Coated Optical Substrates

Abstract

An ophthalmic article and a method for making an ophthalmic article, the ophthalmic article comprising an ophthalmic substrate having an ophthalmic surface and an ophthalmic structure, the ophthalmic structure comprising: (a) a polymeric receiving layer having a first surface fixedly attached to the ophthalmic surface and a second surface disposed opposite the first surface, the polymeric receiving layer comprising a polymer; (b) a photochromic dye disposed within the polymeric receiving layer; and (c) an overcoat layer coating the polymeric receiving layer and fixedly attached to the second surface, the polymer having an ultimate elongation in the range of 250% to 900%; and a thickness (Toc) of the ophthalmic structure defined by the shortest normal distance between the ophthalmic substrate and an outer surface of the ophthalmic structure disposed distal to the ophthalmic substrate, the Toc being at most 50 micrometers (μm).

Description

[Technical Field]

[0001] The present invention relates to coated optical and ophthalmic devices, such as lenses, having at least one photochromic coating layer, and methods for making such optical and ophthalmic devices. [Background technology]

[0002] Coated optical substrates often contain at least one photochromic colorant, such as a photochromic dye. Such dyes typically undergo a reversible color change in response to ultraviolet light, typically becoming transparent in the absence of sunlight or other ultraviolet light sources. During this photochromic transition, the photochromic dye undergoes a reversible photochemical reaction that changes the intensity or wavelength of an absorption band in the visible portion of the electromagnetic spectrum. To be practical, optical coatings containing photochromic dyes must meet numerous performance criteria, conditions, and constraints.

[0003] The present inventors have recognized a need for improved optical and ophthalmic devices having at least one photochromic coating layer, as well as improved methods of manufacturing such optical and ophthalmic devices. Summary of the Invention

[0004] According to some teachings of the present invention, a method for manufacturing an optical article is provided, the method including: (a) applying a wet receiving layer to an optical surface of an optical substrate; (b) applying at least one photochromic dye-containing ink onto the dry receiving layer after the wet receiving layer has dried to form a dry receiving layer; and (c) applying a first polymer formulation onto the photochromic dye-containing receiving layer to form an overcoat layer after the at least one photochromic dye-containing ink has at least partially penetrated into the top surface of the dry receiving layer and after the ink has at least partially dried to form the photochromic dye-containing receiving layer.

[0005] In accordance with some teachings of the present invention, an ophthalmic article is provided, the article comprising an ophthalmic substrate having an ophthalmic surface and an ophthalmic structure, the ophthalmic structure comprising: (a) a polymeric receiving layer having a first surface fixedly attached to the ophthalmic surface and a second surface disposed opposite the first surface, the polymeric receiving layer comprising a polymer; (b) a photochromic dye disposed within the polymeric receiving layer; and (c) an overcoat layer coating the polymeric receiving layer and fixedly attached to the second surface, the polymer having an ultimate elongation in the range of 250% to 900%; and the thickness (Toc) of the ophthalmic structure is defined by the shortest normal distance between the ophthalmic substrate and an outer surface of the ophthalmic structure disposed distal to the ophthalmic substrate, and Toc is at most 50 micrometers (μm).

[0006] The present invention will now be described, by way of example only, with reference to the accompanying drawings. While the description will now proceed with specific and detailed reference to the drawings, it is emphasized that the detailed description is merely exemplary and is intended to illustrate preferred embodiments of the invention, presented in the course of providing what is believed to be the most useful and readily understandable explanation of the principles and conceptual aspects of the invention. In this regard, only those structural details of the invention necessary for a fundamental understanding will be shown, but, taken together with the drawings, will make apparent to those skilled in the art how several forms of the invention may be embodied in practice. Like reference characters are used throughout the drawings to designate like elements. [Brief explanation of the drawings]

[0007] [Figure 1] 1 provides a schematic block diagram of a method for treating an optical surface according to an aspect of the present invention; [Figure 2A] Provided is an optional step of the schematic block diagram of Figure 1, in which a wet hardcoat layer is applied over the exposed dry overcoat layer. [Figure 2B]An optional step for any of the above schematic block diagrams is provided in which the photochromic dye-containing ink is dried to form a photochromic dye-containing receiving layer. [Figure 2C] An optional step for any of the above-described schematic block diagrams is provided, in which a first surface of an ophthalmic substrate is pretreated to form an ophthalmic surface. [Figure 2D] An optional step of the schematic block diagram of Figure 2C is provided, where the pre-treatment of Figure 2C includes applying a primer to the surface of the ophthalmic substrate, which is dried to obtain a dry primer layer. [Figure 2E] An optional step for any of the above-described schematic block diagrams is provided in which the application of photochromic dyes onto the dry receiving layer (step 106) is performed for at least two photochromic dye-containing inks. [Figure 3] 3A and 3B are schematic cross-sectional views of an optical substrate having an optical structure fixedly attached to a large surface of the optical substrate, shown at time t1 after jetting of a photochromic ink, according to an embodiment of the present invention; FIG. 3A is a schematic cross-sectional view of the optical structure of FIG. 3, shown at a subsequent time t2; and FIG. 3B is a schematic cross-sectional view of the optical structure of FIG. 3, shown at time t3 after t2. [Figure 4] 1 is a schematic cross-sectional view of an optical substrate having an optical structure fixedly attached to a large surface of the optical substrate, the optical structure further comprising a primer layer and a hard coat layer, in accordance with a further independent feature of the present invention. [Figure 5] 1 is a schematic cross-sectional view of an optical substrate having optical structures fixedly attached to both the top and bottom broad surfaces of the optical substrate. DETAILED DESCRIPTION OF THE INVENTION

[0008] The principles and operation of an optical structure according to the present invention may be better understood with reference to the drawings and accompanying descriptions.

[0009] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0010] Coated optical substrates often include at least one photochromic dye.

[0011] For practical use in optical coatings, the properties of photochromic materials must meet a number of performance criteria, conditions, and constraints, a non-exhaustive list of which includes: a significant primary change in color; a specific rate of color change (in both directions); minimal residual color; thermal stability under ambient conditions for both states of the photochromic dye; sufficient efficiency of the photochromic change relative to the amount of light absorbed ("quantum yield"); minimal or sufficient non-overlapping of the active absorption bands of the two states; and long-term stability of the photochromic reversibility ("fatigue resistance"), meaning that the photochromic material will become less reversible over time due to photodegradation, photooxidation, and other processes.

[0012] Various technical challenges exist in producing coated optical substrates, more particularly coated optical substrates in which the coating contains a photochromic dye, and even more particularly coated optical substrates in which the coating includes two or more photochromic dyes.

[0013] Technical challenges may also be related to various stringent performance criteria for coated optical structures, such as overall kinetics of color change, color retention, uniformity of color change, and long-term physical and chemical durability of the coated optical structure.

[0014] Additionally, the surrounding coating must provide the appropriate chemical environment (eg, polarity, pH) for the dye.

[0015] One aspect of the present invention relates to a method of applying multiple formulations to an optical substrate, some of which may be applied before or after the photochromic ink formulation.

[0016] The inventors have discovered that applying multiple optical coatings to an optical substrate presents various technical obstacles. Some of these relate to optical substrates, which tend to be very smooth and substantially non-absorbing. Optical substrates are generally transparent, and multiple optical coatings may require a high degree of transparency. Furthermore, the refractive index of each coating, or the combined refractive index of all coatings, is constrained to be similar to that of the optical substrate. Haze due to light scattering (e.g., caused by microscopic imperfections or texture) must be kept within acceptable limits.

[0017] The multiple optical coatings must meet mechanical criteria such as hardness and / or scratch resistance. Each of the multiple coatings must also be relatively inert to the other coatings with which it comes into contact. Furthermore, because the coatings may be applied sequentially, at least one of the applied wet or uncured formulations may come into contact with and interact with a previously applied coating. This can be particularly problematic when different photochromic ink formulations are applied sequentially, and when other formulations are applied before or after a photochromic ink formulation.

[0018] The cure time for each coating or layer should be reasonable (a few minutes or hours at most), and the cure temperature should be low enough so as not to damage the optical substrate or to avoid damaging previously applied coatings or materials.

[0019] Adhesion to the optical or ophthalmic substrate and resistance to peeling or cracking of the coating(s) can also be important to obtaining a viable coated lens, such as a coated ophthalmic lens.

[0020] In addition to all of the above, the inventors have discovered that achieving sufficient photochromic color density, while an important technical feature of such coated lenses, is difficult to achieve. Furthermore, achieving sufficient photochromic color density may require a thick layer of photochromic pigment, which, among other things, can significantly compromise the mechanical integrity of the coating.

[0021] The present inventors have found that insufficient photochromic color density can be attributed to various constraints when preparing photochromic formulations. The solubility of photochromic dyes can be disadvantageously low in a wide variety of conventional solvents. Furthermore, the present inventors have found that such low solubility can be exacerbated and amplified by the presence of polymeric materials (e.g., resins) in the photochromic formulation. First, it is necessary to find a solvent medium in which both the photochromic dye and the polymer have reasonably high solubility. Second, solubilization of the polymer can significantly reduce the solubility of the photochromic dye in the solvent medium.

[0022] The inventors have discovered that it is possible to form a polymeric receiving layer on an optical surface that is capable of receiving and absorbing high concentrations of photochromic dye. Photochromic ink may be applied to the top surface of this receiving layer, and the ink (typically as ink droplets, such as ink jetted ink droplets) may penetrate the top surface and become completely immersed within the receiving layer.

[0023] This process relaxes the constraint on photochromic inks that the inks must contain a relatively high concentration of polymer, thereby allowing for a significant increase in the concentration of photochromic dye within the photochromic ink, which in turn serves to further improve the acceptance of the photochromic dye within the receiving layer, and may result in further improvements in the optical density provided by the photochromic dye accepted and absorbed within the receiving layer of the present invention.

[0024] It is well known in the art of lens coatings that coating materials need to be hard in order to withstand abrasion, scratches, and the like. The receiving layer of the present invention may be substantially softer than materials typically utilized in lens coatings. This may be particularly disadvantageous from a mechanical standpoint. However, the inventors have discovered that this deficiency can be significantly reduced or overcome by the high optical density achieved per unit thickness of the receiving layer, which may significantly reduce the overall required thickness of the polymer layer containing the photochromic dye.

[0025] Some teachings of the present invention relate to a method of treating an ophthalmic (or more typically, optical) surface. As presented generally in Figure 1, the method includes providing an ophthalmic substrate having an ophthalmic surface (step 102). Typically, the ophthalmic substrate is a lens, and the ophthalmic surface is the surface of the lens. The lens may be a glass lens, but more typically, the lens is a polymer lens, such as a thermoplastic polymer lens.

[0026] Typically, the optical surface is a curved optical surface, such as a curved lens surface.

[0027] As used herein and in the claims that follow, the term "SAGITTA" or "SAG" refers to the convex curvature of an optical substrate and represents the physical distance between the apex (the highest point of convex curvature) along the curved surface of the optical substrate and the center point of a line drawn perpendicular to the curved surface from one end of the optical substrate to the other end. SAG can be measured or determined according to the following established formula:

number

[0028] In some embodiments, the SAG number of the optical substrate is at least 0.5 mm, at least 1 mm, at least 2 mm, at least 3.5 mm, or at least 5 mm.

[0029] The method further includes applying a first receiving layer onto the ophthalmic surface (Step 104).

[0030] In some embodiments, the first receiving layer is an untreated or raw receiving layer, such as a wet receiving layer, an uncured, or at least partially uncured receiving layer.

[0031] In some embodiments, the application of the wetness receptive layer is by spin coating.

[0032] In some embodiments, the application of the wet receptive layer is by dip coating.

[0033] In some embodiments, the application of the wet receptive layer is by slit coating.

[0034] In some embodiments, the application of the wet receptive layer is by die coating.

[0035] In some embodiments, the application of the wet receptive layer is by stamp coating.

[0036] In some embodiments, the application of the wet receptive layer is by spraying.

[0037] In some embodiments, the application of the wet receptive layer is by jetting.

[0038] In some embodiments, as described in more detail below, this jetting is accomplished by inkjet jetting.

[0039] In some embodiments, as described in more detail below, this jetting is accomplished by a microvalve, such as a single nozzle microvalve.

[0040] In some embodiments, the wetness receiving layer has an average thickness in the range of 1 to 120 micrometers (μm), 1 to 100 μm, 2 to 100 μm, or 4 to 70 μm, more typically in the range of 1 to 70 μm, 1.5 to 50 μm, 1.5 to 40 μm, 5 to 70 μm, 5 to 50 μm, 7 to 70 μm, 7 to 50 μm, 10 to 70 μm, 12 to 50 μm, 12 to 70 μm, 12 to 60 μm, 15 to 70 μm, 15 to 50 μm, 18 to 70 μm, 18 to 60 μm, 20 to 70 μm, or 20 to 50 μm.

[0041] The method further includes applying or depositing (e.g., printing and / or jetting) at least one photochromic dye-containing ink onto the dry receiving layer after the wet receiving layer has dried to form a dry receiving layer (step 106).

[0042] The dry or completely dried receiving layer may be somewhat soft to conventional lens coatings.

[0043] In some embodiments, the dried or fully dried receiving layer has a hardness of up to 40 Shore D. In this specification and claims, all Shore hardness values ​​are measured according to ASTM D2240.

[0044] In some embodiments, the dry receiving layer, the dry receiving layer, or the fully dried receiving layer has a Konig hardness, measured in seconds, of at most 100, at most 95, or at most 90. All Konig hardness values ​​in this specification and claims are measured according to ASTM D4366-95.

[0045] In some embodiments, the Konig hardness is at least 10.

[0046] In some embodiments, the Konig hardness is at least 15.

[0047] In some embodiments, the Konig hardness is within the range of 20-95, 20-90, 20-85, 20-80, 20-75, 20-70, 20-65, or 20-60.

[0048] In some embodiments, the Konig hardness is within the range of 10-100, 10-95, 15-95, 15-90, 15-85, 15-80, 15-75, 15-70, 15-65, 15-60, or 15-55.

[0049] In some embodiments, the Konig hardness is at least 25.

[0050] In some embodiments, the Konig hardness is at least 30.

[0051] In some embodiments, the Konig hardness is at least 35.

[0052] In some embodiments, the Konig hardness is at least 40.

[0053] In some embodiments, the dried or fully dried receiving layer has an ultimate elongation in the range of 100% to 2000%, more typically in the range of 150% to 1200%, 200% to 1200%, 200% to 1000%, 250% to 800%, 250% to 600%, 300% to 1000%, 300% to 800%, or 300% to 600%.

[0054] In this specification and claims, all ultimate elongation values ​​are measured in accordance with ASTM D638.

[0055] In some embodiments, the dried or fully dried receiving layer has a pencil hardness of up to 4H. More typically, the pencil hardness of the dried receiving layer is in the range of 2B-3H, 2B-2H, B-3H, B-2H, HB-3H, or HB-2H.

[0056] In this specification and claims, all pencil hardness values ​​are measured in accordance with ASTM D3363.

[0057] In some embodiments, the ophthalmic substrate or lens may be coated or pre-coated with a hard coat, and the receiving layer may be applied directly over this coating.

[0058] In some embodiments, a primer may first be applied to this hardcoat before applying the receiving layer to enhance adhesion of the receiving layer to the substrate.

[0059] The application or deposition (eg, printing and / or jetting) of at least one photochromic dye-containing ink onto the dried receiving layer (step 106) may be accomplished using a variety of techniques.

[0060] In some embodiments, the application or deposition of the at least one photochromic dye-containing ink comprises a coating.

[0061] In some embodiments, the coating comprises spin coating.

[0062] In some embodiments, the application or deposition of the wetness receptive layer is by dip coating.

[0063] In some embodiments, the application or deposition of the wet receptive layer is by slit coating.

[0064] In some embodiments, the application or deposition of the wet receptive layer is by die coating.

[0065] In some embodiments, the application or deposition of the wetness receptive layer is by stamp coating.

[0066] In some embodiments, applying or depositing the at least one photochromic dye-containing ink comprises spraying.

[0067] In some embodiments, applying or depositing the at least one photochromic dye-containing ink comprises printing.

[0068] In some embodiments, in applying or depositing the at least one photochromic dye-containing ink, the at least one photochromic dye-containing ink is applied or deposited as ink droplets onto the dried receiving layer.

[0069] In some embodiments, the application or deposition of ink droplets is performed by printing.

[0070] In some embodiments, the deposition of ink droplets is performed according to a digital pattern.

[0071] In some embodiments, the deposition of the ink droplets follows a predetermined pattern.

[0072] In some embodiments, the application of the wet receptive layer is by jetting.

[0073] In some embodiments, the deposition of the ink droplets is performed by inkjet printing.

[0074] In some embodiments, the inkjet printing is drop-on-demand.

[0075] In some embodiments, the inkjet printing is continuous (CIJ).

[0076] In some embodiments, jetting is accomplished by a microvalve, such as a single nozzle microvalve. Microjetting of the ink formulation onto the optical / ophthalmic substrate may be accomplished using a variety of microjet jetting technologies, all of which utilize microvalves.

[0077] The microvalve may be a component in a microvalve system.

[0078] In some embodiments, the microvalve is piezoelectrically actuated (eg, using a Nordson Pulse Jet Valve, a Vermes MDS1560 series, or a Techcon 9800 series).

[0079] In some embodiments, the microvalve is electromagnetically actuated (e.g., using a solenoid valve). The fluid or dispersion flows directly through the microvalve. When current is applied through the valve coil, a movable anchor attached to the valve ball is magnetically attracted by the magnetic field of the stationary anchor. The microvalve opens, allowing a portion of the medium to be expelled. When no current is applied, a closing spring acts on the movable anchor associated with the valve ball, keeping the microvalve closed.

[0080] Exemplary microvalves of this type are manufactured by Fritz Gyger AG and Lee Company.

[0081] In some embodiments, the microvalve is electro-pneumatically actuated. An exemplary microvalve of this type is the Liquidyn® P-Jet series manufactured by Nordson.

[0082] The photochromic dye-containing ink and the receiving layer are matched to one another so that the photochromic dye-containing ink can at least partially penetrate, and typically completely penetrate, the top surface of the dried receiving layer.

[0083] In some embodiments, the compatibility of the ink and receiving layer allows the photochromic dye-containing ink to at least partially penetrate, and typically completely penetrate, the top surface of the dried receiving layer within 10 minutes, more typically within 3 minutes, 1 minute, or 20 seconds.

[0084] In some embodiments, the ink and receiving layer are adapted to one another to allow the photochromic dye-containing ink to at least partially penetrate, and typically completely penetrate, substantially, almost instantaneously into the top surface of the dried receiving layer.

[0085] 3 is a schematic cross-sectional view of an optical article 303 shown at time t1 after jetting of a photochromic ink, according to an embodiment of the present invention, in which an optical structure 350 is fixedly attached to a large surface 301 of an optical substrate 302. The layer of optical structure 350 immediately above optical substrate 302 is a receiving layer 304, which has a thickness Trec. FIG. 3 also shows the partial penetration of an ink droplet 307 into an upper surface 305 of receiving layer 304.

[0086] In some embodiments, the compatibility of the ink and receiving layer allows the photochromic dye-containing ink to completely penetrate the top surface of the dried receiving layer within 10 minutes, more typically within 3 minutes, 1 minute, or 20 seconds.

[0087] 3 shows a schematic representation of the complete penetration of an ink droplet, such as ink droplet 312, into the upper surface 305 of the receiving layer 304. The chemical and physical compatibility of the photochromic ink solvent with the receiving layer, as well as the relative flexibility of the polymer matrix, contribute materially to this process.

[0088] In particular, the inventors have found that solvent properties can be important for this process. Solvents with relatively low evaporation rates evaporate slowly relative to the penetration of the solvent into the receiving layer, which can cause pooling or flooding. Solvents with relatively high evaporation rates can evaporate quickly enough to increase the viscosity of the ink and fix the dye to the polymeric receiving layer. However, rapid evaporation can disadvantageously leave a significant portion of the dye on the surface, reducing absorption efficiency and potentially causing scattering. Furthermore, even the portion of the dye that penetrates the surface quickly becomes fixed (a disadvantageous "pixelation"), resulting in the failure to achieve a continuous layer of photochromic dye.

[0089] However, the inventors have discovered that by combining a solvent with a relatively high evaporation rate with a solvent with a particularly low evaporation rate, they can achieve adequate penetration into the receiving layer while simultaneously immobilizing the photochromic dye in a predictable manner. The solvent with a low evaporation rate helps the dye not dry out on the surface and, surprisingly, allows for controlled diffusion of the dye within the ink vehicle within the receiving layer. This occurs in both the XY plane and in the Z direction toward the lens surface, resulting in a continuous and fairly uniform layer of photochromic dye within the receiving layer.

[0090] This allows for surprisingly high loadings of photochromic dye in the receiving layer on a volumetric or weight basis, and importantly, because flexibility of the receiving layer is a mechanical disadvantage, this allows for even higher optical densities, and therefore much thinner receiving layers per unit of photochromic dye.

[0091] Referring again to FIG. 3, FIG. 3 further shows a first set of photochromic ink droplets (Photochromic Ink #1), such as ink droplets 316, and a second set of photochromic ink droplets (Photochromic Ink #2), such as ink droplets 317.

[0092] In some embodiments, photochromic ink (or dye) #1 is deposited on the receiving layer 304 based on a digital or predetermined pattern or array. Similarly, photochromic ink (or dye) #2 may be deposited on the receiving layer 304 based on a digital or predetermined pattern or array.

[0093] In some embodiments, the photochromic ink or dye may be deposited drop-on-drop onto the receiving layer 304. Such an operation may produce "pillars" of ink (or dye) droplets, such as Photochromic Ink #1 ink (or dye) pillar 330 and Photochromic Ink #2 ink (or dye) pillar 340. Note that the ink droplets may not be deposited exactly on top of each other, as shown schematically in pillar 340, and as a result, the width of the pillar may be appreciably larger than the width of the individual droplets.

[0094] Ink columns (or "pillars") such as ink column 330 and ink column 340 can be advantageous in that they maintain separation between different photochromic dyes having different properties (e.g., activation and fade rates). Such ink columns advantageously allow for high photochromic dye densities per unit (display) area. Such ink columns further advantageously allow for high photochromic dye densities per unit area within a single layer (in this case, the "receiving layer") of an ophthalmic medium. Despite all these advantages, the inventors have discovered that such "pixelation" of different photochromic dyes using drop-on-drop jetting can adversely affect the optical or ophthalmic properties of the optical structure. For example, such ink columns can create a "slit"-type effect, which can be detrimental to many ophthalmic products and applications. At the very least, the color density may be noticeably non-uniform, compromising optical quality.

[0095] The inventors further discovered that by applying multiple drop-on-drops, some of the droplets do not function to thicken the pillars but rather "flood" the receiving layer between the pillars, for example, between Photochromic Ink #1 ink drop 322 and Photochromic Ink #2 ink drop 308. In some cases, such ink drops may not completely penetrate the receiving layer's upper surface 305, as shown diagrammatically by ink drops 310 and 311. The inventors surprisingly discovered that applying such multiple drop-on-drops can actually improve the optical or ophthalmic properties of the optical structure. The pixelation benefits can remain substantially intact, while the detrimental "slit" effect can be significantly reduced or mitigated.

[0096] Thus, in some embodiments, at least 4 ink drops, or at least 6 ink drops are applied drop-on-drop, more typically at least 8, at least 10, at least 12, at least 15, at least 18, at least 20, at least 22, at least 25, at least 28, at least 30, at least 32, or at least 35. The number of ink drops applied drop-on-drop in such a manner may be up to 100, more typically up to 80, up to 70, up to 60, up to 50, or up to 45.

[0097] The inventors have further discovered that in addition to various features of the present invention (e.g., properties of the receiving layer, ink solvents and solvent combinations, and printing strategies such as drop-on-drop), a high DPI can further mitigate the deleterious effects of slits. The DPI may be at least 200, at least 250, or at least 300, typically up to 2400, or up to 1800.

[0098] The inventors have discovered that photochromic dyes disposed on the upper surface 305 of the receiving layer can adversely affect the optical or ophthalmic properties of the optical structure. However, the inventors have further discovered that by applying an overcoat layer 306 over the receiving layer 404, such exposed photochromic dyes can be covered, which can somewhat mitigate some of the deleterious effects (e.g., reduce scattering).

[0099] The inventors have also discovered that various hardcoat formulations can dissolve or otherwise attack the photochromic dye-containing receiving layer, but have further discovered that such attack can be inhibited or significantly mitigated by applying an overcoat layer 306 over the outer or exposed dye-containing ink layer and optionally drying / curing.

[0100] In some embodiments, the first overcoat layer is or includes a thermoplastic polymer.

[0101] In some embodiments, the first overcoat layer is or includes a thermosetting polymer.

[0102] In some embodiments, the first overcoat formulation is a polymer emulsion.

[0103] In some embodiments, the first overcoat formulation is a polymer dispersion.

[0104] In some embodiments, the first overcoat formulation is a polymer solution.

[0105] In some embodiments, the first overcoat formulation comprises an acrylic polymer.

[0106] In some embodiments, the first overcoat formulation comprises a polyurethane.

[0107] In some embodiments, the first overcoat formulation comprises polyvinyl butyral.

[0108] In some embodiments, the dried or fully cured overcoat layer material has a Konig hardness of at least 80 seconds, more typically within the range of 80 to 180, 80 to 160, 90 to 180, 100 to 160, 100 to 150, 100 to 140, 110 to 180, 110 to 160, or 110 to 150.

[0109] In some embodiments, the method further comprises applying a second or additional overcoat layer over the dried first overcoat layer following drying / curing of the overcoat layer.

[0110] In some embodiments, the method further comprises drying / curing the second or additional overcoat layer.

[0111] In some embodiments, the dried second or additional overcoat layer may exhibit increased hardness (eg, at least one grade higher pencil hardness) relative to the dried first overcoat layer.

[0112] In some embodiments, the dried second or additional overcoat layer may exhibit a lower increase in linear coefficient of thermal expansion (CTE) relative to the dried first overcoat layer.

[0113] Thus, now also referring to FIG. 1 , the method of the present invention may further include, after the at least one photochromic dye-containing ink has at least partially penetrated into the top surface of the dried receiving layer, and after the ink has at least partially dried to form the photochromic dye-containing receiving layer, applying a first polymer formulation onto the photochromic dye-containing receiving layer to form a first overcoat layer (step 108).

[0114] The application of the overcoat layer may be carried out according to any of the application methods described above for the application of the receptor layer and the application of the photochromic ink. In some embodiments, drying may be completely passive.

[0115] In some embodiments, as shown in FIG. 2B, the method of the present invention may further include drying at least one photochromic dye-containing ink or ink droplets to form a photochromic dye-containing receiving layer.

[0116] In some embodiments, the receiving layer, or photochromic dye-containing receiving layer (i.e., after printing of the photochromic ink), after being fully dried / cured, has a thickness in the range of 0.6 μm to 30 μm, or 0.8 μm to 30 μm, more typically 1 to 20 μm, 1 to 15 μm, 1 to 12 μm, 1 to 10 μm, 1 to 8 μm, 1 to 7 μm, 1 to 6 μm, 1 to 5 μm, 1.5 to 15 μm, 1.5 to 12 μm, 1.5 to 10 μm, 1.5 to 8 μm, 1.5 to 7 μm, The thickness or average thickness may be within the range of 1.5 to 6 μm, 1.5 to 5 μm, 1.5 to 4 μm, 1.5 to 3.2 μm, 2 to 12 μm, 2 to 10 μm, 2 to 8 μm, 2 to 7 μm, 2 to 6 μm, 2 to 5 μm, 2 to 4 μm, 2 to 3.2 μm, 3 to 12 μm, 3 to 10 μm, 3 to 8 μm, 3 to 6 μm, 4 to 10 μm, 4 to 8 μm, 4 to 7 μm, 4.5 to 10 μm, 4.5 to 8 μm, 4.5 to 7 μm, 5 to 10 μm, 5 to 8 μm, 5 to 7 μm, or 6 to 10 μm.

[0117] 3A and 3B, FIG. 3A is a schematic cross-sectional view of the optical structure of FIG. 3 shown at a subsequent time t2, and FIG. 3B is the same schematic cross-sectional view shown at a time t3 following t2.

[0118] As mentioned above, the solvent's low evaporation rate helps the dye not dry out on the surface and, surprisingly, allows for controlled diffusion of the dye within the ink vehicle within the receiving layer. This occurs both in the XY plane, as the material within the droplets expands and contacts each other in the XY direction, and in the Z direction toward the lens surface (see "deep" droplets 309 and 317), resulting in a continuous and fairly uniform layer of photochromic dye within the receiving layer.

[0119] With respect to the overcoat, in some embodiments, the application or deposition of the first polymer formulation occurs after the ink droplets have completely penetrated the top surface of the dried receiving layer.

[0120] A first overcoat layer may be disposed over the polymeric photochromic dye-containing receiver layer and fixedly attached thereto.

[0121] In some embodiments, the first overcoat layer as a wetting layer has a thickness or average thickness in the range of 1.5 to 70 μm micrometers (μm), or in the range of 2.5 to 70 μm, more typically in the range of 4 to 70 μm, 5 to 70 μm, 5 to 50 μm, 5 to 40 μm, 5 to 30 μm, 7 to 50 μm, or 7 to 30 μm.

[0122] In some embodiments, the first overcoat layer as a dry layer has a thickness or average thickness in the range of 1 to 15 μm, or in the range of 1 to 12 μm, more typically in the range of 1 to 10 μm, 1 to 8 μm, 1 to 7 μm, 1 to 6 μm, 1.5 to 8 μm, 1.5 to 6 μm, 1.5 to 5 μm, 1.5 to 4 μm, 2 to 8 μm, 2 to 6 μm, 2 to 5 μm, or 2 to 4 μm.

[0123] In some embodiments, the dried or cured overcoat layer material has a Konig hardness of at least 100 seconds. More typically, the Konig hardness is within the range of 100 to 150, 100 to 140, 100 to 130, 110 to 150, or 110 to 130.

[0124] Figure 2A provides an optional block of the schematic block diagram of Figure 1, in which a wet hardcoat layer is applied over the exposed dry overcoat layer. The resulting exemplary optical structure is shown schematically in Figure 4.

[0125] 2C provides an optional block for any of the above-described schematic block diagrams, in which the first or top surface of the ophthalmic substrate is pre-treated (e.g., surface energy treatment) to form an ophthalmic surface.

[0126] In some embodiments, the surface energy treatment comprises a corona treatment.

[0127] In some embodiments, the surface energy treatment comprises a plasma treatment.

[0128] In some embodiments, the surface energy treatment comprises electron beam treatment.

[0129] In some embodiments, the surface energy treatment comprises an electrical discharge treatment.

[0130] In some embodiments, the lens surface pretreatment comprises an etching process.

[0131] In some embodiments, the etching process comprises laser etching.

[0132] In some embodiments, the etching process comprises chemical etching.

[0133] Figure 2D provides an optional block to the schematic block diagram of Figure 2C. Here, the pre-treatment of Figure 2C includes applying a primer (or wet primer layer) to the surface of the ophthalmic substrate (lens surface). This primer is then dried or allowed to dry to obtain a dry primer layer. The resulting exemplary optical structure is shown schematically in Figure 4.

[0134] In some embodiments, the primer pretreatment is intended to promote wetting of the wetting receptive layer to the lens surface.

[0135] In some embodiments, the primer pretreatment is intended to promote adhesion of the wet receptive layer to the lens surface.

[0136] In some embodiments, the primer is a polymeric primer.

[0137] In some embodiments, the polymer primer is in the form of an aqueous emulsion (eg, an acrylic emulsion).

[0138] In some embodiments, the polymer primer is in the form of a solution (eg, a polyurethane resin solution).

[0139] In some embodiments, the wet primer layer has at least one of a thickness and an average thickness in the range of 0.3 to 10 μm, 0.3 to 5 μm, or 0.3 to 3 μm, more typically in the range of 0.3 to 2.5 μm, 0.3 to 2 μm, 0.4 to 2 μm, 0.4 to 1.5 μm, 0.5 to 2 μm, 0.5 to 1.8 μm, 0.5 to 1.5 μm, or 0.5 to 1.2 μm.

[0140] In some embodiments, the dried primer layer or dry primer layer has at least one of a thickness and an average thickness in the range of 0.3 to 4 μm, or in the range of 0.3 to 2.5 μm, more typically in the range of 0.3 to 2 μm, 0.3 to 1.5 μm, 0.4 to 2 μm, 0.4 to 1.5 μm, 0.5 to 2 μm, 0.5 to 1.8 μm, 0.5 to 1.5 μm, or 0.5 to 1.2 μm.

[0141] 2E provides an optional block for any of the above-described schematic block diagrams, in which the application of photochromic dyes onto the dried receiving layer (step 106) is performed for at least two photochromic dye-containing inks.

[0142] 4 is a schematic cross-sectional view of an optical article 403, in which an optical structure 450 is fixedly attached to a broad surface 401 of an optical substrate 402. The optical structure 450 further includes an optional primer layer 440 disposed between the broad surface 401 and a photochromic dye-containing receiver layer 404. The thickness of the primer layer 440 is designated Tp. An overcoat layer 406 may be disposed on the receiver layer 404, substantially as described above. The thickness of the overcoat layer 406 is designated Tov. According to a further independent feature of the present invention, a hardcoat layer 420 may be disposed on the overcoat layer 406. The thickness of the hardcoat layer 420 is designated Th1.

[0143] In some embodiments, a second or top hardcoat layer 430 having a thickness Th2 may be disposed over the hardcoat layer 420.

[0144] The total thickness of optical structure 450 (and 350 in FIG. 3) is designated Toc, and is intended to include any additional layers that make up the optical structure, including anti-glare, anti-wetting, anti-reflective, superhydrophobic and superhydrophilic anti-fog, polarizing layers, mirror coatings, and blue light layers.

[0145] In some embodiments, the one or more hard coat layers (Th1, Th2) prior to drying / curing have at least one of a wet thickness and an average wet thickness in the range of 1 to 6 μm or in the range of 1 to 5 μm, more typically in the range of 1 to 4.5 μm, 1 to 4 μm, 1 to 3.5 μm, 1.2 to 3.5 μm, 1.2 to 3 μm, or 1.5 to 3 μm.

[0146] In some embodiments, the dried hard coat layer (Th1, Th2) has at least one of a thickness Th and an average thickness (Th1-a, Th2-a) in the range of 0.8 to 5.5 μm, or in the range of 0.8 to 5 μm, more typically in the range of 0.8 to 4 μm, 0.8 to 3.5 μm, 1 to 3.5 μm, 0.8 to 3 μm, 1 to 3 μm, or 1.2 to 3 μm.

[0147] With respect to the overall thickness Toc of the optical structures 303 and 403, in some embodiments, the dry optical structures have an average thickness in the range of 5 to 60 μm, more typically in the range of 7 to 50 μm, 7 to 40 μm, 7 to 35 μm, 7 to 30 μm, 7 to 25 μm, 7 to 20 μm, 7 to 18 μm, or 7 to 15 μm.

[0148] Referring now to Figure 5, Figure 5 is a schematic cross-sectional view of an optical article 503 having an optical structure 550 having a first (top, or outward-facing) optical structure 550 fixedly attached to a top broad surface 501 of an optical substrate 502 and a second, opposite (bottom, or inward-facing) optical structure 580 fixedly attached to a bottom broad surface 581 of the optical substrate 502.

[0149] As will be apparent to one skilled in the art, an optical article such as optical article 503 may be configured to have (i) only a top optical structure, (ii) only a bottom optical structure, or (iii) both a top and a bottom optical structure. It will be further apparent that the bottom optical structure may have any or all of the structural features shown and / or described with respect to optical structures 350 and 450. Typically, bottom broad surface 581 is concave.

[0150] Example Reference is now made to the following examples, which together with the above descriptions, illustrate the invention in a non limiting sense. material Lens material Polycarbonate, a thermoplastic polymer Trivex® (PPG), a urethane-based thermosetting polymer CR-39® (PPG), a thermosetting polymer made from allyl diglycol carbonate Photochromic dyes: Reversacol Amazon Green (James Robinson Specialty Ingredients Ltd.): A photochromic dye in powder form. Reversacol Midnight Gray (James Robinson Specialty Ingredients Ltd.): A photochromic dye in powder form. Reversacol Leather Brown (James Robinson Specialty Ingredients Ltd.): A photochromic dye in powder form. Reversacol Corn Yellow (James Robinson Specialty Ingredients Ltd.): A photochromic dye in powder form. solvent High evaporation rate / high vapor pressure at 25°C Dowanol™ PMA Glycol Ether (Propylene Glycol Monomethyl Ether Acetate) Methyl ethyl ketone (2-butanone or MEK) (Shell Chemicals) Dowanol™ PM Glycol Ether (Propylene Glycol Monomethyl Ether) Low evaporation rate / low vapor pressure at 25°C Dowanol™ TPM Glycol Ether (Tripropylene Glycol Monomethyl Ether, or TPM) (Dow), CAS 25498-49-1) ·PPH (Ph-O-CH2-CHMe-OH, CAS770-35-4) Eastman™ DB Acetate (2-(2-butoxyethoxy)ethyl acetate, or DBA, CAS 124-17-4) TPnB (tripropylene glycol n-butyl ether, 55934-93-5) DOWANOL™ dipropylene glycol n-propyl ether, or DPnP, (CAS 29911-27-1) Acetone glycerol (ALDRICH, 2,2-dimethyl-1,3-dioxolane-4-methanol, CAS 100-79-8) Butyl carbitol (CAS112-34-5) Butyl CELLOSOLVE™ EGBE (Ethylene Glycol Monobutyl Ether, CAS 111-76-2), DOW Hexyl CELLOSOLVE™ (diethylene glycol monobutyl ether, or n-hexyl glycol), DOW DOWANOL™ dipropylene glycol monomethyl ether, or DPM Augeo® SL 191 racemic mixture (+ / -)-2,2-dimethyl-4-hydroxymethyl-1,3-dioxolane. Coating Materials for Receptor Layer Formulation: ·PUD-water-based Alberdingk® U-3251 - Highly flexible, solvent-free, aliphatic polyester polyurethane dispersion (Alberdingk Boley) Alberdingk® U-9150 waterborne aliphatic polyester polycarbonate-polyurethane dispersion (TPU) (Alberdingk Boley) Alberdingk® U-6100VP - Aqueous colloidal, anionic, low-viscosity dispersion of an aliphatic polyester-polyurethane containing no free isocyanate groups (Alberdingk Boley) Lubrijet™ T800 - Aqueous aliphatic polyurethane dispersion (Lubrizol) designed for inkjet applications Lubrijet™ N240 - Aqueous acrylic colloidal dispersion polymer (Lubrizol) for inkjet printing Lubrijet™ T340 - Water-based acrylic emulsion polymer (Lubrizol) Alberdingk APU-10610 - Solvent-free, self-crosslinking, aliphatic polyester polyurethane, acrylic hybrid dispersion (Alberdingk Boley) · Eternacoll UW‐5502D‐C1 – Aqueous polyurethane dispersion (UBE). Acrylic polymer emulsion JONCRYL® 2136-A - Water-based acrylic emulsion JONCRYL® 2121 - Water-based acrylic emulsion JONCRYL® 659-A - Water-based acrylic emulsion ·Thermoplastic resin Pearlcoat™ DIPP119 - Aromatic polycaprolactone copolyester-based thermoplastic polyurethane (TPU) (Lubrizol) Pearlbond™ 360 - Polyether-based thermoplastic polyurethane (TPU) (Lubrizol) SETALUX® 2127XX-60 - A thermoplastic acrylic resin (Alnex) with good adhesion to plastics Laropal A-81 - Thermoplastic aldehyde resin (BASF) Evatane® 33-45 - Random ethylene vinyl acetate copolymer (SK Functional Polymer) Evatane® 33-400 - Random ethylene vinyl acetate copolymer (SK Functional Polymer). ·Thermosetting resin UV-curable acrylic monomers and oligomers BR-744SD - Functional aliphatic polyester urethane acrylate oligomer (DYMAX) SR-610 polyethylene glycol 600 diacrylate (Arkema) BR-3641AJ - Aliphatic polyether urethane acrylate oligomer (DYMAX) SR506E (Isobornyl acrylate, CAS#5888-33, IBOA) monofunctional acrylic monomer (Arkema) SR484 (Octyldecyl acrylate, CAS#4813-57-4, a monofunctional acrylate monomer with a hydrophobic backbone (Arkema) Self-crosslinking polymer emulsion Bondthane™ UD-610 - Flexible self-crosslinking aliphatic polyurethane dispersion (BPI) Bondthane™ UD-615 - Self-crosslinking aliphatic polyurethane dispersion (BPI) [Table 1] 1 The polymer provided above passed the haze transparency test of ASTM1003 and ISO13468. Ink and Receptor Layer Formulation Additives BYK® 3760, polyether-modified polydimethylsiloxane (BYK, Germany) – a silicone-containing surface additive for solvent-borne, water-based, and UV systems that reduces surface tension and increases surface slip. BYK® 333, wetting agent, silicone-containing surface additive for solvent-free, solvent-borne, and water-based coating systems; powerful surface tension reducer BYK® 358, leveling agent, polyacrylate-based surface additive for solvent-borne and solvent-free coatings and thermosetting systems to improve leveling BYK® 346 Wetting Additive BYK® 044 Defoamer BYK® 024 Defoamer EFKA® FL3277 Leveling Agent, Fluorocarbon-Modified Polyacrylate EFKA® SL3035 leveling agent, an organically modified polysiloxane suitable for water-based and solvent-based coatings EFKA® SL3200 Leveling Agent, a silicone-based solventless slip and leveling agent; suitable for water-based, solvent-based, and UV formulations EFKA® FL3778 Leveling Agent, Acrylic Copolymer Additives for UV thermosetting polymers ADDITOL® TPO (diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide, CAS#75980-60-8) - A radical photoinitiator that can be used alone or in combination with other photoinitiators. (Allnex) · CN3715 - Monofunctional acrylated amine synergist (Arkema) for use in UV / LED and EB curing applications. Primer and Overcoat Acrylic polymer emulsion Joncryl® 1532 - A water-based acrylic emulsion (BASF) that provides excellent adhesion to a variety of substrates, including plastics; primer Joncryl® 1534 - a water-based acrylic emulsion (BASF) that provides excellent adhesion to a variety of substrates, including plastics; primer Joncryl® 2110 - Water-based acrylic emulsion primer styrene acrylate copolymer (BASF); primer Joncryl® 9530-A: A water-based acrylic emulsion self-crosslinking polymer designed for use in topcoats and primers; overcoats Joncryl® 617-A - Water-based acrylic polymer emulsion film-forming overprint varnish formulation (BASF); overcoat SETALUX® 17-7202 is an acetoacetate-functional acrylic resin combined with a ketimine resin (SETALUX® 10-1440) for the primer; overcoat SETALUX® 17-1246 is a fast-drying thermoplastic acrylic resin solution that offers an excellent balance of hardness, adhesion, and film toughness along with clarity and transparency; overcoat. PU polymer emulsion ALBERDINGK® APU10600 self-crosslinking acrylic, PES / PC-polyurethane hybrid dispersion (Alberdingk Boley); overcoat Bondthane™ UD-620 - Self-crosslinking polyurethane ideal for hard, clear, or pigmented coatings on rigid plastics (BPI); overcoats Resin solvent-based solution Versamid® PUR1010 - Thermoplastic aliphatic polyurethane resin solution in alcohol / acetic acid solution (BASF); primer Laroflex® HS-9000 - A high molecular weight polyester resin solution in n-propanol (BASF); primer. Hard Coat Layer CrystalCoat™ TC-3000 Polysiloxane-based tintable abrasion-resistant hardcoat (SDC); refractive index 1.49. CrystalCoat™ MP-1154D Polysiloxane-based abrasion-resistant hardcoat (SDC); refractive index 1.49. CrystalCoat™ MP-2020B - Highly crosslinked, abrasion-resistant hard coat SDC; refractive index 1.49. NANOMYTE® SR-100 - Polysiloxane-based two-component liquid coating (NEI); provides abrasion and scratch resistance to plastic substrates NANOMYTE® SR-100RT Polysiloxane-based single-component liquid coating (NEI); provides abrasion and scratch resistance to plastic substrates Device Coating equipment Printer: Dimatix material printer DMP-2831 (Fujifilm Dimatix™ Inc.) equipped with a 10p Dimatix material cartridge Spin coater: MUTECH μCoater (Mutech Microsystems SAS) UV LED curing system (lamp): FJ100Gen2, 395nm, 12W / cm 2 (Phoseon Technology) Heat curing system: Venticell ECO forced air oven (MMM) Surface activation: Corona treatment device Electric surface treatment HF Spot TEC Single (Tantec). Test equipment ·Spectrophotometer: Cary4000UV-Vis.Double beam spectrophotometer, ISO / EN8980-3:2013 (Agilent) Light transmittance and haze measuring instrument: TH-100, ASTM D1003 / D1044 (Hangzhou CHN SpecTechnology Co., Ltd.) Thickness measurement: ThetaMetrisis layer thickness analyzer

[0151] Example 1: Corona Surface Treatment Procedure The head of a corona treatment device (Tantec) was set 1 cm from the surface of the ophthalmic lens and activated for 10 seconds. This process was repeated twice before various coating materials were applied to the ophthalmic lens.

[0152] Example 2: Primer application procedure using spin coating The ophthalmic lens was attached to a vacuum chuck of a spin coating device, and the ophthalmic lens was rotated at a rotation speed of 3000 rpm and an acceleration rate of 1000 rpm / sec for 10 seconds.

[0153] Example 3: Receptor layer application procedure using spin coating The ophthalmic lens was attached to the vacuum chuck of the spin-coating apparatus. The ophthalmic device was rotated at a rotation speed of 800 rpm with an acceleration rate of 500 rpm / sec for 10 seconds. After drying / curing, the spin-coating operation may be repeated as needed to produce a thicker receiving layer.

[0154] Example 3A: Overcoat Application Procedure Using Spin Coating The ophthalmic lens was attached to the vacuum chuck of the spin-coating apparatus. The ophthalmic device was rotated at a rotation speed of 1800 rpm with an acceleration of 800 rpm / sec for 10 seconds. After drying / curing, the spin-coating operation may be repeated as needed to produce a thicker receiving layer.

[0155] Example 3B: Hardcoat Application Procedure Using Spin Coating The ophthalmic lens was attached to the vacuum chuck of the spin coating apparatus, and the ophthalmic device was rotated at a rotation speed of 1500 rpm with an acceleration rate of 500 rpm / sec for 10 seconds.

[0156] Example 4: Optimization of inkjet parameters The Dimatix™ printhead was preheated to 40°C. The droplet characteristics of each photochromic ink were then optimized using a stroboscope attached to the printer (camera and light source synchronized with the jet frequency). Waveforms were optimized for each photochromic ink, which were jetted at frequencies between 0.5 and 3 kHz. The distance between the printhead and the substrate was 0.6 to 1.0 mm. Jetting typically resulted in a droplet (dot) size of approximately 50 micrometers (on the test substrate). The resolution was set to 300 dots per inch (dpi).

[0157] Example 5A: Jetting of Photochromic Ink onto Receptor Layer Optical structures with photochromic functionality were fabricated by printing (using a Fujifilm Dimatix™ inkjet printer) an inkjet-compatible ink containing a photochromic dye onto a lens substrate coated with a receiving layer, preferably utilizing the inkjet optimization technique of Example 5A. The optical structures were fabricated by inkjetting an array of ink droplets containing the photochromic dye such that the distance between the center of the first droplet and the center of the adjacent jetted droplet was approximately 85 micrometers. This distance can be adjusted as needed. Both the printhead and the substrate were heated to 40° C. to control the viscosity and droplet spreading during jetting.

[0158] Example 5B: Jetting of Multiple Photochromic Inks onto a Receptor Layer Optical structures with dual photochromic functionality were fabricated by printing two different inks (using a Fujifilm Dimatix™ inkjet printer), each containing a different photochromic dye, preferably utilizing the inkjet optimization technique of Example 5A. The optical structures were fabricated in a two-step process, in which an array of ink droplets containing a first dye was printed such that the droplets were spaced such that the distance between the center of the first droplet and the center of the adjacent jetted droplet was 100 micrometers. Both the printhead and the substrate were heated to 40° C. to control the viscosity and droplet spreading during jetting.

[0159] A second dye was added to the layer by jetting droplets of a second ink containing the second dye between the droplets of the first droplet array. The droplets of the second ink were printed under the same general conditions as above, but were jetted so as to be positioned 50 micrometers from the droplets of the first ink, as measured from the center of the droplets of the first ink to the center of the droplets of the second ink.

[0160] Example 6: Jetting of Photochromic Ink onto Receptor Layer: Photochromic Color Intensity Using the procedure of Example 5A and the method of Example 5B, multiple photochromic ink droplets of two or more photochromic inks were applied to various lenses coated with the receiver formulations provided below to create optical structures having a receiver layer containing photochromic dye(s). In some cases, a single pass of inkjet ink was applied, but typically 2 to 80 passes, and more typically 5 to 50 passes, of the photochromic ink were applied drop-on-drop as an array, followed by drying at 60°C for 60 minutes.

[0161] Example 7 30 grams of TPM was mixed with 67.8 grams of PMA in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the ingredients for 5 minutes, 0.2 grams of surfactant BYK®-333 was added to the solvent mixture with mixing. Next, 2 grams of Reversacol Midnight Gray pigment was added with mixing. Mixing was continued at 60°C for an additional 20 minutes to produce the photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0162] Example 8 30 grams of TPM was mixed with 67.8 grams of PMA in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the ingredients for 5 minutes, 0.2 grams of surfactant BYK®-358 was added to the solvent mixture with mixing. Next, 2 grams of Reversacol Leather Brown pigment was added with mixing. Mixing was continued for an additional 20 minutes at 60°C to produce the photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0163] Example 9 30 grams of TPM was mixed with 20 grams of EB and 47.5 grams of PMA in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the ingredients for 5 minutes, 0.5 grams of surfactant EFKA®-3277 was added to the solvent mixture, and 2 grams of Reversacol Amazon Green dye was simultaneously added with mixing. Mixing was continued for an additional 20 minutes at 60°C to produce the photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0164] Example 10 30 grams of TPM was mixed with 20.65 grams of PMA and 47 grams of MEK in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the ingredients for 5 minutes, 0.35 grams of surfactant EFKA® SL3200 was added to the solvent mixture, and 2 grams of Reversacol Corn Yellow dye was simultaneously added with mixing. Mixing was continued for an additional 20 minutes at 60°C to produce the photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0165] Example 11 30 grams of Augeo SL-191 was mixed with 67.9 grams of PMA in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.1 grams of surfactant BYK®-358 was added to the solvent mixture, while 2 grams of Reversacol Amazon Green dye were simultaneously added with mixing. Mixing was continued for an additional 20 minutes at 60°C to produce the photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0166] Example 12 30 grams of Augeo SL-191 was mixed with 67.7 grams of PM in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.3 grams of surfactant EFKA®-3778 was added to the solvent mixture with mixing. Next, 2 grams of Reversacol Amazon Green dye was added with mixing, and mixing was continued for an additional 20 minutes at 60°C to produce a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0167] Example 13 30 grams of n-hexyl glycol was mixed with 25 grams of PMA and 42.8 grams of MEK in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the ingredients for 5 minutes, 0.2 grams of surfactant BYK®-3760 was added to the solvent mixture while mixing. Next, 2 grams of Reversacol Midnight Gray was added while mixing, and mixing was continued for an additional 20 minutes at 60°C to produce a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0168] Example 14 30 grams of DPnP was mixed with 67.9 grams of PM in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.1 grams of surfactant BYK®-346 was added to the solvent mixture, while simultaneously adding 1 gram of Reversacol Midnight Gray dye and 1 gram of Reversacol Amazon Green dye with mixing. Mixing was continued for an additional 20 minutes at 60°C to produce the photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0169] Example 14A 65 grams of Joncryl® 1532 was mixed with 20 grams of water in a 200 ml glass beaker equipped with a magnetic stirrer. Next, 9.5 grams of EB solvent, 4.8 grams of DPM solvent, and 0.2 grams of BYK® 024 were added with mixing. After mixing the ingredients for 5 minutes, 0.5 grams of surfactant BYK®-346 was added to the mixture, and mixing was continued for an additional 10 minutes at 30°C.

[0170] Example 14B 70 grams of Joncryl® 1534 was mixed with 15 grams of water in a 200 ml glass beaker equipped with a magnetic stirrer. Next, 9.5 grams of EB solvent, 4.8 grams of DPM solvent, and 0.2 grams of BYK® 024 were added with mixing. After mixing the ingredients for 5 minutes, 0.5 grams of surfactant EFKA® 3200 was added to the mixture, and mixing was continued for an additional 10 minutes at 30°C.

[0171] Example 15 8 grams of Evatane® 33-45 was mixed with 46 grams of xylene and 46 grams of toluene in a 200 ml glass beaker equipped with a magnetic stirrer at room temperature for 30 minutes.

[0172] Example 16 8 grams of Evatane® 33-400 was mixed with 46 grams of xylene and 46 grams of toluene in a 200 ml glass beaker equipped with a magnetic stirrer at room temperature for 30 minutes.

[0173] Example 17 75 grams of Joncryl® 2110 was mixed with 10 grams of water in a 200 ml glass beaker equipped with a magnetic stirrer. Next, 10 grams of EB, 4.5 grams of DPM, and 0.25 grams of BYK® 044 were added with mixing. After mixing the ingredients for 5 minutes, 0.25 grams of surfactant BYK® 346 was added to the mixture, and mixing was continued for an additional 10 minutes at 30°C.

[0174] Example 18 According to Example 1, Trivex® (PPG) lenses made of a urethane-based prepolymer were subjected to a corona surface treatment procedure.

[0175] Example 19 Polycarbonate lenses were subjected to a corona surface treatment procedure according to Example 1.

[0176] Example 20 The hardcoat precoated polycarbonate lenses were subjected to the corona surface treatment procedure of Example 1.

[0177] Example 21 The corona surface treatment procedure of Example 1 was performed on Trivex® (PPG) lenses that had been pre-coated with a hard coat.

[0178] Example 22 The corona surface treatment procedure of Example 1 was performed on CR-39® (PPG) lenses made of poly(allyl diglycol carbonate) (PADC) precoated with a hard coat.

[0179] Example 23 Versamid® PUR1010 was applied as a primer onto a polycarbonate lens. Spin coating was performed according to Example 2, resulting in a calculated (average) wet thickness of 2.86 μm. The wet layer was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 10 minutes, to produce a primer layer with a thickness of 1.0 μm.

[0180] Example 24 Laroflax® HS-9000 was applied as a primer onto a polycarbonate lens. Spin coating was performed according to Example 2, resulting in a calculated wet thickness of 2.14 μm. The wet layer was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 10 minutes, to produce a primer layer with a thickness of approximately 1.5 μm.

[0181] Example 25 The Joncryl® 1534 formulation of Example 14B was applied as a primer onto a polycarbonate lens. Spin coating was performed according to Example 2, resulting in a calculated wet thickness of 0.65 μm. The wet layer was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 10 minutes, to produce a primer layer having a thickness of approximately 0.25 μm.

[0182] Example 26 The Joncryl® 1532 formulation of Example 14A was applied as a primer onto a hard-coated Trivex® (PPG) lens. Spin coating was performed according to Example 2, resulting in a calculated wet thickness of 1.48 μm. The wet layer was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 10 minutes, to produce a primer layer having a thickness of approximately 0.5 μm.

[0183] Example 27 The Joncryl® 2110 formulation of Example 17 was applied as a primer onto a CR-39® (PPG) lens precoated with a hard coat. Spin coating was performed according to Example 2, resulting in a calculated wet thickness of 6.71 μm. The wet layer was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 10 minutes, to produce a primer layer having a thickness of approximately 2.5 μm.

[0184] Example 28 The Joncryl® 1534 formulation of Example 14B was applied as a primer onto a Trivex® (PPG) lens that had been corona treated according to Example 21. Spin coating was performed according to Example 2, resulting in a calculated wet thickness of 2.6 μm. The wet layer was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 10 minutes, to produce a primer layer having a thickness of approximately 0.8 μm.

[0185] Example 29 The Joncryl® 1534 formulation of Example 14B was applied as a primer onto a polycarbonate lens that had been corona treated according to Example 20. Spin coating was performed according to Example 2. The wet layer was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 10 minutes.

[0186] Example 30 The Joncryl® 1534 formulation of Example 14B was applied as a primer onto a CR-39® lens that had been corona treated according to Example 22. Spin coating was performed according to Example 2. The wet layer was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 10 minutes.

[0187] Example 31 The Joncryl® 2110 formulation of Example 17 was applied as a primer to the Trivex® lens of Example 18. Spin coating was carried out according to Example 2. The wet layer was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 10 minutes.

[0188] Example 32 65 grams of difunctional aliphatic polyester urethane acrylate oligomer (BR-744D) was mixed with 30 grams of SR-610 (polyethylene glycol 600 diacrylate) in a 200 ml glass beaker equipped with a magnetic stirrer. Five grams of photoinitiator TPO were then added and mixing was continued for an additional 10 minutes at 30°C.

[0189] Example 33 60 grams of BR-744D was mixed with 30 grams of SR-610 polyethylene glycol 600 diacrylate in a 200 ml glass beaker equipped with a magnetic stirrer. Five grams of photoinitiator TPO and 5 grams of CN3715 were then added, and mixing was continued for an additional 10 minutes at 30°C.

[0190] Example 34 50 grams of BR-3641AJ was mixed with 45 grams of SR506 (IBOA) in a 200 ml glass beaker equipped with a magnetic stirrer. Five grams of TPO was then added as a photoinitiator, and mixing was continued for an additional 10 minutes at 30°C.

[0191] Example 35 50 grams of BR-3641AJ was mixed with 25 grams of SR506 and 20 grams of SR484 (octyl acrylate monomer) in a 200 ml glass beaker equipped with a magnetic stirrer. 5 grams of TPO was then added and mixing was continued for an additional 10 minutes at 30°C.

[0192] Example 36 30.5 grams of TPM solvent was mixed with 55 grams of PMA solvent in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA® SL3200 was added to the solvent mixture while mixing. Next, 10 grams of Pearlbond™ 360 was added while continuing to mix. Mixing was continued for an additional 40 minutes at 60°C to produce a receiving layer lacquer, which was then filtered through a syringe filter (0.45 micrometers).

[0193] Example 37 30.5 grams of TPM solvent was mixed with 55 grams of PMA solvent in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA® SL3035 was added to the solvent mixture while mixing. While continuing to mix, 10 grams of Pearlcoat™ DIPP119 was added. Mixing was continued for an additional 40 minutes at 60°C to produce a receiving layer lacquer, which was then filtered through a syringe filter (0.45 micrometers).

[0194] Example 38 10.5 grams of TPM solvent was mixed with 10 grams of PMA solvent in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA® SL3778 was added to the solvent mixture while mixing. Next, 70 grams of SETALUX® 2127XX-60 was added while continuing to mix. Mixing was continued for an additional 40 minutes at 60°C to produce a receiving layer lacquer, which was then filtered through a syringe filter (0.45 micrometers).

[0195] Example 39 33 grams of TPM solvent was mixed with 52.5 grams of PMA solvent in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA® SL3035 was added to the solvent mixture while mixing. Next, 10 grams of Pearlcoat™ DIPP119 was added while continuing to mix. Mixing was continued for an additional 40 minutes at 60°C to produce a receiving layer lacquer, which was then filtered through a syringe filter (0.45 micrometers).

[0196] Example 40 30.5 grams of TPM solvent was mixed with 55 grams of PMA solvent in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA® SL3035 was added to the solvent mixture while mixing. Next, 10 grams of Laropal A-81 was added while continuing to mix. Mixing was continued for an additional 40 minutes at 60°C to produce a receiving layer lacquer, which was then filtered through a syringe filter (0.45 micrometers).

[0197] Example 41 Alberdingk® U-3251 was applied as a receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 17.5 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 7 μm.

[0198] Example 41A Alberdingk® U-3200 was applied as the receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer, with a calculated average thickness of 28.3 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (measured) thickness was approximately 8.5 μm.

[0199] Example 42 Alberdingk® U-3251 was applied as the receiver layer formulation onto a CR-39® lens. Spin coating was performed according to Example 3. The wet layer, with a calculated average thickness of 12.5 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 5 μm.

[0200] Example 42A Alberdingk® U-3251 was applied as the receiver layer formulation onto a CR-39® lens. Spin coating was performed according to Example 3. The wet layer, with a calculated average thickness of 5 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 2 μm.

[0201] Example 43 Alberdingk® U-6100VP was applied as the receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 21.7 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 7.8 μm.

[0202] Example 44 Lubrijet™ T800 was applied as the receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 32.3 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 10 μm.

[0203] Example 45 Lubrijet™ N240 was applied as a receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 30.0 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 12 μm.

[0204] Example 46 Lubrijet™ T340 was applied as a receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer, with a calculated average thickness of 34.9 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The measured dry thickness was approximately 11.5 μm.

[0205] Example 47 Alberdingk® APU-10610 was applied as the receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 16.2 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 5.5 μm.

[0206] Example 48 The primed Trivex® (PPG) lenses of Example 26 were coated with Eternacoll UW-5502D-C1 as the receiver layer formulation. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 21.4 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 7.5 μm.

[0207] Example 48A JONCRYL 2136-A was applied as a receiver layer formulation onto a Trivex® (PPG) lens. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 21.4 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 9 μm.

[0208] Example 48B Trivex (registered trademark) )JONCRYL 2121 was applied as the receiver layer formulation onto a (PPG) lens. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 19.6 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 10 μm.

[0209] Example 49 The formulation of Example 15 was applied as a receiver layer formulation onto a CR-39® lens. Spin coating was performed according to Example 3, but at 2000 rpm (and 500 rpm-s) for 5 seconds. The wet layer, with a calculated average thickness of 65 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 60 minutes. The dry (calculated average) thickness was approximately 5.2 μm.

[0210] Example 50 The formulation of Example 16 was applied as a receiver layer formulation onto a CR-39® lens. Spin coating was performed according to Example 3, but at 2000 rpm (and 500 rpm-s) for 5 seconds. The wet layer, with a calculated average thickness of 65 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 60 minutes. The dry (calculated average) thickness was approximately 5 μm.

[0211] Example 51 JONCRYL 2136-A was applied as a receiver layer formulation onto the primed CR-39® lenses of Example 27. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 10.7 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 4.5 μm.

[0212] Example 52 JONCRYL 659-A was applied as the receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 25.45 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 11.2 μm.

[0213] Example 53 Alberdingk® U-3200 was applied as the receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer, having a calculated average thickness of 48.7 μm, was then heat dried and cured in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes. The dry (calculated average) thickness was approximately 14.6 μm.

[0214] Example 54 The formulation of Example 32 was applied onto a polycarbonate lens, then spin coated according to Example 3, and the wet layer was UV cured for 10-20 seconds using a UV curing LED.

[0215] Example 55 The formulation of Example 33 was applied onto a polycarbonate lens, then spin coated according to Example 3, and the wet layer was UV cured for 10-20 seconds using a UV curing LED.

[0216] Example 56 The formulation of Example 34 was applied onto a CR-39® lens, then spin coated according to Example 3, and the wet layer was UV cured for 10-20 seconds using a UV curing LED.

[0217] Example 57 The formulation of Example 35 was applied onto the primed polycarbonate lens of Example 24. The wet layer was then spin coated according to Example 3 and UV cured for 10-20 seconds using a UV curing LED.

[0218] Example 58 The receiver layer formulation was applied onto a CR-39® lens using the Pearlbond™ 360 TPU formulation of Example 36. Spin coating was performed according to Example 3. The wet layer was then heat dried in a Venticell ECO forced air oven at 60° C. for 30 minutes.

[0219] Example 59 The Pearlbond™ DIPP119 formulation of Example 37 was applied as the receptor layer formulation onto a polycarbonate lens. Spin coating was carried out according to Example 3. The wet layer was then heat dried at 60° C. for 30 minutes in a Venticell ECO forced air oven.

[0220] Example 60 The SETALUX® 2127XX-60 formulation of Example 38 was applied as a receiving layer formulation onto a polycarbonate lens. Spin coating was performed according to Example 3. The wet layer was then heat dried at 60° C. for 30 minutes in a Venticell ECO forced air oven.

[0221] Example 61 The Pearlcoat™ DIPP119 formulation of Example 39 was applied as the receptor layer formulation onto a Trivex® lens. Spin coating was carried out according to Example 3. The wet layer was then heat dried at 60° C. for 30 minutes in a Venticell ECO forced air oven.

[0222] Example 62 The Laropal A-81 formulation of Example 40 was applied as a receiving layer formulation onto the primed polycarbonate lens of Example 27. Spin coating was performed according to Example 3. The wet layer was then heat dried at 60°C for 30 minutes in a Venticell ECO forced air oven.

[0223] Example 63 Bondthane™ UD-610, a self-crosslinking aliphatic polyurethane dispersion, was applied as the receptor layer formulation onto Trivex® lenses. Spin coating was performed according to Example 3. The wet layer was then heat dried in a Venticell ECO forced air oven at 60°C for 10 minutes, then at 100°C for 20 minutes.

[0224] Example 64 Bondthane™ UD-615, a self-crosslinking aliphatic polyurethane dispersion, was applied as the receiver layer formulation onto the Trivex® (PPG) lenses of Example 26. Spin coating was performed according to Example 3. The wet layer was then heat dried in a Venticell ECO forced air oven at 60° C. for 10 minutes, then at 100° C. for 20 minutes.

[0225] Example 65 The Pearlbond™ DIPP119 formulation of Example 37 was applied as a receptor layer formulation onto the corona surface treated polycarbonate lens of Example 19. Spin coating was carried out according to Example 3. The wet layer was then heat dried at 60° C. for 30 minutes in a Venticell ECO forced air oven.

[0226] Example 66 The BR-3641AJ formulation of Example 34 was applied as a receptor layer formulation onto the corona surface treated polycarbonate lens of Example 20. Spin coating was performed according to Example 3. The wet layer was then UV cured for 10-20 seconds using a UV curing LED.

[0227] Example 67 The Pearlcoat™ DIPP119 formulation of Example 39 was applied as a receptor layer formulation onto the corona-surface-treated Trivex® lens of Example 21. Spin coating was carried out according to Example 3. The wet layer was then heat dried at 60° C. for 30 minutes in a Venticell ECO forced air oven.

[0228] Example 68 The Pearlbond™ DIPP119 formulation of Example 37 was applied as a receptor layer formulation onto the primed, corona surface treated Trivex® lens of Example 28. Spin coating was carried out according to Example 3. The wet layer was then heat dried at 60° C. for 30 minutes in a Venticell ECO forced air oven.

[0229] Example 69 The BR-3641AJ formulation of Example 34 was applied as a receptor layer formulation onto the primed, corona surface treated Trivex® lens of Example 31. Spin coating was performed according to Example 3. The wet layer was then UV cured for 10-20 seconds using a UV curing LED.

[0230] Example 70 The Pearlcoat™ DIPP119 formulation of Example 39 was applied as a receptor layer formulation onto the primed, corona surface treated polycarbonate lens of Example 29. Spin coating was carried out according to Example 3. The wet layer was then heat dried at 60° C. for 30 minutes in a Venticell ECO forced air oven.

[0231] Example 71 The BR-744D formulation of Example 33 was applied as a receptor layer formulation onto the primed, corona surface treated CR-39® lenses of Example 30. Spin coating was performed according to Example 3. The wet layer was then UV cured for 10-20 seconds using a UV curing LED.

[0232] Example 72 Bondthane™ UD-615 was applied as a receptor layer formulation to the primed, corona surface treated CR-39® lenses of Example 30. Spin coating was performed according to Example 3. The wet layer was then heat dried at 60° C. for 30 minutes in a Venticell ECO forced air oven.

[0233] Examples 73-108: Jetting onto a lens coated with a receptor layer After optimizing the inkjet parameters according to the procedure of Example 4, the photochromic dye-containing inkjet ink formulations of Examples 7-14 were inkjetted onto lens substrates coated with the various receiving layers described above.

[0234] In Examples 73-80 and 102C-D, a single photochromic dye-containing inkjet ink formulation was inkjetted onto the receiving layer surface according to the procedure of Example 5A. In Examples 81-108, two different photochromic ink formulations were inkjetted onto the receiving layer surface according to the procedure of Example 5B. To increase the intensity of the photochromic color(s), an ink droplet array was applied drop-on-drop (4-72 drop-on-drop) according to the procedure of Example 6.

[0235] Examples 73-108 are summarized in the table below. [Table 2] Note that in Examples 94 and 95, haze was observed, possibly indicating that the receiving layer was overloaded with photochromic dye.

[0236] Example 109 SETALUX® 17-7202 was applied as an overcoat formulation onto the coated polycarbonate lens prepared in Example 76. Spin coating was performed according to Example 3A. The wet layer, having a calculated average thickness of 15 μm, was then heat dried in a Venticell ECO forced air oven at 60° C. for 30 minutes. The dry (calculated average) thickness was approximately 7.5 μm.

[0237] Example 110 ALBERDINGK® APU10600 was applied as an overcoat formulation onto the coated CR-39® lenses prepared in Example 93. Spin coating was performed according to Example 3A. The wet layer, having a calculated average thickness of 6.1 μm, was then heat dried at 60° C. for 30 minutes in a Venticell ECO forced air oven. The dry (calculated average) thickness was approximately 2.0 μm.

[0238] Example 111 Bondthane™ UD-620 was applied as an overcoat formulation onto the primed and coated Trivex® lens prepared in Example 83. Spin coating was performed according to Example 3A. The wet layer, having a calculated average thickness of 8.8 μm, was then heat dried in a Venticell ECO forced air oven at 60° C. for 30 minutes. The dry (calculated average) thickness was approximately 3 μm.

[0239] Example 112 SETALUX® 17-1246 was applied as an overcoat formulation onto the corona-treated, primed, and coated CR-39® lenses prepared in Example 79. Spin coating was performed according to Example 3A. The wet layer, having a calculated average thickness of 7.5 μm, was then thermally dried at 60° C. for 30 minutes in a Venticell ECO forced air oven. The dry (calculated average) thickness was approximately 3 μm.

[0240] Example 113 Joncryl® 9530-A was applied as an overcoat formulation onto the primed and coated polycarbonate lenses prepared in Example 107. Spin coating was performed according to Example 3A. The wet layer, having a calculated average thickness of 4 μm, was then thermally dried at 60° C. for 30 minutes in a Venticell ECO forced air oven. The dry (calculated average) thickness was approximately 1.6 μm.

[0241] Example 114 Joncryl® 617-A was applied as an overcoat formulation onto the coated Trivex® lens prepared in Example 82. Spin coating was performed according to Example 3A. The wet layer, having a calculated average thickness of 6.5 μm, was then thermally dried at 60° C. for 30 minutes in a Venticell ECO forced air oven. The dry (calculated average) thickness was approximately 3 μm.

[0242] Example 115 CrystalCoat™ TC-3000 was applied as a hard coat onto the coated lens prepared in Example 110. Spin coating was performed according to Example 3B. The wet layer, having a calculated average thickness of 11 μm, was then thermally dried at 60° C. for 30 minutes in a Venticell ECO forced air oven. The dry (calculated average) thickness was approximately 2.2 μm.

[0243] Example 116 CrystalCoat™ MP-1154D was applied as a hard coat onto the coated CR-39 lens prepared in Example 111. Spin coating was performed according to Example 3B. The wet layer, having a calculated average thickness of 27.8 μm, was then thermally dried in a Venticell ECO forced air oven at 60° C. for 30 minutes. The dry (calculated average) thickness was approximately 5 μm.

[0244] Example 117 CrystalCoat™ MP-2020B was applied as a hard coat onto the coated Trivex® lens prepared in Example 114. Spin coating was performed according to Example 3B. The wet layer, having a calculated average thickness of 13.6 μm, was then thermally dried at 60° C. for 30 minutes in a Venticell ECO forced air oven. The dry (calculated average) thickness was approximately 3 μm.

[0245] Example 118: Measuring Haze and % Transmittance After calibrating the T-100 instrument, a target lens was measured (an uncoated reference lens). Next, in sample mode, the coated lens was tested. The instrument then displayed the % transmission, Δ% transmission, haze, and Δ haze results for the coated and uncoated lenses. A low delta value between the coated and uncoated lenses indicates good optical clarity / transparency.

[0246] Example 119: Measuring photochromic properties Spectrophotometric studies were performed using a Cary 4000 UV-Vis dual-beam spectrophotometer. The light source was a UV-LED lamp (395 nm). Activation and fading characteristics, as well as kinetics, were characterized. For spectrophotometric studies, coated samples were characterized against uncoated reference slides or lenses. Spectral data were typically collected at 1 nm resolution over the 350-700 nm range. Kinetic measurements of activation and fading rates were performed at the wavelength of maximum absorbance for each photochromic dye, with a typical resolution of 0.2 seconds. Measurements were initiated when the UV-LED lamp was turned off. After 3-5 seconds, the UV-LED lamp was turned on for 120-180 seconds to achieve maximum absorbance. The lamp was then turned off, and fading monitoring was performed.

[0247] Example 120: Photochromic Dye Density and Photochromic Dye Concentration Exemplary photochromic dye densities are calculated as follows using the parameters of Example 80: print density is 300 dpi (Examples 4, 5A), which is approximately 13,924 dots / cm 2 The ink droplet volume is 10 pL and contains 2% photochromic dye. 2 =10 -5 μm, so the calculated pigment thickness per pass (or layer) is 0.028 μm, which translates to a calculated photochromic pigment content per lens area of ​​0.028 mg / cm, assuming a specific gravity of the component of approximately 1.0. 2Example 80 has 48 DoD (pass) and therefore, on a pure dye basis, the total calculated dye thickness is 1.34 μm.

[0248] Based on the above, the photochromic dye concentration of an exemplary receiving layer can be calculated depending on the photochromic dye formulation. The calculated total thickness of the dye is 1.34 μm, the calculated total thickness of the other ink solids is 0.13 μm (Example 13), and the calculated thickness of the receiving layer is 7.5 μm (Example 47). Therefore, the calculated photochromic dye concentration of the receiving layer is equal to 100·1.34 / (1.34+0.13+7.5), or 14.9% (volume % or weight %). Similarly, the calculated photochromic dye concentration of Example 102B is equal to 100·1.34 / (1.34+0.13+2.0), or 38.6%.

[0249] Continuing with Example 102B, assuming the receiving layer is covered with an overcoat having a thickness of 2.2 μm, followed by a hardcoat having a thickness of 2.5 μm, the calculated photochromic dye concentration (volume % or weight %) for the entire optical structure is equal to 100·1.34 / (1.34+0.13+2.0+2.2+2.5), or 16.4%.

[0250] Additional Embodiments Various methods and apparatus, as well as additional systems, are disclosed herein.

[0251] Additional embodiments (or "clauses") 1-214 are provided below.

[0252] Embodiment 1. An optical article comprising an optical substrate having an optical surface and an optical structure, wherein the optical structure comprises a polymeric receiving layer having a first surface fixedly attached to the optical surface and a second surface disposed opposite the first surface, the polymeric receiving layer comprising a polymer, a photochromic dye disposed within the receiving layer, and an overcoat layer coating the receiving layer and fixedly attached to the second surface.

[0253] Embodiment 1A. The article of embodiment 1, wherein said optical substrate having an optical surface is an ophthalmic substrate having an ophthalmic surface.

[0254] Embodiment 2. Optionally, at least one of the polymer and the polymer receiving layer has a Konig hardness, measured in seconds, in the range of 20 to 100; Optionally, the thickness (Toc) of the article is defined by the shortest distance or shortest normal distance between the substrate and an outer surface of the article disposed distally relative to the substrate, wherein Toc is at most 175 μm; and Optionally, the ultimate elongation of the polymer is in the range of 150% to 2000%. The article of embodiment 1 or 1A.

[0255] Embodiment 3. The article of embodiment 2, wherein the Konig hardness of at least one of the polymer and the polymer receiving layer is in the range of 20 to 100.

[0256] Embodiment 3A. The article of embodiment 3, wherein the Konig hardness is at most 90.

[0257] Embodiment 4. The article of embodiment 3, wherein the Konig hardness is at most 85.

[0258] Embodiment 5. The article of embodiment 3, wherein the Konig hardness is at most 80.

[0259] Embodiment 6. The article of embodiment 3, wherein the Konig hardness is at most 75.

[0260] Embodiment 7. The article of embodiment 3, wherein the Konig hardness is at most 70.

[0261] Embodiment 8. The article of embodiment 3, wherein the Konig hardness is at most 65.

[0262] Embodiment 9. The article of any one of embodiments 2-8, wherein the Konig hardness is at least 30.

[0263] Embodiment 10. The article of embodiment 9, wherein the Konig hardness is at least 40.

[0264] Embodiment 10A. The article of any one of claims 1-10, wherein the photochromic dye disposed in the polymeric receiving layer is a first portion of the photochromic dye P1, a second portion of the photochromic dye P2 is disposed in the optical substrate, and a third portion of the photochromic dye P3 is disposed in the overcoat layer, and wherein the dye ratio defined by P1 / (P2+P3) is at least 10.

[0265] Embodiment 10B. The article of embodiment 10A, wherein the pigment ratio is at least 20.

[0266] Embodiment 10C. The article of embodiment 10A or 10B, wherein P2 is 0.

[0267] Embodiment 10D. The article of any one of embodiments 10A-10C, wherein P3 is 0.

[0268] Embodiment 11. The article of any one of embodiments 2 to 10D, wherein the ultimate elongation of the polymer is in the range of 150% to 2000%.

[0269] Embodiment 12. The article of embodiment 11, wherein the ultimate elongation of the polymer is at least 175%.

[0270] Embodiment 13. The article of embodiment 11, wherein the ultimate elongation of the polymer is at least 200%.

[0271] Embodiment 14. The article of embodiment 11, wherein the ultimate elongation of the polymer is at least 250%.

[0272] Embodiment 15. The article of embodiment 11, wherein the ultimate elongation of the polymer is at least 300%.

[0273] Embodiment 16. The article of embodiment 11, wherein the ultimate elongation of the polymer is at least 350%.

[0274] Embodiment 17. The article of embodiment 11, wherein the ultimate elongation of the polymer is at least 400%.

[0275] Embodiment 18. The article of any one of embodiments 2-17, wherein the ultimate elongation of the polymer is at most 1500%.

[0276] Embodiment 19. The article of embodiment 18, wherein the ultimate elongation of the polymer is at most 1200%.

[0277] Embodiment 20. The article of embodiment 18, wherein the ultimate elongation of the polymer is at most 900%.

[0278] Embodiment 21. The article of embodiment 18, wherein the ultimate elongation of the polymer is at most 800%.

[0279] Embodiment 22. The article of embodiment 18, wherein the ultimate elongation of the polymer is at most 700%.

[0280] Embodiment 23. An article described in any one of embodiments 2 to 22, wherein the thickness (Toc) of the article is defined by the shortest distance between the substrate and the outer surface of the article located distal to the substrate, and Toc is at most 60 μm.

[0281] Embodiment 24. The article of embodiment 23, wherein Toc is at most 50 μm.

[0282] Embodiment 25. The article of embodiment 23, wherein Toc is at most 45 μm.

[0283] Embodiment 26. The article of embodiment 23, wherein Toc is at most 40 μm.

[0284] Embodiment 27. The article of embodiment 23, wherein Toc is at most 35 μm.

[0285] Embodiment 28. The article of embodiment 23, wherein Toc is at most 30 μm.

[0286] Embodiment 29. The article of embodiment 23, wherein Toc is at most 25 μm.

[0287] Embodiment 30. The article of embodiment 23, wherein Toc is at most 20 μm.

[0288] Embodiment 31. The article of embodiment 23, wherein Toc is at most 15 μm.

[0289] Embodiment 32. The article of embodiment 23, wherein Toc is at most 12 μm.

[0290] Embodiment 33. The article of embodiment 23, wherein Toc is at most 10 μm.

[0291] Embodiment 34. An article according to any one of embodiments 23 to 33, wherein Toc is at least 4 μm.

[0292] Embodiment 35. The article of embodiment 34, wherein Toc is at least 6 μm.

[0293] Embodiment 36. The article of embodiment 34, wherein Toc is at least 8 μm.

[0294] Embodiment 37. The article of embodiment 23, wherein Toc is in the range of 5 to 45 μm.

[0295] Embodiment 38. The article of embodiment 23, wherein Toc is in the range of 6 to 35 μm.

[0296] Embodiment 39. The article of embodiment 23, wherein Toc is in the range of 7 to 30 μm.

[0297] Embodiment 40. An article described in any one of embodiments 2 to 39, further comprising a first hardcoat layer coating the overcoat layer, the first hardcoat layer being fixedly attached to the side of the overcoat layer facing the outer surface of the article.

[0298] Embodiment 41. The article of embodiment 40, wherein the first hardcoat layer has a Konig hardness, measured in seconds, of at least 100.

[0299] Embodiment 42. The article of embodiment 40, wherein the first hardcoat layer has a Konig hardness, measured in seconds, of at least 110.

[0300] Embodiment 43. The article of embodiment 40, wherein the first hardcoat layer has a Konig hardness, measured in seconds, of at least 120.

[0301] Embodiment 44. The article of any one of embodiments 40-43, wherein the Konig hardness of the first hard coat layer is at most 160.

[0302] Embodiment 45. The article of embodiment 44, wherein the Konig hardness of the first hardcoat layer is at most 150.

[0303] Embodiment 46. The article of embodiment 44, wherein the Konig hardness of the first hardcoat layer is at most 140.

[0304] Embodiment 47. The article of any one of embodiments 2 to 46, wherein the thickness (Trec) of the polymer receiving layer is in the range of 0.6 to 30 μm.

[0305] Embodiment 48. The article of any one of embodiments 2 to 47, wherein the average thickness (Trec-avg) of the polymeric receiving layer is in the range of 0.6 to 30 μm.

[0306] Embodiment 49. The article of embodiment 47 or 48, wherein at least one of Trec and Trec-avg is at least 1 μm.

[0307] Embodiment 50. The article of embodiment 47 or 48, wherein at least one of Trec and Trec-avg is at least 1.5 μm.

[0308] Embodiment 51. The article of embodiment 47 or 48, wherein at least one of Trec and Trec-avg is at least 2.5 μm.

[0309] Embodiment 52. The article of embodiment 47 or 48, wherein at least one of Trec and Trec-avg is at least 3.5 μm.

[0310] Embodiment 53. The article of embodiment 47 or 48, wherein at least one of Trec and Trec-avg is at least 5 μm.

[0311] Embodiment 54. The article of embodiment 47 or 48, wherein at least one of Trec and Trec-avg is at least 6 μm.

[0312] Embodiment 55. The article of embodiment 47 or 48, wherein at least one of Trec and Trec-avg is at least 8 μm.

[0313] Embodiment 56. An article described in any one of embodiments 47 to 55, wherein at least one of Trec and Trec-avg is at most 25 μm.

[0314] Embodiment 57. The article of embodiment 56, wherein at least one of Trec and Trec-avg is at most 20 μm.

[0315] Embodiment 58. The article of embodiment 56, wherein at least one of Trec and Trec-avg is at most 15 μm.

[0316] Embodiment 59. The article of embodiment 56, wherein at least one of Trec and Trec-avg is at most 12 μm.

[0317] Embodiment 60. The article of embodiment 56, wherein at least one of Trec and Trec-avg is at most 10 μm.

[0318] Embodiment 61. The article of embodiment 59, wherein at least one of Trec and Trec-avg is at most 8 μm.

[0319] Embodiment 62. The article of embodiment 59, wherein at least one of Trec and Trec-avg is at most 6 μm.

[0320] Embodiment 63. The article of embodiment 47, wherein the Trec of the polymeric receiving layer is in the range of 1 to 18 μm.

[0321] Embodiment 64. The article of embodiment 47, wherein the Trec of the polymeric receiving layer is in the range of 1.5 to 9 μm.

[0322] Embodiment 65. The article of embodiment 48, wherein the polymeric receiving layer has a Trec-avg in the range of 1 to 18 μm.

[0323] Embodiment 66. The article of embodiment 48, wherein the polymeric receiving layer has a Trec-avg in the range of 1.5 to 9 μm.

[0324] Embodiment 67. The article of any one of embodiments 1 to 66, wherein the substrate is a lens.

[0325] Embodiment 68. The article of any one of embodiments 1 to 67, wherein the substrate is a curved ophthalmic substrate having a SAG of at least 0.5 mm.

[0326] Embodiment 69. The article of embodiment 68, wherein the SAG is at least 1 mm.

[0327] Embodiment 70. The article of embodiment 68, wherein the SAG is at least 2 mm.

[0328] Embodiment 71. The article of embodiment 68, wherein the SAG is at least 3.5 mm.

[0329] Embodiment 72. The article of embodiment 68, wherein the SAG is at least 5 mm.

[0330] Embodiment 73. The article of any one of embodiments 68-72, wherein the SAG is at most 15 mm, or at most 12 mm.

[0331] Embodiment 74. The article of any one of embodiments 1 to 73, wherein the dried receiving layer has a pencil hardness of at most 4H.

[0332] Embodiment 75. The article of embodiment 74, wherein the pencil hardness is at most 3H.

[0333] Embodiment 76. The article of embodiment 74, wherein the pencil hardness is at most 2H.

[0334] Embodiment 77. The article of any one of embodiments 74-76, wherein the pencil hardness is at least 2B.

[0335] Embodiment 78. The article of embodiment 77, wherein the pencil hardness is at least B.

[0336] Embodiment 79. The article of embodiment 83, wherein the pencil hardness is at least HB.

[0337] Embodiment 80. The article of any one of embodiments 1 to 79, wherein the substrate is or comprises a thermoplastic substrate.

[0338] Embodiment 81. The article of embodiment 80, wherein the thermoplastic substrate is or comprises polycarbonate.

[0339] Embodiment 82. The article of any one of embodiments 1 to 79, wherein the substrate is or comprises a thermoset substrate.

[0340] Embodiment 83. The article of any one of embodiments 1 to 82, wherein the overcoat layer is a hardcoat layer.

[0341] Embodiment 84. The article of embodiment 83, wherein the hard coat layer is a scratch resistant layer.

[0342] Embodiment 85. The article of embodiment 83 or 84, wherein the hardcoat layer is, comprises, or consists essentially of amorphous silica.

[0343] Embodiment 86. The article of any one of embodiments 1 to 82, further comprising a hardcoat layer disposed over the overcoat layer and fixedly attached to the overcoat layer.

[0344] Embodiment 87. The article of embodiment 86, wherein the hard coat layer is a scratch resistant layer.

[0345] Embodiment 88. The article of embodiment 86 or 87, wherein the hard coat layer is, comprises, or consists essentially of amorphous silica.

[0346] Embodiment 89. The article of any one of embodiments 1 to 88, wherein the photochromic dye comprises at least two photochromic dyes.

[0347] Embodiment 90. The article of any one of embodiments 1 to 89, further comprising a primer layer adhered to and disposed between both the ophthalmic surface and the first surface of the polymeric receiving layer.

[0348] Embodiment 91. The article of embodiment 90, wherein the primer layer has at least one of a spot thickness and an average thickness of at most 2.5 μm.

[0349] Embodiment 92. The article of embodiment 90, wherein the primer layer has at least one of a spot thickness and an average thickness of at most 1.8 μm.

[0350] Embodiment 93. The article of embodiment 90, wherein the primer layer has at least one of a spot thickness and an average thickness of at most 1.0 μm.

[0351] Embodiment 94. An article described in any one of embodiments 91 to 93, wherein at least one of the spot thickness and the average thickness is at least 0.2 μm.

[0352] Embodiment 95. An article described in any one of embodiments 91 to 93, wherein at least one of the spot thickness and the average thickness is at least 0.5 μm.

[0353] Embodiment 96. The article of any one of embodiments 1 to 95, further comprising an inner hardcoat layer disposed between the substrate and the polymeric receiving layer, the inner hardcoat layer adhering to the surface of the substrate.

[0354] Embodiment 97. The calculated receiving layer photochromic dye concentration C recipience 97. The article of any one of embodiments 1-96, wherein the .lambda.

[0355] Embodiment 98.C recipience 91. The article of embodiment 90, wherein the thickness is at least 5%.

[0356] Embodiment 99.C recipience 91. The article of embodiment 90, wherein the tensile strength is at least 8%.

[0357] Embodiment 100.C recipience 91. The article of embodiment 90, wherein the tensile strength is at least 12%.

[0358] Embodiment 100A.C recipience 91. The article of embodiment 90, wherein the tensile strength is at least 18%.

[0359] Embodiment 100B.C recipience 91. The article of embodiment 90, wherein the tensile strength is at least 24%.

[0360] Embodiment 100C.C recipience 91. The article of embodiment 90, wherein the thickness is at least 30%.

[0361] Embodiment 100D.C recipience The article of any one of embodiments 97-100C, wherein the tensile strength is at most 48%.

[0362] Embodiment 100E.C recipience is at most 45%, at most 42%, at most 40%, at most 37%, at most 35%, or at most 32%.

[0363] Embodiment 101. Photochromic dye concentration C calculated for the entire optical structure entire The article of any one of embodiments 1-100E, wherein the % ...

[0364] Embodiment 101A.C entire 102. The article of embodiment 101, wherein the tensile strength is at least 3.5%.

[0365] Embodiment 101B.C entire 102. The article of embodiment 101, wherein the tensile strength is at least 5%.

[0366] Embodiment 101C.C entire102. The article of embodiment 101, wherein the tensile strength is at least 8%.

[0367] Embodiment 101D.C entire 102. The article of embodiment 101, wherein the tensile strength is at least 12%.

[0368] Embodiment 101E.C entire The article of any one of embodiments 101-101D, wherein the tensile strength is at most 25%.

[0369] Embodiment 101F.C entire The article of embodiment 101E, wherein the tensile strength is at most 22%.

[0370] Embodiment 101G.C entire The article of embodiment 101E, wherein the tensile strength of the cellulose acetate layer is at most 20%.

[0371] Embodiment 101H.C entire 102. The article of embodiment 101, wherein the tensile strength of the cellulose acetate layer is at most 18%.

[0372] Embodiment 102. Calculated total thickness T of the pigment dye The article of any one of embodiments 1-101H, wherein the thickness is at least 0.25 μm.

[0373] Embodiment 102A.T dye 103. The article of embodiment 102, wherein the thickness is at least 0.5 μm.

[0374] Embodiment 102B.T dye 103. The article of embodiment 102, wherein the thickness is at least 0.75 μm.

[0375] Embodiment 102C.T dye 103. The article of embodiment 102, wherein the thickness is at least 1.0 μm.

[0376] Embodiment 102C.T dye 103. The article of embodiment 102, wherein the thickness is at least 1.25 μm.

[0377] Embodiment 102D.T dye The article of any one of embodiments 102-102C, wherein the thickness is at most 2 μm.

[0378] Embodiment 102E.T dye The article of embodiment 102D, wherein the thickness is at most 1.5 μm.

[0379] Embodiment 103. The article of any one of embodiments 1 to 102E, wherein the haze value of the optical article or of the optical structure is at most 1.5%.

[0380] Embodiment 103A. The article of embodiment 103, wherein the haze value of the optical article or of the optical structure is at most 1.0%.

[0381] Embodiment 103B. The article of embodiment 103, wherein the haze value of the optical article or of the optical structure is at most 0.5%.

[0382] Embodiment 104A. The article of any one of embodiments 1-103B, wherein the shortest distance between the first surface and the optical surface is at most 10 μm.

[0383] Embodiment 104B. The article of embodiment 104A, wherein the shortest distance is at most 5 μm.

[0384] Embodiment 104C. The article of any one of embodiments 1-104B, wherein the polymeric receiving layer contains up to 5% by weight, or up to 2% by weight, of a three-dimensional network structure, such as amorphous silica nanoparticles, or is substantially devoid of such a network structure.

[0385] Embodiment 104D. The article of any one of embodiments 1-104C, wherein the article has a transparency according to ASTM D1746-15 of at least 90%, at least 92%, or at least 95%.

[0386] Embodiment 104E. An article described in any one of embodiments 1 to 104D, wherein the optical surface is or includes a top or outward-facing surface of the optical substrate, and optionally the top or outward-facing surface has a convex curvature.

[0387] Embodiment 104F. The article of embodiment 104E, wherein the bottom or inward-facing surface has a convex curvature.

[0388] Embodiment 104G. An article described in any one of embodiments 1 to 104F, wherein the optical surface is or includes a bottom or inward-facing surface of the optical substrate, and optionally the bottom or inward-facing surface has a concave curvature.

[0389] Embodiment 104H. The article of embodiment 104G, wherein the bottom surface or the inward-facing surface has a concave curvature.

[0390] Embodiment 104I. An article described in any one of embodiments 1 to 104H, wherein the optical surface comprises a first top optical surface and a second bottom optical surface, the optical structure comprises a first top optical structure and a second bottom optical structure, the first top optical surface attached to the first top optical structure and the second bottom optical surface attached to the second bottom optical structure.

[0391] Embodiment 105. A method for producing an optical or ophthalmic article, comprising: (a) applying a wet receptive layer to an optical surface of an optical substrate; (b) applying at least one photochromic dye-containing ink onto the dry receiving layer after the wet receiving layer has dried to form a dry receiving layer; (c) applying a first polymer formulation onto the photochromic dye-containing receiving layer to form an overcoat layer after the at least one photochromic dye-containing ink has at least partially penetrated into the top surface of the dried receiving layer and after the ink has at least partially dried to form the photochromic dye-containing receiving layer; The method comprising:

[0392] Embodiment 106. The method of embodiment 105, wherein the at least one photochromic dye-containing ink is applied to the dry receiving layer as photochromic ink droplets.

[0393] Embodiment 107. The method of embodiment 106, wherein the application of the photochromic ink droplets is performed digitally.

[0394] Embodiment 108. The method of embodiment 106 or 107, wherein the application of the photochromic ink droplets is performed according to a predetermined pattern.

[0395] Embodiment 109. The method of any one of embodiments 106 to 108, wherein the application of the first polymer formulation occurs after the ink droplets have completely penetrated the top surface of the dry receiving layer.

[0396] Embodiment 110. The method of any one of embodiments 106 to 109, wherein the application of the ink droplets is performed by printing.

[0397] Embodiment 111. The method of any one of embodiments 106 to 110, wherein the application of the ink droplets is performed according to a digital pattern.

[0398] Embodiment 112. The method of any one of embodiments 106 to 110, wherein the application of the ink droplets is performed by jetting.

[0399] Embodiment 112A. The method of embodiment 112, wherein the jetting of the ink droplets is performed by inkjet ejection, such as drop-on-drop (DOD) inkjet ejection.

[0400] Embodiment 113. The method of any one of embodiments 105 to 111, wherein the applying of the at least one photochromic dye-containing ink comprises spraying.

[0401] Embodiment 114. The method of any one of embodiments 105 to 113, wherein said applying said at least one photochromic dye-containing ink comprises printing.

[0402] Embodiment 115. The method of any one of embodiments 105 to 114, wherein the moisture receiving layer has a first thickness (spot thickness or average thickness) in the range of 1 to 120 μm.

[0403] Embodiment 116. The method of embodiment 115, wherein the first thickness is at least 1.5 μm.

[0404] Embodiment 117. The method of embodiment 115, wherein the first thickness is at least 2 μm.

[0405] Embodiment 118. The method of embodiment 115, wherein the first thickness is at least 3 μm.

[0406] Embodiment 119. The method of embodiment 115, wherein the first thickness is at least 5 μm.

[0407] Embodiment 120. The method of embodiment 115, wherein the first thickness is at least 7 μm.

[0408] Embodiment 121. The method of embodiment 115, wherein the first thickness is at least 10 μm.

[0409] Embodiment 122. The method of embodiment 115, wherein the first thickness is at least 12 μm.

[0410] Embodiment 123. The method of embodiment 115, wherein the first thickness is at least 15 μm.

[0411] Embodiment 124. The method of embodiment 115, wherein the first thickness is at least 20 μm.

[0412] Embodiment 125. The method of embodiment 115, wherein the first thickness is at least 25 μm.

[0413] Embodiment 126. The method of embodiment 115, wherein the first thickness is at least 30 μm.

[0414] Embodiment 127. The method of any one of embodiments 115 to 126, wherein the first thickness is at most 100 μm.

[0415] Embodiment 128. The method of embodiment 127, wherein the first thickness is at most 70 μm.

[0416] Embodiment 129. The method of embodiment 127, wherein the first thickness is at most 50 μm.

[0417] Embodiment 130. The method of embodiment 127, wherein the first thickness is at most 40 μm.

[0418] Embodiment 131. The method of embodiment 127, wherein the first thickness is at most 30 μm.

[0419] Embodiment 132. The method of embodiment 127, wherein the first thickness is in the range of 1 μm to 45 μm.

[0420] Embodiment 133. The method of embodiment 127, wherein the first thickness is in the range of 1.5 μm to 35 μm.

[0421] Embodiment 134. The method of embodiment 127, wherein the first thickness is in the range of 1.5 μm to 25 μm.

[0422] Embodiment 135. The method of embodiment 127, wherein the first thickness is in the range of 1.5 μm to 18 μm.

[0423] Embodiment 136. The method of embodiment 127, wherein the first thickness is in the range of 1.5 μm to 12 μm.

[0424] Embodiment 137. The method of embodiment 127, wherein the first thickness is in the range of 6 μm to 80 μm.

[0425] Embodiment 138. The method of any one of embodiments 105 to 137, wherein the photochromic dye-containing receiving layer, after being completely dried, has a second thickness (spot thickness or average thickness) in the range of 0.6 μm to 30 μm.

[0426] Embodiment 139. The method of embodiment 138, wherein the second thickness is at most 20 μm.

[0427] Embodiment 140. The method of embodiment 138, wherein the second thickness is at most 10 μm.

[0428] Embodiment 141. The method of embodiment 138, wherein the second thickness is at most 7 μm.

[0429] Embodiment 146. The method of any one of the above embodiments, wherein the dry receptive layer has a transparency according to ASTM D1746-15 of at least 95%, at least 97%, or at least 99%.

[0430] Embodiment 148. The dry receptive layer has a solubility S in the solvent of the ink droplets, and the solubility S is It is defined as S=Wd / (Wd+Wsolvent), During the ceremony, Wd is the weight of the dissolved dry receptive layer; Wsolvent is the weight of the solvent in the ink droplet, S is measured at 25°C, S is at least 0.005, The method according to any one of embodiments 105 to 147.

[0431] Embodiment 149. The method of embodiment 148, wherein S is at least 0.015.

[0432] Embodiment 150. The method of embodiment 148, wherein S is at least 0.03.

[0433] Embodiment 151. The method of embodiment 148, wherein S is at least 0.05.

[0434] Embodiment 152. The method of embodiment 148, wherein S is at most 0.60.

[0435] Embodiment 153. The method of embodiment 148, wherein S is at most 0.45.

[0436] Embodiment 154. The method of embodiment 148, wherein S is at most 0.35.

[0437] Embodiment 155. The method of any one of embodiments 105-154, wherein the first overcoat layer is a hardcoat.

[0438] Embodiment 156. The method of any one of embodiments 105-155, further comprising, after the first overcoat layer has dried to form a first dry overcoat layer, applying a second formulation over the first dry overcoat layer to form a wet hardcoat layer.

[0439] Embodiment 157. The method of embodiment 156, wherein the second formulation comprises a silane or alkoxide adapted to produce amorphous silica.

[0440] Embodiment 158 ​​The method of embodiment 156 or 157, further comprising drying the wet hardcoat layer to form a dry hardcoat layer.

[0441] Embodiment 159. The method of any one of embodiments 105 to 158, further comprising drying the at least one photochromic dye-containing ink or the ink droplets to form the photochromic dye-containing receiving layer.

[0442] Embodiment 160. The method of any one of embodiments 105 to 159, further comprising pretreating a first surface of the ophthalmic substrate to form the ophthalmic surface prior to providing the ophthalmic substrate.

[0443] Embodiment 161. The method of embodiment 160, wherein the pretreatment of the first surface comprises a corona treatment.

[0444] Embodiment 162. The method of embodiment 160, wherein the pretreatment of the first surface comprises a plasma treatment.

[0445] Embodiment 163. The method of embodiment 160, wherein the pretreatment of the first surface comprises electron beam treatment.

[0446] Embodiment 164. The method of embodiment 160, wherein the pretreatment of the first surface comprises an electrical discharge treatment.

[0447] Embodiment 165. The method of embodiment 160, wherein the pretreatment of the first surface comprises an etching treatment.

[0448] Embodiment 166. The method of embodiment 165, wherein the etching process comprises laser etching.

[0449] Embodiment 167. The method of embodiment 165 or embodiment 166, wherein the etching process comprises chemical etching.

[0450] Embodiment 168. The method of any one of embodiments 160 to 167, wherein the pretreatment comprises applying a primer to the first surface to promote wetting of the wetting receptive layer to the first surface.

[0451] Embodiment 169. The method of any one of embodiments 160 to 168, wherein the pretreatment comprises applying a primer to the first surface to promote adhesion of the moisture-receiving layer to the first surface.

[0452] Embodiment 170. The method of any one of embodiments 160 to 167, wherein the pretreatment comprises applying a primer to the first surface.

[0453] Embodiment 171. The method according to any one of embodiments 168 to 170, further comprising drying the primer to obtain a dry primer layer, the large exposed surface of the dry primer layer forming the (ophthalmic) surface.

[0454] Embodiment 172. The method of any one of embodiments 168 to 171, wherein the application of the primer comprises application by coating.

[0455] Embodiment 173. The method of embodiment 172, wherein the coating is a spin coating.

[0456] Embodiment 174. The method of embodiment 172, wherein the coating is a dip coating.

[0457] Embodiment 175. The method of any one of embodiments 105 to 174, wherein after the wet receptive layer has dried to form a dry receptive layer, the application or deposition of the at least one photochromic dye-containing ink onto the dry receptive layer is performed as a drop-on-drop application of the photochromic ink droplets.

[0458] Embodiment 176. The method of embodiment 175, wherein the drop-on-drop application is performed or repeated to generate at least a first drop-on-drop ink pillar and a second drop-on-drop ink pillar, the first drop-on-drop ink pillar having at least three of the ink drops.

[0459] Embodiment 177. The method of embodiment 176, wherein the drop-on-drop application is performed such that the first ink column includes at least four of the ink drops.

[0460] Embodiment 178. The method of embodiment 176, wherein the drop-on-drop application is performed such that the first ink column includes at least six of the ink drops.

[0461] Embodiment 179. The method of embodiment 176, wherein the drop-on-drop application is performed such that the first ink column includes at least eight of the ink drops.

[0462] Embodiment 180. The method of embodiment 176, wherein the drop-on-drop application is performed such that the first ink column includes at least 10 of the ink drops.

[0463] Embodiment 181. The method of embodiment 176, wherein the drop-on-drop application is performed such that the first ink column includes at least 12 of the ink drops.

[0464] Embodiment 182. The method of embodiment 176, wherein the drop-on-drop application is performed such that the first ink column includes at least 15 of the ink drops.

[0465] Embodiment 183. The method of embodiment 176, wherein the drop-on-drop application is performed such that the first ink column includes at least 20 of the ink drops.

[0466] Embodiment 184. The method of embodiment 176, wherein the drop-on-drop application is performed such that the first ink column includes at least 25 of the ink drops.

[0467] Embodiment 188. The method of any one of embodiments 175 to 184, wherein the drop-on-drop application is performed such that the first ink column includes a maximum of 60 of the ink drops.

[0468] Embodiment 189. The method of embodiment 185, wherein the drop-on-drop application is performed such that the first ink column includes a maximum of 50 of the ink drops.

[0469] Embodiment 190. The method of embodiment 185, wherein the drop-on-drop application is performed such that the first ink column includes a maximum of 40 of the ink drops.

[0470] Embodiment 191. The method of embodiment 185, wherein the drop-on-drop application is performed such that the first ink column includes a maximum of 35 of the ink drops.

[0471] Embodiment 192. The method of embodiment 185, wherein the drop-on-drop application is performed such that the first ink column includes a maximum of 30 of the ink drops.

[0472] Embodiment 193. The method of any one of embodiments 175 to 192, wherein applying the first polymer formulation onto the photochromic dye-containing receiving layer to form the first overcoat layer occurs only after all of the ink droplets have at least partially dried to form the photochromic dye-containing receiving layer.

[0473] Embodiment 194. The method of any one of embodiments 105 to 193, wherein the application of the wet receptive layer is by at least one of spin coating, dip coating, slit coating, die coating, and stamp coating.

[0474] Embodiment 195. The method of any one of the preceding method embodiments, wherein the photochromic dye-containing ink is a solvent-based photochromic dye-containing ink.

[0475] Embodiment 196. Relative n-butyl acetate normalized evaporation rate scale at 25°C (Evaporation Rate Scale) nba-norm), and at least 10 wt. % of the total solvents in the ink formulation have a normalized evaporation rate (Evap) of at most 0.10. norm 196. The method of embodiment 195, wherein

[0476] Embodiment 197. At least 15 wt.% of the total solvents in the ink formulation have an Evaporative Evaporation Rate of up to 0.10 norm 197. The method of embodiment 196, comprising:

[0477] Embodiment 198. At least 20% by weight of the total solvents in the ink formulation are at most 0.25Evap norm 198. The method of embodiment 196 or 197, wherein

[0478] Embodiment 199. At least 20% by weight of the total solvents in the ink formulation have an Evaporative Evaporation Rate of up to 0.10 norm 199. The method of any one of embodiments 196 to 198, comprising:

[0479] Embodiment 200. At least 10% by weight of the total solvents in the ink formulation have an Evaporative Evaporation Rate of up to 0.02 norm 199. The method of any one of embodiments 196 to 199, comprising:

[0480] Embodiment 201. At least 25% by weight of the total solvents in the ink formulation are at least 0.3 Evaporative norm 201. The method of any one of embodiments 196 to 200, comprising:

[0481] Embodiment 202. At least 45% by weight of the total solvents in the ink formulation are at least 0.3 Evaporative norm 202. The method of embodiment 201, comprising:

[0482] Embodiment 203. At least 35% by weight of the total solvents in the ink formulation have an Evaporation Rate of at least 0.4 norm 203. The method of embodiment 201 or 202, wherein

[0483] Embodiment 204. At least 60% by weight of the total solvents in the ink formulation have an Evaporation Rate of at least 0.25 norm 204. The method according to any one of embodiments 201 to 203, comprising:

[0484] Embodiment 205. The method of any one of embodiments 195-204, wherein up to 5% by weight of the total solvent is water.

[0485] Embodiment 206. The method of any one of the preceding method embodiments, wherein the photochromic dye-containing ink has a surface tension of at most 38 mN / m.

[0486] Embodiment 206A. The method of embodiment 206, wherein the surface tension is at most 35 mN / m, at most 32 mN / m, or at most 30 mN / m.

[0487] Embodiment 206B. The method of embodiment 206 or 206A, wherein the surface tension is at least 20 mN / m, at least 22 mN / m, or at least 24 mN / m.

[0488] Embodiment 206C. The method of any one of the preceding embodiments, wherein at least one of the receiving layer and the photochromic dye-containing receiving layer has a surface energy in the range of 20 to 35 or 20 to 33 mN / m.

[0489] Embodiment 207. The method of any one of the preceding method embodiments, wherein the first polymer formulation is an aqueous polymer formulation.

[0490] Embodiment 208. The method of embodiment 207, wherein the aqueous polymer formulation comprises polyurethane.

[0491] Embodiment 209. The method of embodiment 207, wherein the aqueous polymer formulation comprises a polyurethane dispersion.

[0492] Embodiment 210. The method of any one of embodiments 105-206C, wherein the first polymer formulation is a solvent-based polymer formulation.

[0493] Embodiment 211. The method of embodiment 210, wherein the solvent-based polymer formulation comprises a polyurethane.

[0494] Embodiment 211A. A method according to any one of the preceding method embodiments, wherein the at least partial penetration of the upper surface of the dry receiving layer is at least 80%, at least 90%, or at least 95%, by weight or volume.

[0495] Embodiment 212. The method or article of any one of the preceding embodiments, wherein the polymer of the polymer receiving layer is a thermosetting polymer.

[0496] Embodiment 213. The method or article of any one of embodiments 1 to 212, wherein the polymer of the polymeric receiving layer is a thermoplastic polymer.

[0497] Embodiment 213. The method or article of any one of embodiments 1 to 212, wherein there is a Konig hardness difference between each of the layers in the optical structure (between each layer of the structure and the layer disposed immediately below it) of at least 5 seconds, more typically 5 to 40, 5 to 35, 3 to 30, 5 to 25, or 5 to 20 seconds.

[0498] Embodiment 213A. The method or article of any one of embodiments 1 to 213, wherein there is a delta pencil hardness of at least 1 hardness grade (+1) between each of the layers in the optical structure and the layer disposed immediately below it.

[0499] Embodiment 214. The article of any one of embodiments 1 to 104, produced by the method of any one of embodiments 105 to 213.

[0500] As used in this specification and the claims that follow, unless otherwise specified, the terms "percent" or "%" refer to percent by weight.

[0501] As used herein and in the claims that follow, the terms "anti-glare," "anti-reflective," "anti-fog," "UV absorber," "photochromic," and the like are intended to be used in the art of optical substrate coatings, unless otherwise specified.

[0502] As used herein and in the claims that follow, the term "scratch resistant" in reference to a material such as a formulation or coating refers to a material in which the dried and cured coating exhibits a haze value of less than 6% using the following Taber abrasion properties: ASTM D1004-08: CS10F wheel, 500g load, 500 cycles.

[0503] Alternatively, the term "scratch resistant" with respect to a material such as a formulation or coating refers to a material having a Bayer number of at least 5 or at least 6 using ASTM F735-21.

[0504] As used herein and in the claims that follow, the term "relative n-butyl acetate normalized 25°C evaporation rate scale" and the like may be determined using test method ASTM D3539.

[0505] As used in this specification and the claims that follow, the term "continuous" means

[0506] As used herein and in the claims that follow, the term "ratio" refers to weight ratio unless otherwise specified.

[0507] The "thickness" of a layer or layers at a particular location is measured in the direction perpendicular (N) to the lens substrate at that location.

[0508] Various types of thin film thickness measurements are known to those skilled in the art. For example, single spot thickness measurements may be made by spectroscopic reflectance or spectroscopic ellipsometry.

[0509] Additionally, mapping of thin film surfaces and calculation of the average thickness of such films may be performed using these techniques.

[0510] The "thickness" of a layer or layers at a particular location is measured in the direction perpendicular (N) to the lens substrate at that location.

[0511] Various types of thin film thickness measurements are known to those skilled in the art. For example, single spot thickness measurements may be made by spectroscopic reflectance or spectroscopic ellipsometry.

[0512] Additionally, mapping of thin film surfaces and calculation of the average thickness of such films may be performed using these techniques.

[0513] The "average thickness" of a wetting layer may be defined as follows: when a volume of material, vol, covers a surface area, SA, of a surface having an area with a wetting layer, the thickness of the wetting layer is assumed to be vol / SA. If the weight of the material is known, vol may be calculated by dividing by the specific gravity of the material. Typically, the specific gravity of various coating materials can be safely approximated as 1.00.

[0514] The "average thickness" of a dry film may be calculated as follows: when a volume vol of material that is x% liquid by weight wets or covers the surface area SA of a surface, and all the liquid evaporates, turning the wet layer into a dry film, the thickness of the dry film is calculated as follows: vol / ρ wet layer (100-x) / (SA·ρ dry layer ) In the formula, ρ wet layer is the specific gravity of the wet layer, and ρ dry layer is the specific gravity of the dry layer. This calculation requires knowledge of various properties of the membrane's wet coating material, such as its specific gravity. As mentioned above, the specific gravity can usually be assumed to be 1.

[0515] Similarly, the average diameter of droplets (Ddrop), such as jetted or microjetted droplets, can be calculated by weighing a number of jetted droplets, converting the total weight to volume using their specific gravity, and dividing by the number of droplets to obtain the formula for spherical droplet diameter to spherical volume: D=(6*V / π) 1 / 3 can be calculated using

[0516] Those skilled in the art will understand that the various layers disposed on the optical or ophthalmic surfaces (e.g., lens surfaces) of the present invention are generally of substantially uniform thickness, and therefore "average thickness" may be determined by assessing the thickness of one or more spots on the film or layer.

[0517] As used herein and in the claims that follow, the term "average" refers to the arithmetic mean of a dimension of a plurality of dots, e.g., their height, length, or diameter, calculated for each dot of the plurality of dots using a characteristic dimension.

[0518] As used herein and in the claims that follow, the terms "transparency" and "haze" may typically be determined in accordance with ASTM D1003-21 with respect to materials, such as those used in coatings or as substrates. Utilizing ASTM D1003-21, a material having a haze measurement of less than 2% and a total transmittance (Tt) of at least 85% is considered "transparent." More typically, the haze is at most 1.5% or at most 1.0%. More typically, the Tt is at least 90% or at least 95%. Even more typically, the haze is at most 1.0% and the Tt is at least 95%.

[0519] The term "ophthalmic formulation" is intended to be understood as used in the art of ophthalmic substrate coatings.

[0520] As used herein, the term "film-forming," typically in reference to a resin, polymer, or formulation, is intended to be understood as commonly used in the art of ophthalmic substrate coatings.

[0521] As used herein, the term "wet" may be used contextually to include uncured UV material.

[0522] As used herein, the terms "drying," "dried," and the like may be used contextually to refer to or include the curing of UV materials.

[0523] As used herein and in the claims that follow, the term "liquid" refers to the state of a material at 25°C.

[0524] As used herein and in the claims that follow, terms such as "liquid medium" refer to a medium that is liquid at its temperature of use. For example, the liquid medium of an ink-jet ink jetted at 38°C is liquid at 38°C. A "liquid medium" is typically liquid at 25°C.

[0525] As used herein and in the claims that follow, the term "ophthalmic" is always a subset of the term "optical."

[0526] As used herein and in the claims that follow, the structural features "calculated receiver layer photochromic dye concentration," "calculated photochromic dye concentration for the entire optical structure," "calculated total dye thickness," and "calculated photochromic dye content per lens area," as well as the methodological feature "calculated total dye thickness per pass," refer to the terms calculated in Example 120. These features can be evaluated in a variety of ways by those skilled in the art.

[0527] As used herein and in the claims that follow, the term "drop-on-drop" refers to a printing method in which two or more droplets, typically 6 to 60 droplets, are fired or jetted on top of each other.

[0528] As used herein and in the claims that follow, the term "drop-on-drop" is met if at least one of the following is true: (a) the overlap of a second jetted droplet with a first jetted droplet is, in fact, at least 50% by area of ​​the first droplet after impact, and (b) the jetting algorithm is designed such that the jet nozzle fires the first and second droplets (idealized as spheres with a center and radius R based on the nominal drop volume) to land on the substrate at nominal locations within 1.5R of each other, more typically within 1.25R, 1.00R, 0.75R, 0.5R, or 0.25R of each other.

[0529] As used herein and in the claims that follow, the terms "continuous dry layer," "continuous layer," or "continuous" in reference to a layer or coating means a layer having an area of ​​at least 0.5 cm 2 (and more typically at least 1 cm 2 , at least 2 cm 2 , at least 4 cm 2 , at least 10 cm 2 , optional, up to 100cm 2 Or up to 40cm 2 , most typically 0.5 to 20 cm 2 , 0.5~10cm 2 , or 0.5 to 5 cm 2 The optical surface may be on an externally disposed broad surface or an internally disposed broad surface of the substrate.

[0530] As used herein and in the claims that follow, the term "continuous" with respect to a layer or coating means continuity as perceived by the unaided human eye when viewed through an optical article. Alternatively, the term "continuous" with respect to a layer or coating means continuity verifiable by spectrophotometric means or other tools known to those skilled in the art.

[0531] In the context of this application and the claims, the phrase "at least one of A and B" is equivalent to an inclusive "or" and includes any one of "A only," "B only," or "A and B." Similarly, the phrase "at least one of A, B, and C" is equivalent to an inclusive "or" and includes any one of "A only," "B only," "C only," "A and B," "A and C," "B and C," or "A and B and C."

[0532] As used in this specification and the claims that follow, terms such as "top," "bottom," "above," "below," "upper," "lower," "height," and "side" are used for convenience of description or with respect to relative orientation and are not necessarily intended to indicate absolute orientation in space.

[0533] It will be appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.

[0534] While the present invention has been described in conjunction with specific embodiments thereof, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and scope of the appended claims. All publications, patents, and patent applications mentioned herein, including U.S. Patent No. 10,310,151, are herein incorporated by reference in their entirety to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. Furthermore, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention.

Claims

1. An ophthalmic article comprising: an ophthalmic substrate having an ophthalmic surface; an ophthalmic structure; The ophthalmic structure comprises: (a) a polymer receiving layer having a first surface fixedly attached to the ophthalmic surface and a second surface disposed opposite the first surface, the polymer receiving layer comprising a polymer; (b) a photochromic dye disposed within the polymeric receiving layer; and (c) an overcoat layer coating the polymeric receiving layer and fixedly attached to the second surface; and Including, the ultimate elongation of the polymer is in the range of 250% to 900%; a thickness (Toc) of the ophthalmic structure defined by the shortest normal distance between the ophthalmic substrate and an outer surface of the ophthalmic structure disposed distal to the ophthalmic substrate, and Toc is at most 50 micrometers (μm); the ophthalmic substrate is a lens; The entire optical structure (C ｅｎｔｉｒｅ ) has a photochromic dye concentration calculated for at least 3.5% by weight or volume; The ophthalmic article.

2. C ｅｎｔｉｒｅ 10. The ophthalmic article of claim 1, wherein is at least 5%.

3. C ｅｎｔｉｒｅ The ophthalmic article of claim 1 , wherein is at least 8%.

4. The calculated photochromic dye concentration C of the receiving layer ｒｅｃｉｐｉｅｎｃｅ The ophthalmic article of any one of claims 1 to 3, wherein is at least 12%.

5. 5. The ophthalmic article of claim 1, wherein, from a vertical viewing direction (Z-direction) intersecting the broad outer surface of the lens, the photochromic dye disposed within the polymeric receiving layer forms continuous dye protrusions.

6. The ophthalmic article of any one of claims 1 to 5, wherein the polymeric receiving layer has a thickness in the range of 1 to 6 micrometers (μm).

7. The ophthalmic article of any one of claims 1 to 6, wherein the lens has a lens curvature expressed in SAG numbers of at least 5 mm.

8. 8. The ophthalmic article of any one of claims 1 to 7, wherein the photochromic dye disposed in the polymeric receiving layer is a first portion of the photochromic dye P1, a second portion of the photochromic dye P2 is disposed in the lens, and a third portion of the photochromic dye P3 is disposed in the overcoat layer, and P1 / (P2+P3) is at least 10.

9. The ophthalmic article of any one of claims 1 to 8, wherein at least one of the polymer and the polymeric receiving layer has a Konig hardness, measured in seconds, in the range of 20 to 80.

10. The ophthalmic article of any one of claims 1 to 9, wherein the ophthalmic structure further comprises a hardcoat layer disposed on and adhering to the overcoat layer.

11. The ophthalmic article of claim 10 , wherein the ophthalmic structure further comprises a second hardcoat layer disposed on and adhered to the first hardcoat layer.

12. A method for producing an article according to any one of claims 1 to 11, said method comprising: (a) applying a wetness receiving layer onto the ophthalmic surface; (b) jetting at least one photochromic dye-containing ink onto the dry receiving layer after the wet receiving layer has dried to form a dry receiving layer; (c) applying a first polymer formulation onto the photochromic dye-containing receiving layer to form the overcoat layer after the at least one photochromic dye-containing ink has at least partially penetrated into the top surface of the dried receiving layer and after the ink has at least partially dried to form the photochromic dye-containing receiving layer; The method comprising:

13. 13. The method of claim 12, wherein the jetting of the at least one photochromic dye-containing ink onto the dry receiving layer is performed as a drop-on-drop application of the photochromic ink droplets.

14. the dry receptive layer has a solubility S in the solvent of the ink droplet, the solubility S being: S=Wd / (Wd+Wsolvent) where: Wd is the weight of the dissolved dry receptive layer; Wsolvent is the weight of the solvent in the ink droplet, S is measured at 25°C, S is at least 0.03 and at most 0.45; 14. The method of claim 12 or 13.

15. 15. The method of claim 12, wherein the drop-on-drop application is performed to generate at least a first drop-on-drop ink pillar and a second drop-on-drop ink pillar, the first drop-on-drop ink pillar including at least six of the ink drops.

16. Relative n-butyl acetate normalized evaporation rate scale at 25°C (Evaporation ｎｂａ－ｎｏｒｍ ) and at least 15 wt. % of the total solvents in the ink formulation have a normalized evaporation rate (Evap) of at most 0.

10. ｎｏｒｍ 16. The method according to any one of claims 12 to 15, wherein

17. At least 20% by weight of the total solvent in the ink formulation has an Evaporation Ratio of up to 0.

25. ｎｏｒｍ 17. The method of claim 16, comprising:

18. At least 10% by weight of the total solvents in the ink formulation have an Evaporation Ratio of at most 0.02 ｎｏｒｍ 18. The method of claim 16 or 17, comprising:

19. At least 45% by weight of the total solvent in the ink formulation has an Evaporation Ratio of at least 0.3 ｎｏｒｍ The method according to any one of claims 16 to 18, comprising:

20. At least 60% by weight of the total solvent in the ink formulation has an Evaporation Ratio of at least 0.25 ｎｏｒｍ The method according to any one of claims 16 to 19, comprising:

21. 21. The method of any one of claims 12 to 20, wherein up to 5% by weight of the total solvent is water.

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