Method and system for producing coated optical substrates and photochromic ink formulations thereof.

Abstract

A method for manufacturing an optical structure on an optical substrate, one such method comprising (a) discharging droplets of a liquid photochromic dye-containing formulation onto the optical surface of an optical substrate using a microvalve to form a continuous wet layer, and (b) processing the wet layer to form a continuous dry photochromic dye-containing layer on the optical surface, wherein the optical surface is curved and the optical surface is a polymer surface.

Description

[Technical Field]

[0001] Cross-references to other publications This application claims priority to U.S. Patent Application No. 63 / 580,003 filed on 1 September 2023, No. 63 / 541,293 filed on 28 September 2023, No. 63 / 541,279 filed on 28 September 2023, No. 63 / 541,292 filed on 28 September 2023, and UK Application No. 2409920.2 filed on 8 July 2024 and GB2409979.8 filed on 9 July 2024, all of which are incorporated herein by reference. [Background technology]

[0002] The present invention relates to coated optical and ophthalmic instruments and articles having a photochromic coating, formulations for manufacturing such coated instruments and articles, and systems and methods for applying such formulations to form such photochromic coatings on these instruments and articles.

[0003] Commercial high-throughput manufacturing of eyeglass coatings is often carried out using a variety of analog coating processes, such as dipping and spin coating processes.

[0004] An ultrathin anti-reflective coating with a thickness of 200-300 nanometers can be applied layer by layer by vacuum deposition.

[0005] In various known processes, when the target surface is a curved optical surface such as an eyeglass lens, optical damage can be significantly worsened, especially in the case of eyeglass lenses with a high SAG number or base curve.

[0006] The inventors recognized the need for improved optical and ophthalmic instruments and articles having photochromic coatings, improved photochromic formulations, and systems and methods for manufacturing such instruments and articles. [Overview of the project]

[0007] In accordance with some teachings of the present invention, we provide an ink formulation comprising (a) a resin, (b) a photochromic dye, (c) a softener for softening the resin, and (d) a solvent system comprising at least one of an ultra-low vapor pressure solvent (LLevap), a high vapor pressure solvent (Hevap), and an ultra-high vapor pressure solvent (HHevap), wherein the softener is optionally a non-volatile liquid softener, and the resin and photochromic dye are dissolved in the solvent system.

[0008] Further teachings of the present invention provide a method and system for producing an optical structure on a curved polymer optical substrate, one such method comprising (a) microvalve dispensing droplets of a liquid photochromic dye-containing formulation onto the optical surface of an optical substrate to form a wet layer, and (b) processing the wet layer to produce a dry photochromic dye-containing layer on the optical surface.

[0009] The present invention will be described with reference to the attached drawings, which are merely illustrative examples. While the description will refer to the drawings in detail, it is important to emphasize that the details presented here are merely illustrative and serve only to illustrate preferred embodiments of the present invention, and are presented to provide what is considered to be the most useful and easily understandable explanation of the principles and conceptual aspects of the present invention. In this regard, the structural details of the present invention are shown only to the extent necessary for a basic understanding of the invention, but by understanding the description together with the drawings, it will be clear to those skilled in the art how several forms of the present invention can be actually realized. Throughout the drawings, the same reference numerals are used to designate the same elements. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic block diagram showing a method for processing an optical surface according to an aspect of the present invention. [Figure 2]This is a schematic block diagram showing a method for generating a photochromic layer by processing an optical surface according to an aspect of the present invention. [Figure 3] The schematic block diagram in Figure 2 provides optional steps, in which pretreatment may include applying a liquid primer formulation to the exposed surface of an ophthalmic substrate and then drying / curing it. [Figure 4] This is a schematic cross-sectional view of a multilayer ophthalmic structure, which includes an ophthalmic substrate, the substrate having a photochromic ophthalmic structure fixedly arranged on its broad surface. [Figure 4A] This is a schematic diagram of a microvalve device that jets ink droplets onto the surface of a convex lens. [Figure 4B] This is a schematic diagram of a microvalve device that jets ink droplets onto the surface of a concave lens. [Figure 5] This diagram illustrates a conceptual process for coating and finishing an optical substrate or an ophthalmic substrate using a coating system according to an embodiment of the present invention. [Figure 6A] The following are block diagrams of exemplary coating systems according to embodiments of the present invention. [Figure 6B] The following are block diagrams of exemplary coating systems according to embodiments of the present invention. [Figure 6C] The following are block diagrams of exemplary coating systems according to embodiments of the present invention. [Figure 7A] This is a conceptual diagram of a process for coating an optical substrate or an ophthalmic substrate using a coating system combined with a surface treatment apparatus according to an embodiment of the present invention. [Figure 7B] This is a conceptual diagram of a process for coating an optical substrate or an ophthalmic substrate using a coating system combined with a surface treatment apparatus according to an embodiment of the present invention. [Figure 8] A block diagram of an exemplary coating system according to an embodiment of the present invention is shown. [Figure 9] A block diagram of an exemplary surface treatment apparatus according to an embodiment of the present invention is shown. [Figure 10]The following are conceptual representations of the processes for coating and drying an optical substrate or an ophthalmic substrate according to embodiments of the present invention. [Figure 11] The following are conceptual representations of the processes for coating and drying an optical substrate or an ophthalmic substrate according to embodiments of the present invention. [Figure 12A] The following are schematic diagrams of exemplary optical substrates according to embodiments of the present invention. [Figure 12B] The following are schematic diagrams of exemplary optical substrates according to embodiments of the present invention. [Figure 12C] The following are schematic diagrams of exemplary optical substrates according to embodiments of the present invention. [Figure 12D] The following are schematic diagrams of exemplary optical substrates according to embodiments of the present invention. [Figure 13A] This shows a schematic side view of a virtual two-dimensional projection of a curved surface of an optical substrate according to an embodiment of the present invention. [Figure 13B] This shows a schematic perspective view of a virtual two-dimensional projection of a curved surface of an optical substrate according to an embodiment of the present invention. [Figure 14] This diagram shows a schematic side view of an embodiment of the present invention in which droplets are deposited on the curved surface of an optical substrate according to a virtual two-dimensional projection of the surface. [Figure 15] This shows a schematic top view of an optical substrate including a virtual annular portion with an edge, according to an embodiment of the present invention. [Figure 16] A schematic side view of a curved optical substrate, showing a specific aspect of the surface shape according to an embodiment of the present invention, is shown. [Modes for carrying out the invention]

[0011] The principle and operation of the optical structure according to the present invention can be better understood by referring to the drawings and the descriptions therefor.

[0012] The present invention is not limited in its application to the structural and arrangement details of the components described below or shown in the drawings. This should be understood before describing in detail at least one embodiment of the present invention. Other embodiments of the present invention are possible, or it can be practiced or implemented in various ways. Naturally, the expressions and terms used herein are for illustrative purposes only and should not be construed as limiting.

[0013] The inventors have found that applying one or more optical coatings to an optical substrate presents various technical challenges. Some of these relate to optical substrates that tend to be very smooth and substantially non-absorbent. Optical substrates are generally transparent, and a high degree of transparency may be required for multiple optical coatings. Furthermore, the refractive index of each coating, or the combined refractive index of all coatings, may be constrained to be similar to the refractive index of the optical substrate.

[0014] Optical structures or articles must meet physical criteria such as hardness and / or scratch resistance. Furthermore, each coating must be relatively inert to any other coatings it comes into contact with. Additionally, since 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.

[0015] The curing time for each coating or layer should be reasonable (a maximum of several minutes or several hours), and the curing temperature should be sufficiently low so as not to damage the optical substrate and any previously applied coatings.

[0016] Along with adhesion to optical or ophthalmic substrates, resistance to peeling or cracking of one or more coatings can also be important in obtaining practical coated lenses, such as coated ophthalmic lenses.

[0017] From a throughput standpoint, it would be advantageous to apply very large ink droplets (e.g., on the order of nanoliters rather than picoliters) to the curved, smooth surface of such glasses.

[0018] However, the inventors have found that even with precise digital coating, the image resolution is unfavorably impaired by such large ink droplets.

[0019] Furthermore, ink droplets, especially low-viscosity ink droplets, tend to slide easily on such curved, smooth spectacle surfaces. Such uncontrolled flow can make the final position of the droplet nondeterministic. This problem is exacerbated in the case of larger droplets of nanoliter size (e.g., 10 nanoliters in volume), because the ratio of volume to surface area is significantly higher for nanoliter-sized ink droplets compared to picoliter-sized droplets, which have a volume of approximately 1 / 1000, and the ratio of droplet volume to contact area of ​​the attached droplet is also higher. As a result, the inventors have found that the effectiveness of various surface-based fixing means (e.g., adhesive underlayers) may be limited, and the deposition of such nanoliter-sized droplets can generate discontinuous or at least non-uniform wetted layers, resulting in bald spots, cloudiness, uneven thickness, uneven optical density, and other optical defects in the finished product.

[0020] Rotation, spinning, and other methods have been considered to generate a smooth and uniform wet layer. However, the inventors have found that such methods cannot address various technical challenges, and that they themselves may have significant technical drawbacks, especially within the framework of an industrial environment.

[0021] Therefore, it is highly desirable to produce a thin, continuous, and smooth moist layer of ophthalmic quality without employing these methods. For the colored layer and coating, it is even more desirable that the optical density be uniform, at least to the point of being distinguishable to the naked eye.

[0022] It should be understood that, in the case of highly curved lens surfaces (e.g., base curve 4, base curve 6, or higher), especially with large lens diameters, the problem of uncontrollable flow becomes even more severe.

[0023] In addition, the inventors have further discovered that the possibility of optical defects in the finished product can become even more pronounced in the manufacture of ultrathin optical coatings (e.g., dry thickness of up to 2 μm, up to 1.6 μm, or up to 1.2 μm).

[0024] While we do not wish to be bound by theory, the inventors believe that by achieving the conditions for "controlled flow" of ink on an optical surface, continuous, relatively smooth, and uniform layers of photochromic dye-containing ink on an optical surface (more specifically, curved optical surfaces such as spectacle lenses) can be achieved by microvalve ejection. When photochromic ink droplets are microvalve ejected onto an optical surface without the use of fixing means (e.g., when the solvent is mainly a low-evaporation-rate solvent), the applied photochromic dye-containing ink may flow undesirably in a substantially uncontrollable manner, resulting in at least one of the following: flooding, bald spots, coffee ring effect, uneven layer thickness, and uneven color intensity within the layer. Furthermore, covering the entire surface of the substrate with ink droplets can obviously exacerbate the flooding phenomenon. However, when ink droplets are rapidly and strongly fixed onto the optical surface (e.g., when the solvent is mainly a very high-evaporation-rate solvent), the dye-containing layer may not be continuous, or even if continuous, it may lack the smoothness and uniformity required for optical and ophthalmic layers and coatings.

[0025] The inventors have found that by balancing the solvent system with a specific mixture of solvents with relatively low evaporation rates and solvents with relatively high evaporation rates, a degree of controlled flow can be achieved, and surprisingly, a layer with the smoothness and uniformity required for photochromic optical and ophthalmic layers or coatings can be obtained.

[0026] In this specification, methods and systems for achieving such controlled flow velocities are described below.

[0027] As schematically shown in Figure 1, the method of the present invention includes forming a wet layer (step 102) by discharging droplets of a liquid photochromic dye-containing formulation onto the optical surface of an optical substrate using a microvalve (i.e., spraying through a microvalve).

[0028] Microvalve dispensing of photochromic formulations onto optical / ophthalmic substrates can be performed using various microvalve dispensing technologies, all of which utilize microvalves.

[0029] Microvalves may be components within a microvalve system, and several microvalves can preferably be used in parallel to improve throughput.

[0030] Typically, microvalve dispensing of photochromatic formulations is performed according to a predetermined pattern, such as a predetermined digital pattern.

[0031] In some embodiments, the microvalve is piezoelectrically operated (for example, using Nordson Pulse Jet Valve, Vermes MDS1560 series, or Techcon 9800 series).

[0032] In some embodiments, the microvalve is electromagnetically actuated (e.g., using a solenoid valve). The fluid or dispersion flows directly through the microvalve. When an electric current is applied through the valve coil, a movable anchor attached to the valve ball is magnetically attracted by the magnetic field of a stationary anchor. The microvalve opens, and a portion of the medium is discharged. When no electric current is applied, a closing spring acts on the movable anchor associated with the valve ball, keeping the microvalve closed.

[0033] Exemplary microvalves of this type are manufactured by Fritz Gyger AG and Lee Company.

[0034] In some embodiments, the microvalve is electro-pneumatically operated. An exemplary microvalve of this type is the Liquidyn® P-Jet series manufactured by Nordson.

[0035] In some embodiments, the optical surface is a curved optical surface, such as a curved lens surface.

[0036] In some embodiments, the optical surface is a polymer surface.

[0037] In some embodiments, the optical substrate is an ophthalmic substrate, and the optical surface is an ophthalmic surface.

[0038] In some embodiments, the ophthalmic substrate is a prescription lens, such as an eyeglass lens.

[0039] As used herein, the term “ophthalmic substrate” refers to a substrate used for viewing through the human eye. An ophthalmic substrate is a component of an ophthalmic instrument or system, or an ophthalmic component of such an instrument or system. Generally, an ophthalmic substrate is a lens, and an ophthalmic surface is the surface of a lens.

[0040] More generally, when the term “ophthalmic” is used herein to modify components such as “substrate,” “surface,” “structure,” “construction,” “apparatus,” “device,” and “system,” it means “that, by its nature, it is possible for the human eye to see an object effectively through it.” Coated lenses are a typical example of ophthalmic instruments, but as will be obvious to those skilled in the art, other uses include, for example, helmets with clear visors.

[0041] An ophthalmic structure may consist of, or include, an ophthalmic component of such an ophthalmic instrument or ophthalmic system.

[0042] With respect to the wetted layer of a photochromic ink, at least one of the wetted layer thickness TH, characteristic thickness THc, and average thickness THav (and generally any two or all three of TH, THc, and THav) is at most 100 micrometers (μm), or at most 80 μm, and more commonly at most 70 μm, 60 μm, or 50 μm.

[0043] Typically, at least one of TH, THc, and THav (and generally any two or all three of TH, THc, and THv) is at least 10 μm, at least 14 μm, at least 18 μm, at least 25 μm, at least 30 μm, at least 40 μm, or at least 45 μm.

[0044] The method may further include processing the wetted layer to produce a dry photochromic dye-containing layer on the optical surface (step 104). This process includes drying and / or curing the wetted layer. The preferred curing method may be determined mainly by the properties of the formulation.

[0045] Therefore, in some embodiments, drying / curing (film formation) is effective insofar as, or solely by, drying (solvent evaporation), for example, when the polymer is dissolved (e.g., vinyl ester resin or alkyd resin in an organic solvent), dispersed (e.g., an aqueous dispersion such as PUD), or in the form of an emulsion (e.g., a styrene-acrylic emulsion polymer). Such drying is usually carried out at high temperatures ("thermal drying").

[0046] In some embodiments, drying / curing is performed by chemical drying / curing (e.g., polymerization from prepolymers (monomers and oligomers), crosslinking of polymers, oxidative chemical curing using ambient oxygen, cation or radical curing using ultraviolet light, oxidative chemical curing using ambient oxygen, dehydration chemical curing using ambient humidity).

[0047] In some embodiments, chemical drying / curing is curing by chemical rays, i.e., electromagnetic rays (e.g., ultraviolet rays, electron beams, infrared rays, and microwaves) that can initiate a chemical reaction, or includes such curing.

[0048] The drying / curing of the wetted layer can be advantageously performed to achieve a "fully cured" layer or coating. The inventors have found that a partially cured layer can cause solvent erosion, migration, mixing, etc., from adjacent layers in the stack or subsequently applied layers. These phenomena can significantly impair optical quality.

[0049] Furthermore, particularly with respect to solvent erosion, the penetration of solvents from later-applied layers can impair adhesion at the interfaces between these layers, between two previously applied layers, or between a previously applied layer and the base. Therefore, complete curing of the wetted layer can be crucial in producing an optical stack or structure with desirable optical and mechanical properties.

[0050] Importantly, the inventors have found that a solvent system containing both high-evaporation-rate and low-evaporation-rate solvents can significantly mitigate solvent turbidity, even when it cannot be completely avoided.

[0051] Further methods for producing high-quality optical stacks will become clear from the following explanation.

[0052] As used herein and in the following claims, the terms “SAGITTA” or “SAG” refer to the convex or concave curvature of an optical substrate, representing the physical distance between a vertex (the point of highest 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 to the other of the optical substrate. SAG may be measured or determined according to the following established formula: In the formula JPEG2026533961000001.jpg32159, R is the radius of curvature of the optical surface, and D is the diameter of the optical surface.

[0053] 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, at least 5 mm, or at least 6 mm.

[0054] Generally, the SAG number of optical substrates is a maximum of 15 mm, a maximum of 13.5 mm, a maximum of 12 mm, or a maximum of 10.5 mm.

[0055] The base curve of the optical substrate may be at least 2, at least 3, at least 4, at least 5, at least 6, or at least 8.

[0056] The base curve may be up to 14, and more commonly, up to 12 or up to 10. At high base curves and SAG numbers, ink flow on the optical surface can become uncontrollable to the extent that it impairs the optical quality of the layer or coating.

[0057] As used herein, the term “base curve” refers to a theoretical base curve, or “true curve.”

[0058] Similarly, uncontrollable flow phenomena can also correlate with the lens angle α (described in more detail below). The method of the present invention is generally suitable for controlling the flow velocity on the lens for α up to 37°, up to 42°, or even up to 50°.

[0059] In some embodiments, the photochromic ink formulation may include a resin, a photochromic dye, and a solvent system comprising an ultra-low vapor pressure solvent (LLevap) and at least one of a low vapor pressure solvent (Levap), a medium vapor pressure solvent (Mevap), a high vapor pressure solvent (Hevap), and an ultra-high vapor pressure solvent (HHevap), in which case the resin and the photochromic dye are dissolved in the solvent system.

[0060] Softeners include liquid softeners. Typically, liquid softeners are, contain, or are essentially non-volatile liquid softeners.

[0061] In some embodiments, the softener further comprises a solid softener, such as a solid polymer softener.

[0062] In some embodiments, the ink formulation is an ophthalmic formulation.

[0063] In some embodiments, the ink formulation is suitable for forming an ophthalmic film on an ophthalmic substrate.

[0064] In some embodiments, the resin is an ophthalmic film-forming resin.

[0065] In some embodiments, the non-volatile content of the ink formulation is in the range of 2.5 to 15%.

[0066] In some embodiments, the first solvent weight ratio of Hevap, HHevap, and LLevap relative to the total amount of solvent T in the ink formulation, (Hevap+HHevap+LLevap) / Ts It is at least 0.6, 0.65, or 0.7.

[0067] In some embodiments, Hevap and HHevap total T H+HH The relative solvent weight ratio (RWSR) of LLevap to , LLevap / T H+HH The ratio is at least 0.15:1.

[0068] In some embodiments, the ink formulation is a solvent-type or organic ink formulation, and the solvent system is an organic solvent system. The organic solvent system may advantageously contain a low vapor pressure solvent (Levap) and / or an ultra-low vapor pressure solvent (LLevap) that form a single organic phase.

[0069] In some embodiments, the organic solvent system may further contain one or more high vapor pressure solvents (Mevap and / or Hevap and / or HHevap), and the additional(s) high vapor pressure solvents may form a single phase in the organic solvent system together with the Levap and LLevap solvents(s).

[0070] As used herein and in the claims, the term “maximum high vapor pressure (Hevap) solvent” means that solvents with an evaporation rate faster than Hevap (in this case, HHevap) are excluded.

[0071] Similarly, the term "solvents with a maximum medium vapor pressure (Mevap)" means that solvents with a faster evaporation rate than Mevap (in this case, HHevap and Hevap) are excluded.

[0072] Similarly, the term "solvents with at least a medium vapor pressure (Mevap)" means that solvents with a slower evaporation rate than Mevap (in this case, Llevap and Levap) are excluded.

[0073] More specifically, volatile liquids are classified into the following five categories: LLevap < 0.1 (e.g., TPM, DPM, EB, NMP, DMSO, ethylene glycol monobutyl ether, DPM acetate).

[0074] 0.1 ≤ Levap < 0.5 (e.g., EEP, EP, PP, PMA, n-butyl propionate, n-butanol, amyl acetate, water).

[0075] 0.5 ≤ Mevap < 0.85 (e.g., PM, isobutanol).

[0076] 0.85 ≤ Hevap < 1.8 (e.g., xylene, n-butyl acetate, isobutyl acetate, methyl isobutyl ketone, isopropanol, ethanol).

[0077] 1.8 ≤ HHevap (e.g., toluene, methanol, n-propyl acetate, isopropyl acetate, ethyl acetate, methyl propyl ketone, methyl ethyl ketone).

[0078] The designated standard material, n-butyl acetate, is assigned a vaporization rate or evaporation rate of 1.0. Therefore, terms such as "relative evaporation rate" are used in relation to n-butyl acetate.

[0079] Referring to Figure 2, Figure 2 shows a schematic block diagram of a process for processing the optical surface of an optical substrate (generally a lens blank such as a curved lens blank) to produce a dried hard coat layer, according to an aspect of the present invention. The lens blanks provided to the process may or may not have a protective hard coat attached.

[0080] Before applying the wetted photochromic layer to the optical surface of the optical substrate, the optical surface may be subjected to an optional pretreatment step 205.

[0081] Within the pretreatment step 205, the lens blank / optical substrate may be subjected to surface treatment before applying the wet photochromic layer (optional step 206). Such surface treatment may include washing in water or an aqueous cleaning solution, followed optionally by drying (optional step 207).

[0082] In some embodiments, surface preparation of the lens surface includes an etching process.

[0083] In some embodiments, the etching process includes laser etching.

[0084] In some embodiments, the etching process includes chemical etching.

[0085] Before applying the photochromic compound, the lens blank may be subjected to at least one surface treatment (optional step 208), for example, an energy treatment that increases the surface energy of the optical surface.

[0086] In some embodiments, this energy treatment includes corona treatment.

[0087] In some embodiments, this energy treatment includes plasma treatment.

[0088] In some embodiments, this energy treatment includes electron beam treatment.

[0089] In some embodiments, this energy treatment includes electromagnetic (e.g., chemical beam) irradiation.

[0090] In some embodiments, this energy treatment is a discharge treatment.

[0091] Figure 3 shows optional steps of the schematic block diagram of Figure 2, where surface treatment or pretreatment (e.g., optional step 208) includes applying a liquid primer formulation to the exposed (lens) surface of the ophthalmic substrate to form a wet primer layer or coating. The wet primer layer or coating is then dried or otherwise cured (e.g., in step 210) to obtain a dried primer layer or coating. Exemplary treatments include oven drying, microwave, and IR.

[0092] Drying / curing of the wet primer layer formulation may be carried out by conventional curing means for forming a cured primer layer (as described above with respect to step 104). The curing of the wet primer layer may be carried out conveniently to achieve a “fully cured” primer layer.

[0093] The liquid primer formulation may be applied using various conventional techniques such as spin coating, slit coating, and dip coating (each of which has various technical drawbacks).

[0094] In some embodiments, most typically, the primer is micro-valve-dispensed onto the exposed surface of the ophthalmic substrate, as described in more detail below.

[0095] In some embodiments, primer pretreatment is intended to facilitate wetting of the photochromic layer to the lens surface.

[0096] In some embodiments, pretreatment with a primer is intended to facilitate the adhesion of the photochromic layer to the lens surface.

[0097] In some embodiments, the primer is a polymer primer.

[0098] In some embodiments, the polymer primer is in the form of an aqueous emulsion (e.g., an acrylic emulsion).

[0099] In some embodiments, the polymer primer is in the form of an aqueous dispersion (e.g., a polyurethane dispersion).

[0100] In some embodiments, the polymer primer is or comprises UV-curable materials such as UV-curable oligomers, epoxy acrylates, polyester acrylates, and urethane acrylates.

[0101] In some embodiments, the polymer primer is in the form of a solution (e.g., a polyurethane resin solution).

[0102] In some of these embodiments, the thickness and / or average thickness of the wet primer layer is at least 0.5 μm, at least 0.8 μm, at least 1 μm, at least 1.5 μm, at least 2 μm, at least 3 μm, at least 5 μm, or at least 7 μm.

[0103] In some of these embodiments, the thickness and / or average thickness of the wet primer layer is up to 80 μm, up to 60 μm, up to 40 μm, and more commonly, up to 25 μm, up to 20 μm, or up to 15 μm.

[0104] In some embodiments, the method includes subjecting the upper / exposed surface of the fully cured primer layer to such energy treatment (e.g., corona, plasma, or chemical radiation treatment) after step 210 and before the photochromic dye formulation is microvalve-dispensed.

[0105] In some embodiments of these energy treatments, the energy treatment increases the surface energy of the target surface of the optical substrate by at least 2, 3, 5, 8, or 12 millinewtons / meter (mN / m).

[0106] In some of these embodiments, the energy treatment increases the surface energy of the target surface by up to 40, up to 30, up to 20, up to 17, or up to 14 mN / m.

[0107] Referring again to Figure 2, following an optional pretreatment step 205, the method generally includes microvalving droplets of a liquid photochromic dye formulation onto an optional pretreated lens blank / optical substrate via a microvalve (step 224).

[0108] As schematically shown in Figures 4A and 4B, a microvalve device may be used to spray ink droplets onto surfaces with different contours, including a convex lens surface (Figure 4A) and a concave lens surface (Figure 4B).

[0109] In some embodiments, the liquid photochromic dye formulation is directly dispensed onto the surface of the lens / lens blank / optical substrate using a microvalve.

[0110] In some embodiments, a liquid photochromic dye formulation is micro-discharged onto a primer layer, for example, a primer layer coated with an optional surface treatment 208.

[0111] In some embodiments, the photochromic ink formulation contains at least one photochromic dye.

[0112] In some embodiments, the photochromic ink formulation lacks pigment.

[0113] In some embodiments, the photochromic ink formulation lacks a photochromic pigment.

[0114] In some embodiments, the photochromic ink formulation includes at least one polymer resin (for example, as a binder).

[0115] In some embodiments, the resulting photochromic ink layer may be dried or cured (step 226) to produce a dried and cured photochromic ink layer.

[0116] The drying / curing of the photochromic ink may be carried out by conventional curing means for forming a cured photochromic layer (as described above with respect to steps 104 and 210). The curing of the photochromic ink layer may be conveniently carried out to achieve a “fully cured” primer layer.

[0117] In some embodiments, the photochromic dye-containing layer, after complete drying and curing, is in the range of 0.6-30 μm or 1-20 μm, more generally 1.2-20 μm, 1.5-20 μm, 1.5-15 μm, 1.5-12 μm, 1.5-10 μm, 1.5-8 μm, 1.5-6 μm, 1.5-5 μm, 1.5-4 μm, 2-25 μm, 2-15 μm, 2-1 It has a thickness or average thickness within the range of 2 μm, 2-10 μm, 2-8 μm, 2-6 μm, 2.5-20 μm, 2.5-15 μm, 2.5-12 μm, 2.5-8 μm, 2.5-6 μm, 1.5-5 μm, 3-20 μm, 3-15 μm, 3-8 μm, 3-6 μm, 3.5-20 μm, 3.5-12 μm, 3.5-10 μm, 3.5-8 μm, or 3.5-6 μm.

[0118] In some embodiments, steps 224 and 226 are repeated at least once or twice using the same photochromic ink or one or more different photochromic inks (for example, having different colors).

[0119] In some embodiments, an additional non-photochromic ink layer may be applied and dried or cured following steps 224 and 226 (as described herein, for example, with respect to step 104).

[0120] In some embodiments, the additional ink formulation contains at least one dissolved pigment (e.g., a dye).

[0121] In some embodiments, the additional ink formulation is a solvent-type formulation.

[0122] The inventors have found that various hard coat formulations may dissolve or erode the colorant-containing ink layer, more specifically, the photochromic pigment-containing layer formed and cured in steps 224 and 226. However, the inventors have further found that such erosion can be suppressed or significantly reduced by applying an overcoat layer over the colorant-containing ink layer (step 228) and drying / curing it as necessary (step 230).

[0123] In some embodiments, the method includes, following step 226, applying an energy treatment (e.g., one of the energy treatments described above) to the top / exposed surface of the cured or fully cured photochromic layer before applying the overcoat formulation (step 228). This can significantly improve the adhesion between the fully cured photochromic layer and the overcoat layer.

[0124] In some embodiments, the first overcoat layer as a wet layer has a thickness or average thickness in the range of 6-100 μm, 6-80 μm, 6-60 μm, or 6-50 μm.

[0125] In some of these embodiments, the layer has a thickness or average thickness of at least 8 μm, at least 12 μm, at least 20 μm, at least 30 μm, or at least 40 μm.

[0126] In some embodiments, the first overcoat layer, as a dry layer, has a thickness or average thickness in the range of 3 to 15 μm.

[0127] In some of these embodiments, this dry thickness or average thickness is at least 4 μm, at least 5.5 μm, at least 6.5 μm, or at least 7.5 μm.

[0128] In some of these embodiments, this dry thickness or average thickness is up to 13.5 μm, up to 12 μm, up to 11 μm, or up to 10 μm.

[0129] In some embodiments, the material of the dried or fully cured overcoat layer has a König hardness of at least 80 (sec). More generally, the König hardness is in the range of 80-180, 80-160, 90-180, 100-160, 100-150, 100-140, 110-180, 110-160, or 110-150.

[0130] In some embodiments, the first overcoat layer is a thermoplastic polymer or comprises a thermoplastic polymer.

[0131] In some embodiments, the first overcoat layer is a thermosetting polymer or comprises a thermosetting polymer.

[0132] In some embodiments, the first overcoat formulation is a polymer emulsion.

[0133] In some embodiments, the first overcoat formulation is a polymer dispersion.

[0134] In some embodiments, the first overcoat formulation is a polymer solution.

[0135] In some embodiments, the first overcoat formulation includes an acrylic polymer.

[0136] In some embodiments, the first overcoat formulation includes polyurethane.

[0137] In some embodiments, the first overcoat formulation includes a polyvinyl ester resin such as polyvinyl butyral and polyvinylpyrrolidone vinyl acetate copolymer.

[0138] In some embodiments, the first overcoat formulation includes an epoxy resin.

[0139] In some embodiments, the material of the fully cured overcoat layer contains, primarily contains, or consists of one of the above polymers.

[0140] In some embodiments, the PVB-based overcoat formulation may be a PVB-containing aqueous dispersion, as disclosed in, for example, EP3587106 (e.g., Example 1A).

[0141] In some embodiments, the method further includes applying a second or additional overcoat layer on top of the dried first overcoat layer, following drying / curing of the overcoat layer (step 230).

[0142] In some embodiments, the method further includes drying / curing a second or additional overcoat layer.

[0143] In some embodiments, a dried second or additional overcoat layer may exhibit increased hardness relative to the dried first overcoat layer.

[0144] In some embodiments, a dried second or additional overcoat layer may exhibit a lower increase in the coefficient of linear thermal expansion (CTE) compared to the dried first overcoat layer.

[0145] In some embodiments, the method further includes, after curing (step 226 or 228), applying a liquid (film-forming) hard coat ("first hard coat" or "inner hard coat") formulation to the exposed optical or ophthalmic surface of an optical or ophthalmic substrate to form a wet hard coat layer (step 232). Subsequently, the wet layer may be treated to produce a dry, usually transparent hard coat layer on the optical surface (step 234).

[0146] In some embodiments, the method includes, following step 226 or 230, and before applying the hard coat formulation (step 232), applying an energy treatment (e.g., one of the energy treatments described above) to the top / exposed surface of the cured or fully cured photochromic layer or overcoat layer, respectively. This can significantly improve adhesion between the fully cured underlayer and the hard coat layer.

[0147] In some embodiments, the (first) liquid hard coat formulation is applied by micro-valve dispensing the formulation onto the exposed surface of the ophthalmic substrate.

[0148] In some embodiments, the method further comprises applying a second liquid (film-forming) hard coat ("second hard coat" or "outer hard coat") formulation to an exposed optical or ophthalmic surface of an optical or ophthalmic substrate after the first hard coat layer has cured to form a second wet hard coat layer. Following this optional step, the wet layer may be treated to produce a dry, typically transparent, second hard coat layer on the optical surface.

[0149] In some embodiments, the (second) liquid hard coat formulation is applied by micro-valve dispensing the formulation onto the exposed surface of the ophthalmic substrate.

[0150] In some embodiments, the hard coat formulation substrate comprises one or more acrylates, methacrylates, etc., some of which are listed below without exhaustion: hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxybutyl acrylate, hydroxypoly(alkyleneoxy)alkyl acrylate, caprolactone acrylate, ethylene glycol diacrylate, butanediol diacrylate, hexanediol diacrylate, hexamethylene diacrylate, diethylene glycol diacrylate, and triethylene glycol diacrylate.

[0151] UV catalysts for initiating photopolymerization may include, for example, any of the following materials: benzyl, benzoin, benzoin methyl ether, benzoin isobutyl ether, benzophenol, acetophenone, benzophenone, or mixtures thereof. Those skilled in the art will readily understand that other suitable UV catalysts may be used.

[0152] In some embodiments, the ophthalmic hard coat formulation is based on sol-gel monomers and oligomers.

[0153] In some embodiments, the coating composition used in combination with the present invention comprises an aqueous organic solvent mixture containing a mixture of hydrolysis products and partial condensates of epoxy-functional silanes and tetrafunctional silanes in an amount of about 10 to about 99.9 weight percent based on the total solids content of the composition, and a crosslinkable polyfunctional compound selected from the group consisting of crosslinkable polyfunctional carboxylic acids, crosslinkable polyfunctional anhydrides, and combinations thereof in an amount of about 0.1 to about 30 weight percent based on the total solids content of the composition.

[0154] Hard coat coating compositions are well known to those skilled in the art. For example, thermosetting coating technologies are disclosed in various U.S. patents, including U.S. Patents No. 4,547,397, No. 5,385,955, and No. 6,538,092, and radiation-curable coatings are disclosed in U.S. Patents No. 4,478,876 and No. 5,409,965.

[0155] Referring again to Figure 2, when two or more hard coats are applied to a substrate, the outermost layer is usually the hardest. One or more inner layers of the hard coat may be somewhat flexible and may be adapted so that their physical properties (hardness, coefficient of thermal expansion, etc.) change gradually in order to impart improved mechanical properties to the layered stack. This can be particularly important when the stack includes one or more relatively flexible photochromic layers, as will be developed in more detail below. When applying a single hard coat layer, it should be emphasized that this layer is the “outer hard coat” or the “overcoat” in step 228.

[0156] In some embodiments, the outermost hard coat layer or coating as a wetted layer has a thickness or average thickness in the range of 1.5–40 μm, 2.5–40 μm, 4–40 μm, 6–40 μm, 4–25 μm, 6–25 μm, 4–15 μm, or 6–15 μm.

[0157] In some embodiments, at least one optional inner hard coat layer or coating as a wetted layer has a thickness or average thickness in the range of 1 to 25 μm, or in the range of 1.5 to 20 μm, more commonly in the range of 1.5 to 15 μm, 1.5 to 10 μm, 1.5 to 7 μm, 1.5 to 5 μm, 2 to 10 μm, 2 to 7 μm, or 3 to 7 μm.

[0158] The inner coating layer, after being completely dried, generally has a thickness in the range of 0.6–5 μm or 0.6–4 μm, more commonly in the range of 0.6–3.5 μm, 0.6–3 μm, 0.6–2.5 μm, 0.8–2.2 μm, 0.8–2.0 μm, 0.8–1.8 μm, 0.8–1.6 μm, or 1.0–1.5 μm.

[0159] In some embodiments, the hard coat formulation includes, for example, one or more types of nanoparticles to increase hardness or strength. Such nanoparticles may include boron nitride, B4C, cubic BC2N, silicon carbide, crystalline alpha alumina (sapphire), aluminum oxide, silicon oxide, tin oxide, zirconium oxide, and titanium oxide.

[0160] Following drying / curing step 230 or drying / curing step 232, the method may include applying a liquid (film-forming) post-hardcoat formulation to the optical or ophthalmic surface of an optical or ophthalmic substrate to form a wet layer. Subsequently, the wet layer may be treated to produce a dry (fully cured) transparent post-hardcoat layer on the optical surface. These steps are described above in general terms.

[0161] Such a post-hardcoat layer may include at least one of the following functions: • Moisture-resistant layer · Anti-reflection layer • Superhydrophobic / anti-fog layer · Super hydrophilic / anti-fog layer · Anti-glare layer · blue light

[0162] Those skilled in the art will understand that these post-hard coat formulations may be applied by microvalve ejection or inkjet ejection, or by conventional coating processes such as spin coating and dip coating, or, in the case of ultrathin layers, by PVD or CVD.

[0163] In several embodiments, the microvalve coating system includes a photochromic ink formulation application station, which includes a microvalve device configured to dispense droplets of the formulation onto a target surface of an optical substrate using a microvalve to form a wet layer of the photochromic ink formulation on the target surface; a drying and / or curing station configured to dry and / or cure the wet layer of the photochromic formulation on the target surface to form a dry coating; and an optical substrate transfer device, which is optionally, but generally, configured to transfer the optical substrate and the wet layer on its target surface from the photochromic ink formulation application station to the drying and / or curing station.

[0164] In some embodiments, the optical substrate transfer device includes at least one of a robotic arm, a gripper, a conveyor belt, and an elevator for raising or lowering the height of the optical substrate and the wet layer on its target surface.

[0165] In some embodiments, the microvalve coating system further includes a controller that controls an optical substrate transfer device so that the optical substrate is transferred in response to the detection of a wet layer being formed on the target surface of the optical substrate at the photochromic ink formulation application station.

[0166] In some embodiments, the drying and / or curing station includes at least one of a heat lamp and an oven.

[0167] In some embodiments, the drying and / or curing station includes an oven which (i) opens when an optical substrate having a wet layer on a target surface is transferred into a housing of the optical substrate having a wet layer on a target, and (ii) closes after the optical substrate has been transferred to the oven and remains closed during drying and / or curing.

[0168] In some embodiments, the system further comprises a primer application station for microvalve-dispensing droplets of primer formulation onto a target surface of the optical substrate before the optical substrate is subsequently transferred to a photochromic ink formulation application station.

[0169] In some embodiments, the microvalve device of the photochromic ink formulation dispensing station is configured to microvalve-dispense droplets of photochromic ink onto a target surface of an optical substrate.

[0170] In some embodiments, the microbulb coating system further comprises a surface treatment station for increasing the surface energy of the target surface of the optical substrate before applying a primer or photochromic ink formulation to the target surface using microbulbs.

[0171] In some embodiments, the microbulb coating system further comprises a cleaning station for subjecting the target surface of the optical substrate to a cleaning process before applying a primer or photochromic ink formulation to the target surface using microbulbs.

[0172] In some embodiments, the surface treatment station includes at least one of a corona treatment device and a plasma treatment device.

[0173] In some embodiments, the hard coating formulation dispensing station includes a hard coating formulation reservoir and is configured to dispense the hard coating formulation stored in the reservoir onto a target surface of an optical substrate using microvalves.

[0174] In some embodiments, the system does not include any dip coating apparatus.

[0175] In some embodiments, the system does not include any spin coating apparatus.

[0176] Figure 4 is a schematic cross-sectional view showing a component or structure 400 of a multilayer optical or ophthalmic instrument, the component or structure 400 including an optical substrate 402 or ophthalmic substrate 402, the substrate 402 having an optical structure 403 or ophthalmic structure 403 fixedly arranged on its broad surface 401. The structure 403 further includes a primer layer 440 disposed between the broad surface 401 and the photochromic layer 404. The thickness of the photochromic layer 404 is denoted as TPC, and the thickness of the primer layer 440 is denoted as Tp. An overcoat layer 406 may be placed on the photochromic layer 404, as fully described above. The thickness of the overcoat layer 406 is denoted as Tov. According to further features of the present invention, one or more hardcoat layers 420 may be placed on the overcoat layer 406. One or more post-hardcoat layers 430 may be placed on the hardcoat layer(s) 420 whose thickness is denoted as Th. The total thickness of the optical structure 403 is represented by Toc.

[0177] In some embodiments, Tp is in the range of 0.2 to 3 μm.

[0178] In some embodiments, Tp is at least 0.4, at least 0.6, or at least 0.8 μm.

[0179] In some embodiments, Tp is up to 2.5 μm, up to 2 μm, up to 1.6 μm, up to 1.3 μm, or up to 1.0 μm.

[0180] In some embodiments, T PC The size is within the range of 1 to 10 μm.

[0181] In some embodiments, T PC The range is 1.2 to 8 μm.

[0182] In some embodiments, T PC The thickness is at least 1.5, at least 1.8, at least 2.0, at least 2.5, or at least 3 μm.

[0183] In some embodiments, T PC The maximum thickness is 7 μm, 6 μm, 5 μm, 4.5 μm, or 4 μm.

[0184] In some embodiments, Tov is at least 4 μm, at least 6 μm, at least 7 μm, or at least 7.5 μm.

[0185] In some embodiments, Tov is up to 18 μm, up to 15 μm, up to 13 μm, up to 12 μm, or up to 11 μm.

[0186] In some embodiments, the fully cured hard coat layer has a local thickness Th-l and an average thickness Th-a of at least one of these, which is at least 1.2 μm, at least 1.5 μm, at least 1.8 μm, at least 2 μm, at least 2.5 μm, more generally at least 3 μm, or at least 3.5 μm.

[0187] In some embodiments, at least one of Th-l and Th-a is up to 8 μm, up to 6 μm, or up to 4.5 μm, up to 3.5 μm.

[0188] When applied directly onto an overcoat layer, a fully cured hard coat may have a thickness or average thickness in the range of 1.2–3.5 μm, 1.5–3.5 μm, or 1.8–3 μm. More commonly, the thickness or average thickness is up to 2.7 μm, up to 2.4 μm, up to 2.2 μm, or up to 2 μm.

[0189] In some embodiments, at least one of Th-l and Th-a is up to 8 μm, up to 6 μm, up to 4.5 μm, up to 3.5 μm, up to 3 μm, up to 2.7 μm, up to 2.4 μm, or up to 2.2 μm.

[0190] With respect to the overall thickness Toc of the optical structure 403, in some embodiments, the average thickness of the dried (cured) optical structure is in the range of 1-50 μm, 3-50 μm, 5-50 μm, or 8-50 μm.

[0191] In some embodiments, Toc is at least 10 μm, at least 12 μm, or at least 15 μm.

[0192] In some embodiments, Toc is up to 40 μm, up to 30 μm, up to 25 μm, up to 20 μm, or up to 16 μm.

[0193] Figure 5 schematically illustrates selected steps in a process of coating an optical or ophthalmic substrate (OS) 1100, such as a lens blank, using the coating system 1300.

[0194] Examples of OS1100 (for example, for applying one or more coatings using any teaching or combination of teachings disclosed herein) include, but are not limited to, (i) spectacle lenses, (ii) monofocal lenses, (iii) multifocal lenses, (iv) fatigue-reducing lenses (e.g., including single-vision prescriptions and lower-lens magnification boosts), (v) progressive lenses (e.g., designed to correct multiple viewing distances including far, intermediate, and near with a single lens), (vi) prism lenses, (vii) spherical lenses, and (viii) cylindrical lenses. Other examples of OS1110 include lenses for VR devices, including but not limited to virtual reality (VR) glasses or VR goggles.

[0195] Element 1110 schematically represents a target surface of an optical substrate 1100 coated with at least one dry layer, for example, multiple dry layers directly or indirectly stacked on top of each other. For example, the optical substrate (OS) 1110 may correspond to an optical or ophthalmic instrument, component, or structure 400 (for example, an uncoated or partially uncoated version thereof). For example, the target surface 1110 may correspond to surface 401, or to any other surface of any other layer in Figure 4.

[0196] For example, the target surface 1110 may correspond to an "outward-facing surface," that is, the surface of the eyeglass lens that faces away from the wearer of the eyeglasses.

[0197] The target surface 1110 may not be coated before being modified by the coating system 1300, or it may be pre-coated, for example, before "delivery". In contrast, the coated substrate OS 1100' has a coated version of the target surface 1110 (i.e., after the coating has been applied by the coating system 1300).

[0198] In several embodiments, the optical coating system 1300 may be employed to provide “customization” of optical articles (e.g., eyeglasses). For example, the optical coating system 1300 may be deployed, for example, in a factory or, for example, in a retail store where an optometrist is present. For example, the optical coating system 1300 may include, or communicate with, a digital computer (not shown) that stores and / or includes instructions for manufacturing customized optical products.

[0199] In one non-limiting use case, a customer with a specific eyeglass prescription may request, for example, any combination of one or more of the following: (i) a specific shade or target color (i.e., customizing the lenses to a specific color), and / or (ii) a specific physical property (e.g., wear resistance), and / or (iii) the presence or absence of photochromic functionality, and / or (iv) a desired gloss, and / or (v) the presence or absence of a desired varnish.

[0200] For example, the manufacturing of lens geometric shapes to meet specific optical formulations and / or shapes may optionally be carried out “off-site” at a location different from where the coating system 1300 is deployed.

[0201] Because the possible product combinations can be so diverse—including many types of lens shapes, multiple types of "color features" for coating the lenses, or the target color for coating the lenses, or the target digital pixel pattern of the lenses—maintaining inventory for "all possibilities" may not be practical.

[0202] Alternatively, it may be desirable to maintain a supply 1120 of multiple types of “raw material” substrates 1100 based on the lens shape. Thus, a particular workpiece such as OS 1100 may be selected from multiple candidates according to specified geometric properties, such as g-characteristics expressed as optical prescriptions, and can be optionally stored in a digital computer. The “input” OS 1100 may be selected by prioritizing the “preferred candidate” OS 1100 whose geometric properties best match the required lens shape and / or refractive index and / or multifocal indication and / or astigmatism indication and / or optical prescription data, and rejecting several other candidates.

[0203] Coated OS1100', such as eyeglass blanks or eyeglass lenses, can be cut and / or mounted within the lens cutting and / or eyeglass frame mounting device 1200.

[0204] In some embodiments, the OS1100 is rigid and has, for example, an average thickness of at least 0.5 mm, or at least 1 mm, or at least 2 mm, or at least 3 mm (or, alternatively, the thickness at at least one location of the OS1100).

[0205] As will be described later, various embodiments of the coating system 1300 apply one or more dry layers of a transparent material, a dry layer of a material, or multiple dry layers on or above the surface 1110 of the OS 1100.

[0206] Any combination of (A) operating parameters of the coating system 1300 and / or (B) physical and / or chemical properties of the material (e.g., viscosity and / or solids content and / or surface energy) used in any implementation or embodiment of the coating system 1300 may be such that the layer formed on or above the surface 1110 of OS 1100, i.e., the dry layer and / or transparent layer, has one or more specific properties.

[0207] Such properties include, but are not limited to, (i) the thickness of a particular dry transparent layer or the ratio between different transparent layers, (ii) the region in which a transparent layer or its convex underparts is continuous over the entire area of ​​the convex underparts, (iii) the color and / or optical density of any dry layer, and (iv) the mechanical properties of any dry layer or combination of layers. Accordingly, system 1300 may be manufactured on the surface 1110 of OS 1100 to obtain any properties or combinations of properties of the wet or dry layers disclosed herein.

[0208] As described later, the operating parameters of the coating system 1300 or one or more of its components (including, for example, components controllable by the controller 1250 (not shown in Figure 5)) are, but are not limited to, (i) parameters of droplets (or, as used herein, synonymously, "droplet") by microvalve ejection or inkjet ejection, e.g., droplet velocity, droplet deposition frequency, droplet size and / or volume, spacing between droplets, or other operating parameters for depositing droplets or droplets, droplet or droplet ejection speed, and the nozzle of the microvalve or inkjet device. (ii) the gap distance between the nozzle and the target surface 1110, (ii) drying time, drying temperature, or drying intensity or drying force, or other parameters related to drying the wet layer, e.g., oven temperature, parameters for convection drying and / or radiation drying, e.g., UV intensity, (iii) the relative motion between any nozzle for delivering a drop or droplet and the target surface 1110, (iv) properties related to the treatment of the surface 1110 of OS 1100, e.g., obtaining a desired surface energy or a specific range of energy, (v) the selection of a formulation from a plurality of candidates, or a container, cartridge or reservoir for the formulation, and / or mixing of the formulations, and ventilation operation parameters.

[0209] In different embodiments, the term “apparatus” may refer to a specific station (e.g., a drying station and / or a wet layer coating station for any wet layer). Thus, references to “apparatus” may also be interpreted as “station” (i.e., in embodiments of the present invention).

[0210] In various embodiments, the components of the optical coating system 1300 are configured and / or arranged to perform any of the methods described herein (for example, all steps or any combination of any steps (not all steps are required) to provide any feature or combination of features, as shown in Figures 1-3).

[0211] The resulting coating OS1100' may include any dry layer or combination of layers, or their features or combinations thereof, as taught in Figure 4 (not all layers are required), and the generated layers and their properties (e.g., within the framework of Figure 4) will depend on specific elements (and their operating parameters and formulations) of a particular implementation of the coating system 1300 (note that various versions of system 1300 are described herein).

[0212] Various examples and / or embodiments of the coating system 1300 and / or processes related to the coating system are schematically shown in Figures 6A-6C, 7A-7B, 8, 9, 10A-10C, and 11 as block diagrams and / or flow diagrams illustrating various systems and methods according to various embodiments of the present disclosure.

[0213] Figure 6A shows a block diagram of an exemplary coating system 1300A. The coating system 1300A may comprise one or more (or all) of the following: (i) a hard coating formulation applicator 1350 for applying a coating or layer of a hard coating formulation, for example by microvalve dispensing; (ii) a hard coat drying and / or curing apparatus 1370 for drying and / or curing a wet layer of the hard coat formulation; (iii) a selection and / or transfer apparatus 1330; and (iv) a controller 1250. In some embodiments, the hard coat formulation includes, for example, inks for coloring and / or photochromic coloring, and / or electrochromic inks. The wet layer may be "thin" and is characterized by having a thickness of up to 100, or 90, or 75, or 50, or 25, or 20, or 15, or 10 microns.

[0214] Figure 6B shows a block diagram of another exemplary coating system 1300B. The coating system 1300B may include one or more of the following: (i) a microvalve-based coating apparatus 1900 for coating the surface of an optical substrate 1100 to form one or more thin layers of a formulation by, for example, dispensing droplets onto the surface 1110 of the optical substrate 1100 by microvalve ejection (such thin layers may be characterized by having a thickness of up to 100 or 90 or 75 or 50 or 25 or 20 or 15 or 10 microns); (ii) a drying and / or curing apparatus 1910; (iii) a selection and / or transfer apparatus 1330; and (iv) a controller 1250. In one example, one or more wet layers applied by the microvalve-based coating apparatus 1900 are subjected to a drying and / or curing process by the drying and / or curing apparatus 1910. Examples of “compounds” that can be applied by the microvalve-based coating apparatus 1900 are: (i) hard coating compound that can be extruded by a microvalve to form a layer of hard coating compound; (ii) ink compound for forming a layer of ink compound (e.g., for coloring, or for photochromic and / or electrochromic inks); and (iii) surface energy increasing compound that can be extruded by a microvalve to form a layer of surface energy increasing compound, thereby increasing the surface energy of the target surface 1110 of the optical substrate 1100.

[0215] In an embodiment related to Figure 6B, the coating system 1300B (or its elements) provides one or more features: (i) a microvalve-based coating apparatus 1900 forms one or more continuous wet layers that can be laminated by microvalve ejecting droplets onto a target surface 1110 and drying the preceding layer; (ii) a microvalve-based coating apparatus 1900 forms a thin, continuous wet layer having a maximum thickness of 100, 90, 75, 50, 25, 20, 15, or 10 microns by microvalve ejecting droplets onto the target surface 1110; and (iii) a drying and / or curing apparatus 1910 converts the continuous wet layers into a continuous dry layer of one or more laminated layers.

[0216] Those skilled in the art will understand that the microvalve-based coating apparatus 1900 may deliver only one such layer, or may deliver multiple layers such that the layers are stacked on top of each other. For example, the first layer may be dried first by a drying and / or curing apparatus 1910, and then the second layer may be applied directly or indirectly on top of the first layer.

[0217] The exemplary coating system 1300C in Figure 6C is a specific example of the coating system 1300B in Figure 6B, in which multiple layers are laminated on the upper target surface 1110 of the optical substrate 1100. At least one of such layers is generated, for example, by microvalve ejection of droplets by a microvalve-based coating apparatus 1900 or 1920.

[0218] Please refer to Figure 7A. In the example in Figure 7A, the optical substrate 1100 is first treated with a surface energy increasing device 1310 to increase the surface energy of the target surface 1110, and then coated with a coating system 1300A or other coating systems 1300 disclosed herein, for example, by applying one or more layers using a hard coating formulation.

[0219] Figure 7B shows another example of a coating system in which the optical substrate 1100 is first treated by a surface energy increasing device and then coated by a hard coating formulation application device 1350 to apply a wet layer and / or coating of the hard coating formulation. This wet layer and / or coating of the hard coating formulation is then dried and / or cured by a hard coat drying and / or curing device 1370 to obtain the coated optical substrate 1100'. The system in Figure 7B may also include (i) a selection and / or transfer device 1330 and / or (ii) a controller 1250.

[0220] According to one embodiment, the coating system 1300 may include one or more of the following components:

[0221] One or more controllers 1250: For simplicity, various drawings show only a single controller 1250. The controller 1250 can adjust the operating parameters of any other elements of the coating system 1300, including (but not exhaustively) the microvalve device, drying device, inkjet device, transfer device, or any other device or combination, if present. The controller 1250 may be part of the coating system 1300 and / or located within the coating system 1300 or on any of its components and / or located separately and / or remotely. The controller 1250 may include any electrical and / or electronic components necessary to perform its function of controlling any component or combination of components.

[0222] In some embodiments of the present invention, any of the coating systems 1300 disclosed herein may include, for example, a data acquisition and / or monitoring device 1430, such as an imaging and / or inspection component. The controller 1250 may receive data directly or indirectly from such a data acquisition and / or monitoring device 1430.

[0223] The hard coat formulation application apparatus 1350 microvalves droplets of the hard coat formulation onto the target surface 1110 of the OS 1100 in order to generate a wet layer of the hard coat formulation on the surface 1110 from microvalve-dispensed droplets of the hard coat formulation. The hard coating apparatus 1350 can communicate with and / or load the hard coat formulation. In any embodiment of the coating system, the formulation, including but not limited to the hard coat formulation, can be placed in a cartridge or any other container or reservoir.

[0224] The hard coating formulation used by the hard coating apparatus 1350 may be any of the hard coating formulations disclosed herein, or any combination of the teachings. As disclosed above in this specification, the hard coating formulation used in a microvalve-based apparatus, such as the microvalve apparatus 1900, may optionally be an ink.

[0225] In various embodiments, the hard coating apparatus 1350 may be configured and / or controlled by the controller 1250 to produce a wetted layer of a hard coat formulation having specific properties. For example, the wetted layer may include a wetted layer of the hard coat formulation less than 100 μm thick. For example, the wetted layer may have a thickness of up to 90 microns, or up to 75 microns, or up to 50 microns, or up to 25 microns, or up to 20 microns, or up to 15 microns, or up to 10 microns. For example, the wetted layer may be continuous over at least a specific area (e.g., a convex region having a specific area of ​​at least 1 cm², or at least 2 cm², or at least 4 cm², or at least 8 cm²).

[0226] In various embodiments, the apparatus 1350 is configured to perform step 102 in Figure 1 and / or step 224 in Figure 2, for example, by the controller 1250 and / or by the properties of the formulation.

[0227] The hard coat drying and / or curing apparatus 1370 may be provided and configured to apply thermal energy to a wet layer of a hard coat formulation produced by the hard coat apparatus 1350 and having the thickness or other properties taught herein, thereby converting this wet layer of the hard coat formulation into a dry hard coat layer having the properties disclosed herein. In various embodiments, the hard coating apparatus 1350 is configured, for example, by a controller 1250 and / or by the properties of the formulation, to perform step 102 in Figure 1 and / or step 224 in Figure 2.

[0228] A selection and / or transfer device 1330 for selecting and / or providing relative motion of OS 1110 to any device and / or unit and / or station or component of 1300. This “relative motion” may, for example, move OS 1100 or a part thereof, and / or any device and / or component and / or station of coating system 1300 relative to OS 1100 by translational and / or rotational motion.

[0229] In different embodiments, the selection and / or transfer device 1330 may be at least partially controlled by the controller 1250 to achieve commands stored in a digital computer, such as target characteristics of a hard coating layer.

[0230] In various embodiments, the selection and / or transfer device 1330 may include one or more of a robotic arm, a gripper, a conveyor belt, and an elevator for raising or lowering the height of the optical substrate and the wet layer on its target surface.

[0231] The selection and / or transfer device 1330 may be configured to select OS 1110 from a plurality of candidates due to such relative motion between components of the coating system 1300 and / or according to instructions in computer storage and / or instructions read by a digital computer, such as optical instructions.

[0232] Microvalve-based coating apparatus 1900 or 1920: Any wet layer disclosed in the present specification may be applied by the microvalve apparatus 1900, and in a plurality of embodiments, this apparatus can be controlled by the controller 1250, for example, as in step 102 of FIG. 1. The operating parameters of 1900 may vary depending on the particular layer to be formed or the formulation from which this layer is to be produced. Accordingly, the apparatus 1900 may, in different embodiments, perform step 224 of FIG. 2, and / or 228 of FIG. 2, and / or 310 of FIG. 2A, and / or 324 of FIG. 3, and / or step 228 of FIG. 3.

[0233] The coating system may comprise a single instance of the microvalve apparatus 1900 or 1920 configured to operate according to a plurality of operating parameter sets, depending on the wet layer to be dried / converted into a dry layer.

[0234] Any dry layer disclosed or claimed in the present specification, for example, by any method or system disclosed in the present specification, for example, by step 104 of FIG. 1, steps 210 / 310 of FIG. 2 / 3, steps 226 / 326 of FIG. 2 / 3, steps 230 / 330 of FIG. 2 / 3, steps 234 / 334 of FIG. 2 / 4, and / or by elements 1370, 1910, 1420, 1530, element 1630, element 1650, or element 1670, may be considered continuous and / or thin in accordance with the terms defined in the present specification.

[0235] A "continuous" dry layer is a layer that is continuous over the entire hypothetical convex region, for example, as schematically shown in FIG. 12D, where region 1962, region 1966, and region 1968 are examples of convex regions, and region 1964 is a counterexample. In a plurality of examples, the area of the convex region of the target surface 1110 is, in different embodiments, at least 0.5 cm 2 , or at least 1 cm 2 , or at least 2 cm 2 , or at least 4 cm 2 , or at least 8 cm2 , or at least 10 cm 2 , or at least 20 cm 2 may be.

[0236] The boundaries of the region are not physical boundaries but "virtual" boundaries, therefore, the term "convex region" refers to the shape of these "virtual" boundaries, rather than the geometric properties of the physical topography of the target surface 1110 of the optical substrate 1100.

[0237] Therefore, as shown in FIGS. 12B and 12C, even if the surface 1100 is topographically completely concave as in FIG. 12C, it is possible to define a convex portion or a convex region within the topographically concave surface 1100 by the defined / virtual boundaries.

[0238] The thickness of the "thin" dry layer is at most 20 microns, or at most 15 microns, or at most 10 microns, or at most 5 microns, or at most 3 microns, or at most 1 micron.

[0239] In any of the embodiments disclosed herein, any "dry layer" formed from the "wet layer formed by droplets ejected by a microvalve" is at least 75% wt / wt, or at least 80% wt / wt, or at least 90% wt / wt derived from the microvalve droplets.

[0240] In any of the embodiments disclosed herein, any "dry layer" generated from the "wet layer formed mainly by droplets in the range of [r mm, s mm] (r and s are both positive numbers, and mm is millimeter)" is a dried (i.e., forming a precursor wet layer and then drying it) layer of which at least 75% wt / wt, or at least 80% wt / wt, or at least 90% wt / wt is derived from the droplets, and the width thereof is at least r mm and at most s mm. In different embodiments, any dry layer disclosed herein is mainly formed from droplets in the range of [0.1 mm, 3 mm].

[0241] In various embodiments, any dry layer disclosed herein is primarily formed from droplets in the range of [0.1mm, 2mm]. In different embodiments, any dry layer disclosed herein is primarily formed from droplets in the range of [0.1mm, 1.5mm]. In different embodiments, any dry layer disclosed herein is primarily formed from droplets in the range of [0.1mm, 1mm]. In different embodiments, any dry layer disclosed herein is primarily formed from droplets in the range of [0.01mm, 1mm]. In different embodiments, any dry layer disclosed herein is primarily formed from droplets in the range of [0.15mm, 3mm]. In different embodiments, any dry layer disclosed herein is primarily formed from droplets in the range of [0.2mm, 1mm].

[0242] Alternatively or additionally, multiple instances of 1900 or 1920 may be provided, each drying a different wet layer of the formulation and each operating according to different operating parameters.

[0243] (A) The drying and / or curing apparatus 1910 may, in different implementations, include an oven and / or UV apparatus, or other elements, for converting a wet layer of the formulation into a dry layer (optionally comprising a transparent layer). The operating parameters of the drying and / or curing apparatus 1910 depend on the particular formulation and its properties. For example, in the case of a hard coating formulation, the drying temperature and / or energy and / or the time required / used may exceed those required / used for a "primer formulation". Any coating system 1300 comprises a single 1910 or a plurality of drying and / or curing apparatuses 1910, the operating parameter(s) of which depend on the formulation and / or structure of the particular wet layer that is converted into a dry layer.

[0244] In various embodiments, the drying and / or curing apparatus 1910 may be configured to perform steps 104 in Figure 1, and / or 207 in Figure 2, and / or 210 in Figure 2, and / or 226 in Figure 2, and / or 230 in Figure 2, and / or 234 in Figure 2, and / or 320 in Figure 2A, and / or 307 in Figure 3, and / or 310 in Figure 3, and / or 326 in Figure 3, and / or 330 in Figure 3, and / or 334 in Figure 3.

[0245] (B) As shown in more detail in Figure 9, a surface energy enhancer 1310 can be provided to increase the surface energy of the target surface 1110 of the optical substrate 1100. In various embodiments, the surface energy enhancer 1310 operates to increase the surface energy of the target surface 1110 of the OS 1100 by at least 2 mN / m, or at least 3 mN / m, or at least 5 mN / m, or at least 8 mN / m, or at least 12 mN / m. Alternatively or further, the surface energy enhancer 1310 operates to increase the surface energy of the target surface 1110 of the OS 1100 by up to 40 mN / m, or up to 30 mN / m, or up to 20 mN / m, or up to 17 mN / m, or up to 14 mN / m. Figures 7C-7E show non-limiting examples of coating systems 1300 including the surface energy enhancer 1310. In different examples, as shown in the block diagram of Figure 9, the surface energy increasing apparatus 1310 includes a plasma processing apparatus 1501A and / or a corona processing apparatus 1510B and / or an electron beam apparatus 1510C and / or an electron discharge apparatus 1510D. Alternatively or further, the apparatus 1310 includes (i) a drop and / or droplet deposition apparatus 1520 (e.g., a microvalve or inkjet loaded with a suitable surface energy increasing formulation according to any of the teachings herein, or in fluid communication), and (ii) a drying and / or curing apparatus 1530 that operates at lower power and / or lower temperature and / or shorter duration than when drying a wet hard coating layer, for example, due to a wet layer of the surface energy increasing formulation. In various embodiments, the apparatus 1310 is configured to perform step 208 of Figure 2 and / or step 308 of Figure 3. Alternatively, or further, the apparatus 1520 (i.e., any instance thereof, if it exists) is configured to perform step 310 in Figure 2A.

[0246] (C) With respect to the microvalve coating apparatus 1490 and additional drying and / or curing apparatus 1420 in Figure 8, there may be multiple microvalve-based layer coating apparatuses. Similarly, there may be multiple drying apparatuses, as described elsewhere.

[0247] Furthermore, as shown in Figure 8, any coating system 1300 disclosed herein may include, in any combination, any of the following: (i) A cleaning apparatus 1440 may be provided for treating a target surface 1110 of an optical substrate 1100, for example, for surface cleaning. For example, the cleaning apparatus 1440 may be configured to apply a cleaning fluid and / or soap and / or surfactant to the target surface 1110 of the optical substrate 1100. For example, the cleaning apparatus 1440 may be configured to dry the applied cleaning fluid and / or subject the target surface 1110 to a dust removal process. For example, the cleaning apparatus 1440 can treat the target surface 1110 before subjecting the target surface 1110 to a surface energy increase process (for example, by apparatus 1310) or before subjecting the target surface 1110 to a coating by any of the coating apparatuses disclosed herein. (ii) For example, additional drying and / or curing apparatus(s) 1420 in addition to 1370 or 1910. For example, multiple wet coatings may be applied to the target surface 1110 of the optical substrate 1100. For example, a first wet coating or coating layer may be dried and / or cured by the first drying and / or curing apparatus(s) (e.g., 1370 or 1910), or a second wet coating or coating layer may be dried by element 1420. (iii) Ventilation device 1450, (iv) Housing 1442, (v) Microvalve-based additional layer coating apparatus(s) 1490 (as described above, there may be multiple microvalve-based layer coatings), and (vi) Selection and / or transfer device 1330 (e.g., for substrates and / or solvents and / or cartridges and / or other devices).

[0248] Figures 10A–10C and 11 schematically illustrate non-limiting examples of the operation of each exemplary coating system 1300, which includes one or more ovens for drying and / or curing a wet coating on an optical substrate 1100.

[0249] Figure 10A shows an exemplary operating process as follows: (i) A first microvalve device 1610 is provided to communicate with and / or load a surface energy increasing compound, in order to increase the surface energy of the target surface 1110 of the optical substrate 1100, thereby causing droplets ejected by the microvalve onto the surface 1110 to collectively form a wet coating of the surface energy increasing compound on the target surface 1110. (ii) In order to dry the wet coating delivered by the microvalve device 1610, a first oven 1630 is provided to carry out the drying process at a "low" temperature and / or for a short duration (i.e., a relatively "short" duration drying process): (iii) After drying the wet coating of the surface energy increasing formulation in the first oven 1630, a second microvalve device 1640 is provided to apply a second wet coating by microvalve dispensing droplets of the second formulation (e.g., hard coating) onto the target surface 1110, and (iv) A second oven 1650 is provided for drying and / or curing the wet coating of the second formulation.

[0250] The example in Figure 10B shows a setup including a single oven 1670, rather than multiple ovens. A first transfer of the optical substrate 1100 into the single oven 1670 is performed to dry / cure the wet coating from the microvalve device 1610. After the first drying / curing process, a first transfer is performed from the single oven 1670. A second transfer is performed into the single oven 1670 to dry or cure the wet coating from the second microvalve device 1640. The required movement of the substrate 1100 may be performed at least partially by the optical substrate transfer device 1602, and at least part of the movement may be performed automatically or robotically.

[0251] Figure 10C shows a third setup in which the coating is performed by an inkjet device 1690 instead of a microvalve device. The rest of the setup and process are the same as those shown in Figure 10A.

[0252] Figure 11 shows a fourth configuration, similar to that in Figure 7B, with the addition of an ink compounding device 1646 and an ink layer drying and / or curing device (or multiple devices) 1420.

[0253] Referring here to Figures 13A, 13B, 14, 15, and 16, Figure 13A shows a lateral cross-sectional view of a hypothetical two-dimensional projection 1800 of a curved surface 1110 of an exemplary optical substrate 1100, and Figure 13B shows an upward perspective view. In several embodiments, any one of the coating systems disclosed herein, including a controller 1250, may be configured to microvalve discharge at a constant density with respect to the volume of the formulation per unit area of ​​the two-dimensional projection 1800. As used herein, the term “constant density” may mean exactly constant, or it may mean an average value of “density,” i.e., within ±10%, ±5%, ±2%, or ±1% of the ratio of the volume of the formulation per unit area of ​​the two-dimensional projection to the entire two-dimensional projection. A constant density, or a density within a given range from the average value, can be measured in a small area of ​​the two-dimensional projection drawing, such as any portion of the two-dimensional projection drawing 1800 having an area of ​​5% or more of the area of ​​the projection drawing 1800.

[0254] The formulation to be applied may comprise one or more of the inks and / or coating formulations disclosed herein. In some embodiments, the formulation is selected particularly with respect to its physical properties that make it suitable for deposition on curved surfaces in the manner described herein.

[0255] The aforementioned term “configured” should be understood to include “programmed” and / or “programmable,” that is, the controller 1250 is programmed or programmable to control the microvalve device accordingly.

[0256] In some embodiments, the controller 1250 may be programmed to generate a two-dimensional projection 1800 and / or to calculate or select a target value and / or average value of the volume ratio of the formulation per unit area of ​​the two-dimensional projection 1800.

[0257] Figure 14 schematically shows how the microvalve device 1610 applies droplets 175 of the compound to a two-dimensional projection at a constant density. However, for clarity, it should be noted again that the two-dimensional projection is a hypothetical projection. The droplets 175 are actually applied to the curved surface 1100, but at a density determined by the area of ​​the two-dimensional projection 1800, or at an equivalent frequency. As can be understood from the schematicly shown shape, the surface area of ​​the curved surface 1110 is larger than that of the two-dimensional projection. Furthermore, in the case of a single-focus convex lens surface shown in the non-limiting examples of Figures 13A-14, the discrepancy between the area of ​​the curved surface 1110 and the area of ​​the two-dimensional projection 1800 is greater at the periphery of the optical substrate 1100 than at the center. As is known, the degree of discrepancy between the area of ​​the curved surface 1110 and the area of ​​the two-dimensional projection 1800 can be determined by the curve shape parameters of the curved surface, such as the sagittal plane 180 of the surface 1110, or the radius in the case of a spherical curve. Furthermore, the actual density, i.e., the amount of the mixture actually applied to the curved surface 1110 per unit area of ​​the actual curved surface 1110, is usually inversely proportional to the ratio of the area of ​​the curved surface 1110 to the area of ​​the two-dimensional projection, and this also applies to any part of the surface 1110.

[0258] Therefore, in some embodiments, when selecting or calculating the coating density, the formulation can be deposited in a manner or distribution suitable for a particular formulation and curve shape, without needing to consider the curve shape in the coating process. Furthermore, in some embodiments, the coating of the formulation can cover an area larger than the surface of the optical substrate without needing to consider other geometric parameters such as the diameter or shape of the optical substrate in the coating process.

[0259] FIG. 15 schematically shows an annular portion 1150 around an exemplary optical substrate 1100, which is useful for characterizing the deviation between the area of the curved surface 1110 of the optical substrate 1100 and the corresponding area of the two-dimensional projection view 1800, and is also useful for characterizing the actual density decrease on the actual curved surface 1110 as a function of the distance from the center. In this non-limiting example, the annular portion 1150 represents a region characterized by being located at 90% to 100% of the distance from the center of gravity of the optical substrate 1100 to the edge 1151. In an exemplary embodiment, the controller 1250 controls the microvalve ejection of the droplets 175 of the formulation, such that the average volume ratio of the formulation applied per unit area of the curved surface 1110 in the outer annular portion 1150, which is characterized by being located at a distance of 90% to 100% from the center of gravity of the curved surface 1110 and the periphery 1151, is usually 0.6 to 0.97 times, or 0.6 to 0.96 times, or 0.6 to 0.94 times the maximum value of the volume ratio of the formulation applied per unit area of the curved surface 1100.

[0260] Referring now to FIG. 16, a virtual tangent line 1111 (or plane) is drawn at a point (x, y) on the curved surface 1110 of the optical substrate 1110. The tangent line can be used to characterize the angle α of the curved surface 1110 relative to the horizontal plane, and to describe the local deviation between the region of the actual curved surface 1110 and the corresponding local portion of the virtual two-dimensional projection view 1800. In multiple embodiments, the angle α may be within 5° to 50°, or 10° to 40°, or 5° to 20°, or 20° to 50°, or any intervening range of 5° to 50°. In multiple embodiments, the microvalve ejection of the droplets 175 of the formulation is performed such that the average volume ratio of the formulation applied per unit area of the curved surface 1110 at a given point on the surface 1110 is equal to the maximum value of the volume ratio of the formulation applied per unit area at any point on the surface 1100 multiplied by a reduction factor, and the aforementioned reduction factor is equal to the cosine of the acute angle α formed between (i) the plane or line 1111 tangent to the curved surface 1110 at the aforementioned given point and (ii) the horizontal plane.

[0261] In this specification, horizontal planes refer to planes that are parallel to the floor, and tangential planes or angles refer to the plane or angle at which the optical substrate is at rest on a horizontal plane.

[0262] In the first embodiment, the optical substrate 1100, such as a lens blank, has a front surface characterized by a base curve of 6.00 diopters. The lens blank has a diameter of 60 mm and a SAG number of 5.25 mm. A virtual tangent line 1111 (or plane) drawn at a point on the edge of the curved surface 1110 forms an angle α of 19.9° with respect to the horizontal plane. The discrepancy between the area of ​​the curved surface 1110 and the area of ​​the two-dimensional projection 1800 is such that at a point on the periphery 1151 of the curved surface 1110, the area of ​​the curved surface 1110 is approximately 6.3% larger than that of the corresponding point on the two-dimensional projection 1800. The area of ​​the outer annular portion 1150, which is located at a distance of 90% to 100% from the centroid of the curved surface 1110 and the perimeter 1151, is 5.6% to 5.7% larger than the area of ​​the outer annular portion 1150, which is located at a distance of 0% to 10% from the centroid of the curved surface 1110 and the perimeter 1151, in proportion to the deviation rate from the corresponding inner region on the two-dimensional projection drawing 1800.

[0263] In the second embodiment, the optical substrate 1100, such as a lens blank, has a front surface characterized by a base curve of 4.00 diopters. The lens blank has a diameter of 80 mm and a SAG number of 6.2 mm. A virtual tangent line 1111 (or plane) drawn at a point on the edge of the curved surface 1110 forms an angle α of 17.6° with respect to the horizontal plane. The discrepancy between the area of ​​the curved surface 1110 and the area of ​​the two-dimensional projection 1800 is such that at a point on the periphery 1151 of the curved surface 1110, the area of ​​the curved surface 1110 is approximately 4.9% larger than that of the corresponding point on the two-dimensional projection 1800. The area of ​​the outer annular portion 1150, which is located at a distance of 90% to 100% from the centroid of the curved surface 1110 and the perimeter 1151, is 4.4% larger than the area of ​​the outer annular portion 1150, which is located at a distance of 0% to 10% from the centroid of the curved surface 1110 and the perimeter 1151, in proportion to the deviation rate from the corresponding inner region on the two-dimensional projection drawing 1800.

[0264] In the third embodiment, the optical substrate 1100, such as a lens blank, has a front surface characterized by a base curve of 10.00 diopters. The lens blank has a diameter of 70 mm and a SAG number of 13.2 mm. A virtual tangent line 1111 (or plane) drawn at a point on the edge of the curved surface 1110 forms an angle α of 41.3° with respect to the horizontal plane. The discrepancy between the area of ​​the curved surface 1110 and the area of ​​the two-dimensional projection 1800 is such that at a point on the periphery 1151 of the curved surface 1110, the area of ​​the curved surface 1110 is approximately 33.2% larger than that of the corresponding point on the two-dimensional projection 1800. The area of ​​the outer annular portion 1150, which is located at a distance of 90% to 100% from the centroid of the curved surface 1110 and the perimeter 1151, is 28.5 to 28.6% larger than the area of ​​the outer annular portion 1150, which is located at a distance of 0% to 10% from the centroid of the curved surface 1110 and the perimeter 1151, in proportion to the deviation rate of the inner region from the corresponding inner region on the two-dimensional projection drawing 1800.

[0265] In the fourth embodiment, the optical substrate 1100, such as a lens blank, has a front surface characterized by a base curve of 6.00 diopters. The lens blank has a diameter of 80 mm and a SAG number of 9.6 mm. A virtual tangent line 1111 (or plane) drawn at a point on the edge of the curved surface 1110 forms an angle α of 26.9° with respect to the horizontal plane. The discrepancy between the area of ​​the curved surface 1110 and the area of ​​the two-dimensional projection 1800 is such that at a point on the periphery 1151 of the curved surface 1110, the area of ​​the curved surface 1110 is approximately 12.2% larger than that of the corresponding point on the two-dimensional projection 1800. The area of ​​the outer annular portion 1150, which is located at a distance of 90% to 100% from the centroid of the curved surface 1110 and the perimeter 1151, is 10.8% larger than the area of ​​the outer annular portion 1150, which is located at a distance of 0% to 10% from the centroid of the curved surface 1110 and the perimeter 1151, in proportion to the deviation rate from the corresponding inner region on the two-dimensional projection drawing 1800.

[0266] In the fifth embodiment, the optical substrate 1100, such as a lens blank, has a front surface characterized by a base curve of 8.00 diopters. The lens blank has a diameter of 80 mm and a SAG number of 13.4 mm. A virtual tangent line 1111 (or plane) drawn at a point on the edge of the curved surface 1110 forms an angle α of 37.1° with respect to the horizontal plane. The discrepancy between the area of ​​the curved surface 1110 and the area of ​​the two-dimensional projection 1800 is such that at a point on the periphery 1151 of the curved surface 1110, the area of ​​the curved surface 1110 is approximately 25.4% larger than that of the corresponding point on the two-dimensional projection 1800. The area of ​​the outer annular portion 1150, which is located at a distance of 90% to 100% from the centroid of the curved surface 1110 and the perimeter 1151, is 22.1 to 22.2% larger than the area of ​​the outer annular portion 1150, which is located at a distance of 0% to 10% from the centroid of the curved surface 1110 and the perimeter 1151, in proportion to the deviation rate of the inner region from the corresponding inner region on the two-dimensional projection drawing 1800. [Examples]

[0267] The following examples will be discussed, but these examples, along with the above description, are intended to explain the present invention in a non-limiting manner.

[0268] material Lens materials • Polycarbonate, thermoplastic polymer • Trivex® (PPG), urethane-based thermosetting polymer • CR-39(registered trademark) (PPG), a thermosetting polymer made from allyl diglycol carbonate. Photochromic dyes (Powders, James Robinson Specialty Ingredients Ltd.): Reversacol Amazon Green Reversacol Midnight Gray Reversacol Leather Brown Reversacol Corn Yellow Reversacol Ocean Blue Liquid softener • Emoltene (trademark) 3GO (Perstorp): Triethylene glycol-mono-2-ethyl-hexanoate • Pevalen (Persorp): Pentaerythritol tetramethylamine (PETV) Jayflex (trademark) DIDP: Diisodecyl phthalate (Exxon Mobile) • Jayflex™ L9™: Trinonyl Trimelitate (Exxon Mobile) • Jayflex(trademark) MB10: Isodecyl benzoate (Exxon Mobile) DEHP: Di-2-ethylhexyl phthalate (Arkema) DEHTP: Di-2-ethylhexyl terephthalate (Arkema) • Palatinol N: Diisononyl phthalate (BASF) Palatinol 10-P: Di-2-propylheptyl phthalate (BASF) Paraplex(registered trademark) A-8000: Low molecular weight polyester adipate (Hallstar) Paraplex(registered trademark) A-8200: Intermediate molecular weight polyester adipate (Hallstar) thermoplastic resin o Pearlcoat (trademark) DIPP119: Aromatic polycaprolactone copolymer polyester thermoplastic polyurethane (TPU) (Lubrizol) o Pearlbond(trademark) 360: Polyether-based thermoplastic polyurethane (TPU) (Lubrizol) o Pearlstick (trademark) 47-60 Linear thermoplastic polyurethane elastomer (Lubrizol) o SETALUX(registered trademark) 2127XX-60: Thermoplastic acrylic resin (Alnex) with good adhesion to plastics. o Polyvinyl butyral (or PVB) (also for primer and overcoat) o Laropal A-81: Thermoplastic aldehyde resin (BASF) Primer and overcoat · Acrylic polymer emulsion: o Joncryl(registered trademark) 1532: A water-based acrylic emulsion (BASF) (primer) that exhibits excellent adhesion to various substrates such as plastics. o Joncryl(registered trademark) 1534: A water-based acrylic emulsion (BASF) (primer) that exhibits excellent adhesion to various substrates such as plastics. o Joncryl(registered trademark) 2110: Water-based acrylic emulsion, styrene acrylate copolymer (BASF) (primer) o Joncryl® 9530-A: A water-based acrylic emulsion self-crosslinking polymer (overcoat) designed for use as a topcoat and primer. o Joncryl(registered trademark) 617-A: A varnish formulation for overprinting that forms a water-based acrylic polymer emulsion film (BASF) (overcoat) o SETALUX(registered trademark) 17-7202: Acetacetate-functionalized acrylic resin (overcoat) combined with ketimine resin for primer (SETALUX(registered trademark) 10-1440) o SETALUX (registered trademark) 17-1246: A fast-drying thermoplastic acrylic resin solution (overcoat) that provides a superior balance of clarity, transparency, hardness, adhesion, and film toughness. · PU polymer emulsions and dispersions: o ALBERDINGK(registered trademark) APU10600: Self-crosslinking acrylic PES / PC-polyurethane hybrid dispersion (Alberdingk Boley) (overcoat) Bondthane® UD-620: A self-crosslinking polyurethane, ideally suited for hard, clear, or colored coatings (overcoats) on rigid plastics (BPI). CrystalCoat (registered trademark) PR670: Water-based emulsion (SDC) (primer) o ALBERDINGK(registered trademark) U9800: Solvent-free aliphatic polyester polyurethane dispersion (Alberdingk Boley) (overcoat) · Solvent-based solutions for resins: o Versamid(registered trademark) PUR1010: Primer o Laroflex(registered trademark) HS-9000: Primer Solvent: Ultra-low evaporation rate / ultra-low vapor pressure at 25°C • TPM (Tripropylene glycol methyl ether, CAS 25498-49-1) · PPH(Ph-O-CH2-CHMe-OH, CAS770-35-4) • DBA (2-(2-butoxyethoxy)ethyl acetate, CAS 124-17-4) • TPnB (Tripropylene glycol n-butyl ether, 55934-93-5) • DPnP (Dipropylene glycol propyl ether, Pr-O-[CH2-CHMe-O]2-H, CAS 29911-27-1) • Acetone glycerol (ALDRICH, 2,2-dimethyl-1,3-dioxolane-4-methanol, CAS 100-79-8) • Butylcarbitol (CAS 112-34-5) • EGBE (Ethylene Glycol Monobutyl Ether, CAS 111-76-2) Solvent: High evaporation rate / high vapor pressure at 25°C • n-butyl acetate Isobutyl acetate Methyl isobutyl ketone Isopropanol Ethanol Solvent: Ultra-high evaporation rate / high vapor pressure at 25°C • Ethyl acetate Methylpropyl ketone n-propyl acetate Isopropyl acetate Methyl ethyl ketone Device • Coating equipment o Inkjet printer: Ricoh gen4I mh2620 driven by a Dimatix Materials printer DMP-2831 (Fujifilm Dimatix® Inc.) equipped with a 10pL Dimatix Materials cartridge, GIS PMB C8 and hib-rh-384 (ink supply system: MeganaJet LabJet). o Microvalve: Electromagnetically operated (Fritz Gyger AG), nozzle diameter -0.1mm, pressure 0.5~2.0bar o Spin coater: MUTECH μCoater (Mutech Microsystems SAS) UV LED curing system: FJ100Gen2, 395nm, 12W / cm 2 (Phoseon Technology) o Thermosetting system: Venticell ECO forced-air oven (MMM) o Surface activation: Corona treatment device Electrical Surface Treatment HF SpotTEC Single (Tantec) • Test equipment o Spectrophotometer: Cary4000UV-Vis double-beam spectrophotometer, ISO / EN8980-3:2013 (Agilent) o Light transmittance and haze measuring instrument: TH-100, ASTM D1003 / D1044 (Hangzhou CHN Spec Technology Co.,Ltd.) o Thickness measurement: ThetaMetrisis layer thickness measuring device

[0269] Example 1: Corona surface treatment method The head of the corona treatment device (Tantec) was positioned 1 cm from the surface of the ophthalmic lens and operated for 10 seconds. This process was repeated twice, after which various coating materials were applied to the ophthalmic lens.

[0270] Example 2: Primer coating method using spin coating The ophthalmic lens was mounted on a vacuum chuck of a spin coating apparatus. The ophthalmic lens was rotated at a rotational speed of 3000 rpm and an acceleration of 1000 rpm / second for 10 seconds.

[0271] Example 3: Method for applying a post-hard coat layer using spin coating The ophthalmic lens was mounted in the vacuum chuck of the spin coating apparatus. The ophthalmic lens was rotated at a rotational speed of 1500 rpm and an acceleration of 500 rpm / second for 10 seconds.

[0272] Example 4: Optimization of inkjet parameters In various ink application steps, inkjet ink formulations may be used, and inkjet ejection may be optionally employed. A Ricoh printhead was used and typically preheated to 40°C. Next, the droplet characteristics of each ink were optimized using a Jet Expert stroboscope (Image Expert) attached to the printer (with the camera and light source synchronized with the ejection frequency). The waveform was optimized for each inkjet ink ejected at frequencies from 0.5 to 3 kHz. The distance between the printhead and the substrate was 0.6 to 1.0 mm. The resolution was set to 300 dots per inch (dpi).

[0273] Example 5: Microvalve dispensing of film-forming ink onto lens substrate An electromagnetically driven microvalve (Fritz Gyger AG) with a nozzle diameter of 0.1 mm was used to extrude film-forming ink onto a lens substrate, thereby preparing optical structures with at least one of various functions (primer, photochromic ink, overcoat, hardcoat, post-hardcoat coating, etc.). The microvalve was mounted on a controllable XYZ stage, and the operation of the microvalve and the positioning of the lens were synchronized using a PLC. Both the frequency and relative velocity between the stage and the microvalve were maintained at fixed values. Microvalve extrusion was performed according to one of several predetermined digital patterns.

[0274] Example 6A: Drying Unless otherwise specified, the primer, overcoat, and photochromic ink were typically dried at 60°C for 30 minutes.

[0275] Example 6B: Thermosetting The hard coat (inside, during use, and outside) was typically cured at 120°C for 3 hours.

[0276] Example 6C: UV curing UV LED curing system: FJ100Gen2, 395nm, 12W / cm 2 UV curing was performed for 10 seconds using (Phoseon Technology).

[0277] Example 7 In a 200 ml glass beaker equipped with a magnetic stirrer, 29 grams of DBA (2-(2-butoxyethoxy)ethyl acetate) solvent was mixed with 66.6 grams of propylene glycol methyl ether solvent. After mixing these components at room temperature for 5 minutes, 0.2 grams of surfactant BYK®-333 was added to the solvent mixture while mixing. Next, 2 grams of Reversacol Midnight Gray dye was added along with 2.2 grams of Pearlbond® 360 while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0278] Example 8 In a 200 ml glass beaker equipped with a magnetic stirrer, 22 grams of DBA solvent were mixed with 72.3 grams of DPnP solvent. After mixing these components for 5 minutes, 0.15 grams of surfactant BYK®-346 and 1.45 grams of Emoltene® 3GO were added to the solvent mixture while mixing. Next, 2 grams of Reversacol Amazon Green dye were added along with 2.1 grams of Mowital® B 30 HH resin while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0279] Example 9 17 grams of TPM solvent and 74.5 grams of DPnP solvent were mixed in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing these components at room temperature for 5 minutes, 0.25 grams of surfactant BYK®-346 and 1.85 grams of Emoltene® 3GO were added to the solvent mixture while mixing. Next, 2 grams of Reversacol Corn Yellow and 1.4 grams of Reversacol Ocean Blue dye were added along with 3 grams of Mowital® B 16 H resin while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0280] Example 10 In a 200 ml glass beaker equipped with a magnetic stirrer, 35.5 g of TPM solvent was mixed with 55.4 g of ethyl acetate solvent. After mixing these components at room temperature for 5 minutes, 2 g of Pevalen was added to the solvent mixture while mixing. Next, 1.6 g of Reversacol Corn Yellow dye and 1.6 g of Reversacol Ocean Blue dye were added while mixing, along with 3.8 g of Pearlcoat® DIPP 119 as a resin / binder. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0281] Example 11 13.7 grams of TPM solvent and 76.8 grams of isopropyl acetate solvent were mixed in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing these components at room temperature for 5 minutes, 2.6 grams of Jayflex® MB 10 were added to the solvent mixture while mixing. Next, 0.9 grams of Reversacol Corn Yellow, 0.6 grams of Reversacol Ocean Blue, and 0.2 grams of Reversacol Leather Brown dyes were added along with 5.2 grams of Mowital® B 16 H resin while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0282] Example 12 11.8 grams of DBA solvent, 2 grams of PMA solvent, and 77 grams of n-propyl acetate solvent were mixed in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing for 5 minutes, 0.2 grams of surfactant BYK®-333 and 2.6 grams of Jayflex® DIDP were added to the solvent mixture while mixing. Next, 1.3 grams of Reversacol Corn Yellow and 1.3 grams of Reversacol Ocean Blue dye were added together with 3.8 grams of Mowital® B 16 H resin while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0283] Example 13 41 grams of DBA solvent, 3 grams of isopropanol solvent, and 47 grams of methylpropyl ketone solvent were mixed in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing for 5 minutes, 0.2 grams of surfactant BYK®-333 and 2.3 grams of Palatinol N were added to the solvent mixture while mixing. Next, 2.2 grams of Reversacol Corn Yellow and 1.4 grams of Reversacol Ocean Blue dye were added together with 2.9 grams of Mowital® B 30 HH resin while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0284] Example 14 39 grams of DBA solvent, 12.8 grams of PMA solvent, and 40.5 grams of methyl propyl ketone solvent were mixed in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing for 5 minutes, 0.2 grams of surfactant BYK®-346 and 2.1 grams of Palatinol N were added to the solvent mixture while mixing. Next, 2.2 grams of Reversacol Corn Yellow and 0.7 grams of Reversacol Ocean Blue dye were added along with 2.5 grams of Mowital® B 30 HH resin while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0285] Example 15 In a 200 ml glass beaker equipped with a magnetic stirrer, 35.5 g of TPM solvent, 12.2 g of n-butyl acetate solvent, and 43 g of ethyl acetate solvent were mixed. After mixing these components at room temperature for 5 minutes, 0.2 g of surfactant BYK®-333 and 1.5 g of Jayflex® DIDP were added to the solvent mixture while mixing. Next, 1.6 g of Reversacol Corn Yellow and 1.6 g of Reversacol Ocean Blue dyes were added while mixing, along with 3.9 g of Mowital® B 16 H resin as a binder and 0.5 g of Laropal A-81 resin as a solid softener. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0286] Example 16 In a 200 ml glass beaker equipped with a magnetic stirrer, 34.4 g of butyl carbitol solvent, 48 g of isobutyl acetate solvent, and 10 g of ethyl acetate solvent were mixed. After mixing these components for 5 minutes, 0.1 g of surfactant BYK®-358 and 1.5 g of Jayflex® MB 10 were added to the solvent mixture while mixing. Next, 2 g of Reversacol Amazon Green dye was added along with 2.9 g of Mowital® B 16 H resin while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0287] Example 17 41 grams of acetone glycerol solvent, 6 grams of isopropanol solvent, and 43.3 grams of methyl propyl ketone solvent were mixed in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing for 5 minutes, 0.2 grams of surfactant BYK®-346 and 2.5 grams of Palatinol N were added to the solvent mixture while mixing. Next, 1.7 grams of Reversacol Corn Yellow and 1.9 grams of Reversacol Ocean Blue dye were added together with 3.4 grams of Mowital® B 30 HH resin while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0288] Example 18 In a 200 ml glass beaker equipped with a magnetic stirrer, 13.7 g of TPnB solvent was mixed with 28 g of ethyl acetate solvent and 48.8 g of DPnP solvent. After mixing these components at room temperature for 5 minutes, 2.6 g of Jayflex® MB 10 was added to the solvent mixture while mixing. Next, 0.9 g of Reversacol Corn Yellow, 0.6 g of Reversacol Ocean Blue, and 0.2 g of Reversacol Leather Brown dyes were added while mixing, along with 5.2 g of Pearlcoat® DIPP119 as a binder. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0289] Example 19 11.3 grams of EB solvent, 10.2 grams of DBA solvent, and 68.2 grams of isopropyl acetate solvent were mixed in a 200 ml glass beaker equipped with a magnetic stirrer. After mixing these components at room temperature for 5 minutes, 3.4 grams of Paraplex® A-8200 and 0.3 grams of the surfactant BYK®-333 were added to the solvent mixture while mixing. Next, 1.3 grams of Reversacol Corn Yellow, 1.3 grams of Reversacol Ocean Blue, and 0.5 grams of Reversacol Leather Brown dyes were added along with 5.5 grams of Mowital® B16H resin while mixing. Mixing was continued for a further 20 minutes at 60°C to prepare a photochromic ink, which was then filtered through a syringe filter (0.45 micrometers).

[0290] Example 20 4 grams of Mowital PVB 16H were mixed with 74 grams of TPM in a 200 ml glass flask equipped with a magnetic stirrer. Next, 1.5 grams of Jayflex® DIDP, 19 grams of ethyl acetate solvent, and 1.2 grams of Reversacol Leather Brown dye were added while mixing. After mixing these components for 30 minutes, 0.3 grams of surfactant BYK® 307 was added to the mixture, and mixing was continued for a further 10 minutes at 30°C.

[0291] Example 21 3.7 grams of Mowital PVB 30HH were mixed with 77 grams of TPM in a 200 ml glass flask equipped with a magnetic stirrer. Next, 1.3 grams of Jayflex® MB10, 16.7 grams of ethyl acetate solvent, and 1.05 grams of Reversacol Amazon Green dye were added while mixing. After mixing these components for 30 minutes, 0.25 grams of surfactant BYK® 307 was added to the mixture, and mixing was continued for a further 10 minutes at 30°C.

[0292] Example 22 In a 200 ml glass beaker equipped with a magnetic stirrer, 65 grams of Joncryl® 1532 were mixed with 20 grams of water. Next, 9.5 grams of EB solvent, 4.8 grams of DPM solvent, and 0.2 grams of BYK® 024 were added while mixing. After mixing these components for 5 minutes, 0.5 grams of surfactant BYK®-346 was added to the mixture, and mixing was continued for a further 10 minutes at 30°C to produce a primer formulation.

[0293] Example 23 In a 200 ml glass beaker equipped with a magnetic stirrer, 70 grams of Joncryl® 1534 were mixed with 15 grams of water. Next, 9.5 grams of EB solvent, 4.8 grams of DPM solvent, and 0.2 grams of BYK® 024 were added while mixing. After mixing these components for 5 minutes, 0.5 grams of surfactant EFKA® 3200 was added to the mixture, and mixing was continued for a further 10 minutes at 30°C to produce a primer formulation.

[0294] Example 24 In a 200 ml glass beaker equipped with a magnetic stirrer, 75 grams of Joncryl® 2110 were mixed with 10 grams of water. Next, 10 grams of EB solvent, 4.5 grams of DPM solvent, and 0.25 grams of BYK® 044 were added while mixing. After mixing these components for 5 minutes, 0.25 grams of surfactant BYK® 346 was added to the mixture, and mixing was continued for a further 10 minutes at 30°C to produce a primer formulation.

[0295] Example 25 2.0 grams of Mowital PVB 16H were mixed with 97.7 grams of ethyl acetate in a 200 ml glass flask equipped with a magnetic stirrer. After mixing these components for 30 minutes, 0.3 grams of the surfactant BYK®-307 was added to the mixture, and mixing was continued for a further 10 minutes at 30°C to produce a primer formulation.

[0296] Example 26 1.77 grams of Mowital PVB 30H was mixed with 98.2 grams of ethyl acetate in a 200 ml glass flask equipped with a magnetic stirrer. After mixing these components for 30 minutes, 0.3 grams of the surfactant BYK®-307 was added to the mixture, and mixing was continued for a further 10 minutes at 30°C to produce a primer formulation.

[0297] Example 27 2.0 grams of Pearlcoat® DIPP119 were mixed with 98 grams of ethyl acetate in a 200 ml glass flask equipped with a magnetic stirrer at 40°C for 1 hour. After mixing these components for 60 minutes, 0.3 grams of the surfactant BYK®-307 was added to the mixture, and mixing was continued for a further 20 minutes to produce a primer formulation.

[0298] Example 28 2.0 grams of Pearlstick® 47-60 were mixed with 98 grams of ethyl acetate in a 200 ml glass flask equipped with a magnetic stirrer at 40°C for 1 hour. After mixing these components for 60 minutes, 0.3 grams of the surfactant BYK®-307 was added to the mixture, and mixing was continued for a further 20 minutes to produce a primer formulation.

[0299] Example 29 An overcoat formulation was prepared by mixing 80 grams of U9800 with 19.5 grams of water and 0.5 grams of BYK346 in a 200 ml glass flask equipped with a magnetic stirrer for 1 hour.

[0300] Example 30 A Trivex® (PPG) lens was subjected to corona surface treatment according to Example 1.

[0301] Example 31 A polycarbonate lens was subjected to corona surface treatment according to Example 1.

[0302] Example 32 The corona surface treatment method of Example 1 was applied to a polycarbonate lens pre-coated with a hard coat.

[0303] Example 33 Trivex® (PPG) lenses, pre-coated with a hard coat, were subjected to the corona surface treatment method of Example 1.

[0304] Example 34 The corona surface treatment method of Example 1 was applied to a CR-39(registered trademark)(PPG) lens that had been pre-coated with a hard coat.

[0305] Example 35 A polycarbonate lens was coated with Versamid® PUR1010 as a primer. Microvalve dispensing was performed according to Example 5, and a calculated (average) wet thickness of 6.8 μm was obtained. Next, the wet layer was heat-dried and cured in a Venticell ECO forced-air oven at 60°C for 10 minutes, and then at 100°C for 10 minutes to form a primer layer.

[0306] Example 36 Laroflax® HS-9000 was applied as a primer to a polycarbonate lens. Microvalve dispensing was performed according to Example 5, and a calculated wet thickness of 5.9 μm was obtained. Next, the wet layer was heat-dried and cured in a Venticell ECO forced-air oven at 60°C for 10 minutes, and then at 100°C for 10 minutes, to form a primer layer with a thickness of approximately 1.5 μm.

[0307] Example 37 A polycarbonate lens was coated with the Joncryl® 1534 formulation from Example 23 as a primer. Spin coating was performed according to Example 2 to obtain a calculated wet thickness of 1.9 μm. Next, the wet layer was heat-dried and cured in a Venticell ECO forced-air oven at 60°C for 10 minutes, followed by 100°C for 10 minutes.

[0308] Example 38 A polycarbonate lens treated with corona treatment according to Example 32 was coated with the Joncryl® 1534 formulation from Example 23 as a primer. Spin coating was performed according to Example 2. Next, the wet layer was heat-dried and cured in a Venticell ECO forced-air oven at 60°C for 10 minutes, followed by 100°C for 10 minutes.

[0309] Examples 39-53: Microvalve ejection of photochromic ink onto a lens surface The photochromic dye formulations of Examples 7-21, containing a photochromic dye, a polymer binder, and typically a non-volatile liquid softener, were micro-valve-discharged onto various lens substrates at a pressure maintained at less than 1 bar, according to Example 5. The micro-valve discharging experiments are outlined in the table below. JPEG2026533961000002.jpg90159

[0310] Example 54 The overcoat formulation of Example 29 was microvalve-dispensed onto the coated CR-39® lens prepared in Example 34. Next, the wet layer, having a calculated average wet thickness of 11 μm, was heat-dried in a Venticell ECO forced-air oven at 60°C for 30 minutes. The dry (calculated average) thickness was approximately 3.1 μm.

[0311] Examples 55-59: Hard coat varnish formulations Example 55: Hard coat varnish 15.0 grams of 3-glycidoxypropyltrimethoxysilane, 33.6 grams of tetraethyl orthosilicate, 22.5 grams of itaconic acid, and 24.8 grams of ethyl acetate were mixed with stirring for 10 minutes until a homogeneous mixture was achieved. 24.8 grams of water were added dropwise to the premixed silane solution using a peristaltic pump to produce the resulting mixture. The mixture was then stirred for 12 hours to produce the coating composition.

[0312] Example 56: HC varnish + catalyst 0.2 grams of benzyldimethylamine was added dropwise to 99.8 grams of the mixture from Example 44 and mixed for 10 hours.

[0313] Example 57: HC varnish + nanoparticles 15.5 grams of 3-glycidoxypropyltrimethoxysilane, 25.5 grams of tetraethyl orthosilicate, 2.3 grams of itaconic acid, and 23.2 grams of ethyl acetate were mixed with stirring for 20 minutes until a homogeneous mixture was achieved. 19.1 grams of water were added to 16.3 grams of Ludox HS-30 (Grace) nanosilica colloidal dispersion and mixed for 15 minutes. The mixture was then added dropwise to the premixed silane solution using a peristaltic pump to produce the resulting mixture. The mixture was then stirred for 24 hours to produce the coating composition.

[0314] Example 58: HC varnish + silane additive 12.0 grams of methyltrimethoxysilane (Gelest), 8.0 grams of 3-glycidoxypropyltrimethoxysilane (Gelest), 29.1 grams of tetraethyl orthosilicate (Merck), 22.5 grams of succinic anhydride (Merck), and 24.8 grams of isopropyl acetate (Dow) were mixed with stirring for 10 minutes until a homogeneous mixture was achieved. 24.8 grams of water were added dropwise to the premixed silane solution using a peristaltic pump to produce the resulting mixture. The mixture was then stirred for 7 hours to produce the coating composition.

[0315] Example 59: HC varnish + catalyst 1.5 grams of a 10% w / w potassium hydroxide aqueous solution was added dropwise to 98.5 grams of the mixture from Example 58, and the mixture was mixed for 15 hours.

[0316] Example 60: Measurement of haze and transmittance (%) After calibrating the T-100 instrument, the target lens (uncoated reference lens) was measured. Next, the coated lens was measured in sample mode. As a result, the instrument revealed the transmittance %, transmittance difference Δ%, haze, and haze difference Δ for the coated and uncoated lenses. A low difference (delta value) between the coated and uncoated lenses indicates good optical clarity / light transmission.

[0317] Example 61: Measurement of Photochromic Properties Spectrophotometric measurements were performed using a Cary4000UV-Vis dual-beam spectrophotometer. The light source was a UV-LED lamp (395 nm). Activation and fading characteristics, as well as reaction rates, were investigated. For spectrophotometric measurements, coated samples were examined against an uncoated reference slide or lens. Spectral data were typically collected in the range of 350–700 nm with a resolution of 1 nm. Dynamical 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 started with the UV-LED lamp off. After 3–5 seconds, the UV-LED lamp was turned on for 120–180 seconds to obtain maximum absorbance. The lamp was then turned off, and fading was monitored.

[0318] As used herein and in the subsequent claims, unless otherwise specified, the terms “percent” or “%” refer to weight percent.

[0319] As used herein and in the subsequent claims, the terms “anti-glare,” “anti-reflective,” “anti-fogging,” “hard coat,” “ultraviolet absorber,” “photochromic,” “coloring,” and “blue light absorber” have the meanings used in the art of optical substrate coatings, unless otherwise specified.

[0320] As used herein and in the subsequent claims, the term “scratch resistance” with respect to materials such as formulations or coatings means that a dried and cured coating of a material exhibits a haze value of less than 6% in Taber wear characteristics according to ASTM D1004-08:CS10F wheel, 500g load, 500 cycles.

[0321] Alternatively, the term "scratch resistance" in relation to materials such as formulations or coatings refers to materials that have a Bayer number of at least 5 or at least 6, according to ASTM F735-21.

[0322] As used herein and in the subsequent claims, the term “ratio” means weight ratio unless otherwise specified.

[0323] In this specification and in the claims, the term “non-volatile component” as used with respect to formulations or formulations on lens / optical substrates refers to the residue after oven-drying a lens / optical substrate coated with a formulation at 120°C for 3 hours, and then removing some or all of the solvent and carrier liquid from the lens / optical surface. The residue includes solid particles in the formulation, along with dissolved solids remaining after the removal of the solvent.

[0324] As used herein and in the claims, the term “drying / curing” (e.g., of a formulation or layer) refers to drying or curing of a formulation or layer. It will be understood that for many types of formulations, thermal drying is the mechanism for achieving complete curing.

[0325] As used herein and in the claims, the term “complete drying and curing” means that the liquid solvent / support is completely removed along with 100% curing of the layer or coating.

[0326] As used herein and in the claims, the terms “fully cured” and “fully cured” (e.g., of a formulation or layer) refer to at least 85% curing of a polymer material as measured by a König hardness test according to the standard test method for hardness of organic coatings, ASTM D4366, by pendulum damping test. Thus, for a 100% fully cured reference polymer sheet with a König hardness of 80, “fully cured” or the same material having undergone “fully cured” will have a König hardness in the range of 68 (0.85·80) to 80. Thus, a “fully cured” polymer material has a minimum hardness coefficient (C) of at least 0.85. H ) has.

[0327] The "thickness" of one or more layers at a specific location is measured in the (N) direction perpendicular to the lens substrate at that location.

[0328] Various types of thin film thickness measurement methods are well known to those skilled in the art. For example, single-point film thickness measurement can be performed by spectral reflectance or spectral polarization analysis.

[0329] Furthermore, mapping of thin film surfaces and calculation of the average thickness of such films can be performed using these techniques.

[0330] The "average thickness" of the wetted layer can be defined as follows: When a volume vol of material covers a surface area SA with a wetted layer, the thickness of the wetted layer is estimated to be vol / SA. If the weight of the material is known, vol can be calculated by dividing it by the specific gravity of the material. Typically, the specific gravity of various coating materials can be safely approximated as 1.00.

[0331] The "average thickness" of a dry film can be calculated as follows: When a material that is x% (by weight) of liquid by volume vol wets or covers a surface of area SA, and all the liquid evaporates, changing from a wet layer to a dry film, the thickness of the dry film is calculated as follows: vol / ρ 湿潤層 (100-x) / (SA·ρ 乾燥層 ) In the formula, ρ 湿潤層 ρ is the specific gravity of the wet layer. 乾燥層 This is the specific gravity of the dry layer. This calculation requires knowledge of various properties (e.g., specific gravity) of the wet coating material of the film. As mentioned above, the specific gravity can usually be assumed to be 1.

[0332] Similarly, the average diameter (Ddrop) of droplets such as jet-dispensed droplets or micro-valve-dispensed droplets can be calculated by weighing a large number of jet-dispensed droplets, converting the total weight to volume using its specific gravity, dividing by the number of droplets, and using the formula D = (6 * V / π) for the diameter of a spherical droplet relative to its spherical volume. 1 / 3 It can be calculated using [this method].

[0333] As will be apparent to those skilled in the art, the various layers arranged on the optical surface or ophthalmic surface (e.g., lens surface) of the present invention are generally substantially uniform in thickness, and therefore the "average thickness" may be determined by evaluating the thickness of one or more points on the film or layer.

[0334] As used herein and in the subsequent claims, the term “inherent” with respect to ink dot dimensions such as height, length, or diameter refers to the maximum value of that dot dimension. For example, for a square dot with sides of 30 micrometers, the inherent diameter is the diagonal (i.e., 30√2 = 42.4 micrometers). For a dot having several peaks on the upper surface distal to the optical substrate, the dot height is the maximum height measured perpendicular to the upper surface of the substrate. In the case of multiple dots, the inherent dimension is the average of the inherent dimensions of the individual dots within the multiple dots.

[0335] As used herein and in the subsequent claims, the term “average” with respect to the dimensions of a plurality of dots (e.g., their height, length, or diameter) refers to the arithmetic mean of those dimensions, calculated using the unique dimensions for each of the plurality of dots.

[0336] In this specification and the subsequent claims, the term “transparent” as commonly used with respect to materials (e.g., materials used for coatings or materials used as substrates) may be measured according to ASTM D1003. Using ASTM D1003, a material having a haze measurement of less than 2% and a total transmittance (Tt) of at least 85% is considered “transparent.” More generally, the haze is at most 1.5% or at most 1.0%. More generally, the Tt is at least 90% or at least 95%. Even more generally, the haze is at most 1.0% and the Tt is at least 95%.

[0337] As used herein and in the subsequent claims, terms such as “liquid medium” refer to a medium that is liquid at its operating temperature. For example, the liquid medium of an inkjet ink ejected at 38°C is liquid at 38°C. Typically, a “liquid medium” is liquid at 25°C.

[0338] The term "ophthalmic formulations" is intended to be understood as being used in the technical field of ophthalmic substrate coatings.

[0339] The term "non-volatile" is intended to be understood as generally used in solvent-type formulations, for example, with respect to liquid softeners.

[0340] Similarly, the term "non-volatile content" in relation to formulations such as inks is generally intended to be understood as the term commonly used in solvent-based formulations. Specifically, it is intended to include high-boiling point liquids (290°C) such as glycerol.

[0341] As used herein, the term “film-forming” generally refers to resins, polymers, or formulations and is intended to be understood as commonly used in the art of ophthalmic substrate coatings. Typically, the dried film of a film-forming material has an average or characteristic thickness in the range of 0.2 to 5 micrometers.

[0342] Where used herein and in the subsequent claims, terms such as “softener” shall be used essentially as they are understood in the art.

[0343] As used herein and in the following claims, the term “liquid” refers to the state of a material at 25°C.

[0344] As used herein and in the following claims, the terms “LLevap,” “Levap,” “Mevap,” “Hevap,” and “HHevap” refer to volatile liquids within their respective characteristic ranges of relative evaporation rate to n-butyl acetate at 25°C and atmospheric pressure, according to ASTM D3539. More specifically, volatile liquids are classified into five categories as follows: LLevap < 0.1 (e.g., TPM, DPM, EB, NMP, DMSO, ethylene glycol monobutyl ether, DPM acetate) 0.1 ≤ Levap < 0.5 (e.g., EEP, EP, PP, PMA, n-butyl propionate, n-butanol, amyl acetate, water) 0.5 ≤ Mevap < 0.85 (e.g., PM, isobutanol) 0.85 ≤ Hevap < 1.8 (e.g., xylene, n-butyl acetate, isobutyl acetate, methyl isobutyl ketone, isopropanol, ethanol) 1.8 ≤ HHevap (e.g., toluene, methanol, n-propyl acetate, isopropyl acetate, ethyl acetate, methyl propyl ketone, methyl ethyl ketone) The designated standard material, n-butyl acetate, is assigned a vaporization rate or evaporation rate of 1.0. Therefore, terms such as "relative evaporation rate" are used in relation to n-butyl acetate.

[0345] 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 implies 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 implies any one of "A only," "B only," "C only," "A and B," "A and C," "B and C," or "A, B, and C."

[0346] As used herein and in the subsequent claims, terms such as “top,” “bottom,” “up,” “down,” “up,” “down,” “height,” and “side” are used for explanatory convenience or to indicate a relative orientation and are not necessarily intended to indicate an absolute orientation in space.

[0347] Further embodiments: Various formulations, methods, optical structures, and systems are disclosed herein. Further embodiments are shown below.

[0348] Embodiment of ink formulation 1. (a) resin, (b) Photochromic dyes, (c) A softening agent for making the resin flexible, and (d) A solvent system comprising an ultra-low vapor pressure solvent (LLevap) and at least one of the low vapor pressure solvent (Levap), medium vapor pressure solvent (Mevap), high vapor pressure solvent (Hevap), and ultra-high vapor pressure solvent (HHevap). An ink formulation containing, The aforementioned softening agent is optionally a non-volatile liquid softening agent. The ink formulation wherein the resin and the photochromic dye are dissolved in the solvent system.

[0349] 2. The formulation according to Embodiment 1, wherein the solvent system and the softener form a single liquid phase.

[0350] 3. The formulation according to Embodiment 1 or 2, wherein the formulation is a film-forming formulation.

[0351] 4. The formulation according to any of the prior embodiments, wherein the formulation lacks a pigment or a photochromic pigment.

[0352] 5. The formulation according to any of the prior embodiments, wherein the formulation is suitable for forming an ophthalmic film on an ophthalmic substrate.

[0353] 6. The formulation according to any of the prior embodiments, wherein the resin is a film-forming resin for use in the eye.

[0354] 7. The formulation according to any of the prior embodiments, wherein the non-volatile content of the formulation is in the range of 2.5 to 15%.

[0355] 8. The formulation according to any of the prior embodiments, wherein the first weight ratio of the resin to the photochromic dye is at least 0.5:1.

[0356] 9. The formulation according to Embodiment 8, wherein the first weight ratio is at least 1.25:1.

[0357] 10. The formulation according to Embodiment 8, wherein the first weight ratio is at least 1.75:1.

[0358] 11. The formulation according to Embodiment 8, wherein the first weight ratio is at least 2.25:1.

[0359] 12. The formulation according to Embodiment 8, wherein the first weight ratio is at least 2.6:1.

[0360] 13. The formulation according to Embodiment 8, wherein the first weight ratio is at least 3:1.

[0361] 14. The formulation according to any of embodiments 8 to 13, wherein the first weight ratio is a maximum of 7:1.

[0362] 15. The formulation according to Embodiment 14, wherein the first weight ratio is a maximum of 5.5:1.

[0363] 16. The formulation according to Embodiment 14, wherein the first weight ratio is a maximum of 4.5:1.

[0364] 17. The formulation according to Embodiment 14, wherein the first weight ratio is a maximum of 3.5:1.

[0365] 18. The formulation according to any of the prior embodiments, wherein the softening agent is a non-volatile liquid softening agent.

[0366] 19. The formulation according to Embodiment 18, wherein the second weight ratio of the non-volatile liquid softener to the photochromic dye is at least 0.2:1.

[0367] 20. The formulation according to Embodiment 19, wherein the second weight ratio is at least 0.25:1.

[0368] 21. The formulation according to Embodiment 19, wherein the second weight ratio is at least 0.3:1.

[0369] 22. The formulation according to Embodiment 19, wherein the second weight ratio is at least 0.4:1.

[0370] 23. The formulation according to Embodiment 19, wherein the second weight ratio is at least 0.6:1 or at least 0.8:1.

[0371] 24. The formulation according to any one of embodiments 19 to 23, wherein the second weight ratio is at most 2:1.

[0372] 25. The formulation according to Embodiment 24, wherein the second weight ratio is a maximum of 1.4:1.

[0373] 26. The formulation according to Embodiment 24, wherein the second weight ratio is a maximum of 1.1:1.

[0374] 27. The formulation according to Embodiment 24, wherein the second weight ratio is a maximum of 0.85:1.

[0375] 28. The formulation according to any one of embodiments 19 to 23, wherein the second weight ratio is a maximum of 0.75.

[0376] 29. The formulation according to any one of embodiments 19 to 22, wherein the second weight ratio is a maximum of 0.6.

[0377] 30. The formulation according to any of the prior embodiments, wherein the minimum film formation temperature (MFFT) of the resin (polymer) is a maximum of 90°C.

[0378] 31. The formulation according to Embodiment 30, wherein the MFFT is a maximum of 60°C.

[0379] 32. The formulation according to Embodiment 30, wherein the MFFT is a maximum of 50°C.

[0380] 33. The formulation according to Embodiment 30, wherein the MFFT is a maximum of 40°C.

[0381] 34. The formulation according to Embodiment 30, wherein the MFFT is a maximum of 35°C.

[0382] 35. The formulation according to Embodiment 30, wherein the MFFT is a maximum of 30°C.

[0383] 36. The formulation according to Embodiment 30, wherein the MFFT is a maximum of 25°C.

[0384] 37. The formulation according to Embodiment 30, wherein the MFFT is a maximum of 20°C.

[0385] 38. The formulation according to Embodiment 30, wherein the MFFT is a maximum of 15°C.

[0386] 39. The formulation according to Embodiments 30 to 38, wherein the MFFT is at least -50°C.

[0387] 40. The formulation according to Embodiment 39, wherein the MFFT is at least -35°C.

[0388] 41. The formulation according to Embodiment 39, wherein the MFFT is at least -20°C.

[0389] 42. The formulation according to Embodiment 39, wherein the MFFT is at least -10°C.

[0390] 43. The formulation according to any of the prior embodiments, wherein the static viscosity of the formulation at 25°C is a maximum of 65 cP.

[0391] 44. The formulation according to Embodiment 43, wherein the viscosity is a maximum of 50 cP.

[0392] 45. The formulation according to Embodiment 43, wherein the viscosity is a maximum of 35 cP.

[0393] 46. ​​The formulation according to Embodiment 43, wherein the viscosity is a maximum of 25 cP.

[0394] 47. The formulation according to Embodiment 43, wherein the viscosity is a maximum of 20 cP.

[0395] 48. The formulation according to Embodiment 43, wherein the viscosity is a maximum of 15 cP.

[0396] 49. The formulation according to Embodiment 43, wherein the viscosity is a maximum of 12 cP.

[0397] 50. The formulation according to any one of Embodiments 43 to 49, wherein the viscosity of the liquid film-forming formulation is at least 1.5 cP.

[0398] 51. The formulation according to Embodiment 50, wherein the viscosity is at least 2.5 cP.

[0399] 52. The formulation according to Embodiment 50, wherein the viscosity is at least 4 cP.

[0400] 53. The formulation according to Embodiment 50, wherein the viscosity is at least 6 cP.

[0401] 54. The ink formulation according to any of the prior embodiments, wherein the non-volatile content of the formulation is at least 5%.

[0402] 55. The formulation according to Embodiment 54, wherein the non-volatile content is at least 7%.

[0403] 56. The formulation according to Embodiment 54, wherein the non-volatile content is at least 9%.

[0404] 57. The formulation according to Embodiment 54, wherein the non-volatile content is at least 10%.

[0405] 58. The formulation according to Embodiment 54, wherein the non-volatile content is at least 11%.

[0406] 59. The formulation according to Embodiment 54, wherein the non-volatile content is at least 12%.

[0407] 60. An ink formulation according to any of the prior embodiments, wherein the non-volatile content of the formulation is a maximum of 20%.

[0408] 61. The formulation according to Embodiment 60, wherein the non-volatile content is a maximum of 18%.

[0409] 62. The formulation according to Embodiment 60, wherein the non-volatile content is a maximum of 16.5%.

[0410] 63. The formulation according to Embodiment 60, wherein the non-volatile content is a maximum of 15.5%.

[0411] 64. The formulation according to Embodiment 60, wherein the non-volatile content is a maximum of 15%.

[0412] 65. The formulation according to Embodiment 60, wherein the non-volatile content is a maximum of 14.5%.

[0413] 66. The formulation according to Embodiment 60, wherein the non-volatile content is a maximum of 14%.

[0414] 67. Polymer R in the ink formulation P-L A formulation according to any one of the prior embodiments, wherein the weight ratio of liquid to is up to 0.20.

[0415] 68. R P-L However, the formulation according to Embodiment 67 has a maximum of 0.18.

[0416] 69. R P-L However, the formulation according to Embodiment 67 has a maximum of 0.16.

[0417] 70. R P-L However, the formulation according to Embodiment 67 has a maximum of 0.14.

[0418] 71. R P-L The formulation according to any one of embodiments 67 to 70, wherein the ratio is at least 0.06.

[0419] 72. R P-L The formulation according to Embodiment 71, wherein the ratio is at least 0.08.

[0420] 73. R P-L The formulation according to Embodiment 71, wherein the ratio is at least 0.09.

[0421] 74. R L-P The formulation according to Embodiment 71, wherein the ratio is at least 0.095.

[0422] 75. R P-L The formulation according to Embodiment 71, wherein the ratio is at least 0.1.

[0423] 76. The formulation according to Embodiment 67, wherein RP-L is in the range of 0.075 to 0.15.

[0424] 77. R P-L However, the composition described in Embodiment 67 is within the range of 0.085 to 0.135.

[0425] 78. R P-L However, the formulation according to Embodiment 67 is within the range of 0.09 to 0.13.

[0426] 79. The formulation according to any of the prior embodiments, wherein the surface tension σ of the ink formulation at 25°C is a maximum of 35 dynes / cm.

[0427] 80. The formulation according to Embodiment 79, wherein σ is a maximum of 32 dynes / cm.

[0428] 81. The formulation according to Embodiment 79, wherein σ is a maximum of 30 dynes / cm.

[0429] 82. The formulation according to Embodiment 79, wherein σ is a maximum of 29 dynes / cm.

[0430] 83. The formulation according to any one of embodiments 79 to 82, wherein the σ of the ink formulation is at least 24 dynes / cm.

[0431] 84. The formulation according to Embodiment 83, wherein σ is at least 25 dynes / cm.

[0432] 85. The formulation according to Embodiment 83, wherein σ is at least 26 dynes / cm.

[0433] 86. The formulation according to any of the prior embodiments, wherein at least 85% by weight of the total polymer content in the ink formulation is a film-forming polymer.

[0434] 87. The formulation according to Embodiment 86, wherein at least 90% by weight of the total polymer content in the ink formulation is a film-forming polymer.

[0435] 88. The formulation according to any of the prior embodiments, wherein, on a weight basis, at least 50% of the total solvent in the formulation is a high vapor pressure solvent (Hevap) on an evaporation rate scale at 25°C normalized with n-butyl acetate.

[0436] 89. The formulation according to Embodiment 88, wherein at least 60% of the total solvent is at most Hevap.

[0437] 90. The formulation according to Embodiment 88, wherein at least 70% of the total solvent is at most Hevap.

[0438] 91. The formulation according to Embodiment 88, wherein at least 80% of the total solvent is at most Hevap.

[0439] 92. The formulation according to Embodiment 88, wherein at least 90% of the total solvent is at most Hevap.

[0440] 93. The formulation according to Embodiment 88, wherein at least 95% of the total solvent is at most Hevap.

[0441] 94. The formulation according to any of the prior embodiments, wherein, on a weight basis, at least 70% of the total solvent in the formulation is at most a medium vapor pressure solvent (Mevap), on an evaporation rate scale at 25°C normalized with n-butyl acetate.

[0442] 95. The formulation according to Embodiment 94, wherein at least 75% of the total solvent is at most Mevap.

[0443] 96. The formulation according to Embodiment 94, wherein at least 80% of the total solvent is at most Mevap.

[0444] 97. The formulation according to Embodiment 94, wherein at least 85% of the total solvent is at most Mevap.

[0445] 98. The formulation according to Embodiment 94, wherein at least 85% of the total solvent is at most Mevap.

[0446] 99. The formulation according to any of the prior embodiments, wherein, on a weight basis, at least 25% of the total solvent in the formulation is at most a low vapor pressure solvent (Levap), on an evaporation rate scale at 25°C normalized with n-butyl acetate.

[0447] 100. The formulation according to Embodiment 94, wherein at least 30% of the total solvent is at most Levap.

[0448] 101. The formulation according to Embodiment 94, wherein at least 40% of the total solvent is at most Levap.

[0449] 102. The formulation according to Embodiment 94, wherein at least 50% of the total solvent is at most Levap.

[0450] 103. The formulation according to Embodiment 94, wherein at least 60% of the total solvent is at most Levap.

[0451] 104. The formulation according to Embodiment 94, wherein at least 70% of the total solvent is at most Levap.

[0452] 105. The formulation according to Embodiment 94, wherein at least 80% of the total solvent is at most Levap.

[0453] 106. Evaporation rate scale at 25°C normalized with n-butyl acetate (S nba The formulation according to any of the prior embodiments, wherein at least 30% of the total solvent (Ts) in the formulation has a relative evaporation rate (Rev) of up to 0.35 by weight.

[0454] 107. The formulation according to Embodiment 106, wherein Rev is up to 0.35 for at least 40% of Ts.

[0455] 108. The formulation according to Embodiment 106, wherein Rev is up to 0.35 for at least 50% of Ts.

[0456] 109. The formulation according to Embodiment 106, wherein Rev is up to 0.35 for at least 60% of Ts.

[0457] 110. The formulation according to Embodiment 106, wherein Rev is up to 0.35 for at least 70% of Ts.

[0458] 111. The formulation according to Embodiment 106, wherein Rev is up to 0.35 for at least 75% of Ts.

[0459] 112. The formulation according to Embodiment 106, wherein Rev is up to 0.4 for at least 80% of Ts.

[0460] 113. The formulation according to Embodiment 106, wherein Rev is up to 0.4 for at least 90% of Ts.

[0461] 114. The formulation according to Embodiment 106, wherein Rev is up to 0.6 for at least 50% of Ts.

[0462] 115. The formulation according to Embodiment 106, wherein Rev is up to 0.6 for at least 60% of Ts.

[0463] 116. The formulation according to Embodiment 106, wherein Rev is up to 0.6 for at least 70% of Ts.

[0464] 117. The formulation according to Embodiment 106, wherein Rev is up to 0.6 for at least 75% of Ts.

[0465] 118. The formulation according to Embodiment 106, wherein Rev is up to 0.6 for at least 80% of Ts.

[0466] 119. The formulation according to Embodiment 106, wherein Rev is up to 0.6 for at least 90% of Ts.

[0467] 120. A formulation according to any of the prior embodiments, wherein, on a weight basis, at least 20% of the total solvent (Ts) in the formulation is at most an ultra-low vapor pressure solvent (LLevap), on an evaporation rate scale normalized with n-butyl acetate at 25°C.

[0468] 121. The formulation according to Embodiment 120, wherein at least 30% of Ts is at most LLevap.

[0469] 122. The formulation according to Embodiment 120, wherein at least 35% of Ts is at most LLevap.

[0470] 123. The formulation according to Embodiment 120, wherein at least 40% of Ts is at most LLevap.

[0471] 124. The formulation according to Embodiment 120, wherein at least 40% of Ts is at most LLevap.

[0472] 125. The formulation according to Embodiment 120, wherein at least 50% of Ts is at most LLevap.

[0473] 126. The formulation according to Embodiment 120, wherein at least 55% of Ts is at most LLevap.

[0474] 127. The formulation according to Embodiment 120, wherein at least 60% of Ts is at most LLevap.

[0475] 128. The formulation according to Embodiment 120, wherein at least 65% of Ts is at most LLevap.

[0476] 129. The formulation according to Embodiment 120, wherein at least 70% of Ts is at most LLevap.

[0477] 130. The formulation according to Embodiment 120, wherein at least 75% of Ts is at most LLevap.

[0478] 131. The relative evaporation rate (R) of LLevap LL A formulation according to any of the prior embodiments, wherein the ratio is a maximum of 0.05.

[0479] 132. R LL However, the formulation according to Embodiment 131 has a maximum of 0.025.

[0480] 133. RLL However, the formulation according to Embodiment 131 has a maximum of 0.015.

[0481] 134. R LL However, the formulation according to Embodiment 131 has a maximum of 0.012.

[0482] 135. R LL The formulation according to any one of embodiments 131 to 135, wherein the ratio is at least 0.0015.

[0483] 136. R LL The formulation according to Embodiment 135, wherein the ratio is at least 0.004.

[0484] 137. The formulation according to any of the prior embodiments, wherein at least 85% by weight of the total polymer content (Tpc) in the formulation is a film-forming polymer.

[0485] 138. The formulation according to any of the prior embodiments, wherein Tpc is at least 90% by weight.

[0486] 139. The first solvent weight ratio (SWR1) of Hevap, HHevap, and LLevap relative to the total amount Ts of solvent in the above formulation, (Hevap+HHevap+LLevap) / Ts A formulation according to any of the prior embodiments, wherein the ratio is at least 0.6.

[0487] 140. The formulation according to Embodiment 139, wherein the SWR1 is at least 0.7.

[0488] 141. Total T of Hevap and HHevap H+HH The relative solvent weight ratio (RWSR) of LLevap to T H+HH A formulation according to any of the prior embodiments, wherein the ratio of ) is at least 0.15:1.

[0489] 142. The formulation according to Embodiment 141, wherein the RWSR is in the range of 0.15:1 to 2.2:1.

[0490] 143. The formulation according to Embodiment 141, wherein the RWSR is in the range of 0.15:1 to 2:1.

[0491] 144. The formulation according to Embodiment 141, wherein the RWSR is in the range of 0.15:1 to 1.8:1.

[0492] 145. The formulation according to any of the prior embodiments, wherein the third weight ratio (WR3) of the non-volatile liquid softener to the resin (polymer) is at least 0.05:1.

[0493] 146. The formulation according to Embodiment 145, wherein WR3 is at least 0.1:1.

[0494] 147. The formulation according to Embodiment 145, wherein WR3 is at least 0.15:1.

[0495] 148. The formulation according to Embodiment 145, wherein WR3 is at least 0.25:1.

[0496] 149. The formulation according to Embodiment 145, wherein WR3 is at least 0.3:1.

[0497] 150. The formulation according to Embodiment 145, wherein WR3 is at least 0.35:1.

[0498] 151. The formulation according to Embodiment 145, wherein WR3 is at least 0.4:1.

[0499] 152. The formulation according to Embodiment 145, wherein WR3 is at least 0.45:1.

[0500] 153. The formulation according to Embodiment 145, wherein WR3 is at least 0.5:1.

[0501] 154. The formulation according to Embodiment 145, wherein WR3 is at least 0.55:1.

[0502] 155. A formulation according to any of embodiments 145 to 154, wherein WR3 is at most 1.2:1.

[0503] 155. A formulation according to any of embodiments 145 to 154, wherein WR3 is at most 1.1:1.

[0504] 155. The formulation according to any one of embodiments 145 to 154, wherein WR3 is at most 0.9:1.

[0505] 155. A formulation according to any of embodiments 145 to 154, wherein WR3 is at most 0.8:1.

[0506] 155. A formulation according to any of embodiments 145 to 154, wherein WR3 is at most 0.7:1.

[0507] 156. The formulation according to any of the prior embodiments, wherein the fourth weight ratio (WR4) of the non-volatile liquid softener to the non-volatile content of the formulation is at least 0.15:1.

[0508] 157. The formulation according to Embodiment 156, wherein WR4 is at least 0.2:1.

[0509] 158. The formulation according to Embodiment 156, wherein WR4 is at least 0.25:1.

[0510] 159. The formulation according to Embodiment 156, wherein WR4 is at least 0.3:1.

[0511] 160. The formulation according to Embodiment 156, wherein WR4 is at least 0.35:1.

[0512] 161. The formulation according to Embodiment 156, wherein WR4 is at least 0.4:1.

[0513] 162. The formulation according to Embodiment 156, wherein WR4 is at least 0.45:1.

[0514] 163. The formulation according to Embodiment 156, wherein WR4 is at least 0.5:1.

[0515] 164. A formulation according to any one of embodiments 156 to 163, wherein WR4 is at most 0.7:1.

[0516] 165. The formulation according to Embodiment 164, wherein WR4 is at most 0.6:1.

[0517] 166. The formulation according to any one of embodiments 156 to 163, wherein WR4 is at most 0.55:1.

[0518] 167. A formulation according to any one of embodiments 156 to 162, wherein WR4 is at most 0.5:1.

[0519] 168. A formulation according to any of embodiments 156 to 161, wherein WR4 is at most 0.45:1.

[0520] 169. The formulation according to any of the prior embodiments, wherein the fifth weight ratio (WR5) of the photochromic dye to the nonvolatile content of the ink formulation is at least 0.10:1.

[0521] 170. The formulation according to Embodiment 169, wherein WR5 is at least 0.2:1.

[0522] 171. The formulation according to Embodiment 169, wherein WR5 is at least 0.25:1.

[0523] 172. The formulation according to Embodiment 169, wherein WR5 is at least 0.3:1.

[0524] 173. The formulation according to Embodiment 169, wherein WR5 is at least 0.35:1.

[0525] 174. The formulation according to Embodiment 169, wherein WR5 is at least 0.4:1.

[0526] 175. A formulation according to any one of embodiments 169 to 174, wherein WR5 is at most 0.75:1.

[0527] 176. The formulation according to Embodiment 175, wherein WR5 is at most 0.60:1.

[0528] 177. The formulation according to Embodiment 175, wherein WR5 is at most 0.55:1.

[0529] 178. The formulation according to Embodiment 175, wherein WR5 is at most 0.50:1.

[0530] 179. The formulation according to Embodiment 175, wherein WR5 is at most 0.45:1.

[0531] 180. Ink formulations, (a) resin, (b) Photochromic dyes, (c) A non-volatile liquid softener for softening the resin, and (d) A solvent system comprising an ultra-low vapor pressure solvent (LLevap) and at least one of a high vapor pressure solvent (Hevap) and an ultra-high vapor pressure solvent (HHevap), The resin, the photochromic dye, and the non-volatile liquid softener are dissolved in the solvent system, forming a single liquid phase. The first weight ratio of the resin to the photochromic dye is at least 0.5:1. The second weight ratio (WR2) of the non-volatile liquid softener to the photochromic dye is at least 0.15:1. The non-volatile content of the ink formulation is within the range of 2.5 to 15%. The first solvent weight ratio (SWR1) of Hevap, HHevap, and LLevap relative to the total amount Ts of solvent in the ink formulation, (Hevap+HHevap+LLevap) / Ts However, it is at least 0.7, Hevap and HHevap all T H+HH The ink formulation wherein the relative solvent weight ratio (RWSR) of LLevap to is in the range of 0.15:1 to 2.2:1.

[0532] 181. A formulation according to either Embodiment 180 or a prior embodiment, wherein the RWSR is at least 0.20.

[0533] 182. The formulation according to Embodiment 181, wherein the RWSR is at least 0.25.

[0534] 183. The formulation according to Embodiment 181, wherein the RWSR is at least 0.30.

[0535] 184. The formulation according to Embodiment 181, wherein the RWSR is at least 0.35.

[0536] 185. The formulation according to Embodiment 181, wherein the RWSR is at least 0.45.

[0537] 186. The formulation according to Embodiment 181, wherein the RWSR is at least 0.55.

[0538] 187. The formulation according to Embodiment 181, wherein the RWSR is at least 0.65.

[0539] 188. The formulation according to Embodiment 181, wherein the RWSR is at least 0.75.

[0540] 189. A formulation according to either Embodiment 180 or a prior embodiment, wherein the RWSR is up to 2.0.

[0541] 190. The formulation according to Embodiment 189, wherein the RWSR is a maximum of 1.8.

[0542] 191. The formulation according to Embodiment 189, wherein the RWSR is a maximum of 1.6.

[0543] 192. The formulation according to Embodiment 189, wherein the RWSR is a maximum of 1.4.

[0544] 193. The formulation according to Embodiment 189, wherein the RWSR is a maximum of 1.2.

[0545] 194. The formulation according to Embodiment 189, wherein the RWSR is a maximum of 1.0.

[0546] 195. The formulation according to Embodiment 189, wherein the RWSR is a maximum of 0.85.

[0547] 196. A formulation according to any of the prior embodiments, wherein the SWR1 is at least 0.75.

[0548] 197. The formulation according to Embodiment 196, wherein the SWR1 is at least 0.85.

[0549] 198. The formulation according to Embodiment 196, wherein the SWR1 is at least 0.92.

[0550] 199. The formulation according to Embodiment 196, wherein the SWR1 is at least 0.95.

[0551] 200. The formulation according to Embodiment 196, wherein the SWR1 is at least 0.98.

[0552] 201. A formulation according to any of the prior embodiments, wherein the first total concentration of the group consisting of tetrahydrofuran (THF), methyl ethyl ketone (MEK), and acetone is up to 12% by weight.

[0553] 202. The formulation according to Embodiment 201, wherein the first total concentration is a maximum of 8%.

[0554] 203. The formulation according to Embodiment 201, wherein the first total concentration is a maximum of 4%.

[0555] 204. The formulation according to Embodiment 201, wherein the total concentration of the first embodiment is a maximum of 1%.

[0556] 205. The formulation according to any of the prior embodiments, wherein the concentration of the water is a maximum of 3% by weight.

[0557] 206. The formulation according to Embodiment 205, wherein the concentration of the water is a maximum of 1%.

[0558] 207. The formulation according to Embodiment 205, wherein the concentration of the water is a maximum of 0.3%.

[0559] 208. The formulation according to any of the prior embodiments, wherein the concentration of ethanol is a maximum of 3% by weight.

[0560] 209. The formulation according to Embodiment 208, wherein the concentration of the water is a maximum of 1%.

[0561] 210. The formulation according to Embodiment 209, wherein the second total concentration (TC2) of the group consisting of glycerol, triacetin, propylene glycol, ethylene glycol, and polyethylene glycol is up to 3% by weight.

[0562] 211. The formulation according to Embodiment 210, wherein TC2 is up to 2%.

[0563] 212. The formulation according to Embodiment 210, wherein TC2 is up to 1%.

[0564] 213. The formulation according to Embodiment 210, wherein TC2 is a maximum of 0.5%.

[0565] 214. LLevap has a maximum relative evaporation rate of 0.08 (R LL A formulation according to any of the prior embodiments, having ).

[0566] 215. R LL However, the formulation according to Embodiment 214 has a maximum of 0.06.

[0567] 216. R LL However, the formulation described in Embodiment 214 has a maximum of 0.04.

[0568] 217. R LL However, the formulation according to Embodiment 214 has a maximum of 0.03.

[0569] 218. R LL However, the formulation according to Embodiment 214 has a maximum of 0.02.

[0570] 219. R LL However, the formulation according to any of the prior embodiments is at least 0.002.

[0571] 220. R LL The formulation according to Embodiment 219, wherein the ratio is at least 0.003.

[0572] 221. R LL The formulation according to Embodiment 219, wherein the ratio is at least 0.005.

[0573] 222. R LL The formulation according to Embodiment 219, wherein the ratio is at least 0.006.

[0574] 223. R LL The formulation according to Embodiment 219, wherein the ratio is at least 0.007.

[0575] 224. The ink formulation according to any of the prior embodiments, wherein the ink formulation contains the high vapor pressure solvent (HHevap).

[0576] 225. The formulation according to any of the prior embodiments, wherein the ink formulation contains the ultra-high vapor pressure solvent (Hevap).

[0577] 226. HHevap has a maximum relative evaporation rate of 5.5 (R HH A formulation according to any of the prior embodiments, having ).

[0578] 227. R HH However, the formulation according to Embodiment 226 has a maximum of 5.2.

[0579] 228. R HH However, the formulation according to Embodiment 226 has a maximum of 5.0.

[0580] 229. R HH However, the formulation according to Embodiment 226 has a maximum of 4.8.

[0581] 230. R HH However, the formulation according to Embodiment 226 has a maximum of 4.5.

[0582] 231. The formulation according to any of the prior embodiments, wherein the softening agent forms a single liquid phase together with the solvent system, the resin, and the photochromic dye.

[0583] Embodiment of the Method 1. A method for manufacturing an optical structure on an optical substrate, wherein the method is: (a) A wet layer is formed on the optical surface of the optical substrate by dispensing droplets of a liquid ink mixture containing a photochromic dye using a microvalve, (b) The wetted layer is treated to form a dried or cured photochromic dye-containing layer on the optical surface, The manufacturing method wherein, optionally, the optical surface is a curved surface, optionally, the optical surface is a polymer surface, and the wetting layer is typically a continuous wetting layer.

[0584] 2. The method according to Embodiment 1, wherein the ink formulation is an organic or solvent-type ink formulation containing an organic or solvent-type solvent system.

[0585] 3. The method according to Embodiment 2, wherein the organic or solvent-based ink formulation further comprises a polymer (resin) dissolved in an organic or solvent-based solvent system.

[0586] 4. The method according to Embodiment 3, wherein the organic or solvent-type solvent system contains a single liquid phase.

[0587] 5. The method according to any of the prior embodiments, wherein the optical surface has the polymer surface.

[0588] 6. The method according to any of the prior embodiments, wherein the optical surface is the curved surface.

[0589] 7. The method according to Embodiment 6, wherein the SAG number of the optical substrate is defined by any of the features of Embodiments 25 to 36 of the system.

[0590] 8. The method according to any of the prior embodiments, wherein the base curve of the optical substrate is at least 2.

[0591] 9. The method according to embodiment 8, wherein the base curve is at least 3.

[0592] 10. The method according to embodiment 8, wherein the base curve is at least 4.

[0593] 11. The method according to embodiment 8, wherein the base curve is at least 5.

[0594] 12. The method according to embodiment 8, wherein the base curve is at least 6.

[0595] 13. The method according to embodiment 8, wherein the base curve is at least 8.

[0596] 14. The method according to any of the prior embodiments, wherein the base curve of the optical substrate is a maximum of 14.

[0597] 15. The method according to embodiment 14, wherein the base curve is a maximum of 12.

[0598] 16. The method according to embodiment 14, wherein the base curve is a maximum of 10.

[0599] 17. For any point on the target surface, (i) the acute angle formed between the plane tangent to the target surface at the given point and (ii) the horizontal plane is angle (α), and the maximum α on the target surface is α max And α max The method according to any of the prior embodiments, wherein the angle is at least 5°.

[0600] 18. α max The method according to Embodiment 17, wherein the angle is at least 7°.

[0601] 19. α max The method according to Embodiment 17, wherein the angle is at least 10°.

[0602] 20. α max The method according to Embodiment 17, wherein the angle is at least 13°.

[0603] 21. α max The method according to embodiment 17, wherein the angle is at least 16°.

[0604] 22. α max The method according to Embodiment 17, wherein the temperature is at least 19°.

[0605] 23. α max The method according to Embodiment 17, wherein the temperature is at least 23°.

[0606] 24. α max The method according to embodiment 17, wherein the angle is at least 26°.

[0607] 25. α max The method according to Embodiment 17, wherein the angle is at least 31°, at least 34°, or at least 40°.

[0608] 26. α max However, the method according to any one of embodiments 17 to 25, wherein the maximum angle is 50°.

[0609] 27. α max However, the method according to embodiment 26, where the maximum angle is 42°.

[0610] 28. α max However, the method according to embodiment 26, where the maximum is 37°.

[0611] 29. The method according to any of the prior embodiments, wherein at least one of the thickness TH of the wetted layer, characteristic thickness THc, and average thickness THav is up to 100 micrometers (μm).

[0612] 30. The method according to Embodiment 29, wherein at least one of TH, THc, and THav is up to 80 μm.

[0613] 31. The method according to Embodiment 29, wherein at least one of TH, THc, and THav is up to 70 μm.

[0614] 32. The method according to Embodiment 29, wherein at least one of TH, THc, and THav is up to 60 μm.

[0615] 33. The method according to Embodiment 29, wherein at least one of TH, THc, and THav is up to 50 μm.

[0616] 34. The method according to any one of embodiments 29 to 33, wherein at least one of TH, THc, and THav is at least 10 μm.

[0617] 35. The method according to Embodiment 34, wherein at least one of TH, THc, and THav is at least 18 μm.

[0618] 36. The method according to Embodiment 34, wherein at least one of TH, THc, and THav is at least 25 μm.

[0619] 37. The method according to Embodiment 34, wherein at least one of TH, THc, and THav is at least 30 μm.

[0620] 38. The method according to Embodiment 34, wherein at least one of TH, THc, and THav is at least 35 μm.

[0621] 39. The method according to Embodiment 34, wherein at least one of TH, THc, and THav is at least 40 μm.

[0622] 40. The method according to Embodiment 34, wherein at least one of TH, THc, and THav is at least 45 μm.

[0623] 41. The method according to any one of embodiments 29 to 40, wherein at least one of TH, THc, and THav includes TH.

[0624] 42. The method according to any one of embodiments 29 to 40, wherein at least one of TH, THc, and THav includes THav.

[0625] 43. The method according to any one of embodiments 29 to 40, wherein at least one of TH, THc, and THav comprises TH and THav.

[0626] 44. The method according to any one of embodiments 29 to 40, wherein at least one of TH, THc, and THav comprises TH, THc, and THav.

[0627] 45. The method according to any one of embodiments 29-38 and 41-44, wherein at least one of TH, THc, and THav is up to 40 μm.

[0628] 46. ​​The method according to any one of embodiments 29-36 and 41-44, wherein at least one of TH, THc, and THav is up to 30 μm.

[0629] 47. The method according to any one of embodiments 29 to 46, wherein at least one of TH, THc, and THav is at least 4 μm.

[0630] 48. The method according to Embodiment 47, wherein at least one of TH, THc, and THav is at least 5.5 μm.

[0631] 49. The method according to Embodiment 47, wherein at least one of TH, THc, and THav is at least 7 μm.

[0632] 50. The method according to any of the prior embodiments, wherein, with respect to the ink droplet, at least one of the droplet volume Vd, characteristic droplet volume Vd-c, and average droplet volume Vd-av is in the range of 4 to 400 nanoliters (nl).

[0633] 51. The method according to Embodiment 50, wherein at least one of Vd, Vd-c, and Vd-av is at least 5nl.

[0634] 52. The method according to Embodiment 50, wherein at least one of Vd, Vd-c, and Vd-av is at least 6nl.

[0635] 53. The method according to Embodiment 50, wherein at least one of Vd, Vd-c, and Vd-av is at least 8nl.

[0636] 54. The method according to Embodiment 50, wherein at least one of Vd, Vd-c, and Vd-av is at least 10nl.

[0637] 55. The method according to Embodiment 50, wherein at least one of Vd, Vd-c, and Vd-av is at least 12nl.

[0638] 56. The method according to Embodiment 50, wherein at least one of Vd, Vd-c, and Vd-av is at least 15nl.

[0639] 57. The method according to any one of embodiments 50 to 56, wherein at least one of Vd, Vd-c, and Vd-av is up to 250 nl.

[0640] 58. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 100 nl.

[0641] 59. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 70 nl.

[0642] 60. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 50 nl.

[0643] 61. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 45nl.

[0644] 62. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 40 nl.

[0645] 63. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 35nl.

[0646] 64. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 30 nl.

[0647] 65. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 25nl.

[0648] 66. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 22nl.

[0649] 67. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 20 nl.

[0650] 68. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 18nl.

[0651] 69. The method according to Embodiment 57, wherein at least one of Vd, Vd-c, and Vd-av is up to 16nl.

[0652] 70. The method according to any of the prior embodiments, wherein the polymer surface is a thermosetting polymer or comprises one, and the polymer surface is optionally coated with a hard coat.

[0653] 71. The method according to embodiment 70, wherein the polymer surface is coated with the hard coat.

[0654] 72. The method according to Embodiment 70 or 71, wherein the thermosetting polymer is a urethane-based thermosetting polymer such as Trivex®.

[0655] 73. The method according to Embodiment 70 or 71, wherein the thermosetting polymer is made from an allyl diglycol carbonate such as CR-39 (trademark).

[0656] 74. The method of any of the prior embodiments, wherein the polymer surface is a thermoplastic polymer or comprises one, and the polymer surface is optionally coated with a hard coat.

[0657] 75. The method according to embodiment 74, wherein the polymer surface is coated with the hard coat.

[0658] 76. The method according to Embodiment 74 or 75, wherein the thermoplastic polymer is polycarbonate.

[0659] 77. The method of any prior embodiment, further comprising applying at least one surface treatment to the optical surface of the optical substrate before the ink droplets of the ink formulation are ejected from the microvalve.

[0660] 78. The method according to embodiment 77, wherein the at least one surface treatment includes an energy treatment for increasing the surface energy of the optical surface.

[0661] 79. The method according to embodiment 78, wherein the energy treatment includes at least one energy treatment selected from the group consisting of corona, plasma, electron beam, discharge, and chemical radiation treatment.

[0662] 80. The method according to any one of embodiments 77 to 79, wherein the surface (energy) treatment increases the surface energy of the optical substrate by at least 2 mN / m, at least 3 mN / m, at least 5 mN / m, at least 8 mN / m, or at least 12 mN / m.

[0663] 81. The method according to any one of embodiments 77 to 80, wherein the surface treatment increases the surface energy of the optical substrate by a maximum of 40 mN / m, a maximum of 30 mN / m, a maximum of 20 mN / m, or a maximum of 14 mN / m.

[0664] 82. The method according to any one of embodiments 77 to 81, wherein the surface treatment includes applying a primer to the first surface of the optical substrate to form a wet primer coating, and drying the wet primer coating to form the optical surface of the optical substrate.

[0665] 83. The method according to any one of embodiments 77 to 81, wherein the surface treatment includes applying a primer to the first surface of the optical substrate to form a wet primer coating, and curing the wet primer coating to form the optical surface of the optical substrate.

[0666] 84. The method according to Embodiment 82, wherein the curing of the wet primer coating forms a fully cured primer coating before the wet (photochromic) layer is applied.

[0667] 85. The fully cured primer coating has a hardness coefficient (C) of at least 0.9 or at least 0.95. H The method according to embodiment 83, having ).

[0668] 86. The method according to embodiment 83 or 84, wherein the cured primer coating has a non-adhesive top surface.

[0669] 87. The method according to any one of embodiments 218 to 220, wherein the cured primer coating has a thickness (Tp) of at least 0.4 μm.

[0670] 88. The method according to embodiment 87, wherein Tp is at least 0.6 μm.

[0671] 89. The method according to embodiment 87, wherein Tp is at least 0.8 μm.

[0672] 90. The method according to Embodiment 87, wherein Tp is at least 1.0 μm.

[0673] 91. The method according to any one of embodiments 87 to 90, wherein Tp is a maximum of 3 μm.

[0674] 92. The method according to Embodiment 91, wherein Tp is a maximum of 2.5 μm.

[0675] 93. The method according to Embodiment 91, wherein Tp is a maximum of 2.0 μm.

[0676] 94. The method according to Embodiment 91, wherein Tp is a maximum of 1.7 μm.

[0677] 95. The method according to Embodiment 91, wherein Tp is a maximum of 1.4 μm.

[0678] 96. The method according to any one of embodiments 87 to 95, wherein Tp is at least one of the local thickness and the average thickness.

[0679] 97. The method of any prior embodiment, wherein an energy treatment or the energy treatment is applied to the upper surface of the cured or fully cured primer coating.

[0680] 98. The method according to any one of embodiments 78 to 97, wherein the energy treatment is performed on the exposed surface of the optical substrate before applying the primer.

[0681] 99. The method according to any of the prior embodiments, wherein the energy treatment is applied to the upper surface of the dried (fully cured) photochromic dye-containing layer before applying the overcoat layer.

[0682] 100. The method according to any of the prior embodiments, wherein the energy treatment is performed on the upper surface of the dried (fully cured) overcoat layer before applying the hard coat layer.

[0683] 101. The method of any prior embodiment, further comprising applying a wet overcoat layer onto the outer or exposed surface of the dry dye-containing layer after treating the wet layer to produce a dry dye-containing layer on the optical surface.

[0684] 102. The method according to Embodiment 101, wherein the overcoat layer comprises polyvinyl butyral.

[0685] 103. The method according to embodiment 101 or 102, further comprising curing the overcoat layer to produce a fully cured overcoat layer.

[0686] 104. The method according to Embodiment 103, wherein the fully cured overcoat layer has a thickness (Tov) of at least 4 μm.

[0687] 105. The method according to embodiment 103, wherein Tov is at least 6 μm.

[0688] 106. The method according to embodiment 103, wherein Tov is at least 7 μm.

[0689] 107. The method according to embodiment 103, wherein Tov is at least 7.5 μm.

[0690] 108. The method according to any one of embodiments 104 to 107, wherein Tov is up to 18 μm.

[0691] 109. The method according to embodiment 108, wherein Tov is up to 15 μm.

[0692] 110. The method according to embodiment 108, wherein Tov is up to 13 μm.

[0693] 111. The method according to embodiment 108, wherein Tov is up to 12 μm.

[0694] 112. The method according to embodiment 105, wherein Tov is up to 11 μm.

[0695] 113. The method according to any one of embodiments 105 to 112, wherein Tov is at least one of the local thickness and the average thickness.

[0696] 114. The method according to any of the prior embodiments, wherein a first liquid hard coat formulation is applied to the currently exposed optical surface of the optical substrate to form a first wet hard coat layer.

[0697] 115. The method according to Embodiment 114, wherein the currently exposed optical surface is a fully cured overcoat layer or the fully cured overcoat layer.

[0698] 116. The method according to embodiment 114 or 115, further comprising curing the first wet hard coat layer to form a first fully cured hard coat layer.

[0699] 117. Thickness T of the first fully cured hard coat layer h The method according to Example 116, wherein the particle size is at least 1.2 μm.

[0700] 118. T h The method according to Embodiment 117, wherein the particle size is at least 1.5 μm.

[0701] 119. T h The method according to Embodiment 117, wherein the particle size is at least 1.8 μm.

[0702] 120. T h The method according to any one of embodiments 116 to 118, wherein the maximum is 8.0.

[0703] 121. T h However, the method according to Embodiment 119, where the maximum is 6 μm.

[0704] 122. T h However, the method according to Embodiment 119, where the maximum is 4.5 μm.

[0705] 123. T h However, the method according to Embodiment 119, where the maximum is 3.5 μm.

[0706] 124. T h However, the method according to Embodiment 119, where the maximum size is 3 μm.

[0707] 125. T hHowever, the method according to Embodiment 119, where the maximum is 2.7 μm.

[0708] 126. T h However, the method according to Embodiment 119, where the maximum is 2.4 μm.

[0709] 127. T h However, the method according to Embodiment 119, where the maximum is 2.2 μm.

[0710] 128. T h However, the method according to Embodiment 119, where the maximum size is 2 μm.

[0711] 129. T h The method according to any one of embodiments 117 to 128, wherein the thickness is at least one (and usually both) of the local thickness and the average thickness.

[0712] 130. The method according to any one of embodiments 117-118 and 123-129, wherein the currently exposed optical surface is a fully cured overcoat layer or the fully cured overcoat layer.

[0713] 131. Thickness T of the dried photochromic dye-containing layer. PC The method according to any of the prior embodiments, wherein the particle size is at least 1.2 μm.

[0714] 132. T PC The method according to Embodiment 131, wherein the particle size is at least 1.6 μm.

[0715] 133. T PC The method according to Embodiment 131, wherein the particle size is at least 2 μm.

[0716] 134. T PC The method according to Embodiment 131, wherein the particle size is at least 2.4 μm.

[0717] 135. T PC The method according to Embodiment 131, wherein the particle size is at least 2.7 μm.

[0718] 136. T PC is at most 5.5 μm, the method according to any one of Embodiments 131 to 135.

[0719] 137. T PC is at most 5 μm, the method according to Embodiment 136.

[0720] 138. T PC is at most 4.6 μm, the method according to Embodiment 136.

[0721] 139. T PC is at most 4.2 μm, the method according to Embodiment 136.

[0722] 140. T PC is at most 3.8 μm, the method according to Embodiment 136.

[0723] 141. T PC is at least one of a local thickness and an average thickness, the method according to any one of Embodiments 131 to 140.

[0724] 142. The method according to any one of Embodiments 114 to 141, further comprising applying a second liquid hard coat formulation onto the currently exposed optical surface of the optical substrate to form a second wet hard coat layer.

[0725] 143. The method according to Embodiment 142, further comprising curing the second wet hard coat layer to form a second cured hard coat layer.

[0726] 144. The method according to any preceding embodiment, wherein the optical surface is an ophthalmic surface.

[0727] 145. The method according to any preceding embodiment, wherein the optical substrate is an ophthalmic substrate.

[0728] 146. The method according to embodiment 144 or 145, wherein the optical surface or ophthalmic surface is the front surface of the substrate.

[0729] 147. The method according to embodiment 144 or 145, wherein the optical surface or ophthalmic surface is the back surface of the substrate.

[0730] 148. The method according to any one of embodiments 144 to 147, wherein the optical surface or ophthalmic surface is convex.

[0731] 149. The method according to any one of embodiments 144 to 147, wherein the optical surface or ophthalmic surface is concave.

[0732] 150. The method according to any of the prior embodiments, wherein the direction of the relative motion between the nozzle and the optical substrate of the microvalve device lies within the XY plane of the optical substrate.

[0733] 151. The method according to any of the prior embodiments, wherein the direction of the relative motion between the nozzle and the optical substrate of the microvalve device is limited to the XY plane of the optical substrate.

[0734] 152. The method according to any of the prior embodiments, wherein, during the microvalve discharge, the distance (ΔDjet) between the nozzle of the microvalve device and the optical substrate varies by at least 0.5 mm due to the curvature of the optical substrate.

[0735] 153. The method according to embodiment 152, wherein ΔDjet is at least 1.0 mm.

[0736] 154. The method according to embodiment 152, wherein ΔDjet is at least 2 mm.

[0737] 155. The method according to embodiment 152, wherein ΔDjet is at least 3.5 mm.

[0738] 156. The method according to any one of embodiments 152 to 155, wherein ΔDjet is a maximum of 15 mm.

[0739] 157. The method according to any of the prior embodiments, wherein the distance between the nozzle of the microvalve device and the optical substrate is not controlled during the microvalve discharge.

[0740] 158. The method according to any of the prior embodiments, wherein the calculated average thickness of the dye on the optical substrate within the printing area is at least 0.2 μm.

[0741] 159. The method according to Embodiment 158, wherein the calculated average thickness of the dye on the optical substrate is at least 0.3 μm.

[0742] 160. The method according to Embodiment 158, wherein the calculated average thickness of the dye on the optical substrate is at least 0.4 μm.

[0743] 161. The method according to Embodiment 158, wherein the calculated average thickness of the dye on the optical substrate is at least 0.5 μm.

[0744] 162. The method according to any one of embodiments 158 to 161, wherein the calculated average thickness of the dye on the optical substrate is a maximum of 2 μm.

[0745] 163. The method according to Embodiment 162, wherein the calculated average thickness of the dye on the optical substrate is a maximum of 1.5 μm.

[0746] 164. The method according to Embodiment 162, wherein the calculated average thickness of the dye on the optical substrate is a maximum of 1.2 μm.

[0747] 165. The method according to Embodiment 162, wherein the calculated average thickness of the dye on the optical substrate is a maximum of 1.0 μm.

[0748] 166. The method according to Embodiment 162, wherein the calculated average thickness of the dye on the optical substrate is a maximum of 0.9 μm.

[0749] 167. The method according to Embodiment 162, wherein the calculated average thickness of the dye on the optical substrate is a maximum of 0.8 μm.

[0750] 168. The method according to Embodiment 162, wherein the calculated average thickness of the dye on the optical substrate is a maximum of 0.7 μm.

[0751] 169. The method according to Embodiment 162, wherein the calculated average thickness of the dye on the optical substrate is a maximum of 0.6 μm.

[0752] 170. The method according to any of the prior embodiments, wherein the treatment of the wetted layer for generating a dry pigment-containing layer is performed after extruding up to three of the wetted layers using a microvalve.

[0753] 171. The method according to any of the prior embodiments, wherein the treatment of the wetted layer for producing a dry pigment-containing layer is performed after extruding up to two of the wetted layers using a microvalve.

[0754] 172. The method according to any of the prior embodiments, wherein the treatment of the wet layer for producing a dry dye-containing layer is performed after a single wet layer of the wet layer is dispensed via a microvalve.

[0755] 173. The method according to any of the prior embodiments, wherein the optical structure has a single dye layer containing the dye.

[0756] 174. The method according to any of the prior embodiments, wherein the overall thickness Toc of the optical structure is in the range of 3 to 50 μm, 5 to 50 μm, or 8 to 50 μm.

[0757] 175. The method according to Embodiment 174, wherein Toc is at least 10 μm.

[0758] 176. The method according to embodiment 174, wherein Toc is at least 12 μm.

[0759] 177. The method according to embodiment 174, wherein Toc is at least 15 μm.

[0760] 178. The method according to any one of embodiments 174 to 177, wherein Toc is up to 40 μm, up to 30 μm, up to 25 μm, up to 20 μm, or up to 16 μm.

[0761] 179. The method according to any of the prior embodiments, wherein the optical substrate has a diameter of at least 40 mm.

[0762] 180. The method according to any of the prior embodiments, wherein the optical substrate has a diameter of at least 50 mm.

[0763] 181. The method according to any of the prior embodiments, wherein the optical substrate has a diameter of at least 60 mm.

[0764] 182. The method according to any of the prior embodiments, wherein the optical substrate has a diameter of at least 70 mm.

[0765] 183. The method according to any of the prior embodiments, wherein the optical substrate has a diameter of at least 80 mm.

[0766] 184. The method according to any of the prior embodiments, wherein the optical substrate has a maximum diameter of 90 mm.

[0767] 185. The method according to any of the prior embodiments, wherein the optical substrate has a diameter in the range of 50 mm to 80 mm.

[0768] 186. The method according to any of the prior embodiments, wherein the optical substrate is a lens blank.

[0769] 187. The method according to embodiment 186, wherein the lens blank is a semi-finished product.

[0770] 188. The method according to embodiment 186, wherein the lens blank is a finished product.

[0771] 189. The method according to any of the prior embodiments, wherein the optical substrate is a lens (for example, a pre-shaped lens).

[0772] 190. The method according to any prior embodiment, further comprising attaching the optical substrate having the dried dye-containing layer to an eyeglass frame (for example, as a lens therein).

[0773] 191. The method according to any of the prior embodiments, wherein the softening agent for softening the resin is distributed evenly or uniformly within the wet photochromic layer.

[0774] 191. The method according to any of the prior embodiments, wherein the liquid ink formulation is an ink formulation described in any one of Embodiments 1 to 231 of the formulation.

[0775] 192. The method according to any of the prior embodiments, wherein the method utilizes any (or more) properties of the ink formulation described in any one of Embodiments 1 to 231 of the formulation.

[0776] 193. The method according to any of the prior embodiments, wherein the method utilizes any (or more) of the properties described in the embodiment of the compound.

[0777] 194. The method of any prior embodiment, wherein the method utilizes any (or more) of the characteristics of the system embodiments described below.

[0778] 195. The method of any prior embodiment, wherein the method utilizes any(s) of the characteristics described herein.

[0779] Embodiments of optical structures 1. Optical structures as described in this specification.

[0780] 2. An optical structure comprising any of the structural features disclosed in Embodiments 1 to 195 of the Method.

[0781] 3. An optical structure comprising any of the structural features disclosed in Embodiments 1 to 72 of the System.

[0782] 3. The optical structure according to any one of Embodiments 1 to 3, wherein the optical structure is an eyeglass lens or includes one.

[0783] 4. Eyeglasses comprising an eyeglass frame and at least one eyeglass lens as described in Embodiment 4.

[0784] System Embodiment 1. (a) A photochromic ink formulation coating station, including a microvalve device configured to dispense droplets of a photochromic ink formulation onto a target surface of an optical substrate via a microvalve, thereby forming a wet layer on the target surface, and (b) A coating system comprising a drying and / or curing station configured to dry and / or cure the wet layer on the target surface to form a cured coating.

[0785] 2. (c) The system according to Embodiment 1, further comprising an optical substrate transfer device configured to transfer the optical substrate having the wet layer on the target surface from a photochromic ink formulation application station to a drying and / or curing station.

[0786] 3. The system according to Embodiment 1 or 2, wherein the optical substrate transfer device includes at least one of a robotic arm, a gripper, a conveyor belt, and an elevator for raising or lowering the height of the optical substrate on the target surface.

[0787] 4. The system according to any prior embodiment, further comprising a controller that is programmed or programmable to control the optical substrate transfer device so as to transfer the optical substrate in response to the detection at the photochromic ink formulation application station that the wet layer has been formed on the target surface of the optical substrate.

[0788] 5. The system according to any prior embodiment, wherein the drying and / or curing station includes at least one of a heat lamp, an oven, and a UV curing mechanism.

[0789] 6. The system according to any prior embodiment, wherein the drying and / or curing station includes an oven, the oven being (i) opened when transferring the optical substrate having the wet layer on the surface to be transferred into it, and (ii) closed after the optical substrate has been transferred into the oven and remaining closed during drying and / or curing.

[0790] 7. A system according to any of the prior embodiments, comprising a primer application station configured to apply droplets of a primer formulation onto the target surface before a photochromic ink formulation is dispensed thereon via a microvalve.

[0791] 8. The system according to Embodiment 7, wherein the primer application station includes a microvalve device for applying droplets of the primer formulation.

[0792] 9. The system according to any of the prior embodiments, further comprising at least one of the following: (i) a processing station for increasing the surface energy of the target surface before applying the primer or the photochromic ink formulation onto the target surface; and (ii) a cleaning station for subjecting the target surface to a cleaning process before microbubble application of the primer or the photochromic ink formulation onto the target surface.

[0793] 10. The system according to Embodiment 9, further comprising a surface energy treatment station, wherein the surface energy treatment station includes at least one of a corona treatment device and a plasma treatment device.

[0794] 11. The system according to any prior embodiment, wherein the photochromic ink formulation dispensing station includes a reservoir for the photochromic ink formulation, and the photochromic ink formulation stored in the reservoir is micro-valved to dispense the photochromic ink formulation onto the target surface of the optical substrate.

[0795] 12. The system according to any prior embodiment, wherein the system is further configured to apply at least one of the dye formulation and additional photochromic formulation to the target surface of the optical substrate by optionally microvalve dispensing, before applying the wetted layer of the photochromic ink formulation to the target surface of the optical substrate.

[0796] 13. The system according to any prior embodiment, wherein the system does not include a dip coating apparatus.

[0797] 14. The system according to any prior embodiment, wherein the system does not include a spin coating apparatus.

[0798] 15. A system according to any prior embodiment, comprising a controller configured or programmed to control the microvalve dispensing of the droplets of the formulation onto the target surface.

[0799] 16. The system according to any one of the prior embodiments, wherein the target surface is curved.

[0800] 17. The system according to any one of the prior embodiments, wherein the target surface has a SAG number of at least 0.5 mm.

[0801] 18. The system according to any one of embodiments 15 to 17, wherein the controller is configured or programmed to control the microvalve dispensing so that the volume ratio of the formulation applied per unit area of ​​the two-dimensional projection of the target surface remains constant.

[0802] 19. The system according to any one of embodiments 15 to 17, wherein the controller is configured or programmed to control the microvalve dispensing in any portion of the projection having an area of ​​5% or more of the area of ​​the two-dimensional projection of the target surface, such that the volume ratio of the compound applied per unit area of ​​the two-dimensional projection is within ±10%, ±5%, ±2%, or ±1% of the average value of the ratio over the entire two-dimensional projection.

[0803] 20. The system according to any one of embodiments 15 to 19, wherein the controller is configured or programmed to generate the two-dimensional projection of the target surface before the microvalve discharge.

[0804] 21. The system according to any one of embodiments 15 to 20, wherein the controller is configured or programmed to calculate or select the volume ratio of the formulation per unit area of ​​the two-dimensional projection of the target surface before the microvalve discharge.

[0805] 22. The system according to Embodiment 21, wherein the controller is configured or programmed to control the microvalve dispensing in any portion of the projection having an area of ​​5% or more of the area of ​​the two-dimensional projection of the target surface, such that the volume ratio of the compound applied per unit area of ​​the two-dimensional projection is within ±10%, ±5%, ±2%, or ±1% of the calculated or selected ratio.

[0806] 23. The system according to any of the prior embodiments, wherein the microvalve discharge is configured such that the average volume ratio of the compound applied per unit area of ​​the target surface at the edge located at a distance of 90% to 100% from the center of gravity of the target surface and its surroundings is 0.60 to 0.96 times the maximum volume ratio of the compound applied per unit area of ​​the target surface.

[0807] 24. The system according to any one of Embodiments 1 to 22, wherein the microvalve discharge is located at a distance of 90% to 100% from the center of gravity of the target surface and its surroundings, and the average volume ratio of the compound applied per unit area of ​​the target surface at the edge is 0.60 to 0.96 times the average volume ratio of the compound applied per unit area in the central region, which is located at a distance of 0% to 10% from the center of gravity of the target surface and its surroundings.

[0808] 25. The system according to any one of Embodiments 23 or 24, wherein the number of SAGs on the target surface is at least 1 mm and at most 15 mm.

[0809] 26. The system according to embodiment 25, wherein the number of SAGs is at least 2 mm.

[0810] 27. The system according to embodiment 25, wherein the number of SAGs is at least 3.5 mm.

[0811] 28. The system according to embodiment 25, wherein the number of SAGs is at least 4.5 mm.

[0812] 29. The system according to embodiment 25, wherein the number of SAGs is at least 5 mm.

[0813] 30. The system according to embodiment 25, wherein the number of SAGs is at least 6 mm.

[0814] 31. The system according to embodiment 25, wherein the number of SAGs is at least 7 mm.

[0815] 32. The system according to embodiment 25, wherein the number of SAGs is at least 9 mm.

[0816] 33. The system according to any one of embodiments 25 to 32, wherein the number of SAGs is a maximum of 13.5 mm.

[0817] 34. The system according to embodiment 33, wherein the number of SAGs is a maximum of 12 mm.

[0818] 35. The system according to embodiment 33, wherein the number of SAGs is a maximum of 10.5 mm.

[0819] 36. The system according to any one of embodiments 25 to 31, wherein the number of SAGs is a maximum of 8 mm.

[0820] 37. The system according to any one of embodiments 23 to 36, wherein the ratio at the edge is 0.6 to 0.9 times the maximum ratio.

[0821] 38. The system according to any one of embodiments 23 to 36, wherein the ratio at the edge is 0.6 to 0.85 times the maximum ratio.

[0822] 39. The system according to any one of embodiments 23 to 36, wherein the ratio at the edge is 0.8 to 0.96 times the ratio in the central region.

[0823] 40. The system according to any one of embodiments 23 to 36, wherein the ratio at the edge is 0.9 to 0.96 times the ratio in the central region.

[0824] 41. The system according to any one of Embodiments 13 to 22, characterized in that the SAG number of the target surface is 9 mm to 13 mm, and the microvalve discharge is located at a distance of 90% to 100% from the center of gravity of the target surface and its surroundings, and the volume ratio of the compound applied per unit area of ​​the target surface near the edge is configured to be 0.62 to 0.85 times the maximum value of the volume ratio of the compound applied per unit area of ​​the target surface.

[0825] 42. The system according to any one of Embodiments 13 to 22, characterized in that the SAG number of the target surface is 7 mm to 9 mm, and the microvalve discharge is located at a distance of 90% to 100% from the center of gravity of the target surface and its surroundings, and the volume ratio of the compound applied per unit area of ​​the target surface near the edge is configured to be 0.72 to 0.92 times the maximum value of the volume ratio of the compound applied per unit area of ​​the target surface.

[0826] 43. The system according to any one of Embodiments 13 to 22, characterized in that the SAG number of the target surface is 5 mm to 7 mm, and the microvalve discharge is located at a distance of 90% to 100% from the center of gravity of the target surface and its surroundings, and the volume ratio of the compound applied per unit area of ​​the target surface near the edge is configured to be 0.82 to 0.96 times the maximum value of the volume ratio of the compound applied per unit area of ​​the target surface.

[0827] 44. The system according to any one of embodiments 13 to 22, wherein the microvalve dispensing is configured such that the average volume ratio of the compound applied per unit area of ​​the target surface at a given point on the target surface is equal to the maximum value of the volume ratio of the compound applied per unit area at any point on the target surface multiplied by a reduction factor, wherein the reduction factor is equal to the cosine of the acute angle formed between (i) a plane tangent to the target surface at the given point and (ii) a horizontal plane.

[0828] 45. The system according to embodiment 44, wherein the reduction coefficient at any point on the periphery of the curved surface is 0.63 to 0.96.

[0829] 46. ​​The system according to any one of embodiments 13 to 45, wherein for any point on the target surface, the maximum acute angle formed between (i) a plane tangent to the target surface at the given point and (ii) a horizontal plane is 10° to 40°.

[0830] 47. The system according to any one of embodiments 13 to 45, wherein, for any point on the target surface, the maximum acute angle formed between (i) a plane tangent to the target surface at the given point and (ii) a horizontal plane is 5° to 50°.

[0831] 48. The system according to any one of Embodiments 13 to 45, wherein for any point on the target surface, the maximum acute angle formed between (i) a plane tangent to the target surface at the given point and (ii) a horizontal plane is 15° to 40°.

[0832] 49. The system according to any one of embodiments 13 to 45, wherein for any point on the target surface, the maximum acute angle formed between (i) a plane tangent to the target surface at the given point and (ii) a horizontal plane is 5° to 20°.

[0833] 50. The system according to any one of the prior embodiments, wherein the system is configured to perform the microvalve dispensing without relative vertical z-axis movement between the microvalve device and the target surface.

[0834] 51. The system according to any one of the prior embodiments, wherein the system is not configured to perform the microvalve dispensing while the system is performing relative vertical z-axis movement between the microvalve device and the target surface.

[0835] 52. The system according to any one of the preceding embodiments, wherein the system is not configured to perform the microvalve discharge while performing relative vertical z-axis direction movement between the microvalve device and the target surface.

[0836] 53. The system according to any one of the preceding embodiments, wherein the system is configured to perform the microvalve discharge without performing relative rotational movement in the x-y plane between the microvalve device and the target surface while forming the wetting layer.

[0837] 54. The system according to any one of the preceding embodiments, wherein the system is not configured to perform the microvalve discharge while performing relative rotational movement in the x-y plane between the microvalve device and the target surface while forming the wetting layer.

[0838] 55. The system of embodiment 54, wherein the photochromic ink formulation application station comprises a non-rotating optical substrate holder.

[0839] 56. The system according to any of the preceding embodiments, wherein the microvalve device is piezoelectrically actuated.

[0840] 57. The system according to any of embodiments 1 to 55, wherein the microvalve device is electromagnetically actuated.

[0841] 58. For any point on the target surface, the acute angle formed between (i) the plane tangent to the target surface at the given point and (ii) the horizontal plane is angle (α), and the maximum α on the target surface is α max , and α max is at least 5°, the system according to any one of the preceding embodiments.

[0842] 59. α max is at least 10°, the system of embodiment 58.

[0843] 60. α max The system according to embodiment 58, wherein the angle is at least 15°.

[0844] 61. α max The system according to embodiment 58, wherein the temperature is at least 20°.

[0845] 62. α max The system according to embodiment 58, wherein the angle is at least 25°.

[0846] 63. α max The system according to embodiment 58, wherein the angle is at least 30°.

[0847] 64. α max The system according to any one of claims 2 to 4, wherein the maximum angle is 50°.

[0848] 65. α max However, it is within the range of 30-40°, R D1 The system according to any one of embodiments 58 to 64, wherein the value is a maximum of 0.90 or within the range of 0.62 to 0.90.

[0849] 66. α max However, it is within the range of 19-27°, R D1 The system according to any one of embodiments 58 to 64, wherein the value is a maximum of 0.93 or within the range of 0.85 to 0.93.

[0850] 67. α max However, it is within the range of 15-20°, R D1 The system according to any one of embodiments 58 to 64, wherein the value is a maximum of 0.97 or within the range of 0.90 to 0.97.

[0851] 68. The system according to any of the prior embodiments, wherein the liquid ink formulation is an ink formulation according to any one of the embodiments 1 to 231 of the formulation.

[0852] 69. The system according to any of the prior embodiments, wherein the system has any (or more) characteristics of the ink formulation described in any one of the embodiments 1 to 231 of the formulation.

[0853] 70. The system according to any of the prior embodiments, wherein the system has any (or more) of the characteristics described in the embodiment of the formulation.

[0854] 71. The system according to any of the prior embodiments, wherein the system has any (or more) of the characteristics described in the embodiments of the method described above.

[0855] 72. The system according to any prior embodiment, wherein the system has any or more characteristics described herein.

[0856] As is evident, certain features of the present invention described in relation to separate embodiments for clarity may also be shown in combination in one embodiment. Conversely, various features of the present invention described in relation to one embodiment for conciseness may also be shown separately or in any preferred subcombination.

[0857] While the present invention has been described in conjunction with its specific embodiments, many alternatives, modifications, and variations therein will be apparent to those skilled in the art. Therefore, it is intended to encompass all such alternatives, modifications, and variations that fall within the spirit and scope of the appended claims. All publications, patents, and patent applications described herein are incorporated herein by whole to the same extent that each individual publication, patent, or patent application is explicitly and individually incorporated herein by reference. Furthermore, no citation or reference of any reference in this application should be construed as an acknowledgment that such reference is available as prior art of the present invention.

Claims

1. (a) A photochromic ink formulation coating station, including a microvalve device configured to dispense droplets of a photochromic ink formulation onto a target surface of an optical substrate using a microvalve, thereby forming a wet layer on the target surface. (b) A drying and / or curing station configured to dry and / or cure the wet layer on the target surface to form a cured coating, (c) An optical substrate transfer device configured to transfer the optical substrate having the wet layer on the target surface from a photochromic ink formulation application station to a drying and / or curing station, and (d) A processing station for increasing the surface energy of the target surface before applying the primer to the target surface, and (e) A controller configured or programmed to control the microvalve dispensing of the droplets of the formulation onto the target surface. A coating system including, The microvalve discharge is characterized by being located at a distance of 90% to 100% from the center of gravity of the target surface and its surroundings, and the dimensionless ink coverage (R) is defined by the average volume ratio of the formulation applied per unit area of ​​the target surface at the edge. Ｄ１ The coating system is configured such that the average volume ratio of the compound applied per unit area in the central region is 0.60 to 0.96 times, characterized in that the target surface and the surrounding center of gravity are located at a distance of 0% to 10%.

2. For any point on the target surface, (i) the acute angle formed between the plane tangent to the target surface at the given point and (ii) the horizontal plane is angle (α), and the maximum α on the target surface is α ｍａｘ And α ｍａｘ The system according to claim 1, wherein the angle is at least 5°.

3. α ｍａｘ The system according to claim 2, wherein the angle is at least 10°.

4. α ｍａｘ The system according to claim 2, wherein the angle is at least 15°.

5. α ｍａｘ The system according to any one of claims 2 to 4, wherein the maximum angle is 50°.

6. α ｍａｘ However, it is within the range of 30-40°, R Ｄ１ The system according to any one of claims 2 to 4, wherein the value is a maximum of 0.90 or within the range of 0.62 to 0.

90.

7. α ｍａｘ is in the range of 19° to 27°, and R Ｄ１ is at most 0.93, or in the range of 0.85 to 0.93, the system according to any one of claims 2 to 4.

8. α ｍａｘ However, it is within the range of 15-20°, R Ｄ１ The system according to any one of claims 2 to 4, wherein the value is a maximum of 0.97 or within the range of 0.90 to 0.

97.

9. The controller is configured or programmed to calculate or select the volume ratio of the compound per unit area of ​​the two-dimensional projection of the target surface before the microvalve is dispensed. The system according to any one of claims 1 to 8, wherein the controller is configured or programmed to control the microvalve dispensing in any portion of the projection having an area of ​​5% or more of the area of ​​the two-dimensional projection of the target surface, such that the volume ratio of the compound applied per unit area of ​​the two-dimensional projection is within ±10% of the calculated or selected ratio.

10. The system according to any one of claims 1 to 9, wherein the processing station is further for increasing the surface energy of the upper surface of the fully cured coating.

11. The system according to any one of claims 2 to 10, wherein the system does not include a dip coating and spin coating apparatus.

12. The system according to any one of claims 1 to 11, wherein the system is not configured to perform the microvalve dispensing while the system is performing relative rotational motion in the x-y plane between the microvalve device and the target surface while the wet layer is being formed.

13. The system according to claim 12, wherein the photochromic ink formulation application station comprises a non-rotating optical substrate holder.

14. A method for manufacturing an optical structure on an optical substrate, wherein the method is (a) Provides the system according to any one of claims 1 to 13, (b) A wet layer is formed on the optical surface of the optical substrate by dispensing droplets of a liquid ink formulation containing a photochromic dye using a microvalve. (c) Processing the wet layer to form a dried or cured photochromic dye-containing layer on the optical surface. The manufacturing method, including the above.

15. The method according to claim 14, further comprising applying a primer to the first surface of the optical substrate to form a wet primer coating before the microvalve discharge, and completely curing the wet primer coating to form the optical surface of the optical substrate.

16. The method according to claim 15, wherein the cured primer coating has a non-adhesive upper surface.

17. The method according to claim 15 or 16, further comprising subjecting the upper surface of the fully cured primer coating to a surface energy treatment before the microvalve discharge.

18. The method according to any one of claims 14 to 17, further comprising processing the wet layer to produce a dry dye-containing layer on the optical surface, and then applying a wet overcoat layer onto the outer or exposed surface of the dry photochromic dye-containing layer.

19. The aforementioned liquid ink formulation (a) resin, (b) Photochromic dyes, (c) A non-volatile liquid softener for softening the resin, and (d) A solvent system comprising an ultra-low vapor pressure solvent (LLevap) and at least one of a high vapor pressure solvent (Hevap) and an ultra-high vapor pressure solvent (HHevap). Includes, The resin, the photochromic dye, and the non-volatile liquid softener are dissolved in the solvent system, forming a single liquid phase. The first weight ratio of the resin to the photochromic dye is at least 0.5:

1. The second weight ratio (WR2) of the non-volatile liquid softener to the photochromic dye is at least 0.15:

1. The non-volatile content of the ink formulation is within the range of 2.5 to 15%. The first solvent weight ratio (SWR1) of Hevap, HHevap, and LLevap relative to the total amount Ts of solvent in the ink formulation, (Hevap+HHevap+LLevap) / Ts However, it is at least 0.7, Hevap and all T of HHevap Ｈ＋ＨＨ The method according to any one of claims 14 to 18, wherein the relative solvent weight ratio (RWSR) of LLevap to is in the range of 0.15:1 to 2.2:

1.

20. LLevap has a maximum relative evaporation rate R of 0.

04. ＬＬ The method according to claim 19, comprising:

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