Method for producing a functionally coated plastic lens, production device and functionally coated plastic lens

Abstract

One aspect relates to a method for producing a functionally coated plastic lens (1), in particular a plastic spectacle lens, in which the method comprises the following steps: (I) providing (S100) a plastic lens (1) comprising a substrate made of plastic glass; (II) providing (S102) a gas phase of the first precursor compound A to obtain at least one modified surface of the plastic lens, said surface having been modified by adsorption of the precursor compound A; (III) removing (S104) excess material of the precursor compound A that is not adsorbed on the modified surface of the plastic lens; (IV) providing (S106) a gas phase of a second precursor compound B, which reacts with the precursor compound A adsorbed on the modified surface and, as a reaction product, forms a single layer of functional layers (3, 3 ', 3 ") on the surface of the plastic lens; (V) removing (S108) excess material of the precursor compound B that is not attached to the modified surface; (VI) obtaining (S110) a plastic lens (1) provided with a functional coating (2), wherein the functional coating (2) formed imparts hydrophobic and / or oleophobic properties to the plastic lens (1). Other aspects relate to a production apparatus and a functionally coated plastic lens.

Description

Technical Field

[0001] This invention relates to a method, apparatus and a production facility for manufacturing functionally coated plastic lenses. Background Technology

[0002] The production of plastic lenses (particularly plastic spectacle lenses) with or having functional coatings is known in the prior art. For example, functional coatings can impart repellency to dirt and water droplets. To achieve this repellency, functional coatings typically possess oleophobic and hydrophobic properties. One measure of this is the specific contact angle formed by the corresponding liquid on the surface of the spectacle lens. Generally, the larger the contact angle of a particular liquid on the surface of the spectacle lens, the more pronounced its oleophobic and hydrophobic properties. Such hydrophobic and / or oleophobic coatings typically consist of functional molecules containing head groups, coupling groups, or anchoring groups for attachment to the lens surface, and functional or tail groups responsible for imparting the desired properties (e.g., hydrophobicity and / or oleophobicity). Typically, coupling groups are silane-based and contain, for example, alkoxy groups (e.g., trimethoxysilane or triethoxysilane) or chlorine groups (e.g., trichlorosilane). The functional groups that repel, for example, water and / or oil are determined by the remaining alkyl or alkyl ether chain in the molecule. This alkyl or alkyl ether chain may also be fully or partially fluorinated. Coupling is typically achieved by forming silanols (as part of a hydrolysis reaction). Advantageously, as part of a condensation reaction, the silanols can then be linked via reactive OH groups, for example, to OH groups on a lens to which a functional coating is to be provided.

[0003] This type of functional coating (also known as a topcoat or clean coating) is typically applied to lenses in a vacuum coating system, where the coating material is deposited as vapor condensate, forming a functional coating on the lens (particularly on the lens surface). Suitable vacuum coating systems typically include a thermal evaporator in which heat energy is released, specifically by applying an electric current to the ohmic resistance of the evaporator, causing the coating material to evaporate. Typical vacuum coating systems (where coatings such as anti-reflective coatings and / or mirror coatings can be applied to the lens) often include this thermal evaporator, allowing the functional coating to be applied directly after the initial coating without requiring lens repositioning. The coating material used for the functional coating is typically in the form of a carrier material, such as tablets or pellets impregnated with the substance. For example, the carrier material can be a porous ceramic body or a metal body filled with steel wool. Due to their large surface area, these carrier materials are well-suited for storing liquids (e.g., functional molecules). These carriers are heated in a thermal evaporator, causing the material to evaporate. The resulting coating material vapor is then deposited substantially uniformly as condensate in the coating system, thus also depositing onto the lens. Typical deposition rates for hydrophobic and / or oleophobic layers range from 0.1 nm / s to 1.0 nm / s. The water required for the hydrolysis reaction may be present, for example, as a residual gas in the high vacuum environment of the vacuum coating system. However, the water content in the residual gas can vary depending on the background pressure and cleanliness of the chamber. The reaction adhering to the lens surface may also vary accordingly, resulting in better or worse outcomes, which can also affect the quality of the hydrophobic and / or oleophobic layers. Furthermore, reactions may occur between functional molecules, where the coupling groups of two molecules can bind to each other via OH groups formed by the hydrolysis reaction, thus preventing them from binding to the lens surface. Therefore, the reaction conditions may depend on a variety of factors and can only be partially controlled or adjusted.

[0004] An alternative method for providing functional coatings to lenses is dip coating, in which the lens is immersed in a bath containing functional molecules, which are in a substantially dissolved or dispersed form. By immersing the lens to be coated in the bath (especially repeatedly), the lens is wetted by the functional coating molecules present in dissolved form in the bath. During the subsequent drying period, the functional coating hardens, which specifically means that any solvent or carrier still contained in the coating evaporates. The main disadvantage of this method is the need for a separate system (dip coating system), and the lenses to be coated must be arranged in a suitable holding device for the dip coating process, which is associated with a corresponding workload and thus results in higher production costs.

[0005] Atomic layer deposition (ALD) is a well-established coating method used to produce very precise thin layers. ALD is commonly used in the semiconductor industry. The advantage of ALD lies in its ability to precisely control layer thickness, down to the angstrom level. Most ALD processes are based on a binary reaction sequence, in which a surface reaction occurs and a binary compound film (also called a layer) is deposited. For this purpose, a precursor compound, preferably a gas-phase precursor compound, is sequentially circulated in a process chamber housing (multiple) lenses to be coated. In this process, a first precursor compound is first provided, which adsorbs onto the surface of (multiple) lenses to be coated. Excess and unbonded material of the first precursor compound is then removed from the process chamber, and a second precursor compound (reactant) is subsequently provided. This second precursor compound reacts with the first precursor compound adsorbed on the substrate surface. Excess and unbonded material of the second precursor compound in the process chamber is then removed, and another cycle begins. By repeating these steps sequentially, layer-by-layer deposition can be performed with very high precision. Therefore, unlike the coating methods described above, the two precursor compounds only come into direct contact on the surfaces of (multiple) lenses to be coated, rather than in their gas phase. This suppresses potential gas-phase reactions, such as those described above, which could lead to uneven deposition due to inadequate hydrolysis and / or interactions between functional molecules. Thus, ALD is particularly advantageous for thin coatings because it enables the deposition of thin coatings with high precision while maintaining an acceptable process time. For coatings with a total thickness of several hundred nanometers (e.g., typical anti-reflective coatings), ALD is less economically viable due to its longer process time. One drawback of the ALD method is the requirement of high temperatures, typically several hundred degrees Celsius, making it unsuitable for producing coatings on plastic lenses, which typically lose mechanical strength at significantly lower temperatures and would be damaged by this method. Summary of the Invention

[0006] Therefore, the object of the present invention is to provide a method for producing a functionally coated plastic lens that overcomes the aforementioned disadvantages. This object is achieved by a method having the features of claim 1, a production apparatus having the features of claim 14, and a functionally coated plastic lens having the features of claim 16. Preferred embodiments are the subject of the dependent claims.

[0007] One aspect relates to a method for producing a functionally coated plastic lens (particularly a plastic spectacle lens), the method comprising the following steps: (I) Providing a plastic lens, the plastic lens comprising a substrate made of plastic glass; (II) Providing a gas phase of a first precursor compound A to obtain at least one modified surface of a plastic lens, said surface having been modified by adsorbing the precursor compound A; (III) Remove excess material of precursor compound A that is not adsorbed onto the modified surface of the plastic lens; (IV) Provide a gas phase of a second precursor compound B, which reacts with a precursor compound A adsorbed on a modified surface and forms a single layer of a functional layer on the surface of a plastic lens as a reaction product. (V) Remove excess material of precursor compound B that is not bonded to the modified surface; (VI) Obtaining functionally coated plastic lenses, The functional coating (2) formed therein imparts hydrophobic and / or oleophobic properties to the plastic lens (1).

[0008] Preferably, the method, particularly steps (II) and (IV), is performed at a temperature less than or equal to 100°C, preferably at a temperature less than or equal to 75°C, and particularly preferably at a temperature less than or equal to 50°C.

[0009] The proposed method is applicable to the production of functionally coated plastic lenses, i.e., plastic lenses with functional coatings. This method is preferably performed in an apparatus comprising at least one process chamber (also referred to as a rezipient) in which the plastic lens to be coated with the functional coating is provided. Within the meaning of this invention, a functional coating refers to an additional coating applied to a plastic lens and imparting hydrophobic and / or oleophobic properties to the plastic lens.

[0010] A plastic lens is an optical element comprising a substrate made of plastic glass, wherein the plastic glass is preferably made substantially of poly(sulfur)urethane, polymethyl methacrylate, polymethyl acrylate, polycarbonate, polyacrylate, or polyethylene glycol dielyl carbonate. Combinations of the above materials, along with other plastic materials for the plastic glass, may also be considered, provided that these materials are substantially transparent and / or possess optical properties suitable for use as lens plastic glass. Plastic lenses typically have two surfaces, one or both of which may have radii of curvature, particularly different radii of curvature, which imparts optical refractive power to the lens. Such plastic lenses can be finished lenses, i.e., lenses where both surfaces have been processed, meaning that both surfaces already possess the desired optical properties. However, the lens can also be a semi-finished product, wherein only one of the two surfaces possesses the desired optical properties, while the other surface has not been processed, i.e., does not yet possess the desired optical properties. Within the scope of this invention, plastic lenses can advantageously have additional improvements beyond the optical properties (multiple properties). This includes all improvements known to those skilled in the art, particularly additional coatings and / or varnishes. Typical examples of paints are buffer coatings for improving fracture strength and / or hard coatings for improving or enhancing mechanical strength (particularly scratch resistance). Typical examples of coatings include specular coatings and / or anti-reflective coatings. Anti-reflective coatings reduce the reflectivity of plastic lenses, thereby suppressing unwanted reflections. In other words, within the meaning of this invention, plastic lenses are understood to be any raw or processed lens, particularly processed and coated lenses. In particular, as coated lenses, they can have other advantageous properties, such as improved antistatic properties for reducing dust particle adhesion, and / or UV filtering for blocking or reducing ultraviolet radiation transmission, and / or blue filtering for blocking or reducing radiation transmission in the blue spectral range. It should be understood that the methods applied to plastic lenses can also be applied to other plastics or glass bodies, whether they are transparent or opaque, and whether they are used as optical lenses. Therefore, within the meaning of this application, the term "plastic lens" may also be replaced by the terms "plastic body" or "glass body," wherein these plastic or glass bodies are particularly suitable for use as windows, sensor covers, protective glass, light source covers, building facade elements, etc.

[0011] The steps of the method according to the present invention will now be described in more detail:

[0012] In the first step (I), a plastic lens is provided, which, within the scope of the proposed method for producing a functionally coated plastic lens, has a functional coating. This specifically means providing a plastic lens to be coated, a step that includes placing the plastic lens in a device configured for this purpose. Typically, such a device includes at least one process chamber in which the functional coating can be applied to the plastic lens placed therein; that is, in this process chamber, the pressure and / or temperature required for the process can be specifically set and, if necessary, maintained constant. Therefore, the process chamber can preferably be closed, particularly sealed. Advantageously, the providing step also includes inserting the plastic lens into a suitable holding device, thereby securely and immovably holding it within the process chamber of the device during the coating process.

[0013] In the next step (II), a gaseous phase of the first precursor compound A is provided. This providing step may preferably refer to introducing the gaseous phase of the first precursor compound A into the process chamber of the apparatus. The precursor compound A is adsorbed onto the plastic lens, particularly onto at least one surface of the plastic lens, thereby obtaining a plastic lens having at least one modified surface. The aim is to achieve a comprehensive adsorption of the precursor compound A onto the surface of the plastic lens; in other words, to adsorb the precursor compound substantially without gaps onto the entire surface of the plastic lens, so as to obtain a gapless monolayer formed as a reaction product of the reaction between the precursor compound A and the second precursor compound in subsequent steps. The terms "comprehensive" or "gapless" preferably refer to the plastic lens surface being covered by the precursor compound A at least one atomic or molecular layer, with a coverage of more than about 90%, more preferably more than 95%, particularly more than about 99%, or complete coverage reaching 100%.

[0014] In the next step (III), excess material of precursor compound A that is not adhered to or adsorbed onto the modified surface of the plastic lens is removed. The phrase "removal of excess material of precursor compound A" can specifically refer to pumping or suctioning away residual gaseous phase of precursor compound A in the process chamber. Alternatively or additionally, this step may also include rinsing, particularly using a suitable solution and / or compound, which specifically refers to any gas, solution, and / or compound that does not react with precursor compound A or the modified surface of the plastic lens. Depending on the choice of precursor compound used, inert gases (e.g., nitrogen or one of these rare gases) are particularly suitable as rinsing gases. If the method is not carried out under vacuum conditions, but rather under, for example, atmospheric pressure conditions, a combination of pumping or suction removal followed by rinsing is particularly advantageous because pumping or suction may generate undesirable negative pressure.

[0015] The time or period during which the precursor compound is provided in the process chamber is called the residence time. Another related term is exposure time or exposure duration. In other words, residence time refers to the time period from the initial introduction of the precursor compound into the process chamber (or the provision of the precursor compound in the process chamber) to its complete removal from the process chamber. Therefore, during the residence time, the gaseous phase of the precursor compound occupies a non-negligible volume in the process chamber and can undergo reactions, either through the adsorption of a first precursor compound on the surface of the plastic lens, or through a reaction between a second precursor compound and the first precursor compound adsorbed on the surface of the plastic lens, thereby subsequently obtaining a monolayer of the functional layer.

[0016] In the next step (IV), a gaseous form of the second precursor compound B is provided. This providing step may preferably refer to introducing the gaseous form of the second precursor compound B into the process chamber of the apparatus. The provided precursor compound B reacts with the modified surface of the plastic lens, or the provided precursor compound B reacts with the first precursor compound A adsorbed on the modified surface of the plastic lens.

[0017] As a product of the reaction between precursor compounds A and B, a (first) monolayer of the functional layer is formed on the lens surface. In other words, as a product of the reaction between the two precursor compounds A and B, a monolayer of the functional layer is formed on the surface of the plastic lens; that is, the monolayer of the functional layer is a product of the reaction between precursor compounds A and B. The coverage of this functional layer is preferably substantially the same as the coverage of precursor compound A. However, incomplete reaction between precursor compounds A and B may lead to a reduction in the coverage of the functional layer; that is, "coverage" preferably means that the surface of the plastic lens is covered by the functional coating at least one atomic or molecular layer, with a coverage rate exceeding about 85%, more preferably exceeding 90%, particularly exceeding about 95% or 99%, or achieving complete coverage of 100%.

[0018] In the next step (V), excess material of precursor compound B is removed. This means removing excess and unbound material of precursor compound B, i.e., material that has not reacted with precursor compound A adsorbed on the surface of the plastic lens. The statement “removal of excess material of precursor compound B” can specifically refer to pumping or suctioning out residual gaseous phase of precursor compound B located in the process chamber. Alternatively or additionally, this step may also include rinsing, particularly using a suitable solution and / or compound, which specifically refers to any gas and / or solution and / or compound that does not react with precursor compound B or the modified surface of the plastic lens, and particularly any gas and / or solution and / or compound that does not affect, or does not react with, the functional monolayer formed by the reaction of the two precursor compounds A and B. Depending on the choice of precursor compound used, inert gases (e.g., nitrogen or one of the rare gases) are particularly suitable as rinsing gases. If the method is not carried out under vacuum conditions, but rather under, for example, atmospheric pressure conditions, then it is particularly advantageous to use a combination of pumping or suction to remove the material before rinsing, as pumping or suction may generate undesirable negative pressure.

[0019] In the final step (VI), a functionally coated plastic lens is obtained. This means that a functionally coated plastic lens is obtained by this method, the plastic lens having a functional coating comprising at least one monolayer of a functional layer, and thus possessing functional properties such as hydrophobic and / or oleophobic properties. Typically, this step involves removing the functionally coated plastic lens from the process chamber of the apparatus performing the method.

[0020] Preferably, the method is carried out at a low temperature of 100°C or lower, more preferably at 75°C or lower, and particularly preferably at 50°C or lower. By ensuring that the process chamber and the plastic lens to which the functional coating is to be applied are maintained at the aforementioned temperatures, it is advantageous to provide a functional coating specifically for the plastic lens according to this atomic layer deposition method, since it is well known that plastic lenses have lower heat resistance compared to mineral glasses or semiconductors. In particular, the preferred plastic materials for plastic lenses lose their mechanical strength at temperatures above 100°C, especially at 150°C or higher, and therefore conventional atomic layer deposition methods, which are typically carried out at significantly higher temperatures, cannot be applied to such plastic lenses.

[0021] Preferably, the plastic lens includes a substrate, the plastic glass of which is substantially made of poly(sulfur)urethane, polymethyl methacrylate, polymethyl acrylate, polycarbonate, polyacrylate, or polyethylene glycol dielyl carbonate. Therefore, advantageously, this method can provide a functional coating specifically for plastic spectacle lenses made substantially of these materials.

[0022] Preferably, the plastic lens has at least one surface on which a silicon oxide layer is disposed directly or indirectly. This silicon oxide layer is not limited to being formed solely of silicon oxide; organic compounds containing silicon oxide (e.g., siloxane-containing compounds) can also constitute the silicon oxide layer. The silicon oxide layer can also be made of silane compounds, which can, for example, combine with oxygen to form a silicon oxide layer. It is known from the prior art that functional molecules of a functional coating attach to such a silicon oxide layer, particularly through a condensation reaction between the functional molecules and OH groups formed by the silicon oxide layer. Preferably, at least one surface of the plastic lens, particularly the surface on which the functional coating is to be formed, includes a silicon oxide layer as a suitable adhesive layer or binder. In this case, the production of the functional coating is preferably carried out on the surface of the plastic lens having the silicon oxide layer. For example, OH groups can be formed by plasma activation, i.e., by treating the silicon oxide layer with a suitable plasma, through which anchoring groups of the functional molecules of the suitable functional coating can be formed. Preferably, the plastic lens has silicon oxide layers on both of its surfaces. Particularly preferably, by this method, preferably in a single process cycle, the plastic lens can have a functional coating on both sides (i.e., on both surfaces of the plastic lens), and both surfaces include a silicon oxide layer as an adhesive or bonding layer. Preferably, the silicon oxide layer is formed substantially of silicon oxide, and particularly preferably substantially of silicon dioxide.

[0023] Preferably, the outermost silicon oxide layer, which is the farthest single layer from the substrate, is part of a multilayer (particularly interference) coating system. Coatings on plastic lenses typically include a silicon oxide layer as the last or outermost layer. In this way, instead of applying an additional silicon oxide layer as an adhesive or bonding layer for the functional coating, the existing silicon oxide layer on the plastic lens is activated by plasma; that is, by treating the silicon oxide layer with suitable plasma, OH groups can be formed. Through these OH groups, anchoring groups for the functional molecules of the suitable functional coating can be formed and linked. Preferably, the outermost silicon oxide layer, which is the farthest single layer from the substrate, is a silicon dioxide layer.

[0024] The resulting functional coating imparts hydrophobic and / or oleophobic properties to the plastic lens. One metric for this is the contact angle formed by the liquid on the lens surface. Generally, the larger the contact angle of a particular liquid on the lens surface, the more pronounced its oleophobic and / or hydrophobic properties. Preferably, the plastic lens with the functional coating has a contact angle greater than or equal to 90° relative to H2O, preferably greater than or equal to 100°, and / or relative to hexadecane (C... 16 H 34 The contact angle is greater than or equal to 30°. Therefore, this functional coating gives plastic lenses excellent repellency against water droplets and dirt.

[0025] Preferably, the functional coating is formed on the plastic lens as the outermost coating closest to the surface and furthest from the substrate. Advantageously, this allows the plastic lens to achieve very good hydrophobic and / or oleophobic properties. Particularly good hydrophobic and / or oleophobic properties can be obtained in improved examples where the silicon oxide layer is located directly beneath the functional coating, which is the outermost layer before the functional coating is applied.

[0026] Preferably, no other coating is formed on the plastic lens after the functional coating. This is advantageous because: firstly, the surface energy of the formed functional coating is low, making it more difficult for another layer or coating to adhere; secondly, only when the functional coating, which imparts hydrophobic and / or oleophobic properties to the plastic lens, is formed as the outermost coating closest to the surface and furthest from the substrate, can the hydrophobic and / or oleophobic properties have a positive impact on the daily use of the plastic lens in terms of improving cleanliness and reducing the tendency for water droplets and dirt to adhere. In other words, the functional coating formed in this way is the outermost, last, or final layer of the plastic lens, and preferably the only layer on which the plastic lens is directly exposed to environmental influences.

[0027] In one, two, more, or all of steps (I) to (VI), preferably at least one or more of the following conditions are met: - Adjusted pressure conditions; and / or - Adjusted temperature; and / or - (Reactive) plasma; and / or - The presence of a catalyst; and / or - The adjusted residence time of the precursor compound; and / or - Irradiation with laser radiation; and / or - Irradiation with UV radiation; and / or - Bombardment with high-energy particles; and / or - The existence of an electric field.

[0028] It is well known that chemical reactions (e.g., the desired reaction of precursor compounds A and B to form a functional coating monolayer), and processes such as adsorption processes (particularly, for example, the adsorption of the first precursor compound A onto the surface of a plastic lens), typically require an activation energy, or an activation energy exceeding that, to occur. For these reasons, one, two, more, or all of the above conditions may need to be satisfied in one, two, more, or all of the steps (I) to (IV) of the proposed method.

[0029] Especially for methods carried out at relatively low temperatures, additional energy may be required to overcome the activation energy needed to overcome the adsorption of precursor compound A and / or the reaction of precursor compounds A and B, or the activation energy may be intentionally reduced to a value that can be exceeded by the current temperature.

[0030] By generating or setting adjusted pressure conditions, a method for producing functionally coated plastic lenses can be performed at pressures different from atmospheric pressure, for example, under a negative pressure less than or equal to 0.1 mbar or a positive pressure up to 1.5 bar. These pressure conditions refer, in part, to the pressure conditions within the process chamber of the apparatus during the execution of the production method. Advantageously, by adjusting the pressure conditions, the activation energy of the adsorption process of precursor compound A and / or the reaction activation energies of the two precursor compounds A and B can be changed, thereby particularly favoring the occurrence of the desired reaction. Furthermore, the adjusted pressure conditions can also influence the gaseous supply of precursor compounds A and B. Especially at low temperatures, it may be necessary to ensure the gaseous supply of the precursor compounds through vacuum conditions.

[0031] When the precursor compound is introduced into the processing chamber, it must be present in a sufficient quantity to completely cover the substrate. The amount of precursor compound introduced can be adjusted by the vapor pressure of the precursor compound; that is, the adjusted pressure conditions also specifically include a gaseous supply of the precursor compound, particularly in the process chamber of the apparatus and in the storage tank containing the precursor compound. As the temperature increases, the vapor pressure of the substance also increases. However, since the proposed method preferably satisfies low temperatures, and the precursor compound is typically liquid, the phase transition from liquid to gaseous of one or both of precursor compounds A and B can be influenced, for example, by the adjusted pressure conditions. When the pressure decreases, the phase boundary between the liquid and gaseous states can be crossed. Therefore, a negative pressure, particularly less than or equal to 10, can be intentionally applied to the storage tank and / or process chamber of the precursor compound. -5 The negative pressure in mbars is preferably less than or equal to 10 mbars. -8 A negative pressure of mbar allows one or both of precursor compounds A and B to be provided in the gaseous phase. To increase the vapor pressure, the precursor compounds can be mixed with one or more inert gases as carrier gases, for example. Pressure conditions can be influenced, for example, by evacuating the process chamber and / or the precursor compound storage tank via a suitable pump, or by generating overpressure via a suitable compression method.

[0032] Alternatively (or supplementarily), the desired reaction can be promoted by influencing temperature, particularly the temperature within the process chamber, the temperature of the plastic lens to which the functional coating is to be provided, and / or the temperature of the tank containing the precursor compound. It is well known that reactions are typically heat-driven, therefore increasing the ambient temperature favors the occurrence of the desired reaction. Temperature (particularly increasing the temperature) can be influenced by, for example, using an electric heater, wherein it must be ensured that the temperature is maintained below 100°C, preferably below or equal to 75°C, and particularly preferably below or equal to 50°C.

[0033] Alternatively (or supplementally), the presence of plasma, particularly reactive plasma, can favor the occurrence of a desired reaction. For example, treatment with plasma can alter one or two precursor compounds to enhance their reactivity; and / or gaseous particles of the precursor compounds can gain additional energy through collisions with the plasma to have sufficient energy for adsorption and / or to overcome the activation energy of the desired reaction.

[0034] Alternatively (or supplementarily), plasma treatment can be performed, meaning that, particularly after the plastic lens is provided, its surface is treated with plasma to form OH groups, for example, on a silicon oxide layer disposed on the surface of the plastic lens. Typically, plasma can be generated from inert gases such as argon or krypton, but combinations or reactive combinations of these gases, such as argon-oxygen plasma or pure oxygen plasma, can also be considered. The plasma can consist of charged particles, but can also be partially composed of neutral but excited particles, such as excited atomic or molecular oxygen. For example, the plasma can also contain nitrogen or hydrogen.

[0035] Alternatively (or supplementally), the presence of a catalyst can promote adsorption, thereby facilitating the reaction of precursor compounds A and B, or lowering the activation energy. Depending on the type and properties of the precursor compounds A and B used, those skilled in the art can use a variety of possible catalysts, among which preferred catalysts are catalysts such as NH3 (ammonia) or commonly reactive substances such as O3 (ozone).

[0036] Alternatively (or supplementarily), the desired reaction can also be promoted by adjusting the residence time of the precursor compound in the process chamber. Since chemical reactions are generally slower at lower temperatures, adjusting the residence time of the precursor compound in the process chamber, particularly extending the residence time, preferably significantly extending it, can promote the desired reaction. In typical ALD methods, particularly ALD methods with temperatures in the range of 150°C to 300°C, the residence time of the precursor compound can be from a few seconds to 30 seconds. However, the lower temperatures in this method may require significantly extended residence times of the precursor compounds in the process chamber, up to a maximum of 6 hours for each precursor compound. At 50°C, the residence time of one (or two) precursor compounds can advantageously be extended to 300 minutes each, so as to ensure, by extending the residence time of the precursor compounds in the process chamber, that the two precursor compounds react with each other, particularly completely, or that the precursor compounds are completely adsorbed onto at least one surface of the plastic lens.

[0037] Alternatively (or supplementarily), the required energy can be provided by laser radiation. In this process, laser radiation of a suitable wavelength or frequency, particularly pulsed laser radiation, is provided, which is absorbed by one or both of precursor compounds A and B, or by the surface of the plastic lens. Absorption of the laser radiation results in an increase in energy, thereby overcoming the activation energy and promoting or realizing the adsorption and / or reaction of precursor compounds A and B. The wavelength or frequency of the laser radiation is appropriately selected to correspond to the absorption band of one or both of precursor compounds A and B, or the surface of the plastic lens (particularly the silicon oxide layer disposed here). The advantage of pulsed laser radiation is that it can also locally (e.g., only on the substrate surface) induce a temperature rise, thereby promoting the adsorption of one or both precursor compounds and / or the reaction of both precursor compounds, without heating the plastic lens to any significant degree.

[0038] Alternatively (or supplementally), the required energy can be provided by UV radiation. In this process, UV radiation is provided, which is absorbed by one (or both) of the two precursor compounds A and B. The absorption of UV radiation results in an increase in energy, thereby overcoming the activation energy and promoting or realizing the adsorption and / or reaction of precursor compounds A and B. The wavelength or frequency of the UV radiation is appropriately selected so that it corresponds to the absorption band of one or both of the precursor compounds A and B.

[0039] Alternatively (or supplementarily), the required energy can be provided by bombardment with high-energy particles. These particles can be electrons, for example. The precursor compounds can be excited by collisions with electrons, thereby gaining energy. This excitation leads to an increase in energy, which overcomes the activation energy, promoting or enabling the adsorption and / or reaction of precursor compounds A and B. An increase in energy resulting from collisions with charged particles may also lead to an increase in temperature, thereby overcoming the activation energy and promoting or enabling the adsorption and / or reaction of precursor compounds A and B.

[0040] Alternatively (or supplementarily), the required energy can also be provided by applying an electric field. Due to the anisotropic chemical structure of functional molecules, applying a voltage can induce charge transfer. For example, this can be used to accelerate functional molecules in an electric field, thereby increasing their energy. An electric field can also be used to induce the oriented alignment of functional molecules on the surface of a plastic lens by appropriately charging the substrate. For example, oriented alignment of coupling groups on the surface of a plastic lens can promote adsorption.

[0041] A combination of the above conditions can also be considered.

[0042] Specifically, (reactive) plasma treatment of plastic lenses having a silicon oxide layer on at least one surface can promote the formation of OH groups with binding affinity or reactivity on the silicon oxide layer. The formed OH groups, due to their polarity, can promote the adsorption of a first precursor compound, which then, preferably via hydrolysis, bonds or reacts with a second precursor compound. In particular, the requirement that the production of functional coatings on plastic lenses should be carried out at low temperatures may necessitate providing additional energy to overcome the activation energy, or to reduce the activation energy. This can be advantageously achieved through the methods described above, particularly through combinations thereof.

[0043] Adsorption processes, such as the adsorption of precursor compound A in step (II), may typically require an energy input exceeding the activation energy. This energy input can be provided by thermal energy and / or plasma (action) and / or laser irradiation and / or UV irradiation and / or high-energy particle bombardment and / or the presence of a catalyst and / or the application of an electric field. The energy input can act on the surface of the plastic lens and / or the gaseous particles of precursor compound A. Preferably, adsorption is promoted by plasma treatment of a silica layer disposed on the surface of the plastic lens, thereby forming OH groups with binding affinity or reactivity that effectively lower the activation energy, thus reducing the activation energy required for adsorption to occur.

[0044] Reaction processes (e.g., particularly the reaction of precursor compounds A and B) may typically require an energy input exceeding the activation energy. This energy input can be provided by thermal energy and / or plasma (action) and / or laser irradiation and / or UV irradiation and / or high-energy particle bombardment and / or the presence of a catalyst and / or the application of an electric field. This energy input can act on the surface of a plastic lens, particularly a modified surface of the plastic lens (which has been modified by adsorbing precursor compound A), and / or on gaseous particles of precursor compound B.

[0045] Preferably, one of the two precursor compounds is a silane-containing compound, i.e., one of the two precursor compounds is a silane precursor compound. A silane-containing compound is a compound consisting of a silicon backbone and hydrogen, alkyl, or any optional organic group. In particular, silane-containing compounds containing one or more alkoxy groups or one or more chloro groups (e.g., one or more methoxy, ethoxy, or chloro groups) as anchoring groups are particularly suitable for this purpose. The silane precursor compound can be bonded to the plastic lens by substitution with an OH group, followed by a reaction of the substituted OH group with an OH group of the plastic lens. In addition to one or more anchoring groups, suitable silane-containing compounds also contain functional groups, which are typically realized as long-chain alkyl or alkyl ether chains and have the desired hydrophobic and / or oleophobic properties. These alkyl or alkyl ether chains of hydrocarbons can be perfluorinated or polyfluorinated, or they may not be perfluorinated or polyfluorinated. Furthermore, there are no further restrictions on the selection of suitable silane-containing precursor compounds, but they should meet the above-mentioned characteristics and have a sufficiently high vapor pressure at the temperature present during coating so that they can be provided specifically in gaseous form.

[0046] Preferably, the silane precursor compound is substantially composed of the following compounds: octadecyltrichlorosilane (ODTS), hexadecyltrichlorosilane (HDTS), tetradecyltrichlorosilane (TDTS), dodecyltrichlorosilane (DTS), decyltrichlorosilane, octyltrichlorosilane, heptadecafluorotetrahydrodecyltrichlorosilane (FDTS), or perfluorooctyltrichlorosilane (also known as tridecafluorotetrahydrooctyltrichlorosilane (FOTS)). Silane-containing compounds such as those described above are preferred precursor compounds for forming functional coatings with excellent hydrophobic and / or oleophobic properties and excellent adhesion to plastic lenses through suitable anchoring groups. However, silanes with longer or shorter alkyl chains, or silanes with fully, partially, or non-perfluorinated alkyl chains, may also be used.

[0047] Particularly suitable are silanes or silane-containing compounds comprising alkyl chains, particularly alkyl chains having functional groups or tail groups having at least eight carbon atoms, giving such compounds excellent hydrophobic and / or oleophobic properties. Methoxysilanes or ethoxysilanes, such as octadecyltrimethoxysilane (ODTMS), dodecyltrimethoxysilane (DTMS), or hexadecyltrimethoxysilane (HDTMS), and ethoxysilanes, such as octadecyltriethoxysilane, dodecyltriethoxysilane, or hexadecyltriethoxysilane, can also be used. This list is not exhaustive and should be understood as exemplary. The examples above are all linear molecules linked by only one existing coupling group, thus forming essentially two-dimensional connections. Branched or even highly branched molecules with multiple coupling groups can also be used, allowing for a higher degree of crosslinking.

[0048] Preferably, one of the two precursor compounds is a silane-containing compound, and more preferably, one of the aforementioned precursor compounds is a silane-containing compound, while the other precursor compound is essentially H2O. By providing H2O as a reactant, or as one of the two precursor compounds, a hydrolysis reaction can be initiated, thereby allowing the first silane precursor compound to bind to the surface of the plastic lens.

[0049] Preferably, one of the two precursor compounds is a silane-containing compound containing at least one coupling group, preferably having two or more coupling groups, wherein the (at least one) coupling group is preferably hydrolyzable and has one or more chloro, methoxy, ethoxy, or acetoxy groups, or amines, silazanes, or oximes. This allows for very good adhesion of the precursor compounds, particularly during the hydrolysis reaction, thereby forming a functional coating, especially a stable and adherent functional coating.

[0050] The functional coating has at least one monolayer of a functional layer formed from a precursor compound, wherein one of the precursor compounds is preferably DTS, HDTS, TDTS, ODTS, FOTS, FDTS, ODTMS, DTMS, or HDTMS, characterized in that it can achieve a contact angle greater than or equal to 90° relative to H2O, and / or relative to hexadecane (C 16 H 34 The contact angle is greater than or equal to 30°.

[0051] Fluorinated silane compounds can achieve improved hydrophobic and / or oleophobic properties. The functional coating has at least one monolayer of a functional layer formed from a precursor compound, preferably FOTS or FDTS, characterized by achieving a contact angle greater than or equal to 100° relative to H₂O, and / or relative to hexadecane (C₂O₃). 16 H 34The contact angle is greater than or equal to 60°.

[0052] Preferably, steps (II) to (V) constitute a cycle that can be performed multiple times or any number of times; that is, the proposed method is further improved by increasing the number of cycles to repeat steps (II) to (V). For example, the cycle can be performed twice, wherein the sequence of steps (II) to (V) is performed twice, the sequence including the introduction of a first precursor compound A, the removal of unbound components of the first precursor compound A not adsorbed on the surface, the provision of a second precursor compound B, and the removal of unbound components of precursor compound B that have not reacted with precursor compound A. The cycle can be performed three times, wherein steps (II) to (V) are performed three times, and so on. Typically, the cycle is performed n times, where n is the number of cycles. Preferably, n is a number between 1 and 100, and particularly preferably a number between 1 and 50. Advantageously, by repeating steps (II) to (V), a virtually seamless coverage of the plastic lens surface to which the functional coating is to be provided can be achieved. This cyclic execution can be particularly advantageous when used in conjunction with long-chain precursor compounds (preferably silane-containing precursor compounds with long-chain alkyl chains), because the reaction processes (e.g., adsorption of the first precursor compound on the plastic lens surface and / or reaction of the two precursor compounds to form a functional monolayer) can only occur when the desired reactants are in close proximity. For example, if molecules of the first precursor compound aggregate on the plastic lens surface but fail to bind to the plastic lens surface during the hydrolysis reaction step due to misorientation, these areas of the plastic lens surface, although covered by this precursor compound, cannot form an adherent functional monolayer when reacting with the second precursor compound; that is, in particular, a functional monolayer attached to the plastic lens surface cannot be formed there. In step (III) or (V), the unattached material is removed, thereby forming an incompletely closed functional monolayer. This cyclic execution ensures the formation of a functional coating without gaps; in other words, the functional monolayer is formed on the entire surface of the plastic lens to provide the functional coating. Typically, this cycle cannot be performed too frequently because further adhesion cannot occur, for example, on a surface saturated with the first precursor compound through gapless adsorption or when the surface is completely saturated by a functional monolayer.

[0053] Preferably, the method is improved in conjunction with cyclic execution according to the above-described sub-aspects, such that the cycle is extended to include the formation, coating, or arrangement of an adhesive layer as part of the cycle. This (i.e., coating the adhesive layer as part of the cycle) allows for the coating of multiple consecutive monolayers of the functional layer, as the adhesive layer forms crosslinks. This further improves the cyclic execution, making it not only suitable for forming gapless monolayers of the functional layer, but also, due to the formation of additional adhesive layers between the consecutive monolayers, for obtaining a functional coating consisting of multiple consecutive monolayers of the functional layer, thus possessing improved functional properties, particularly hydrophobic and / or oleophobic properties. This advantageously ensures that, in subsequent cycle runs, the first (preferably silane-containing) precursor compound finds binding sites on the surface of one (or more) monolayers of the functional layer already provided, where the formed adhesive layer constitutes these binding sites. Compounds containing silanes and / or siloxanes are particularly suitable for forming such adhesive layers. For example, this adhesive layer can be a silane-containing compound such as tetramethyldisilane (TMDS) or hexamethyldisilane (HMDS), or a siloxane-containing compound such as tetramethyldisiloxane (TMDSO) and / or hexamethyldisiloxane (HMDSO) and / or polydimethylsiloxane (PDMS), but is not limited thereto. Other embodiments are also contemplated, particularly embodiments forming an adhesive layer composed of one and / or two compounds, wherein these compounds react on the surface of the plastic lens to form such an adhesive layer. According to the foregoing aspects, in an improved example of coating the adhesive layer, such a cycle can be performed n times, where n is the number of cycles performed, i.e., by this method a plastic lens with a functional coating comprising n monolayers of a functional layer, wherein an adhesive layer is formed between each of these n consecutive monolayers. According to the foregoing aspects, n is preferably a number between 1 and 100, and particularly preferably a number between 1 and 50.

[0054] On the other hand, an apparatus is disclosed for producing functionally coated plastic lenses (particularly plastic spectacle lenses). This apparatus includes a process chamber (also referred to as a treatment chamber), a holding device arranged within the process chamber for receiving at least one plastic lens, at least one supply device for a precursor compound connected to the process chamber, and a removal device also connected to the process chamber. Preferably, the apparatus is adapted to perform the method according to one aspect.

[0055] There are no other restrictions on the process chamber except that it must be made of a durable material resistant to a variety of substances (preferably stainless steel). Depending on the size of the device, a small process chamber with a holding device for accommodating plastic lenses can be considered, or a significantly larger process chamber can be considered in which multiple plastic lenses can be arranged on the holding device and functional coating can be performed simultaneously to achieve particularly economical production of functionally coated plastic lenses.

[0056] The holding device is not limited other than requiring a suitable receiving structure for at least one plastic lens. A stainless steel retaining ring is a preferred holding device, slightly larger than the functionally coated plastic lens, to hold the plastic lens in place during the production process. Alternatives or improvements are also conceivable, such as holding devices for multiple plastic lenses to be functionally coated, and corresponding holding devices that hold the plastic lenses to be functionally coated such that, in particular, both surfaces of the plastic lenses are freely in contact and uncovered, so that a functional layer can be deposited simultaneously on both surfaces.

[0057] A supply device is a means of connecting to a process chamber and providing the precursor compound, meaning that the supply device is capable of introducing or delivering the precursor compound into the process chamber of the system. A preferred supply device is a storage tank (preferably a compressed gas cylinder) containing the gaseous precursor compound and connected via a pipeline to an adjustable valve connected to the process chamber. Alternatives are also considered, such as containers containing the precursor compound in liquid or even solid phases. In this case, the supply device would first be heated (either by thermal energy or compression) to convert the liquid or solid phase into a gaseous phase before being supplied to the process chamber. Advantageously, this allows for easy filling or filling of the process chamber with the precursor compound. Alternatively, the precursor compound may also be present in liquid form in the storage tank, wherein, under sufficiently high vapor pressure, a portion of the precursor compound will convert into a gaseous phase. This gaseous phase can then be delivered to the processing chamber via an inert carrier gas (e.g., argon or nitrogen).

[0058] The removal device is connected to the process chamber and is capable of removing the gaseous phase of the precursor compound located within the process chamber. A preferred removal device is a commercially available vacuum pump connected to the process chamber via an adjustable valve (preferably a plate valve). Advantageously, this allows any precursor compound located within the process chamber to be removed, for example, by pumping or suction. It is also conceivable that the removal device can be used to pump or suction remove or deliver any gas, and therefore can also be used to control the pressure conditions within the process chamber by targeted evacuation, in order to, for example, intentionally create a negative pressure.

[0059] Preferably, the apparatus includes additional components, such as an electric heater for influencing temperature conditions, a catalyst supply device, a plasma processing device for providing (reactive) plasma, and / or a laser irradiation device for providing laser radiation, and / or a UV irradiation device for providing UV radiation, and / or a supply device for providing high-energy particles, and / or a supply device for providing an electric field. These additional components may be present individually or in combination so that the method according to a preferred embodiment of one aspect can also be advantageously performed within the apparatus, in which additional energy must be provided to promote the adsorption of precursor compounds and / or the reaction of two precursor compounds.

[0060] Preferably, the apparatus further includes a control device connected to the various components of the apparatus, thereby enabling control or adjustment of these components. Advantageously, after the control sequence of the production method is programmed according to the foregoing aspects, the method can be executed automatically.

[0061] On the other hand, a method is provided for operating a production apparatus for functionally coated plastic lenses (particularly plastic spectacle lenses), wherein the production method and the production apparatus possess the features described in the aforementioned aspects.

[0062] The operating method includes setting control parameters, particularly setting setpoints or set values ​​for each component of the production apparatus according to the foregoing aspects, wherein the production apparatus also includes a control device. By inputting appropriate values ​​or process parameters as a program into the control device, the control device is put into a state capable of automatically controlling the production apparatus, thereby automatically executing the production method of functionally coated plastic lenses according to the foregoing aspects. Preferably, this setting only needs to be performed once, and the control device can then automatically control the production apparatus to execute such a production method.

[0063] Preferably, the method is further improved such that after completing a process cycle that includes at least the production of at least one functionally coated plastic lens, the functional characteristics of the produced functionally coated plastic lens are measured. Specifically, if one or more deviations exist from the specified acceptable quality targets(s), the values ​​or process parameters input to the control device as program inputs are adjusted. By appropriately adjusting the process parameters, specific deviations can be corrected in a targeted manner, and in subsequent process cycles that include at least the production of another plastic lens with a functional coating, it can be ensured that the characteristics of the plastic lens are again within the specified quality target range after the functional characteristics of the plastic lens have been determined. This makes it advantageous to provide a feedback control method in which any deviation can be detected by continuously monitoring the quality targets and can be appropriately compensated for in subsequent process cycles. Therefore, this document specifically proposes a method for operating a production apparatus for functionally coated plastic lenses that is feedback-controlled, in other words, adjustable, to achieve constant quality while adhering to or satisfying specified quality targets for functionally coated plastic lenses.

[0064] On the other hand, it relates to functionally coated plastic lenses, particularly plastic eyeglasses, which include a substrate made of plastic glass and at least one monolayer having a functional layer on at least one surface.

[0065] A plastic lens is an optical element comprising a substrate made of plastic glass, wherein the plastic glass is preferably made substantially of poly(sulfur)urethane, polymethyl methacrylate, polymethyl acrylate, polycarbonate, polyacrylate, or polyethylene glycol dielyl carbonate. Combinations of the above materials, along with other plastic materials for the plastic glass, may also be considered, provided that these materials are substantially transparent and / or possess optical properties suitable for use as lens plastic glass. Plastic lenses typically have two surfaces, one or both of which may have radii of curvature, particularly different radii of curvature, which imparts optical refractive power to the lens. Such plastic lenses can be finished lenses, i.e., lenses where both surfaces have been processed, meaning that both surfaces already possess the desired optical properties. However, the lens can also be a semi-finished product, wherein only one of the two surfaces possesses the desired optical properties, while the other surface has not been processed, i.e., does not yet possess the desired optical properties. Within the scope of this invention, plastic lenses can advantageously have additional improvements beyond the optical properties (multiple properties). This includes all improvements known to those skilled in the art, particularly additional coatings and / or varnishes. Typical examples of paints include buffer coatings for improving fracture strength and / or hard coatings for improving or enhancing mechanical strength (especially scratch resistance).

[0066] Typical examples of coatings include specular coatings and / or anti-reflective coatings. These anti-reflective coatings reduce the reflectivity of the plastic lens, thereby suppressing unwanted reflections. In other words, within the scope of this invention, "plastic lens" is understood to refer to any raw or processed lens, particularly processed and coated lenses.

[0067] The plastic lens has a functional coating or is provided with a functional coating; in other words, the functional coating is disposed on at least one surface of the plastic lens. The functional coating consists of at least one (particularly exactly one) monolayer of a functional layer, wherein the functional layer is formed by corresponding functional molecules that impart additional properties (particularly additional functional properties) to the functional layer, thereby imparting additional properties (particularly additional functional properties) to the functional coating, and consequently imparting additional properties (particularly additional functional properties) to the plastic lens provided with the functional coating.

[0068] These functional characteristics can be particularly understood as the repellency of water droplets and dirt.

[0069] Here, the functional coating has at least one (preferably exactly one) monolayer of a functional layer, wherein the monolayer is formed (i.e., in a gapless manner) to cover the surface of the plastic lens, such that the functional properties are present throughout the entire surface of the plastic lens, that is, the functional properties are uniformly present on the surface of the plastic lens, and in particular, there are no areas on the surface of the plastic lens where there are differences in functional properties. The gapless formation of the functional layer monolayer endows the plastic lens with excellent functional properties, wherein these properties have been advantageously formed by the presence of the monolayer.

[0070] Preferably, the functionally coated plastic lens has more than one monolayer of the functional layer, particularly 1 to 100 monolayers, and more preferably 1 to 50 monolayers. Advantageously, the properties of the functional coating can be improved by multiple consecutively coated monolayers of the functional layer.

[0071] Preferably, the plastic glass of the plastic lens substrate is made primarily of poly(sulfur)urethane, polymethyl methacrylate, polymethyl acrylate, polycarbonate, polyacrylate, or polyethylene glycol dielyl carbonate. These are typical and commonly used plastic glass materials, which have the advantages of excellent optical properties and, in particular, relatively low weight compared to mineral glass.

[0072] Preferably, the functional layer of the plastic lens imparts hydrophobic and / or oleophobic properties to the plastic lens, particularly with a contact angle relative to H2O greater than or equal to 90°, preferably greater than or equal to 100°, and / or relative to hexadecane (C 16 H 34 The contact angle is greater than or equal to 30°, preferably greater than or equal to 60°. Therefore, the functionally coated plastic lens advantageously has very good repellency against water droplets and dirt.

[0073] Preferably, the plastic lens has at least one silicon oxide layer disposed directly or indirectly on the surface of the plastic lens. Advantageously, due to appropriate (pre)treatment (especially plasma treatment), silicon oxide tends to form OH groups with binding affinity or reactivity, thus the functional coating can adhere well to or be bonded to the plastic lens.

[0074] Preferably, the plastic lens has a coating, particularly a multilayer interference antireflective or specular coating, wherein the coating has a single layer of silicon oxide as the outermost layer (i.e., the layer furthest from the substrate). Advantageously, due to the tendency of silicon oxide to form OH groups with binding affinity through appropriate (pre)treatment (especially plasma treatment), the functional coating can adhere well to or be bonded to the plastic lens.

[0075] Preferably, the functionally coated plastic lens has a functional coating that is the outermost coating closest to the surface and furthest from the substrate. Advantageously, this allows the plastic lens to achieve very good hydrophobic and / or oleophobic properties. Particularly good hydrophobic and / or oleophobic properties can be achieved in improved examples where the silicon oxide layer is located directly beneath the functional coating, which is the outermost layer before the functional coating is applied.

[0076] Preferably, the plastic lens does not have any other coating after the functional coating. This is advantageous because: on the one hand, the surface energy of the formed functional coating is low, making it more difficult for another layer or coating to adhere; on the other hand, only when the functional coating, which imparts hydrophobic and / or oleophobic properties to the plastic lens, is formed as the outermost coating closest to the surface and furthest from the substrate, can the hydrophobic and / or oleophobic properties have a positive impact on the daily use of the plastic lens in terms of improving cleanliness and reducing the tendency of contaminants to adhere. In other words, the functional coating is the outermost, last, or final layer of the plastic lens, and preferably the only layer on which the plastic lens is directly exposed to environmental influences.

[0077] Preferably, the functionally coated plastic lens is produced according to another method.

[0078] The value expressed as “approximately” can preferably deviate from the given value by + / -10%, more preferably by + / -5%, particularly preferably by + / -2%, and especially can be exactly the same as the given value.

[0079] The term “substantially” means that a substance, material or compound is substantially composed of the specified substance or material. That is, “X is substantially composed of Y” means that the proportion of Y in X is particularly greater than or equal to 50%, preferably greater than or equal to 75%, particularly preferably greater than or equal to 90%, and also includes cases where X is composed of or formed solely of Y. Attached Figure Description

[0080] The embodiments of the present invention will now be described in more detail with reference to the accompanying drawings. It should be understood that the present invention is not limited to these embodiments, and that various features of these embodiments can be combined to form other embodiments within the scope of the appended claims.

[0081] Figure 1 A first preferred embodiment of the plastic lens is shown.

[0082] Figure 2 A second preferred embodiment of the plastic lens is shown.

[0083] Figure 3 A third preferred embodiment of the plastic lens is shown.

[0084] Figure 4 A fourth preferred embodiment of the plastic lens is shown.

[0085] Figure 5 A preferred method for producing plastic lenses is shown.

[0086] Figure 6 Another preferred method is shown.

[0087] Figure 7 Another preferred method is shown.

[0088] Figure 8 A preferred apparatus for producing plastic lenses is shown. Detailed Implementation

[0089] Figure 1 A first embodiment of a plastic lens 1 with a functional coating 2 is shown, wherein the plastic lens 1 comprises a substrate made of plastic glass, the substrate having the functional coating 2 already provided. In this embodiment, the functionally coated plastic lens 1 comprises a single layer of functional layer 3; in other words, the functional coating 2 consists of exactly one single layer of functional coating 3.

[0090] Figure 2 A second embodiment of a plastic lens 1 having a functional coating 2 is shown, wherein the plastic lens 1 comprises a substrate made of plastic glass, and wherein a silicon oxide layer 4 is disposed on at least one surface of the plastic lens 1. The functional coating 2, directly coated onto the silicon oxide layer 4, consists of exactly one monolayer of a functional layer 3. In other words, the plastic lens 1 includes a functional coating 2 consisting of a monolayer of a functional layer 3 formed on or directly disposed on the silicon oxide layer 4.

[0091] Figure 3A third embodiment of a plastic lens 1 with a functional coating 2 is shown, wherein the plastic lens 1 comprises a substrate made of plastic glass, the substrate having the functional coating 2 already applied. In this embodiment, the functionally coated plastic lens 1 comprises six monolayers of a functional layer 3; in other words, the functional coating 2 consists of exactly six monolayers of the functional layer 3. To produce the functionally coated plastic lens 1, a production method according to another aspect is applied, wherein the cycle consisting of steps (II) to (V) is performed a total of six times to sequentially coat the additional five monolayers of the functional layer 3 onto the first monolayer of the functional layer 3, so as to obtain a functionally coated plastic lens 1 with the functional coating 2 comprising the six monolayers of the functional layer 3.

[0092] Figure 4 A fourth embodiment of a plastic lens 1 having a functional coating 2 is shown, wherein the plastic lens 1 comprises a substrate made of plastic glass, wherein a silicon oxide layer 4 is disposed on at least one surface of the plastic lens 1, and the functional coating 2 is coated onto the silicon oxide layer. In this embodiment, the functional coating 2 of the plastic lens 1 comprises three monolayers of functional layers 3, 3', and 3''; in other words, the functional coating 2 is composed of exactly three monolayers of functional layers 3, 3', and 3''. Adhesive layers 5 and 5' are disposed, coated, or formed between the consecutive monolayers of functional layers 3, 3', and 3'', respectively, and the adhesive layers act as adhesion promoters between the monolayers of functional layers 3, 3', and 3''. Adhesive layers 5 and 5' are preferably formed of compounds containing silanes and / or siloxanes, for example, adhesive layers 5 and 5' are preferably formed substantially of tetramethyldisilazane. To produce the functionally coated plastic lens 1, a production method according to another aspect is applied, wherein the cycle consisting of steps (II) to (V) is performed a total of three times to sequentially coat the additional two monolayers of functional layers 3', 3'' onto the first monolayer of functional layer 3, so as to obtain a functionally coated plastic lens 1 comprising three monolayers of functional layers 3, 3', 3'', with functional coating 2. Step S109 (coating adhesive layer 5 or 5') is performed not only after the first cycle of forming the first monolayer of functional layer 3, but also after the second cycle of forming the second monolayer of functional layer 3'. The properties of adhesive layers 5, 5', particularly properties such as physical layer thickness and / or refractive index, can be the same or different. After the final monolayer of functional layer 3'' is formed, it is preferable not to form an additional adhesive layer to maintain its functional properties unaffected. The silicon oxide layer 4 and adhesive layers 5, 5' can also be formed from the same material or the same compound; for example, tetramethyldisilazane is preferably used for this purpose.

[0093] Figure 5A schematic diagram of a method for producing a functionally coated plastic lens 1 is shown. In a first step S100, a plastic lens 1, particularly a plastic spectacle lens, is provided, within the scope of this method, having a functional coating 2. In a next step S102, the precursor compound A is provided, for example, by providing or introducing a gaseous phase of a first precursor compound A, which is adsorbed onto at least one surface of the plastic lens. In a next step S104, excess and unbound material of the first precursor compound A is removed, for example, by pumping or suction removal. In a next step S106, the precursor compound B is provided, for example, by providing or introducing a gaseous phase of a second precursor compound B. The provided second precursor compound B reacts with compound A adsorbed on at least one surface of the plastic lens, and as a reaction product, a monolayer of the functional layer is formed or deposited on at least one surface of the plastic lens. In other words, the monolayer of the functional layer is a product generated by the reaction of precursor compounds A and B. In a next step S108, excess and unbound material of the second precursor compound B is removed, for example, by pumping or suction removal. In the subsequent step S110, a single-layer plastic lens with functional layer 3 is obtained. In other words, within the scope of this method, the plastic lens 1 is provided with functional coating 2, wherein the functional coating 2 includes at least one single layer of functional layer 3.

[0094] Figure 6 yes Figure 5 A schematic diagram of an improved example of a method for producing a functionally coated plastic lens 1 is shown, illustrating a cyclic execution process according to a preferred embodiment of the method. The improved execution is achieved by specifying the number of cycles n to be performed. Figure 5 The method described above involves executing the loop consisting of steps S102 to S108 n times until the loop count n is reached. This loop execution process is as follows: Figure 6 As shown, it begins with the execution variable i, where the initial value i equals 1. The first run of the loop consisting of steps S102 to S108 is executed. Then, it is checked whether the execution variable i is less than the specified loop execution number n. If this is the case (i.e., if i is less than n), i is incremented by 1 (i.e., i is now equal to 2), and another loop consisting of steps S102 to S108 is executed, that is, steps S102 to S108 are executed again in the second loop execution. Then, it is checked again whether the execution variable i is less than the specified loop execution number n. If i is less than n, another loop execution is executed. This process continues until the execution variable i is no longer less than the specified loop execution number n, that is, until the loop execution number is reached. The loop method proposed in this paper is particularly suitable for achieving a preferably gapless coverage of the surface of a plastic lens by repeating the steps required for this purpose multiple times (n times).

[0095] Figure 7 yes Figure 6The diagram illustrates an improved example of a cyclic method for producing a functionally coated plastic lens 1, wherein the improvement to the cycle is the insertion of an additional step S109 in which adhesive layers 5, 5' are formed or coated. This provides a method in which multiple monolayers of functional layer 3 are continuously formed on the surface of the plastic lens by cyclic execution. Without such adhesive layers 5 or these adhesive layers 5, 5', continuous monolayers of functional layers 3, 3', 3'' cannot be formed because cross-linking does not occur between continuous monolayers 3 and 3' or between 3' and 3''. In this improved example, adhesive layers 5 or 5' are formed or coated between continuous monolayers of the functional layer, i.e., between monolayers 3 and 3' and between monolayers 3' and 3''. By coating such adhesive layers 5, 5' between the individual monolayers, good adhesion between the individual monolayers can be advantageously achieved. In particular, when used in combination with silane-containing precursor compounds, the silane- and / or siloxane-containing compounds as preferred adhesive layers 5, 5' have the advantage that, since the first silane-containing precursor compound can advantageously and particularly well adsorb onto the silane- and / or siloxane-containing compounds as adhesive layers 5, 5', the adhesive layer can provide very good adhesion for the next monolayer of the functional layers 3', 3'' to be formed in the next cycle.

[0096] Figure 8A schematic diagram of one embodiment of the production apparatus 8 is shown. Within the process chamber 80 of the production apparatus 8, a holding device 81 for accommodating a plastic lens 1 is arranged. In this embodiment, two holding supports 81 are preferred holding devices 81, clamping the plastic lens 1 to which the functional coating 2 is to be applied between the two holding supports. The holding supports 81 are indicated by dashed lines to show that they are merely two supports and not partitions of the process chamber 80. This allows the provided plastic lens 1 to preferably have the functional coating 2 applied to both sides, i.e., not only on its convex surface but also on its concave surface. The production apparatus 8 includes a compressed gas cylinder, preferably a supply device 82, containing a precursor compound in the gaseous phase, and connected via a stainless steel compressed gas line to an adjustable valve on the wall of the process chamber 80. By opening this valve, a volumetric flow of the gaseous phase of the precursor compound occurs, flowing from the compressed gas cylinder through the compressed gas line and through the valve into the process chamber, thereby supplying the precursor compound into the process chamber 80. The production apparatus 8 also includes a rotary vane pump 83, preferably a removal device, for pumping out or suctioning away unbound material of the precursor compounds to clean the process chamber 80. Rotary vane pumps and / or diaphragm vacuum pumps are particularly suitable for pumping out such precursor compounds. As an optional component, the production apparatus 8 includes a plasma source, preferably a plasma treatment device 84, which provides plasma to promote a reaction between the two precursor compounds to obtain a single layer of functional layer 3. As an optional component, the production apparatus 8 also includes a computer, preferably a control device 90, having a keyboard (preferably an input unit), a processor (preferably a computing unit), a hard disk (preferably a storage unit), and a serial interface (preferably a communication unit), wherein the serial interface is connected to and can appropriately control the supply device 82, the removal device 83, and the plasma source 84.

[0097] The following exemplary embodiments are provided to further explain the present invention, but are not limited thereto.

[0098] Provided as a plastic eyeglass lens, the plastic eyeglass lens comprising a substrate made of plastic glass, the substrate being substantially made of polyurethane, wherein the refractive index is 1.60, the spherical refractive power is -2.25 dpt, and the diameter is 60 mm.

[0099] The plastic eyeglass lenses have been pre-coated. First, a hard varnish is applied as a scratch-resistant layer using a dip-coating process. Then, an interference-type anti-reflective layer is sequentially applied to both sides of the eyeglass lens using ion-assisted physical vapor deposition, wherein the anti-reflective coatings applied to both sides each have a silicon dioxide (SiO2) monolayer as the final layer.

[0100] According to one aspect, the spectacle lenses are then placed in a production apparatus, specifically, the plastic spectacle lenses are arranged in a holding device located within the process chamber of the production apparatus. In this case, the supply step includes performing plasma treatment, wherein the plasma is provided by an optional plasma source connected to the process chamber. Argon plasma is used as the plasma, with an accelerating voltage of 60V. Other parameters of the plasma depend on the production apparatus used and the specific plasma source, and are deliberately omitted as they are irrelevant to further understanding this example. Through plasma treatment, the surface of the spectacle lenses is subjected to plasma erosion, wherein, particularly on the outermost SiO2 layer disposed on the surface, reactive hydroxyl ions with higher polarity than those on the untreated surface are formed. The generated reactive hydroxyl ions have a high binding affinity.

[0101] Not only in the aforementioned supply step, including plasma treatment, but also in all subsequent process steps, the temperature within the process chamber is maintained at approximately 75°C by electric heaters. To this end, the process chamber is equipped with suitable electric heating plates and additionally includes a temperature sensor and a corresponding regulator in the control device. This regulator ensures that the heater is activated or deactivated as needed to maintain the temperature at approximately 75°C throughout the process and, in particular, to prevent the temperature from exceeding this value.

[0102] In the next step, dodecyltrichlorosilane (DTS) is provided in the process chamber as a first precursor compound. DTS is preferred over octadecyltrichlorosilane (ODTS) because DTS typically has a lower boiling point than ODTS, making it particularly suitable for such methods under cryogenic conditions. The DTS is present in liquid form in a tank connected to a valve located on the process chamber via a supply line. Due to the vapor pressure generated at a set process temperature of approximately 75°C, a portion of the DTS is present in gaseous form and introduced into the process chamber via argon, which is the preferred carrier gas. The gaseous DTS resides in the process chamber for approximately one minute. This longer residence time, combined with the regulated temperature of 75°C, ensures sufficient time and energy to overcome the activation energy required for adsorption, compared to the ALD method with significantly higher temperatures and residence times of only a few seconds. This allows the DTS to adsorb onto (multiple) surfaces of the spectacle lens, particularly onto the entire surface or adsorbed without gaps. Because the spectacle lens(s) had been previously subjected to plasma treatment, and in particular because hydroxyl ions were formed on the silicon oxide layer arranged on the spectacle lens(s), there were sufficient binding sites to enable or facilitate the adsorption process.

[0103] In the next step, excess and unbound DTS remaining in the process chamber is removed by pumping or suction using a rotary vane pump. The result is a clean process chamber free of any DTS residue. Specifically, by adsorbing onto the surface of the eyeglass lens, the DTS subsequently exists only in a bound state.

[0104] In the next step, H2O, as a second precursor compound, is provided in the process chamber. The H2O exists in liquid form in a tank connected to a valve located on the process chamber via a supply line. Due to the vapor pressure generated at a set process temperature of approximately 75°C, a portion of the H2O exists in gaseous form and is introduced into the process chamber via argon, which is the preferred carrier gas. The gaseous H2O resides in the process chamber for approximately 100 minutes. This very long residence time, combined with the regulated temperature of 75°C, ensures both sufficient time and energy to overcome the activation energy of the reaction between the precursor compound DTS and H2O, in order to form a functional monolayer as the reaction product of DTS and H2O.

[0105] The provided gaseous H2O (water vapor) initiates a hydrolysis reaction, causing the DTS adsorbed on (multiple) surfaces of the spectacle lens to form a strong bond with the lens surface, and forming a functional monolayer as a product of the reaction between DTS and water vapor. In other words, this provides a functional coating to the spectacle lens, wherein the functional coating consists of exactly one monolayer of the functional layer as a product of the two precursor compounds DTS and water vapor. Removing unbonded DTS in the previous step ensures that the desired reaction for forming the functional monolayer occurs only on (multiple) surfaces of the spectacle lens, and that no other reactions occur in the process chamber, particularly not on the walls of the process chamber, and especially not in the gas phase. This ensures that the formation of the functional monolayer occurs only on (multiple) surfaces of the spectacle lens.

[0106] In the next step, excess and unbound water vapor is removed from the process chamber by pumping.

[0107] Finally, a spectacle lens with a functional coating was obtained. The resulting functionally coated spectacle lens had a contact angle of 95° with H₂O and with hexadecane (C₂O₃). 16 H 34 The contact angle is 35°. Therefore, the functionally coated plastic lens has an advantageously good repellency to water droplets and dirt.

[0108] Therefore, the method proposed in this paper enables the production of plastic lenses with, in particular, a single functional layer, through a precise and controllable manufacturing process. This functional layer constitutes a functional coating that imparts additional properties to the plastic lens. For example, these properties can be specifically understood as hydrophobic and / or oleophobic properties.

Claims

1. A method for producing a functionally coated plastic lens (1), wherein the plastic lens, particularly a plastic spectacle lens, is wherein, The method includes the following steps: (I) Provide (S100) a plastic lens (1), said plastic lens comprising a substrate made of plastic glass; (II) Provide (S102) a gas phase of the first precursor compound A to obtain at least one modified surface of the plastic lens, the surface having been modified by adsorbing the precursor compound A; (III) Remove (S104) excess material of the precursor compound A that has not been adsorbed onto the modified surface of the plastic lens; (IV) Provide (S106) a gas phase of a second precursor compound B, wherein the second precursor compound B reacts with the precursor compound A adsorbed on the modified surface, and as a reaction product, forms a single layer of functional layer (3, 3', 3") on the surface of the plastic lens. (V) Remove (S108) excess material of the precursor compound B that is not bonded to the modified surface; (VI) Obtain (S110) the plastic lens (1) having the functional coating (2), The functional coating (2) formed therein imparts hydrophobic and / or oleophobic properties to the plastic lens (1).

2. The method according to claim 1, wherein, The method is performed at a temperature less than or equal to 100°C, preferably at a temperature less than or equal to 75°C, and particularly preferably at a temperature less than or equal to 50°C.

3. The method according to claim 1 or 2, wherein, The plastic glass of the plastic lens (1) is substantially made of poly(sulfur)urethane, polymethyl methacrylate, polymethyl methacrylate, polycarbonate, polyacrylate or polyethylene glycol dielyl carbonate.

4. The method according to any one of the preceding claims, wherein, The plastic lens (1) has at least one surface on which a silicon oxide layer (4) is disposed directly or indirectly.

5. The method according to claim 4, wherein, The silicon oxide layer (4), which is the outermost single layer furthest from the substrate, is part of a multilayer coating system, particularly a multilayer interference coating system.

6. The method according to any one of the preceding claims, wherein, The formed functional coating (2) causes the contact angle of the plastic lens (1) with respect to H2O to be greater than or equal to 90°, preferably greater than or equal to 100°, and / or with respect to hexadecane (C 16 H 34 The contact angle is greater than or equal to 30°.

7. The method according to any one of the preceding claims, wherein, In one, two, more, or all of steps (I) to (VI), at least one or more of the following conditions are met: - Adjusted pressure conditions; and / or - Adjusted temperature; and / or - (Reactive) plasma; and / or - The presence of a catalyst; and / or - The adjusted residence time of the(multiple) precursor compounds; and / or - Irradiation with laser radiation; and / or - Irradiation with UV radiation; and / or - Bombardment with high-energy particles; and / or - The existence of an electric field.

8. The method according to any one of the preceding claims, wherein, One of the two precursor compounds is a silane-containing compound.

9. The method according to claim 8, wherein, The silane-containing compound has an alkyl chain comprising at least eight carbon atoms.

10. The method according to claim 8, wherein, The silane-containing compounds are essentially the following compounds: octadecyltrichlorosilane (ODTS), hexadecyltrichlorosilane (HDTS), tetradecyltrichlorosilane (TDTS), dodecyltrichlorosilane (DTS), decyltrichlorosilane, octyltrichlorosilane, tridecylfluorotetrahydrooctyltrichlorosilane (FOTS), heptadecafluorotetrahydrodecyltrichlorosilane (FDTS), or octadecyltrimethoxysilane (ODTMS), dodecyltrimethoxysilane (DTMS), hexadecyltrimethoxysilane (HDTMS), octadecyltriethoxysilane, dodecyltriethoxysilane, or hexadecyltriethoxysilane.

11. The method according to any one of claims 8 to 10, wherein, Another of the precursor compounds is essentially H2O.

12. The method according to any one of the preceding claims, wherein, Steps (II) to (V) constitute a loop, which is executed n times, wherein the number of times the loop is executed n is preferably between 1 and 100, particularly preferably between 1 and 50, to obtain a functionally coated plastic lens, wherein the functional coating (2) has n consecutively formed monolayers of the functional layers (3, 3', 3").

13. The method according to claim 12, wherein, An adhesive layer (5, 5') is formed between the continuous single layers of the functional layers (3, 3', 3").

14. A production apparatus (8) for producing functionally coated plastic lenses (1), wherein the plastic lenses are particularly plastic spectacle lenses, The production apparatus includes: a process chamber (80); a holding device (81) disposed within the process chamber and for receiving at least one plastic lens (1); at least one supply device (82) connected to the process chamber (80) and for a precursor compound; and a removal device (83) also connected to the process chamber (80), wherein the production apparatus (8) is adapted to perform the method according to any one of claims 1 to 13.

15. The apparatus according to claim 14, wherein, The device includes at least one of the following components, and preferably includes two or more of the following components: - Electric heaters; and / or - Catalyst supply unit; and / or - Plasma processing equipment; and / or - Laser irradiation device; and / or - UV irradiation device; and / or - A supply device for providing high-energy particles; and / or - A supply device used to provide an electric field.

16. A functionally coated plastic lens (1), particularly a plastic spectacle lens, comprising a substrate made of plastic glass, and having at least one monolayer having a functional layer (3) on at least one surface, particularly exactly one monolayer having said functional layer (3), wherein, The functional layer is preferably formed by the method according to any one of claims 1 to 13.

17. The functionally coated plastic lens (1) according to claim 16, wherein, The single layer of the functional layer (3) imparts hydrophobic and / or oleophobic properties to the functionally coated plastic lens, particularly with a contact angle greater than or equal to 90° relative to H2O, preferably greater than or equal to 100°, and / or relative to hexadecane (C 16 H 34 The contact angle of the ) is greater than or equal to 30°, preferably greater than or equal to 60°.

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