycidyloxypropyl trihydroxysilane, 3-glycidyloxypropyl-dimethylhydroxysilane, 3-glycidyloxypropyl dimethylethoxysilane, 3-glycidyloxypropyl methyldiethoxysilane, 3-glycidyloxypropyl trimethoxysilane, 3-glycidyloxypropyl-triethoxysilane, 3-glycidyloxypropyl-dimethoxymethylsilane, 3-glycidyloxypropyldiethoxymethylsilane and / or 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane can be used in at least one hard coating composition. Preferably, 3-glycidyloxypropyl trimethoxysilane and / or 3-glycidyloxypropyl triethoxysilane are used as the silane derivative of formula (III).

[0105] The at least one colloidal inorganic oxide, hydroxide and / or oxide hydrate may be a metal oxide, metal hydroxide and / or metal oxide hydrate, wherein the metal ions of the metal oxide, metal hydroxide and / or metal oxide hydrate include or are the following metals: titanium, preferably TiO 2 , silicon, preferably SiO 2 , zirconium, preferably ZrO 2 , tin, preferably SnO 2 , antimony, preferably Sb 2 O 3 , aluminum, preferably Al 2 O 3 or AlO(OH), silver, preferably Ag 2 O, copper, preferably CuO or Cu 2 O, and / or mixed oxides and / or mixtures thereof. Preferably, the colloidal inorganic oxide, hydroxide, oxide hydrate is a metal oxide, metal hydroxide and / or metal oxide hydrate, wherein the metal ions of the metal oxide, metal hydroxide and / or metal oxide hydrate include or are metals of the following items: titanium, silicon, zirconium or mixtures thereof, further preferably silicon. Further preferably, at least one colloidal inorganic oxide, hydroxide and / or oxide hydrate forms core-shell particles. In such core-shell particles, the core preferably comprises a metal oxide, metal hydroxide and / or metal oxide hydrate, wherein the metal ions of the metal oxide, metal hydroxide and / or metal oxide hydrate include or are metals of the following items: titanium, preferably TiO 2 , and / or zirconium, preferably ZrO 2 , and the shell preferably comprises a metal oxide, a metal hydroxide and / or a metal oxide hydrate, wherein the metal ion of the metal oxide, the metal hydroxide and / or the metal oxide hydrate comprises or is silicon, preferably SiO 2As colloidal inorganic fluoride, magnesium fluoride can be used. At least one colloidal oxide, hydroxide, oxide hydrate, fluoride and / or oxyfluoride has an average particle size in the range of preferably from 3 nm to 70 nm, further preferably from 6 nm to 64 nm, more preferably from 8 nm to 56 nm and most preferably from 9 nm to 52 nm.

[0106] As at least one epoxy compound (comprising at least two epoxy compounds), for example, diglycidyl ether, ethylene glycol diglycidyl ether, propylene glycol diglycol glycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, trimethylolpropane triglycidyl ether, triglycidyl glycerol and / or trimethylolethane triglycidyl ether can be used in at least one hard coating composition. Preferably, the at least one epoxy compound comprises trimethylolpropane triglycidyl ether, butanediol diglycidyl ether and / or 1,6-hexanediol diglycidyl ether.

[0107] As at least one Lewis acid, for example, ammonium perchlorate, magnesium perchlorate, sulfonic acids and / or sulfonates (such as trifluoromethanesulfonic acid and / or its salts) can be used in at least one catalyst system.

[0108] As at least one Lewis base adduct, it is possible to use, for example, metal complex compounds such as aluminum acetylacetonate, iron acetylacetonate and / or zinc acetylacetonate in at least one catalyst system.

[0109] The use of at least one hard coating composition comprising components (A) to (D) (i.e. at least one silane derivative of formula (III), at least one hydrolysis product and / or at least one condensation product thereof, at least one colloidal inorganic oxide, hydroxide, hydrated oxide, fluoride and / or oxyfluoride, at least one epoxide and at least one catalyst system) enables the production of at least one hard coating having a high hardness; preferably having a high scratch resistance and showing a low tendency to crack formation (despite the modification of the surface morphology by the at least one mechanical means).

[0110] The at least one hard coating composition producing at least one hard coating layer is preferably applied to the uncoated or pre-coated edge surface of the edged lens by a brush and / or a scraper. The at least one hard coating composition producing at least one hard coating layer is preferably applied to the uncoated or pre-coated front surface and / or the uncoated or pre-coated back surface of the ophthalmic lens substrate of the edged lens by dip coating or spin coating. If the at least one hard coating composition producing at least one hard coating layer is applied simultaneously to the uncoated or pre-coated edge surface, the uncoated or pre-coated front surface and the uncoated or pre-coated back surface, preferably the at least one hard coating composition is applied by dip coating.

[0111] The at least one hard coating composition is preferably cured and / or hardened by direct application of heat or by application of at least one electromagnetic pulse.

[0112] The at least one primer coating is preferably based on at least one primer coating composition comprising:

[0113] i) at least one aqueous aliphatic, cycloaliphatic, aromatic or heteroaromatic polyurethane dispersion, at least one aqueous aliphatic, cycloaliphatic, aromatic or heteroaromatic polyurea dispersion, at least one aqueous aliphatic, cycloaliphatic, aromatic or heteroaromatic polyurethane-polyurea dispersion, and / or at least one aqueous aliphatic, cycloaliphatic, aromatic or heteroaromatic polyester dispersion, preferably at least one aqueous aliphatic polyurethane dispersion or at least one aqueous aliphatic polyester dispersion and more preferably at least one aqueous aliphatic polyurethane dispersion,

[0114] ii) at least one solvent,

[0115] iii) optionally at least one additive.

[0116] The at least one aqueous aliphatic, cycloaliphatic, aromatic or heteroaromatic polyurethane dispersion, the at least one aqueous aliphatic, cycloaliphatic, aromatic or heteroaromatic polyurea dispersion, the at least one aqueous aliphatic, cycloaliphatic, aromatic or heteroaromatic polyurethane-polyurea dispersion, and / or the at least one aqueous aliphatic, cycloaliphatic, aromatic or heteroaromatic polyester dispersion are present in the at least one primer coating composition in a total amount selected from the range of preferably from 2 wt % to 38 wt %, further preferably from 4 wt % to 34 wt %, further preferably from 5 wt % to 28 wt %, more preferably from 6 wt % to 25 wt % and most preferably from 7 wt % to 21 wt %, each based on the total weight of the at least one primer coating composition. The total amount includes the amount of only one of the aforementioned dispersions or mixtures thereof.

[0117] The at least one primer coating composition preferably comprises at least one aqueous polyurethane dispersion, wherein the polyurethane comprises polyester units as spacers or the polyurethane dispersion is a polyurethane-polyurea dispersion, characterized in that both urethane groups and urea groups occur in the macromolecular chain of the polyurethane-polyurea. Such polyurethane dispersions are described, for example, in WO 94 / 17116 A1, in particular WO 94 / 17116 A1, page 7, lines 11 to 33. As described in WO 94 / 17116 A1, in particular WO 94 / 17116 A1, page 7, lines 33 to 35, aqueous polyurethane dispersions can be blended with anionically stabilized acrylic emulsions.

[0118] The at least one solvent is present in the at least one primer coating composition in an amount selected from the range of preferably from 68 wt % to 99 wt %, further preferably from 69 wt % to 98 wt %, more preferably from 81 wt % to 97 wt % and most preferably from 89 wt % to 93 wt %, each based on the total weight of the at least one primer coating composition. The aforementioned amounts are applicable to one type of solvent as well as mixtures of different solvents.

[0119] As at least one solvent, preferably at least one organic solvent having a low boiling point of <100°C at normal pressure and at least one organic solvent having a medium boiling point of 100°C to 150°C at normal pressure can be used. As at least one organic solvent having a low boiling point, for example, methanol, ethanol, 1-propanol, 2-propanol, tert-butanol, acetone, ether, tert-butyl methyl ether, tetrahydrofuran, chloroform, 1,2-dichloroethane, dichloromethane, cyclohexane, ethyl acetate, n-hexane, n-heptane and / or methyl ethyl ketone can be used. Preferably, methanol, ethanol, 1-propanol and / or 2-propanol are used as at least one solvent having a low boiling point. As at least one organic solvent having a medium boiling point, for example, 1-methoxy-2-propanol, 1-butanol, dibutyl ether, 1,4-dioxane, 3-methyl-1-butanol, 4-hydroxy-4-methyl-2-pentanone, methyl isobutyl ketone and / or toluene can be used. Preferably, 1-methoxy-2-propanol and / or 4-hydroxy-4-methyl-2-pentanone are used as at least one solvent having a medium boiling point.

[0120] The weight ratio of the at least one solvent having a low boiling point to the at least one solvent having a medium boiling point is preferably 1:1, further preferably 1:1.4, more preferably 1:1.5 and most preferably 1:1.7.

[0121] As at least one solvent, at least one organic solvent with a low boiling point, at least one solvent with a medium boiling point and water can be used. The weight ratio of the at least one solvent with a low boiling point to the at least one solvent with a medium boiling point to water is preferably 2:7:1, further preferably 2.5:6.5:1, further preferably 3:6:1, more preferably 3:5:1 and most preferably 3:6:1.

[0122] The at least one primer coating composition may optionally include at least one additive. The at least one additive may include at least one dispersant, at least one anti-settling agent, at least one wetting agent, at least one biocide, at least one UV absorber, or mixtures thereof.

[0123] The at least one primer coating composition comprising components i) to iii) (i.e. the at least one dispersion, the at least one solvent and optionally the at least one additive) produces at least one primer coating after application, drying and curing. The curing and / or hardening of the at least one primer coating composition is carried out by direct application of heat or by application of at least one single electromagnetic pulse.

[0124] At least one photochromic coating may be based, for example, on a photochromic composition as described in EP 1 433 814 A1, EP 1 602 479 A1 or EP 1 561 571 A1. The at least one coating based on a coating composition that typically produces a photochromic composition may comprise a composition as described in EP 1 433 814 A1, EP 1 602 479 A1 or EP 1 561 571 A1, but without any photochromic dye.

[0125] EP 1 433 814 A1, in particular EP 1 433 814 A1, claim 1, discloses a photochromic composition comprising (1) 100 parts by weight of a free-radically polymerizable monomer; (2) 0.01 to 20 parts by weight of an amine compound; and (3) 0.01 to 20 parts by weight of a photochromic compound, wherein the free-radically polymerizable monomers include free-radically polymerizable monomers having a silanol group or a group that forms a silanol group by hydrolysis, and / or free-radically polymerizable monomers having an isocyanate group. According to EP 1 433 814 A1, in order to increase the adhesion between the photochromic coating produced by the photochromic composition described therein and the substrate of the ophthalmic lens, a free-radically polymerizable monomer having a silanol group or a group that forms a silanol group by hydrolysis or a free-radically polymerizable monomer having an isocyanate group is used. EP 1 433 814 A1, page 3, paragraphs

[0025] to page 7, paragraph

[0046] mentions available monomers. In addition, according to EP 1 433 814 A1, the photochromic composition may contain other free radical polymerizable monomers. As other polymerizable monomers, a free radical polymerizable monomer ("high hardness monomer") having a homopolymer L-level Rockwell hardness of at least 60 and a free radical polymerizable monomer ("low hardness monomer") having a homopolymer L-level Rockwell hardness of 40 or less is preferably used to improve the properties of the resulting photochromic coating, such as solvent resistance, hardness and heat resistance, or its photochromic properties such as color intensity and fading speed. In EP 1 433 814 A1, page 7, paragraphs

[0052] to page 13, paragraph

[0096] , examples and explanations of high hardness monomers and low hardness monomers are given. In order to improve the characteristic properties of the resulting photochromic coating (such as solvent resistance, hardness and heat resistance) or the balance of photochromic properties (such as color intensity and fading speed), the amount of low hardness monomers is preferably 5% to 70% by weight and the amount of high hardness monomers is preferably 5% to 95% by weight, based on the total amount of all other free radical polymerizable monomers except free radical polymerizable monomers having silanol groups or groups forming silanol groups by hydrolysis and free radical polymerizable monomers having isocyanate groups. In addition, according to EP 1 433 814 A1, it is particularly preferred that monomers having at least three free radical polymerizable groups should be included as high hardness monomers in an amount of at least 5% by weight based on the total amount of all other free radical polymerizable monomers. Further preferably, according to EP 1 433 814 A1, in addition to the monomers classified by hardness mentioned, free radical polymerizable monomers also include free radical polymerizable monomers having at least one epoxy group and at least one free radical polymerizable group in the molecule. By using a free radical polymerizable monomer having at least one epoxy group, the durability of the photochromic compound and the adhesion of the photochromic coating can be improved.EP 1 433 814 A1, page 13, paragraph

[0101] to page 14, paragraph

[0105] discloses a free radical polymerizable monomer having at least one epoxy group and at least one free radical polymerizable group in the molecule. According to EP 1 433 814 A1, the amount of the free radical polymerizable monomer having at least one epoxy group and at least one free radical polymerizable group in the molecule is preferably 0.01 wt % to 30 wt %, particularly preferably 0.1 wt % to 20 wt %, based on the total amount of all other free radical polymerizable monomers. The photochromic composition described in EP 1 433 814 A1 contains at least one amine compound in an amount of 0.01 to 20 parts by weight, based on 100 parts by weight of the total amount of all free radical polymerizable monomers other than the above-mentioned free radical polymerizable monomers. Examples of the at least one amine compound are given in EP 1 433 814 A1, page 14, paragraph

[0108] to page 15, paragraph

[0112] . The photochromic composition disclosed in EP 1 433 814 A1 comprises at least one photochromic compound in an amount of 0.01 to 20 parts by weight, preferably 0.05 to 15 parts by weight and more preferably 0.1 to 10 parts by weight, based on 100 parts by weight of the total amount of all free-radically polymerizable monomers. Examples of photochromic compounds are given in EP 1 433 814 A1, page 15, paragraph

[0114] to page 20, paragraph

[0122] .

[0126] EP 1 602 479 A1, in particular EP 1 602 479 A1, claim 9, discloses a photochromic composition comprising 100 parts by weight of a free-radically polymerizable monomer, 0.001 to 5 parts by weight of a silicone-based or fluorine-based surfactant, and 0.01 to 20 parts by weight of a photochromic compound. According to EP 1 602 479 A1, the photochromic composition comprises a free-radically polymerizable monomer having a silanol group or a group that forms a silanol group by hydrolysis, an amine compound, and a photochromic compound. The amount of the free-radically polymerizable monomer having a silanol group or a group that forms a silanol group by hydrolysis is suitably 0.5 to 20% by weight, in particular 1 to 10% by weight, based on the total weight of the entire coating agent. According to EP 1 602 479 A1 can be used together with other radically polymerizable monomers having a silanol group or a group that forms a silanol group by hydrolysis, such as trimethylolpropane trimethacrylate, trimethylolpropane triacrylate, tetramethylolmethane trimethacrylate, tetramethylolmethane triacrylate, trimethylolpropane triethylene glycol triacrylate, pentaerythritol tetramethacrylate, dipentaerythritol hexaacrylate, urethane oligomer tetraacrylate, urethane oligomer hexamethacrylate, urethane Oligomer hexaacrylate, polyester oligomer hexaacrylate, diethylene glycol dimethacrylate, triethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, tripropylene glycol dimethacrylate, bisphenol A dimethacrylate, 2,2-bis(4-methacryloyloxyethoxydiphenyl)propane, glycidyl methacrylate, 2,2-bis(4-acryloyloxypolyethylene glycol phenyl)propane having an average molecular weight of 776 or methyl ether polyethylene glycol methacrylate having an average molecular weight of 475. The amount of other free-radically polymerizable monomers used is suitably 20% to 90% by weight, in particular 40% to 80% by weight, based on the weight of the entire coating agent. The amount of amine compounds (such as triethanolamine, N-methyldiethanolamine, triisopropanolamine, N,N-dimethylaminoethyl methacrylate or N,N-diethylaminoethyl methacrylate) used is, for example, suitably 0.01% to 15% by weight, particularly 0.1% to 10% by weight, based on the weight of the entire coating agent. The amount of photochromic compounds (such as naphthopyran derivatives, chromene derivatives, spirooxazine derivatives, spiropyran derivatives or flugimide derivatives) used is suitably 0.1% to 30% by weight, particularly 1% to 10% by weight, based on the weight of the entire coating agent.

[0127] Provided that the ophthalmic lens comprises at least one photochromic coating, preferably the front surface of the ophthalmic lens comprises the at least one photochromic coating, the ophthalmic lens may optionally comprise at least one photochromic primer. Preferably, the front surface of the ophthalmic lens, preferably a corrective lens, comprises the at least one photochromic primer and the at least one photochromic coating, the photochromic coating being its outermost coating. The at least one photochromic primer may comprise a polyurethane resin layer as disclosed in EP 1 602 479 A1, in particular in claim 1 of EP 1 602 479 A1, or a primer layer as disclosed in WO 03 / 058300 A1, in particular on page 22, line 3 to page 23, line 13 of WO 03 / 058300 A1.

[0128] Preferably, the surface of the at least one hard coating layer and / or the at least one primer coating layer is modified (preferably after pre-curing) by contact with at least one mechanical device.

[0129] The surface of the at least one photochromic coating or of the at least one coating based on a coating composition that typically produces at least one photochromic coating but does not contain at least one photochromic dye can be modified (preferably after precuring) by contact with at least one mechanical device or by contact with at least one medium by the method disclosed in EP 19204745.4. For surface modification using the method disclosed in EP 19204745.4, the at least one photochromic coating or of the at least one coating based on a coating composition that typically produces at least one photochromic coating but does not contain at least one photochromic dye is preferably cured and / or hardened, i.e. no additional curing and / or hardening step is required.

[0130] According to EP19204745.4, the at least one medium capable of modifying the surface of the at least one photochromic coating or the at least one coating based on the coating composition that usually produces at least one photochromic coating but does not contain at least one photochromic dye comprises at least one organic acid. The at least one medium preferably comprises at least one organic aliphatic saturated or unsaturated, optionally substituted monocarboxylic acid. The at least one medium preferably comprises at least one organic aliphatic saturated or unsaturated monocarboxylic acid comprising 2 to 22 carbon atoms, preferably 3 to 18 carbon atoms. As at least one medium, for example, acetic acid, propionic acid, acrylic acid, lactic acid, butyric acid, isobutyric acid, valeric acid, heptanoic acid, caproic acid, octanoic acid, nonanoic acid, myristic acid, palmitoleic acid, linoleic acid, α-linolenic acid, γ-linolenic acid, oleic acid, ricinoleic acid, octadecatetraenoic acid, arachidonic acid, eicosapentaenoic acid, docosapentaenoic acid and / or docosahexaenoic acid can be used. Preferably, the at least one medium comprises at least one acid selected from the group consisting of acetic acid, lactic acid, butyric acid, caproic acid, caprylic acid, nonanoic acid, linoleic acid, α-linolenic acid, γ-linolenic acid, and oleic acid. More preferably, the at least one medium comprises at least one acid selected from the group consisting of lactic acid, caprylic acid and oleic acid. Alternatively or additionally, the at least one medium may comprise a tricarboxylic acid such as citric acid or an inorganic acid such as hydrochloric acid. As at least one medium, one of the aforementioned or any combination thereof may be used. The at least one medium may be used in commercial grade or commercial quality or the at least one medium may be diluted for use. If the at least one medium is applied by inkjet printing, it may be necessary to adjust the viscosity of the at least one medium to be printable. In addition, if the at least one medium is applied by inkjet printing, in addition to at least one specific location and / or at least one specific area to which the at least one medium is to be applied, and / or in addition to changes in parameters for at least one single electromagnetic pulse to be applied, and / or in addition to changes in the total process duration, the ink comprising the at least one medium may also be variable, for example, with respect to the concentration of the at least one medium. Therefore, taking into account all possibilities of the aforementioned variations, a wide variety of achievable modifications are possible.

[0131] As an alternative or in addition to a pre-curing step, the composition of the at least one coating layer may be adapted to increase, for example, the viscosity of the at least one coating layer.

[0132] The at least one coating is preferably applied to the uncoated or pre-coated surface of the lens substrate by a spin coating method or a dip coating method.

[0133] In one embodiment of the invention, the ophthalmic lens comprises at least one coating that is modifiable when in contact with at least one medium according to the method described in EP19204745.4. The corresponding surface modification may include the production of at least one microlens or the production of a final optical surface. In the first case (production of at least one microlens), the at least one microlens preferably only affects peripheral vision without compromising foveal vision. The wearer's foveal vision can be corrected or compensated by the final optical surface achieved by conventional molding, grinding and / or polishing processes. In the second case, the final optical surface based on the prescription of the refractive power required to correct / compensate the wearer's foveal vision is produced by contacting the surface of the at least one coating with at least one medium capable of modifying the surface of the at least one coating (i.e., the method disclosed in EP19204745.4). The method according to EP19204745.4 further allows the two aforementioned cases to be combined. Provided that the ophthalmic lens comprises at least one coating that is modifiable when in contact with at least one medium according to the method described in EP19204745.4 and at least one coating whose surface is modifiable when in contact with at least one mechanical device, both methods are suitable for producing a modified final optical surface of the ophthalmic lens, thereby offering a wide range of modification possibilities.

[0134] In summary, the following embodiments are particularly preferred within the scope of the present invention:

[0135] Embodiment 1: A method for manufacturing an ophthalmic lens comprising a lens substrate and at least one coating, the method comprising at least the following steps in a given order:

[0136] - providing a lens substrate comprising an uncoated or pre-coated front surface and an uncoated or pre-coated back surface,

[0137] - covering at least one of the surfaces of the lens substrate with at least one coating composition,

[0138] - drying and / or pre-curing the at least one coating composition so that the at least one coating composition does not run off the at least one surface covered therewith, the at least one coating composition preferably being adapted to the surface topography of the underlying adjacent surface,

[0139] - contacting at least one surface of the dried and / or precured coating composition with at least one mechanical device,

[0140] - removing the at least one mechanical device,

[0141] - curing and / or hardening the at least one coating,

[0142] - obtaining an ophthalmic lens comprising a lens substrate and at least one coating, the surface topography of the at least one coating being modified.

[0143] Embodiment 2: The method according to the preceding embodiment, wherein the at least one coating composition is selected from at least one of the group consisting of: at least one primer coating composition, at least one hard coating composition, at least one photochromic composition, and at least one composition similar to the at least one photochromic composition that does not contain at least one photochromic dye.

[0144] Embodiment 3: A method according to any of the preceding embodiments, wherein the at least one mechanical device is selected from at least one of the following groups: at least one contact head, an array of contact heads, a device comprising at least one contact head, at least one needle, an array of needles and / or a device comprising at least one needle.

[0145] Example 1

[0146] An uncoated lens substrate (0 dpt, diameter: 75 mm) based on polyallyl diglycol carbonate was coated on both surfaces with a primer precursor material according to Example 1 of US 5,316,791 and subsequently coated with a hard coating composition according to Example 2 of EP 2 578 649A1. The coated lens substrate was first dried at 70°C in ambient air with an IR lamp for 5 minutes. The surface of the hard coating composition on the front surface of the lens substrate was then contacted with a contact head that had been manually dipped into the hard coating composition and manually pulled out of the hard coating composition. Subsequently, in ambient air, the front surface was exposed to an electromagnetic pulse sequence consisting of 60 electromagnetic pulses for a total process duration of 42 seconds. The wavelength of each single electromagnetic pulse was between 200nm and 1000nm. Each of the 60 electromagnetic pulses delivered a dose of 5.8J / cm2. Each of the 60 electromagnetic pulses was divided into 12 micropulses with an average duty cycle of 14%. The envelope of each of the 60 electromagnetic pulses is 126ms. Two hard coating compositions have been cured, and the hard coating on the front surface thus includes a microlens at each contact point of the hard coating composition with the contact head. One of the microlenses has a spherical power of +60 diopters and the other has a spherical power of 39 diopters. The size of the microlens has been determined by using an optical profiler NewView 7100 from Zygo Corporation.

Claims

1. A method for manufacturing an ophthalmic lens, the ophthalmic lens comprising a lens substrate and at least one coating, the method comprising at least the following steps: - providing a lens substrate comprising an uncoated or pre-coated front surface and an uncoated or pre-coated back surface, - partially or completely covering at least one of the surfaces of the lens substrate with at least one coating composition, - drying and / or pre-curing the at least one coating composition, The method is characterized in that it further comprises at least the following steps: - contacting the surface of the at least one coating composition with at least one mechanical device to produce at least one local variation in coating thickness after the at least one mechanical device is removed or pulled away from the at least one coating, - curing and / or hardening the at least one coating composition, - obtaining an ophthalmic lens comprising a lens substrate and at least one coating, the surface topography of the at least one coating being modified by the at least one mechanical device, the modification of the surface topography of the at least one coating producing at least one microlens, The at least one mechanical device is selected from at least one of the following groups: at least one contact head, an array of contact heads, a device including at least one contact head, at least one needle, an array of needles and / or a device including at least one needle, wherein each contact head or needle is controllable or individually handleable.

2. The method according to claim 1, characterized in that The at least one coating composition is selected from at least one of the group consisting of at least one primer coating composition, at least one hard coating composition, at least one photochromic composition, and at least one coating composition similar to the at least one photochromic composition that does not include at least one photochromic dye.

3. The method according to any one of the preceding claims, characterized in that The contacting of the surface of the at least one coating with the at least one mechanical device is performed by bringing the surface of the at least one coating into contact with the at least one mechanical device or by inserting the at least one mechanical device into the at least one coating.

4. The method according to claim 1 or 2, characterized in that: After the surface of the at least one coating is contacted with the at least one mechanical device, the at least one mechanical device is removed from the surface or pulled out of the at least one coating.

5. The method according to claim 1 or 2, characterized in that: At least the viscosity of the at least one coating, the size of the at least one mechanical device, the removal speed of the at least one mechanical device, the removal direction of the at least one mechanical device, the pull-out speed of the at least one mechanical device and / or the pull-out direction of the at least one mechanical device affect the surface morphology of the at least one coating.

6. The method according to claim 1 or 2, characterized in that: The contact of the surface of the at least one coating composition with the at least one mechanical device is temporary.

7. The method according to claim 1 or 2, characterized in that: Curing and / or hardening of the at least one coating composition is performed by applying direct heat.

8. The method according to claim 1 or 2, characterized in that: The curing and / or hardening of the at least one coating composition is performed by applying at least one single electromagnetic pulse.

9. The method according to claim 8, characterized in that The at least one single electromagnetic pulse is applied from at least one electromagnetic source selected from the group consisting of: at least one flash lamp, at least one halogen lamp, at least one directed plasma arc, at least one laser, at least one microwave generator, at least one induction heater, at least one electron beam, at least one stroboscope, and at least one mercury lamp.

10. The method according to claim 8, characterized in that The total time required for curing and / or hardening is within at least one range selected from: (A) Range from 100 μs to 7 min, (B) Range from 300 μs to 5 min, (C) range from 500 μs to 4 min, and (D) Range from 1 ms to 3 min.

11. The method according to claim 9, characterized in that The total time required for curing and / or hardening is within at least one range selected from: (A) Range from 100 μs to 7 min, (B) Range from 300 μs to 5 min, (C) range from 500 μs to 4 min, and (D) Range from 1 ms to 3 min.

12. A method for manufacturing an ophthalmic lens, the ophthalmic lens comprising a lens substrate and at least one coating, the method comprising at least the following steps: - providing a lens substrate comprising an uncoated or pre-coated front surface and an uncoated or pre-coated back surface, - partially or completely covering at least one of the surfaces of the lens substrate with at least one coating composition, - drying and / or pre-curing the at least one coating composition, The method is characterized in that it further comprises at least the following steps: - contacting the surface of the at least one coating composition with at least one mechanical device to produce at least one local variation in coating thickness after the at least one mechanical device is removed or pulled away from the at least one coating, - curing and / or hardening the at least one coating composition by applying a) direct heat or b) (i) at least one single electromagnetic pulse or b) (ii) a plurality of single electromagnetic pulses to at least one of the surfaces of the ophthalmic lens comprising the lens substrate and the at least one coating, - obtaining an ophthalmic lens comprising a lens substrate and at least one coating, the surface topography of the at least one coating being modified by the at least one mechanical device, The at least one mechanical device is selected from at least one of the following groups: at least one contact head, an array of contact heads, a device including at least one contact head, at least one needle, an array of needles and / or a device including at least one needle, wherein each contact head or needle is controllable or individually handleable.

13. The method according to claim 12, characterized in that Modification of the surface topography of the at least one coating produces at least one microlens.

14. The method according to any one of the preceding claims 12 to 13, the contact of the surface of the at least one coating composition with the at least one mechanical device being temporary.

15. The method according to any one of the preceding claims 12 to 13, characterized in that The contacting of the surface of the at least one coating with the at least one mechanical device is performed by bringing the surface of the at least one coating into contact with the at least one mechanical device or by inserting the at least one mechanical device into the at least one coating.

16. The method according to any one of the preceding claims 12 to 13, characterized in that After the surface of the at least one coating is contacted with the at least one mechanical device, the at least one mechanical device is removed from the surface or pulled out of the at least one coating.

17. The method according to any one of the preceding claims 12 to 13, characterized in that The at least one coating composition is selected from at least one of the group consisting of at least one primer coating composition, at least one hard coating composition, at least one photochromic composition, and at least one coating composition similar to the at least one photochromic composition that does not include at least one photochromic dye.

18. The method according to any one of the preceding claims 12 to 13, characterized in that The total process duration required for curing the at least one coating layer by applying at least one single electromagnetic pulse by b)(i) or by applying a plurality of single electromagnetic pulses by b)(ii) is in the range from 100 μs to 7 min.

19. The method according to any one of the preceding claims 12 to 13, characterized in that The or each single electromagnetic pulse has an envelope in the range from 50 μs to 200 ms.

20. The method according to any one of the preceding claims 12 to 13, characterized in that The at least one single electromagnetic pulse or each single electromagnetic pulse comprises light delivered by at least one electromagnetic source selected from the group consisting of: at least one flash lamp, at least one halogen lamp, at least one directed plasma arc, at least one laser, at least one microwave generator, at least one induction heater, at least one electron beam, at least one stroboscope and at least one mercury lamp.

21. The method according to any one of the preceding claims 12 to 13, characterized in that The or each single electromagnetic pulse has a wavelength in the range from 100 nm to 1800 nm.

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