Method for encapsulating microstructured lenses by coating transfer

Abstract

1. A method for forming an optical lens, comprising: providing a lens having microstructures on a surface thereof and coated thereon with an adhesive layer; pressing the coating stack against the adhesive layer via a carrier layer adhered to a first surface of the coating stack by a release coating, contacting a second surface of the coating stack with the adhesive layer; curing the adhesive layer; and removing the carrier layer from the first surface of the coating stack via the release coating, wherein a thickness of the adhesive layer is greater than a depth of the microstructures on the surface of the lens.

Description

[Technical field]

[0001] The present disclosure relates to a method of applying a hard multi-coat onto a lens having a surface microstructure via a carrier layer. [Background technology]

[0002] The discussion of the background art provided herein is intended to generally indicate the context of the present disclosure. The work of the presently named inventors, to the extent that it is described in the Background Art section, and aspects of the description that may not otherwise qualify as prior art at the time of filing, are not admitted expressly or impliedly as prior art to the present disclosure.

[0003] Coating microstructured lenses can result in deviations from the original microlens design and may require several concept loops to arrive at the design compensation for each coating. This can lead to longer development times and higher costs. Additionally, some microstructured lenses, such as Pi-Fresnel, may not be coatable by common methods such as dip coating or spin coating due to losses in the optical design. Summary of the Invention [Problem to be solved by the invention]

[0004] Aspects of the present disclosure may address some of the above-mentioned shortcomings in the art, particularly with the solutions set forth in the claims. [Means for solving the problem]

[0005] The present disclosure relates to a method for forming an ophthalmic lens, the method comprising: providing a lens having microstructures on a surface thereof and coated thereon with an adhesive layer; pressing the coating stack onto the adhesive layer through a carrier layer adhered to a first surface of the coating stack by a release coating, contacting a second surface of the coating stack with the adhesive layer; curing the adhesive layer and removing the carrier layer from the first surface of the coating stack through a release coating, the thickness of the adhesive layer being greater than the depth of the microstructures on the surface of the lens. The present disclosure relates to the method disclosed in claim 1. Advantageous aspects of the method according to the present disclosure are disclosed in claims 2-14. The present disclosure further relates to an optical element obtained according to the method of the present invention, the optical element being an ophthalmic lens.

[0006] Please note that this summary section does not specify every feature and / or incrementally novel aspect of the present disclosure or the present claims. Rather, this summary merely presents a preliminary discussion of different embodiments and corresponding novel points. For additional details and / or possible developments of the present embodiments, please refer to the Detailed Description section and corresponding figures of the present disclosure as further discussed below.

[0007] Various embodiments of the present disclosure, given by way of example only, will now be described in detail with reference to the following figures, in which: [Brief description of the drawings]

[0008] [Figure 1A] FIG. 1 is a schematic diagram of an injection molding process for forming a lens useful within the scope of the present disclosure. [Figure 1B] 1 is an exemplary cross-sectional schematic diagram of a casting process useful within the scope of the present disclosure. [Diagram 2] FIG. 1 is a schematic diagram of a HMC transcription method useful within the present disclosure. [Diagram 3] 1 is an exemplary flow chart of a method of forming an ophthalmic lens useful within the scope of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The following disclosure provides many different variations or examples for implementing different features of the provided subject matter. To make the disclosure easier to understand, specific examples of elements and arrangements are described below. It should be understood that these are merely examples and are not intended to limit the invention or to be operable together in any permutation. Unless otherwise indicated, the features and embodiments described herein can be operated together in any permutation. For example, in the following description, forming a first feature to overlay or rest on a second feature can include embodiments in which the first and second features are formed in direct contact, and can also include embodiments in which additional features can be formed between the first and second features such that the first and second features cannot be in direct contact. Also, the disclosure may repeat reference numbers and / or letters in various examples. This repetition is for the purpose of brevity and clarity and does not in itself refer to a relationship between the various embodiments and / or configurations discussed. Additionally, spatially relative terms, such as "top," "bottom," "lower," "below," "lower," "upper," "above," and the like, may be used herein to facilitate describing the relationship of one element or feature to another element or feature as illustrated. The spatially relative terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figures. Devices of the invention may be oriented in different ways (rotated 90 degrees or at other orientations) and therefore the spatially relative descriptors used herein can be interpreted similarly.

[0010] The order of discussion of different steps described herein is presented for purposes of clarity. In general, these steps can be performed in any suitable order. Also, although different features, techniques, configurations, etc. herein may each be discussed in different parts of this disclosure, it is intended that each concept can be performed independently of each other or in combination with each other. Thus, the present disclosure can be implemented and seen in many different ways.

[0011] As previously mentioned, there may be a need to provide a microstructured lens that can be coated, such as with a hard multicoat (HMC), without affecting the underlying microstructure formed thereon. To that end, a process utilizing a carrier layer may be used.

[0012] As described herein, the HMC can be applied onto a microstructured lens surface via a carrier wafer or coating. In particular, the coating carrier can be transferred and bonded onto the target lens surface using an adhesive or bonding fluid that encapsulates the surface microstructures formed thereon.

[0013] As described herein, the transfer method involves first casting or molding (e.g., injection molding) a semi-finished or finished microstructured lens and depositing an adhesive on the surface of the lens. A carrier layer with an HMC stack can then be pressed onto this surface and the adhesive cured before removing the carrier. This transfer method allows the HMC stack to be transferred and adhered to the lens surface without undesirable deformation or damage to the surface of the lens.

[0014] 1A is a schematic diagram of an injection molding process for forming lens 125 useful within the scope of the present disclosure. In a useful range, a molding apparatus may include a first mold side 101 and a second mold side 102, a first mold insert 198 disposed on a surface of first mold side 101, and a second mold insert 199 disposed on a surface of second mold side 102. First mold side 101 and second mold side 102 may each include a hollow portion within which first mold insert 198 and second mold insert 199 may be removably disposed. First mold insert 198 may include a plurality of inverted microstructures 105 formed on a surface of first mold insert 198. The plurality of inverted microstructures 105 may be of a complementary shape to the microstructures 130 on the resulting molded lens 125 to form microstructures 130 during molding. The second mold insert 199 may have a smooth surface or may include a microstructured surface as well.

[0015] A first mold side 101 having a first mold insert 198 and a second mold side 102 having a second mold insert 199 can be configured to move toward each other to form a cavity or away from each other to open the molding apparatus.

[0016] The cavity may be connected to a hollow line formed by the joining of the first mold side 101 and the second mold side 102. The line may be configured to receive the polymer melt 120, for example, via a screw feeder or similar polymer injector device. The polymer injector may be attached to the molding apparatus and configured to inject the polymer melt 120 into the cavity as the first mold side 101 joins with the second mold side 102 to form a lens 125 from the polymer melt 120 with a microstructure 130 based on the plurality of inverted microstructures 105 and a surface of the second mold insert 199 facing the cavity. The molding apparatus may be left closed for a first predetermined length of time until the lens 125 is formed.

[0017] FIG. 1B shows an exemplary cross-sectional schematic of a casting process useful within the scope of the present disclosure. To the extent useful, referring to the first step of FIG. 1B, a gasket 205, such as a tape, may be applied around the master mold 210 to form a well 220. For example, the master mold 210 is a mold insert and includes a plurality of inverse microstructures 105. The plurality of inverse microstructures 105 may be refractive, diffractive, or discontinuous over a portion or the entire surface of the insert. In the second step of FIG. 1B, the well 220 may be filled with resin. In the third step of FIG. 1B, the resin filled in the master mold 210 and the well 220 may be cured in an oven to form a lens 125. The resin may copy the inverse of the plurality of inverse microstructures 105 on the surface of the master mold 210. In the fourth step of FIG. 1B, the gasket 205 may be removed and the lens 125 may be peeled away from the master mold 210, with the lens 125 replicating the surface of the master mold 210 to form the microstructure 130.

[0018] To the extent useful, the lens 125 can be a thermoplastic or thermoset material. Examples of thermoset lens materials include polyurethane, allyl diglycol carbonate, polythiourethane, episulfur polymer, epoxy, poly(meth)acrylate, polythiomethacrylate, or combinations thereof. Examples of thermoplastic lens materials include polycarbonates (which refers to homopolycarbonates, copolycarbonates, and block copolycarbonates, where the polycarbonates can be aromatic or non-aromatic), isosorbide polycarbonate, polyacrylates, (meth)acrylic (co)polymers (especially methyl PMMA), polyvinyl butyral (PVB), thermoplastic polyurethanes (TPU), thermoplastic copolymers of ethylene and vinyl acetate, polyesters such as polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), copolyesters, copolymers of polycarbonate and polyester, copolymers of cycloolefins such as copolymers of ethylene and norbornene, copolymers of ethylene and cyclopentadiene, and combinations thereof, polystyrene, polyamides, polysulfones, polyphenylsulfones, polyetherimides, polypentenes, polyolefins, ionomers, ethylene methacrylic acid, cyclic olefin copolymers, acrylonitrile, styrene maleic anhydride, copolymers thereof, or derivatives or mixtures thereof.

[0019] The multiple inverse microstructures 105 may be used, for example, to mold refractive microstructures or diffractive micro / nanostructures. The multiple inverse microstructures 105 may be the inverse of the desired final pattern to be formed on the resulting lens after molding. The multiple inverse microstructures 105 may include microlenses or microlenslets, or other types of structures or elements with physical Z deformation / height or depth of 0.1 micrometers (μm) to 50 μm, and width / length of 0.5 μm to 2.0 mm. These structures preferably have a periodic or quasi-periodic layout, but may also have random positions. A preferred layout of the microstructures is a continuous, e.g., no space between microstructures, grid of multiple concentric rings in a honeycomb layout with a constant grid step. The structures can provide optical wavefront modification in intensity, curvature, or optical deviation, where the wavefront intensity is configured such that the structures can be absorptive and can locally absorb the wavefront intensity in the range of 0% to 100%, the curvature is configured such that the structures can locally modify the wavefront curvature in the range of ±20 diopters, and the optical deviation is configured such that the structures can locally scatter the light at angles in the range of ±1° to ±30°. The distance between the structures can range from 0 (contiguous) to 3 times the structures (discrete microstructures) in X and / or Y size.

[0020] In the sense of the present disclosure, two optical elements arranged on the surface of a lens substrate are adjacent if there is a path supported by the surface linking the two optical elements and if along the path the substrate on which the optical elements are arranged is not reached. According to another range, the optical elements are continuous on the pupil if the optical lens on the pupil does not contain a refractive area with a refractive power based on the prescription for the wearer's eye or a refractive area with a refractive power based on the prescription for the wearer's eye consisting of a number of independent islands. According to another range, the two optical elements are continuous if, in the case of a path connecting the two optical elements, along a part of said path the refractive power based on the prescription of the wearer's eye cannot be measured. According to another range, continuous optical elements can also be defined in a superficial or surface-directed manner. The measured surface is 3 mm 2 ~10mm 2 The measured surface is considered to be 1 mm 2 An optical element is considered to be continuous if, over its measured surface, at least 95%, and preferably 98%, of the surface has a different optical power than the surface on which the optical element is located.

[0021] Furthermore, the microstructures forming the microstructured major surface of the ophthalmic lens substrate may include lenslets. The lenslets may form bumps and / or cavities (i.e., raised or concave lenslet structures) in the major surface on which they are disposed. The contours of the lenslets may be round or polygonal, for example hexagonal. More specifically, the lenslets may be microlenses. The microlenses may be spherical, toric, cylindrical, prismatic, aspheric, or combinations thereof to create multi-element shapes. The microlenses may have a single focus, or a cylindrical strength, or a multifocal power, or a non-focusing power. The microlenses may be used to arrest the progression of myopia or hyperopia. In that case, the base substrate comprises a base lens that provides a refractive power to correct myopia or hyperopia, and the microlenses may provide a refractive power greater than that of the base lens if the wearer has myopia, or may have a refractive power less than that of the base lens if the wearer has hyperopia, respectively. The lenslets may also be Fresnel structures, diffractive structures such as microlenses each defining a Fresnel structure, permanent technological bumps (raised structures), or phase shifting elements. The lenslets may also be refractive optical elements such as microprisms, and light dispersive optical elements such as small protrusions or cavities, or any type of element that creates irregularities on a substrate. The lenslets may also be π-Fresnel lenslets as described in US2021109379, i.e. Fresnel lenslets whose phase function has a π phase jump at the nominal wavelength, as opposed to a single-focus Fresnel lens whose phase jump is a multiple of 2π. Such lenslets include structures with discontinuous shapes. In other words, the shape of such structures can be described by an elevation function in terms of the distance from the base level of the main surface of the optical lens to which the lenslet belongs, which function exhibits discontinuities or whose derivative exhibits discontinuities. In the useful range, the microstructures may be branding marks, holographic marks, metasurfaces, etc.

[0022] The lenslets may have a contour shape that can be inscribed in a circle having a diameter of 0.5 micrometers (μm) or more and 2.0 millimeters (mm) or less. The lenslets may have a height, measured in a direction perpendicular to the major surface on which they are disposed, of 0.1 μm or more and 50 μm or less. The lenslets may have a periodic or quasi-periodic layout, but may also have randomized positions. One layout of lenslets is a continuous, e.g., no space between microstructures, grid of multiple concentric rings in a honeycomb layout with regular grid steps. The structures can provide optical wavefront modification in intensity, curvature, or optical deviation, where the wavefront intensity is configured such that the structures can be absorptive and can locally absorb the wavefront intensity in the range of 0% to 100%, the curvature is configured such that the structures can locally modify the wavefront curvature in the range of ±20, 500, or 1000 diopters, and the optical deviation is configured such that the structures can locally scatter the light at angles in the range of ±1° to ±30°. The distance between the structures can be in the range of 0 (contiguous) to 3 times (discrete microstructures).

[0023] 2 is a schematic diagram of an HMC transfer method useful within the scope of the present disclosure. In a useful range, a carrier layer 250 can be adhered to a coating stack or HMC stack 255 having at least one layer. The material of the carrier layer 250 can be, for example, polycarbonate. The carrier layer 250 can be adhered to the HMC stack 255 by a release coating to facilitate release of the carrier layer 250 from the HMC stack 255.

[0024] To the extent that it is useful, the HMC stack 255 may be disposed on the concave surface of the carrier layer 250 (as shown), and the layers of the HMC stack 255 may be disposed in reverse order compared to a standard HMC stack. That is, the carrier layer 250 may be adhered to a first surface of the HMC stack 255, where the first surface is convex. The second surface of the HMC stack 255 may be concave and disposed opposite the carrier layer 250, furthest from the carrier layer 250. The HMC stack 255 may include a hydrophobic topcoat (closest to the carrier layer 250), an antireflective coating (which may include a stack of sublayers deposited in reverse order compared to coating directly on the lens 125), a hardcoat layer, and a latex primer furthest from the carrier layer 250. The hydrophobic topcoat and antireflective coat may be deposited via vacuum deposition. The hardcoat and latex primer may be spin coated and cured. Again, lens 125 may include microstructures 130 on the convex surface of lens 125 (as shown).

[0025] To the extent useful, carrier layer 250 may be adhered to the second (concave) surface of HMC stack 255. In such an arrangement, the first (convex) surface of HMC stack 255 is disposed opposite carrier layer 250 and furthest from carrier layer 250. The layers of HMC stack 255 may be arranged in the reverse order as when carrier layer 250 is adhered to the first surface of HMC stack 255. That is, HMC stack 255 may include a hydrophobic bottom coat (closest to carrier layer 250), an anti-reflective coating (which may include a stack of sublayers deposited in a normal order compared to coating directly on lens 125), a hard coat layer, and a latex primer furthest from carrier layer 250.

[0026] In a useful range, adhesive 260 (or any bonding fluid) may be applied to the surface of the lens having the microstructures 130. The adhesive 260 may include an optical filter, such as a photochromic dye, which will result in a photochromic microstructured lens 125. A predetermined difference or delta in refractive index between the adhesive 260 and the lens 125 material, and a predetermined thickness of the adhesive 260 may be adjusted to preserve the optical function of the microlens (microstructures 130). For example, the refractive index of the adhesive 260 may be less than that of the lens 125, or the refractive index of the adhesive 260 may be greater than that of the lens 125. For example, the depth of the microstructures on the surface of the lens may be 0.1 μm to 10 μm, and the thickness of the adhesive layer may be 0.2 μm to 50 μm. For example, for a concentric microlens design, a depth of 1 μm may be used. For example, for a continuous bifocal microlens design, a depth of 5 to 6 μm may be used.

[0027] The carrier layer 250 with the HMC stack 255 adhered thereto can be contacted with the adhesive 260 on the lens 125 such that the HMC stack 255 is in close proximity to the adhesive 260. As shown, the concave second surface of the HMC stack 255 is contacted with the adhesive 260 applied to the convex surface of the lens 125. The volume of the applied adhesive 260 can be based on the dimensions of the microstructures 130, such that the volume of the adhesive 260 is sufficient to fill any depressions or valleys in the microstructures 130. Additionally, the level of the adhesive 260 can exceed the highest point (maximum height) of the microstructures 130 when the HMC stack 255 contacts the adhesive 260. The adhesive 260 can be cured, for example, via high temperature, UV-Vis, etc., prior to removing the carrier layer 250. This transfer method allows the HMC stack 255 to be transferred and adhered to the surface of the lens 125 without damaging or altering the microstructures 130 on the surface of the lens 125.

[0028] To the extent that it is useful, the HMC stack 255 includes an anti-reflective layer.

[0029] To the extent useful, the adhesive 260 can be cured via UV-visible actinic radiation to bond the HMC stack 255 to the lens 125 before the carrier layer 250 is removed from the HMC stack 255 by breaking the release coating bond.

[0030] To the extent useful, the adhesive 260 can be cured via high temperature to bond the HMC stack 255 to the lens 125 before the carrier layer 250 is removed from the HMC stack 255 by breaking the bond of the release coating.

[0031] In a useful range, the HMC stack 255 includes a latex layer disposed opposite the carrier layer 250 as the last layer of the HMC stack 255 and furthest from the carrier layer 250. The adhesive 260 can be water or a water-based activation liquid. The HMC stack 255 can be contacted with water or a water-based activation liquid on the surface of the lens 125 where the latex layer contacts the water or water-based activation liquid. Upon contact with the water or water-based activation liquid, the latex layer can expand. In particular, the expansion of the latex layer can surround and encapsulate the microstructures 130 to form a bond between the HMC stack 255 and the lens 125. Additionally, the water can be heated to facilitate incorporation into the latex layer. EXAMPLES

[0032] Preparation of carrier layer: A plano polycarbonate (PC) carrier layer with a thickness of 0.5 mm and a base of 2.45 was prepared by injection molding. The PC carrier layer was coated by spin-coating on its concave surface with a protective release coating (see the composition in U.S. Pat. No. 7,476,415). A hydrophobic top coat and an anti-reflective coat (comprising a stack of sub-layers deposited in reverse of the normal order) were deposited by vacuum. Then, a hard coat solution and a latex primer solution were deposited by spin-coating and then cured.

[0033] Lens preparation: a 2D lens with a microstructured anterior surface and a 3.25 base front curve was cleaned, dried and corona treated on the convex side.

[0034] Example 1 - A UV curable adhesive (e.g., OP21 from Dymax Inc.) was pre-measured onto the convex surface of the lens and an inverted HMC stack was applied onto the adhesive. Pressure was applied to the HMC stack to match the curvature of the HMC stack to that of the convex surface of the lens. This resulted in the adhesive spreading between the surface of the lens and the latex primer coating of the carrier layer. The lens / adhesive / HMC stack / carrier layer assembly was placed in a UV curing apparatus and the adhesive was allowed to polymerize. After completion of UV curing, the pressure was released and the carrier layer was removed. The HMC stack was transferred to the convex surface of the lens through the carrier layer such that the microstructures were fully encapsulated by the adhesive and the microstructures were not damaged. The thickness of the adhesive was made larger (or higher) than the depth of the microstructures to ensure complete encapsulation. For example, if the microstructures are 1 micron deep, the thickness of the adhesive can be 1.5 microns or more.

[0035] Example 2 - Deionized water was dropped onto the convex surface of the lens multiple times, and the HMC stack including the latex primer layer was applied on top of the water (contacted). Pressure was applied to the HMC stack to match the curvature of the HMC stack to that of the convex surface of the lens. The assembly was heated under pressure (12 PSI, 30 minutes, 110°C), then cooled, the pressure was released, and the carrier layer was removed. The HMC stack was transferred to the convex surface of the lens such that the microstructures were completely encapsulated by the latex primer layer and the microstructures were not damaged. The latex primer layer was made larger (or higher) than the depth of the microstructures to ensure complete encapsulation. For example, if the microstructures are 1 micron deep, the latex primer layer can be 1.5 microns or more.

[0036] It is noted that the disclosed methods include the following advantages: i) the ability to make Transitions Stellest™ lenses and other photochromic lenses with different μ-structures; ii) the ability to coat new myopia control lens designs (such as continuous μ-lenses and Pi-Fresnel) that could not be coated by standard methods such as dip or spin due to loss of optical design; iii) the ability to include optical filters such as blue cut in the adhesive or latex layer; iv) the ability to provide HMC to the lens surface, thus eliminating the need for additional coatings.

[0037] 3 is an exemplary flow chart of a method 300 of forming an optical lens useful within the scope of the present disclosure. In step 310, a lens 125 can be formed having microstructures 130 formed on a surface of the lens 125, such as a convex surface. In step 320, an adhesive 260 can be applied to the microstructures on the surface of the lens 125. In step 330, an HMC stack 255 can be pressed against the adhesive layer 260 through the carrier layer 250, where the layer in the HMC stack 255 opposite the carrier layer 250 and furthest from the carrier layer 250 contacts the adhesive layer 260. In step 340, the adhesive layer 260 can be cured. In step 350, the carrier layer can be removed from the HMC stack 255. An optical element can be manufactured, the optical element being an ophthalmic lens, in particular a spectacle lens.

[0038] In the above description, specific details such as the particular geometry and various elements of the processing system and the processes used therein are disclosed. However, it will be understood that the technology described herein can be implemented in other embodiments that differ from these specific details, and such details are for illustrative purposes and not for limiting purposes. The embodiments disclosed herein have been described with reference to the accompanying drawings. Similarly, specific numbers, materials and configurations are disclosed for explanatory purposes to provide a detailed understanding. Nevertheless, the embodiments can be implemented without such specific details. Components having substantially the same functional structure are labeled with the same reference numerals, and therefore, any redundant description may be omitted.

[0039] To aid in understanding various embodiments, various techniques have been described as multiple separate operations. The order of description should not be construed as to imply that these operations are necessarily order dependent. In fact, these operations need not be performed in the order presented. The described operations may be performed in an order different from that specifically described, unless expressly indicated otherwise. Various additional operations may be performed and / or described operations may be omitted.

[0040] Those skilled in the art will appreciate that many variations may be made to the operation of the techniques described above while still achieving the same objectives of the present disclosure. Such variations are intended to fall within the scope of the present disclosure. Thus, the above description of the embodiments is not intended to be limiting. Rather, any limitations to the embodiments are presented in the following claims.

[0041] Embodiments of the present disclosure may also be as indicated by the numbers in parentheses below.

[0042] (1) A method for forming an optical lens, comprising: providing a lens (125) having microstructures (130) on a surface thereof and coated thereon with an adhesive layer (260); pressing the coating stack (255) against the adhesive layer (260) via a carrier layer (250) adhered to a first surface of the coating stack (255) by a release coating, contacting a second surface of the coating stack (255) with the adhesive layer (260); curing the adhesive layer (260) and removing the carrier layer (250) from the first surface of the coating stack (255) via the release coating, wherein a thickness of the adhesive layer (260) is greater than a depth of the microstructures (130) on the surface of the lens (125).

[0043] (2) The method according to (1), wherein the coating stack (255) is a hard multi-coat stack.

[0044] (3) The method of (1) or (2), wherein the adhesive layer (260) is UV-visible radiation sensitive, and the adhesive layer (260) is cured with UV-visible actinic radiation.

[0045] (4) The method according to any one of (1) to (3), wherein the adhesive is temperature sensitive and the adhesive layer (260) is cured at an elevated temperature.

[0046] (5) The method of any one of (1) to (4), wherein the adhesive layer (260) is water and the coating stack (255) comprises a latex layer disposed on the second surface.

[0047] (6) The method of (5), wherein the adhesive layer (260) is cured by pressing the coating stack (255) against the adhesive layer (260) for a predetermined length of time, the predetermined length of time being determined by the length of time required for the latex layer to absorb water and for the water to evaporate.

[0048] (7) The method of (6), wherein curing the adhesive layer (260) further comprises heating the water to a predetermined temperature to increase water uptake into the latex layer and promote evaporation of the water.

[0049] (8) The method according to any one of (1) to (7), wherein the adhesive layer (260) comprises a photochromic dye configured to absorb electromagnetic radiation in a predetermined wavelength range.

[0050] (9) The method according to any one of (1) to (8), wherein the refractive index of the adhesive layer (260) is different from the refractive index of the lens (125).

[0051] (10) The method according to any one of (1) to (9), further comprising forming a coating stack (255) and a carrier layer (250) by spin-coating a release coating onto a surface of the carrier layer (250), wherein the surface of the carrier layer (250) is concave.

[0052] (11) The method of (10), further comprising forming a coating stack (255) and a carrier layer (250) by vacuum depositing a hydrophobic topcoat onto the release coating, vacuum depositing an antireflective coating onto the hydrophobic topcoat, spin coating a hardcoat solution onto the antireflective coating, spin coating a latex primer solution onto the hardcoat solution, and curing the hardcoat solution and the latex primer solution.

[0053] (12) The method according to any one of (1) to (11), further comprising forming a coating stack (255) and a carrier layer (250) by spin-coating a release coating onto a surface of the carrier layer (250), wherein the surface of the carrier layer (250) is convex.

[0054] (13) The method according to any one of (1) to (12), wherein providing the surface to the lens (125) further comprises applying a corona treatment to the surface before applying the adhesive layer (260) to the surface.

[0055] (14) The method according to any one of (1) to (13), wherein the depth of the microstructure (130) on the surface of the lens (125) is 0.1 micrometers to 10 micrometers, and the thickness of the adhesive layer (260) is 0.2 micrometers to 50 micrometers.

[0056] (15) An optical element obtained by the method according to any one of (1) to (14), wherein the optical element is an ophthalmic lens.

[0057] (16) The method according to any one of (1) to (15), wherein the material of the carrier layer (250) is polycarbonate.

[0058] (17) The method according to any one of (1) to (16), wherein the coating stack (255) is pressed against the adhesive layer (260) with a force of 12 PSI at a temperature of at least 110° C. for at least 30 minutes.

[0059] (18) The method according to any one of (1) to (17), wherein the material of the lens (125) can be polyurethane, allyl diglycol carbonate, polythiourethane, episulfur polymer, epoxy, poly(meth)acrylate, polythiomethacrylate, or a combination thereof.

[0060] (19) The method according to any one of (1) to (17), wherein the material of the lens (125) can be polycarbonate, isosorbide polycarbonate, polyacrylate, (meth)acrylic (co)polymer, methyl PMMA, polyvinyl butyral (PVB), thermoplastic polyurethane (TPU), thermoplastic copolymer of ethylene, thermoplastic copolymer of vinyl acetate, polyester, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), copolyester, copolymer of polycarbonate, copolymer of polyester, copolymer with cycloolefin, copolymer of ethylene and norbornene, copolymer of ethylene and cyclopentadiene, polystyrene, polyamide, polysulfone, polyphenylsulfone, polyetherimide, polypentene, polyolefin, ionomer, ethylene methacrylic acid, cyclic olefin copolymer, acrylonitrile, styrene maleic anhydride, copolymers thereof, or combinations thereof. [Explanation of symbols]

[0061] 101 First mold side 102 Second mold side 105 Inverted Microstructure 120 Polymer Melt 125 Lens 130 Microstructure 198 First mold insert 199 Second mold insert 205 Gasket 210 Master Mold 220 wells 250 Carrier Layer 255 HMC stack or coating stack 260 Adhesive layer 260 Adhesive

Claims

1. 1. A method of forming an optical lens, comprising the steps of: providing a lens having microstructures on a surface thereof and an adhesive layer coated thereon; pressing the coating stack against the adhesive layer through a carrier layer adhered to a first surface of the coating stack by a release coating, and contacting a second surface of the coating stack with the adhesive layer; curing the adhesive layer and removing the carrier layer from the first surface of the coating stack through the release coating; Including, the thickness of the adhesive layer is greater than the depth of the microstructures on the surface of the lens; method.

2. The method of claim 1 , wherein the coating stack is a hard multi-coat stack.

3. The method of claim 1 , wherein the adhesive layer is UV-visible radiation sensitive, and the adhesive layer is cured with UV-visible actinic radiation.

4. The method of claim 1 , wherein the adhesive is temperature sensitive and the adhesive layer is cured at an elevated temperature.

5. The method of claim 1 , wherein the adhesive layer is water and the coating stack includes a latex layer disposed on the second surface.

6. 6. The method of claim 5, wherein the adhesive layer is cured by pressing the coating stack against the adhesive layer for a predetermined length of time, the predetermined length of time being determined by the length of time required for the latex layer to absorb the water and for the water to evaporate.

7. 7. The method of claim 6, wherein curing the adhesive layer further comprises heating the water to a predetermined temperature to increase water uptake into the latex layer and promote water evaporation.

8. The method of claim 1 , wherein the adhesive layer includes a photochromic dye configured to absorb electromagnetic radiation in a predetermined wavelength range.

9. The method of claim 1 , wherein the refractive index of the adhesive layer is different from the refractive index of the lens.

10. The method of claim 1 , further comprising forming the coating stack and the carrier layer by spin coating the release coating onto a surface of the carrier layer, the surface of the carrier layer being concave.

11. 11. The method of claim 10, further comprising forming the coating stack and the carrier layer by vacuum depositing a hydrophobic topcoat onto the release coating, vacuum depositing an antireflective coating onto the hydrophobic topcoat, spin coating a hardcoat solution onto the antireflective coating, spin coating a latex primer solution onto the hardcoat solution, and curing the hardcoat solution and the latex primer solution.

12. The method of claim 1 , further comprising forming the coating stack and the carrier layer by spin coating the release coating onto a surface of the carrier layer, the surface of the carrier layer being convex.

13. The method of claim 1 , wherein providing the surface to the lens further comprises applying a corona treatment to the surface prior to applying the adhesive layer to the surface.

14. The method of claim 1 , wherein the depth of the microstructures on the surface of the lens is between 0.1 micrometers and 10 micrometers and the thickness of the adhesive layer is between 0.2 micrometers and 50 micrometers.

15. An optical element obtained according to the method of any one of claims 1 to 14, said optical element being an ophthalmic lens.

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