Ophthalmic lenses, and systems and methods for their fabrication

Abstract

A method is disclosed for producing an optical article such as an eyeglass lens or lens blank in a mold. The optical article comprises a base-member layer and an optical layer having a non-zero diopter. A base member is inserted into the mold such that a major surface having a convex spherical contour is facing downward once inserted. The optical layer is formed by introducing a radiation-curable composition into the mold, rotating the mold at a speed of at least 50 rpm and not more than 120 rpm thereby changing a contour of an upper surface to a concave paraboloid shape, and irradiating the curable composition to solidify it. When the optical article is released from the mold, the inserted base member forms the base-member layer.

Description

[0001] OPHTHALMIC LENSES, AND SYSTEMS AND METHODS FOR THEIR FABRICATION

[0002] CROSS-REFERENCE TO OTHER PUBLIC ATIONS

[0003] This application claims priority from GB application no. 2409957.4, filed on July 9, 2024; PCT application no. PCT / IB2025 / 050988 filed on January 29, 2025; and GB application no 2506731.5, filed on May 2, 2025; the teachings of all of which are incorporated herein by reference.

[0004] FIELD OF THE INVENTION

[0005] The present invention relates to methods, apparatus and systems for fabricating optical articles, and particularly to optical articles formed, inter alia, by drop deposition of radiation-polymerizable compositions on a substrate.

[0006] BACKGROUND

[0007] Eyeglass lenses are currently produced in a variety of different processes. A common method for producing an eyeglass lens in an optical laboratory involves first selecting a clear lens blank, which is obtainable commercially in a variety of diopters. The lens blanks are outsourced from large producers who produce them using molding and / or machining. Even a small laboratory must track and maintain inventories of a very large number of differently powered lens blanks. When tints and other coatings are involved, the number of different blanks increases even further. The work of the laboratory may involve measuring or scanning a selected eyeglass frame and trimming or edging the lens blank to fit the frame. Some methods include selecting and then machining a semi-finished or finished lens blank with a given base power, i.e., the curvature of a first surface, to produce a lens with the final diopter.

[0008] At present, there is no known practical approach that gives the optical laboratory more control over the production of the lenses, e.g., setting the optical power, customizing bi-focal, multi-focal and progressive lenses, addressing cylinder and prism, and so on. A practical approach is needed that would reduce the need to manage large, expensive inventories of prescription-specific lens blanks and that would allow the optical laboratory to control all or a large part of lens production while producing precise lenses in an expedited and less expensive manner.

[0009] SUMMARY

[0010] A method is disclosed, according to embodiments, for producing an optical article in a mold. The optical article comprises an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm. The optical article comprises a base-member layer and an optical layer characterized by a non-zero diopter. The method comprises: (a) inserting, into the mold, a base member comprising a major surface characterized at least in part by a convex spherical shape, the inserting being such that said major surface is facing downward; (b) forming the optical layer, the forming including (i) introducing a radiation-curable composition into the mold, (ii), rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape, and (iii) subjecting the curable composition to the curing radiation to solidify the composition; and (c) releasing the optical article from the mold. The base-member layer of the optical article comprises the base member.

[0011] A method is disclosed, according to embodiments, for producing a coated optical article in a mold; the optical article comprises an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm. The method comprises: (a) applying, on a floor of the mold, a coating layer comprising at least one of a protective coating and a functional coating; (b) forming an optical layer over the coating layer, the forming including (i) introducing a radiation-curable composition into the mold, (ii), rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape, and (iii) subjecting the curable composition to the curing radiation to solidify the composition; and (c) releasing the coated optical article from the mold.

[0012] A method is disclosed, according to embodiments, for producing an optical article; the optical article comprises an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter between 40 mm and 100 mm. The optical article comprises a base-member layer and a second layer. The method comprises: (a) forming the base layer in a mold, the forming of the base layer including: (i) introducing a quantity of a radiation-curable base-layer composition into the mold, (ii) rotating the mold at a first speed to create a concave contour on an upper surface of the base-layer composition, and (iii) subjecting the base-layer composition to a first curing radiation to solidify the base-layer composition within the mold, the solidifying being effective to preserve the concave shape; and (b) forming the second layer, the forming of the second layer including: (i) while the solidified base layer is disposed within the mold, introducing a quantity of a radiation-curable second-layer composition into the mold, (ii) rotating the mold at a second speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition to displace so as to change a contour of an upper surface of the second-layer composition to a concave paraboloid shape, and (iii) subjecting the second-layer composition to a second curing radiation to solidify the second-layer composition.

[0013] A method is disclosed, according to embodiments, for producing an optical article comprising an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm. The method comprises: (a) introducing a radiation-curable composition into a mold in which resides a base layer comprising a major surface of the optical article; (b) rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation- curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape; (c) during the rotating of the mold, subjecting the curable composition to a curing radiation to solidify the composition; and (d) releasing the optical article from the mold. The optical article includes the base layer and an optical layer having a non-zero diopter and comprising the solidified composition. The base layer has a first uniform refractive index, and the optical layer has a second uniform refractive index that is more than 0.1 higher or lower than the first uniform refractive index.

[0014] According to embodiments, an optical article comprises an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm. The optical article comprises: (a) a front base layer having a minimum thickness of at least 0.5 mm and comprising a first major surface of the optical article, the first major surface characterized at least in part by a convex spherical shape; and (b) a rear optical layer having a minimum thickness of at least 1.0 mm, comprising a second major surface of the optical article, and characterized by a non-zero diopter, the second major surface characterized at least in part by a concave paraboloid shape, the rear optical layer containing residue of a photoinitiator. The front base layer has a first uniform refractive index, and the rear optical layer has a second uniform refractive index that is more than 0.1 higher or lower than the first uniform refractive index.

[0015] A method is disclosed, according to embodiments, for producing an optical article comprising an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm, the optical article comprising a base-member layer and an optical layer characterized by a non-zero diopter. The method comprises: (a) inserting, into the mold, a base member comprising a first major surface characterized at least in part by a convex spherical shape and a second major surface characterized at least in part by a toric shape, the inserting being such that the first major surface is facing downward; (b) forming the optical layer, the forming including (i) introducing a radiation-curable composition into the mold, (ii), rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation- curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape, and (iii) subjecting the curable composition to the curing radiation to solidify the composition; and (c) releasing the optical article from the mold, the base-member layer of the optical article comprising the base member.

[0016] A method is disclosed, according to embodiments, for producing an optical article comprising an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm. The method comprises: (a) introducing a radiation-curable composition into a mold in which resides a base layer comprising a major surface of the optical article; (b) rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation- curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape; (c) subjecting the curable composition to a curing radiation to solidify the composition; and (d) releasing the optical article from the mold, the optical article including the base layer and an optical layer having a non-zero diopter and comprising the solidified composition. At least one fourth of an area of the optical article surrounding an optical axis thereof has a refractive power within ±0.25 diopter of a refractive power through the optical axis, and an area adjoining a periphery of the optical article comprising at 10% of the area of the optical article has a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis.

[0017] According to embodiments, an optical article comprises an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm. The optical article comprises: (a) a front base layer having a minimum thickness of at least 0.5 mm and comprising a first major surface of the optical article, the first major surface characterized at least in part by a convex spherical shape; and (b) a rear optical layer comprising a second major surface of the optical article, having a minimum thickness of at least 1.0 mm and characterized by a non-zero diopter, the second major surface characterized at least in part by a concave paraboloid shape. At least one fourth of an area of the optical article surrounding an optical axis thereof has a refractive power within ±0.25 diopter of a refractive power through the optical axis, and an area adjoining a periphery of the optical article comprising at 10% of the area of the optical article has a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis.

[0018] BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The invention will now be described further, by way of example, with reference to the accompanying drawings, in which the dimensions of components and features shown in the figures are chosen for convenience and clarity of presentation and not necessarily to scale. In the drawings:

[0020] Fig. l is a schematic perspective view showing a powered, rotatable mold according to embodiments of the invention.

[0021] Fig. 2A schematically shows a cross-section of the mold of Fig. 1, according to embodiments of the invention.

[0022] Fig. 2B schematically shows a cross-section of a mold wherein an inserted base layer performs the function of a mold floor, according to embodiments of the invention.

[0023] Fig. 3 A shows a perspective view of an exemplary optical article according to embodiments of the invention.

[0024] Fig. 3B shows a schematic section contour of the optical article of Fig. 3 A, according to embodiments of the invention.

[0025] Fig. 4A shows a schematic section contour of a base member on a floor of a mold, according to embodiments of the invention.

[0026] Fig. 4B shows a schematic contour of an optical article comprising a base layer and an optical layer, according to embodiments of the invention.

[0027] Fig. 4C shows a schematic contour of a coated base member according to embodiments of the invention.

[0028] Fig. 4D shows a schematic contour of an optical article comprising a base layer and an optical layer, and a coating layer therebetween, according to embodiments of the invention.

[0029] Fig. 4E shows a schematic contour of an optical article comprising a base layer, an optical layer and a rear coating layer applied thereupon, according to embodiments of the invention. Figs. 5A, 5B and 5C show flowcharts of methods and method steps for producing an optical article in a mold, according to embodiments of the invention.

[0030] Fig. 6A shows a schematic section contour of a coating layer applied on the floor of a mold, with a curing device, according to embodiments of the invention.

[0031] Fig. 6B shows a schematic section contour of an optical article including an optical layer formed upon a coating layer applied on the floor of a mold, according to embodiments of the invention.

[0032] Fig. 6C shows a schematic section contour of an optical article including an optical layer formed upon a coating layer, according to embodiments of the invention.

[0033] Fig. 6D shows a schematic section contour of an optical article with a coating layer applied thereupon, according to embodiments of the invention.

[0034] Figs. 7A, 7B and 7C show flowcharts of methods and method steps for producing a coated optical article in a mold, according to embodiments of the invention.

[0035] Fig. 8A shows a schematic section contour of a base layer formed on the floor of a mold, with a curing device, according to embodiments of the invention.

[0036] Fig. 8B shows a schematic section contour of an optical article including a second layer formed upon a base layer formed on the floor of a mold, according to embodiments of the invention.

[0037] Fig. 8C shows a schematic contour of an optical article comprising a base layer, a second layer and coating layer applied therebetween, according to embodiments of the invention.

[0038] Fig. 8D shows a schematic contour of an optical article comprising a base layer, a second layer and multiple coating layers, according to embodiments of the invention.

[0039] Fig. 8E shows a schematic contour of an optical article comprising a base layer, multiple second layers and multiple coating layers, according to embodiments of the invention.

[0040] Figs. 9A, 9B, 9C and 9D show flowcharts of methods and method steps for producing an optical article, according to embodiments of the invention.

[0041] Fig. 10 shows a block diagram of some elements of an apparatus for use in fabricating an optical article, according to embodiments of the invention.

[0042] Fig. 11 is a schematic illustration of using a source of curing radiation to irradiate an upper surface of a curable composition in a mold, according to embodiments of the invention. Fig. 12 is a schematic illustration of using a source of curing radiation to irradiate at least a lower surface of a curable composition in a mold, according to embodiments of the invention.

[0043] Fig. 13 is a schematic illustration of a fluid conveyance delivering a curable composition from a storage vessel to a mold, according to embodiments of the invention.

[0044] Fig. 14 shows a block diagram of some elements of a system for use in fabricating an optical article, according to embodiments of the invention.

[0045] Fig. 15 shows a block diagram showing some elements of the control system of the system of Fig. 14, according to embodiments of the invention.

[0046] Figs. 16A, 16B and 16C show respective examples of a user interface of the system of Fig. 14, according to embodiments of the invention.

[0047] Figs. 17A, 17B and 17C show flowcharts of methods and method steps for producing an optical article, according to embodiments of the invention.

[0048] Fig. 18A shows a schematic section contour of an optical article including an optical layer formed upon a base layer, according to embodiments of the invention.

[0049] Figs. 18B and 18C show a schematic section contour of an optical article including an optical layer formed upon a base layer and a respective coating layer applied therebetween, according to embodiments of the invention.

[0050] Fig. 19 shows an annotated schematic section contour of an optical article according to embodiments of the invention.

[0051] Figs. 20, 21 A and 21B show flowcharts of methods and method steps for producing an optical article, according to embodiments of the invention.

[0052] Fig. 22A shows a schematic section contour of an optical article including an optical layer formed upon a base layer, according to embodiments of the invention.

[0053] Fig. 22B shows the optical article of Fig. 22A with the addition of a rear toric diopter, according to embodiments of the invention.

[0054] DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0055] The invention is herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. Throughout the drawings, like-referenced characters are generally used to designate like elements.

[0056] Embodiments of the invention relate to fabricating of optical articles in a rotating mold. In some implementations, the optical articles comprise eyeglass lens blanks of any variety, i.e., finished, semi-finished or unfinished, and single-vision or multifocal (or progressive). In various implementations, the optical articles can include lenses, including, without limitation, corrective lenses such as eyeglass lenses, including tinted or photochromatic lenses for eyeglasses and sunglasses. In other implementations, the optical articles can comprise elements of optical instruments, such as, and not exhaustively: telescopes, microscopes, binoculars, laser emitters, optical scopes for weapons, and flashlights. As used herein, the term ‘eyeglass lens blank’ includes any eyeglass lens bank, i.e., finished, semi-finished or unfinished, and single-vision or multifocal (or progressive), unless otherwise specified. As the term is used herein, an eyeglass lens blank differs from an eyeglass lens at least in that the eyeglass lens is formed, cut or trimmed to the shape of an eyeglass lens, including in some implementations from an eyeglass lens blank. In contrast, the eyeglass lens blank is generally not shaped like the final eyeglass lens, but rather is round or any other suitable convex shape, and large enough to trim or cut therefrom an eyeglass lens. Eyeglass lens blanks can be of any necessary diameter e.g., 50 mm, 65 mm, 80 mm, or any other diameter to suit different sizes and contours of eyeglass lenses. In some embodiments, eyeglass lens blanks are at least 40 mm in diameter, and / or at most 100 mm in diameter. In contradistinction, eyeglass lenses, according to some embodiments, have a maximum dimension, e.g., a diagonal from one rounded comer to another, of at least 30 mm, and / or at most 85 mms.

[0057] All ranges expressed in this disclosure and in the appended claims are inclusive.

[0058] In the embodiments, the optical articles are at least partly formed in a cavity of the rotating mold from a radiation-polymerizable composition or other curable composition that can be in a liquid phase, or alternatively semi-liquid or semi-solid. In some embodiments, the composition is radiation-curable but not necessarily polymerizable; nonetheless the terms are used interchangeably in the present disclosure and in the appended claims, and both can be understood to mean radiation-polymerized or otherwise radiation-cured. In an illustrative example, a polymeric dispersion such as an aqueous polyurethane dispersion can be radiation cured but does not undergo further polymerization. Examples of suitable radiation-polymerizable compositions include, without limitation, Crystal Coat® UV CS-950, or Crystal Coat® UV CS-NT5, both available commercially from SDC Technologies, Inc., of Irvine, California, USA; PPG TIGARD® 2000, available commercially from PPG Industries, Inc., of Pittsburgh, Pennsylvania, USA; IOC-135, available commercially from Inkron of Espoo, Finland; and the PixClear family of products, available commercially from Pixelligent Technologies LLC of Baltimore, Maryland, USA.

[0059] In embodiments, a suitable polymerizable composition can have one or more of the following exemplary attributes.

[0060] In an example, a suitable polymerizable composition has a static viscosity of no more than 2000 cPs.

[0061] In an example, a suitable polymerizable composition has surface tension of no more than 35N / m.

[0062] In an example, a suitable polymerizable composition can be stored at room temperature, or at a temperature of at least 15°C, and / or at a temperature of up to 28°C, for up to 18 months. In another example, the precursor materials of a suitable radiation- polymerizable composition can be stored within the foregoing temperature ranges for up to 24 months.

[0063] Various methods and processes are disclosed herein relating to polymerizing the compositions, e.g., by irradiating the compositions, e.g., with actinic radiation such as , and not exhaustively, UV, IR, microwave and / or visible light.

[0064] In an example, a suitable polymerizable composition can be cured to 80% of a final hardness (e.g., Rockwell hardness value) within no more than 2 minutes.

[0065] In an example, with respect to a suitable polymerizable composition, a material layer with a thickness of at least 1 mm, or at least 2 mm, or at least 3 mm, can be cured as a single layer.

[0066] In an example, a suitable polymerizable composition undergoes, during the curing process, no more than 2% linear shrinkage, e.g., 1-2% linear shrinkage.

[0067] In an example, a suitable polymerizable composition undergoes, during the curing process, no more than 5% volumetric shrinkage, e.g., 2-5% linear shrinkage.

[0068] In an example, with respect to a suitable polymerizable composition, a radiation- cured polymer can comprise a photoinitiator or a reaction product thereof. Examples of suitable photoinitiators include, and not exhaustively: Aromatic ketones and synergistic amines, Alkyl benzoin ethers, Thioxathones and derivatives, Benzil ketals, Acylphosphine oxide, Ketoxime ester or a acyloxime esters, Cationic curing quaternary ammonium salts, and Acetophenone derivatives. Examples of suitable resins acting as oligomers can include, and not exhaustively: Unsaturated polyester / acrylated polyester, Acrylated epoxy resin, Acrylated urethanes (both aliphatic and aromatic), Acrylated silicone resins, Acrylated polyethers, Acrylated melamines, Acrylated oils, N-vinyl urethanes, and a Thiolene system. Examples of suitable monomers for use in UV-curing include, and not exhaustively: Neopentyl glycol diacrylate, Hexanediol diacrylate 1.6, Polyethylene glycol diacrylate, Trimethylolpropane triacrylate, Pentaerythritol triacrylate, Dianol 2,2 Diacrylate, and UV E70 Polyester acrylate.

[0069] An optical article according to embodiments can be fabricated in a combination of layers, e.g., layers produced in a rotating mold, and of coatings, which can be applied in a rotating mold, or by a printing technique such as inkjet printing, or by any other suitable printing or application technique. Examples of layers include transparent elements, without or without optical power, e.g., refractive power, placed into the mold as a base layer or produced in the rotating mold itself and cured therein. Other examples of layers include additive layers that in combination with the base layer form the optical article and exhibit the optical properties desired in the optical article.

[0070] Examples of coatings include so-called functional coatings such as photochromic coatings, tint coatings, thermochromic coatings, UV-blocking coatings, and blue-light blocking coatings, and also include so-called protective coatings such as hard coats, tintable hard coats, and tinted hard coats.

[0071] Coatings can be provided or applied (e.g., by printing) on the front (convex) surface of a base layer or on the rear (concave) surface of a final optical layer. Additionally or alternatively, coatings, and especially functional coatings, can be applied between layers. Moreover, some layers can be produced, e.g., in the rotating mold, from compositions that after curing provide functionalities associated with functional or protective coatings. For example, it is possible to use a base layer coated with a hard coat or a tint, or alternatively a base layer comprising a composition that when cured has the requisite mechanical hardness or desired tint, and provide such protective and / or functional characteristics to the entire optical article.

[0072] The curable composition can be introduced into a cavity of the mold through an appropriate conveyance that includes, in some embodiments, some form of measuring or metering of the quantity of the composition. In some implementations, an exact (with minimal tolerance), pre-determined quantity of the composition is introduced into the mold, and in some implementations, excess material is removed through a drain in the mold or in a downstream process. The mold can be part of an apparatus that also includes a source of polymerizing radiation capable of solidifying the specific composition, preferably to an extent where the solidified composition retains its shape when removed from the mold. In some embodiments, solidifying means attaining at least 70%, at least 80%, or at least 90%, of the Rockwell-scale hardness value of the final, i.e., fully cured / polymerized material. An example of a polymerizing or curing radiation includes electromagnetic radiation in the ultraviolet spectrum, and especially in the upper end of the EV-A range, e.g., 390-400nm, or 395-405nm, or 395-400nm. In some implementations, a polymerizing wavelength or range of wavelengths depends on the formulation of the specific radiation-polymerizable composition. In some implementations, the wavelength is user- or software-selectable based on the specific composition used, and in some implementations different UV-radiation emitters, e.g., different lamps, are used in conjunction with different compositions requiring different wavelengths.

[0073] Curable compositions can be rotated at a selected rotation speed selected to produce a contour forming a concave paraboloid shape on an upper surface of the composition. This is particularly important when producing the ‘final’ layer of a multi-layer optical article. On the other hand, base or intermediate layers can be rotated at other speeds, e.g., higher speeds, since the precise shape of the upper surface of such layers can be less important in some implementations of the embodiments.

[0074] The term ‘paraboloid’ is used herein to mean a three-dimensional shape having two or more nonparallel two-dimensional parabolic cross sections; the shape can be of a mass, e.g., a solid or a rotated non-solid, and / or the surface of the solid or a rotated non-solid mass. The terms ‘parabola’ and ‘parabolic’ are also used herein in the same sense as paraboloid, and no distinction between the two terms is made, as the term parabolic is often applied to paraboloid shapes in the vernacular. The paraboloid shapes referred to herein can be circular paraboloids, elliptical paraboloids, or any other paraboloid shapes meeting the above definition. In some embodiments, the rotation speed is selected at least in part of the basis of the desired paraboloid shape and / or total diopter (of the finished product). The rotation speed can also be selected at least in part on the basis of material composition, quantity, refractive index, and / or viscosity.

[0075] In some implementations, the contour having the paraboloid (or parabolic) shape extends to the entire upper surface of the composition. In some implementations, the paraboloid contour extends only to a portion of the upper surface. In some embodiments, the curing can cause slight shrinkage of the composition and / or distortion of the pre-curing concave paraboloid shape. For example a height dimension of the cured composition can be reduced by up to 1%, or up to 2%, or up to 3%, or up to 4%, or up to 5%, or up to 10%, or by even more. In another example the final diopter of the cured composition can change by up to 0.05 diopter, or up to 0.1 diopter, or up to 0.15 diopter, or up to 0.2 diopter, or up to 0.25 diopter, or up to 0.3 diopter, or up to 0.35 diopter, or up to 0.4 diopter, or up to 0.45 diopter, or up to 0.5 diopter, or by even more, or less if limited by industry standards. In some embodiments, the shrinkage or distortion is predictable and repeatable for a given material, material quantity and rotation speed, such that a final article can be still produced with great precision. In some embodiments, slight deviations in material composition and / or quantity, rotation speed and / or duration, or any other factor or combination of factors can cause the paraboloid contour to deviate from a ‘perfect’ paraboloid shape. For example, the height of the cured composition can be increased or reduced (or both at different locations) by up to 1%, or up to 2%, or up to 3%, or up to 4%, or up to 5%, or up to 10%. Any of the foregoing shrinkages, distortions or deviations are not substantial, and any resulting contour can still be considered to be ‘paraboloid’ in accordance with any of the embodiments disclosed herein.

[0076] The floor of the mold has a shape selected for defining the shape of one of the two major surfaces of the optical article. For example, if the floor of the mold is planar, the optical article is fabricated with a planar major surface. If the floor of the mold, or at least a portion of the floor, has a concave spherical curvature, the optical article is fabricated with a corresponding convex spherical curvature. The floor portion can be shaped to accommodate, inter alia, a large variety of types of corrective lenses, including not only single-focus lenses but also progressive lenses, multifocal lenses, bifocal lenses, and including not only spherical lenses but also aspheric lenses.

[0077] In some embodiments, the optical article has a major surface characterized at least in part by a convex spherical shape, formed on a mold floor having, at least in part, a concave spherical shape. In some embodiments, slight deviations in material composition and / or quantity, rotation speed and / or duration, or any other factor or combination of factors can cause the spherical contour to deviate from a ‘perfect’ spherical shape. For example, the spherical contour can be distorted by up to 1%, or up to 2%, or up to 3%, or up to 4%, or up to 5%, or up to 10%. Any of the foregoing shrinkages, distortions or deviations are not substantial, and any resulting contour can still be considered to be ‘spherical’ in accordance with any of the embodiments disclosed herein.

[0078] In embodiments, the convex spherical contour of a first major surface is combined with the concave paraboloid contour of the second major surface to form an ophthalmic lens or lens blank. The optical, e.g., refractive, power of each curve is selected such that in combination a target diopter is achieved not only at the point of the optical axis (a straight line joining the two centers of curvature of the two major surfaces), but throughout a large portion of the optical article. For example, at least one fourth of the area of the optical article, e.g., surrounding the optical axis, has a refractive power within ±0.125 diopter or within ±0.25 diopter of the refractive power through the optical axis. In another example, at least one half of the area of the optical article, e.g., surrounding the optical axis, has a refractive power within ±0.125 diopter or within ±0.25 diopter of the refractive power through the optical axis. In some examples, an area at or near a periphery of the optical article (and not surrounding said optical axis), e.g., up to 20% of the area of the optical article, can have a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis.

[0079] The mold is arranged to be rotated, e.g., by a low-speed electric motor. ‘Low speed’ in this context means under 200 revolutions per minute (rpm), e.g., 10-200 rpm, or 50-120 rpm, or 50-100 rpm, or 70-100 rpm, or 70-120 rpm, or any other suitable range below 200 rpm as will be further discussed hereinbelow. In some embodiments, lower speeds, e.g., under 50 rpm or under 30 rpm, can produce unsatisfactory optical results. Alternatively a higher speed motor, i.e., above 200 rpm, can be used in combination with gearing that keeps the rotating speed of the mold between 10 and 200 rpm, including, without limitation, within any of the ranges noted above. In some embodiments, a higher speed can be used for forming layers, such as base layers or intermediate layers, for which the paraboloid shape is not critical because one or more additional layers will yet be formed over such base or intermediate layers. In some embodiments, a higher-speed motor can be employed to provide a higher rotation speed during a pre-production phase including, e.g., mixing or sonication of the polymerizable composition, and / or during a coating that can include, e.g., spin coating. In some designs, the higher-speed motor is capable of sufficiently precise low-speed operation without a reduction gear, and in other designs a gearing arrangement is employed to deliver a low speed suitable for forming the optical article in the mold. Alternatively, other means of rotation such as magnetic induction can be employed to enable selectable-speed rotation across larger ranges. The rotating of the mold and of the radiation-polymerizable composition therewithin, when carried out at an appropriate speed of rotation, is effective to cause an upper surface of a composition to take on a concave paraboloid shape. After solidification of the composition, e.g., by polymerization, the paraboloid shape formed by the rotating characterizes at least a portion of the second of the two major surfaces of the optical article.

[0080] The speed of rotation may be selected on the basis of one or more parameters such as the quantity of material in the mold and the paraboloid curvature desired. Other parameters affecting selection of the rotation speed directly or indirectly can include the prescription, e.g., diopter(s) and the refractive index of the radiation-polymerizable composition. In the case of optical lenses, a total power or diopter is derived from the combined curvatures of the two major surfaces. Thus, for a given final diopter, the shape of the parabola formed on the upper surface in the mold takes into account the shape of the floor on the bottom of the mold and / or of an upper surface of an existing layer resident in the mold at the time of introducing the radiation-polymerizable composition in the mold. The selecting of operating parameters such as rotation speed can be done by one or more processors of a control system provided for executing and / or controlling the lens fabrication process.

[0081] The base curvature selected for the floor of the mold is another parameter that can affect the rotation speed. In various designs, the floor of the mold can be removable and replaceable, e.g., non-destructively removable and available for reuse or repeated reuse. In other designs, the floor of the mold can be permanently installed in the mold as a permanent component, or formed integrally with the mold. In some designs, a user selects a mold for use in a forming a particular optical article because of the floor portion matching a desired base curvature, and in other designs the user need only select a removable / reusable floor element for use, e.g., a non-destructively separable floor element, again based on matching a desired base curvature.

[0082] The rotating of the mold can begin before, during or after the introduction of the composition into the mold. A determination of when the composition is introduced into the mold can depend, for example, on the dimensions of the mold, the viscosity of the composition, the throughput of the apparatus, and so on. The curing by exposure of the composition, or at least a portion of the composition, to the curing radiation can begin as soon as the paraboloid shape formed on the upper surface reaches a steady state, e.g., at a constant speed of rotation. The duration of the rotation before beginning the curing step can be calculated in advance, or based on empirical history, e.g., for similar quantities of composition, for similar compositions, and / or for similar desired curvature. Additionally or alternatively, the shape can be observed by an optical sensor or other sensor which then triggers initiation of the irradiation.

[0083] In some implementations, production of the optical article requires preliminary process steps, including, for example and without limitation: mixing of multiple components of the polymerizable composition, and / or sonication for mixing and / or deaeration (i.e., bubble removal). In some implementations, fabrication of the final optical article requires further processing, including, for example and not exhaustively: machining, edging, cutting, stamping, polishing, grinding, and / or buffing, of one of the two major surfaces and / or of the edge of the article. In some implementations, the optical article leaves the mold in a finished condition, such that the fabrication, not including optional coating or printing, etc., is completed in the mold. In such implementations, it can be desirable to employ a mold having a shape corresponding to the desired contour of a finished optical article. Thus, the mold can be selected for use on the basis of its contour matching that of the final article to be molded. In some embodiments, the mold is designed to have formed therein an eyeglass lens blank. In some embodiments, a removable mold insert corresponding to the contour of the article is employed, such that the same mold can be used for different products such as different eyeglass lenses. The removable mold insert can be held in inventory until needed, and optionally returned to inventory after use. Additionally or alternatively, the removable mold insert can be fabricated as a preliminary process step in the overall process of fabricating the optical article. For example, a 3D printer can be used to produce the removable mold insert, which is then inserted into the mold for fabricating the optical article.

[0084] A system for producing optical articles according to embodiments can be modular or scalable to include multiple molds and / or multiple sources of polymerizing radiation, e.g., multiple apparatuses as the term is used herein. For example, an apparatus in a retail location may include a pair of molds in order to allow parallel production of both lenses of a pair of eyeglasses, or parallel production of two different eyeglass lens blanks for use in producing the final eyeglass lenses. In another implementation, a large array of molds can be arranged for supplier-scale production of lenses or other optical articles. Other elements including, for example, radiation sources, fluid conveyances and storage vessels, can be provided in whatever quantities are appropriate relative to the throughput of the molds. An apparatus according to embodiments can be part of a system that includes additional elements related to the fabrication of the optical articles such as coating and printing stations, as well as a control system that includes, inter alia, a user interface. The user interface can include one or more interface elements such as, and not exhaustively, a screen with a graphical user interface, a microphone, a barcode scanner or other visual sensor (e.g., for determining the power of an existing lens and / or the exact lens volume of a selected eyeglass frame). The control system can be programmed to calculate process parameters based on user inputs and other inputs, and to regulate the operation of any of the system elements, such that any fabrication system as disclosed herein can be mechanized, semi-automated, or fully automated.

[0085] Referring now to the figures and in particular to Figs. 1 and 2, an apparatus 200 for use in fabricating an optical article 100, at least in part (i.e., at least one layer thereof) from a radiation-curable composition 15 comprises a rotatable mold 120. The mold 120 surrounds and / or encompasses a cavity 121 having a suitable diameter, for example (but not exhaustively), 50 mm, 65 mm or 80 mm, or more generally between 40 mm and 100 mm.

[0086] The rotation of the mold is necessary and effective to form the desired concave paraboloid shape on an upper surface of the radiation-curable composition 15 in the mold 120. According to embodiments, the mold 120 is configured, when electrically activated, to rotate at a selected or selectable speed so as to generate a centrifugal force that in combination with a gravitational force changes a contour of a second surface of the polymerizable composition 15 received in the mold 120 to a concave paraboloid shape. In an example, in a first operating mode of the apparatus, when the mold 120 is rotated at a speed between 10 and 200 revolutions per minute while a radiation-polymerizable composition having a viscosity between 20 and 500 cP or between 20 and 2000 cP at ambient temperature is resident therewithin, the rotating is effective to change a contour of a second surface of the polymerizable composition 15 to form a concave paraboloid shape.

[0087] The expressions ‘rotatable’ and ‘arranged to be rotated’ mean, inter alia, that the mold 120 is connected mechanically, either directly or indirectly such as by a gearing arrangement, to a motor 110 (not shown) that is configured for, e.g., designed for and capable of rotation, and that the rotation of the motor 110 causes rotation of the mold 120 at a suitable rotation speed according to embodiments. The term ‘motor’ is used herein to include any means for converting electrical energy to kinetic energy of rotation, including, for purposes of illustration, magnetic induction. In some embodiments, the mold 120 comprises or is mechanically connected to a rotor element such that the mold 120 is part of an integral motor-mold assembly, and in other embodiments, the motor 110 is a separate element of the apparatus 200. The mold 120 can include a power connection 215 for powering a motor 110 (not shown).

[0088] The mold 120 is arranged to be rotated at a selected speed that is appropriate to the process of producing optical elements 100 with a desired set of physical and optical parameters. In embodiments, an appropriate speed of rotation is a speed less than 200 revolutions per minute (rpm), for example (and not exhaustively) between 10 and 200 rpm, or between 10 and 150 rpm, or between 10 and 100 rpm, or between 30 and 200 rpm, or between 30 and 120 rpm, or between 30 and 100 rpm, or between 50 and 200 rpm, or between 50 and 150 rpm, or between 50 and 130 rpm, or between 50 and 120 rpm, or between 50 and 100 rpm, or between 70 and 200 rpm, or between 70 and 150 rpm, or between 70 and 130 rpm, or between 70 and 120 rpm, or between 70 and 100 rpm, or in any other range under 200 rpm. In some embodiments, a base layer, intermediate layer can be formed at a rotation higher speed. In some embodiments, a coating can be applied at a higher rotation speed.

[0089] In embodiments, an internal volume of the mold 120 is defined, inter alia, by the shape of the floor 130 and the height of the surrounding rim, or wall 124.

[0090] The shape of the upward-facing surface of the floor 130 is imparted during production of the optical article 100 to a lower surface of the optical article 100, e.g., surface 82 of Fig. 3B. Thus, a curvature of the floor portion 130 of the mold defines a corresponding curvature of one of the two major surfaces of the optical article 100. For example, if the upward-facing surface of the floor portion 130 is concave, then the corresponding major surface of the optical article 100 is convex. The cross-sectional view of Fig. 2A shows a non-limiting example of a floor portion 130 having a concave, spherical curvature. An optical article 100 formed using this exemplary floor portion 130 has a major surface characterized by a convex, spherical curvature. In some embodiments, a floor portion is removable, i.e., non-destructively removable, from a mold, and optionally reusable with or without further treatment. This type of floor portion 130 allows for selection of an appropriate floor portion 130 on the basis of the design of a specific optical article. In some embodiments, a floor portion 130 is permanently affixed to the mold, i.e., is not removable without damaging the floor portion or the mold, and in some embodiments, the floor portion is an integral element of a mold or even integrally formed with the mold, e.g., formed together with the peripheral wall 124 of the mold 120. The latter two types of floor portion allow for selection of an appropriate mold 120 on the basis of the design of a specific optical article 100. In the non-limiting example of Figs. 1 and 2, the floor portion 130 is secured within the mold 120 by a mechanical arrangement to illustrate a specific design option out of many possible designs for retaining and / or affixing a floor portion 130 in a mold 120 according to the embodiments.

[0091] In some embodiments, the floor portion 130, or at least an upper surface thereof, is treated to enable effective removal of the optical article 100 from the mold 120. The treatment can be pre-production and / or permanent, e.g., by providing the upper surface of the floor portion 130 with an optical-grade hard coating. Additionally or alternatively, the treatment can be performed before each use, e.g., before introduction of a polymerizable composition into the mold, and the treatment can include a material with lubricant or nonstick properties. The floor portion 130 can be fabricated, for example, from a glass or plastic; a transparent floor portion can be desirable in implementations in which irradiation of the polymerizable composition through the floor 130 (e.g., from below) is part of the curing process.

[0092] The wall 124 of the mold, according to embodiments, can serve multiple functions including, without limitation, keeping the curable composition 15 inside the mold, especially during rotation, and to deliver an edge on the periphery of the optical article 100 in accordance with a designed or desired contour. In embodiments, suitable selection of a quantity of the composition 15 is one that avoids undesirable edge effects such as having a surrounding ring formed in the optical article 100, where such a ring would have to be removed post-curing. Suitable selection of the material of the mold wall 124 is one that promotes effective removal of the optical article 100 after curing. An illustrative and nonlimiting example of suitable material for a mold wall 124 is a polyurethane coated with a poly tetrafluoroethyl ene .

[0093] As shown in Fig. 1, the mold 120 is arranged to be rotated about a center of rotation 128. In many implementations, i.e., for many types and forms of optical articles 100, the center of rotation 128 corresponds to an optical axis of the optical article 100. A center of rotation 128 need not be in the center of the mold; in embodiments, forming an optical article 100 having an off-center optical axis is accomplished by rotating the mold 120 asymmetrically about an off-center center of rotation 128 and not necessarily about its own center, as is discussed hereinbelow with reference to Figs. 21 A and 21B.

[0094] In some embodiments, as shown in Fig. 2B, the mold 120 has no floor 130, nor is configured to have a floor 130, e.g., a replaceable floor, installed. Instead a removable base layer 34 of a multilayer optical article is installed in the mold 120 and becomes a part of the final optical article. The base layer 34 can include, for example, an optically transparent polymer provided with a convex major surface, i.e., the major surface facing downward when installed in the mold.

[0095] Fig. 3 A shows a perspective view of an exemplary optical article 100 produced from a radiation-curable composition 15 in a mold 120 such as that of Figs. 1 and 2, and Fig. 3B shows a section contour of the same optical article 100. In the non-limiting example of Figs. 3 A and 3B, the optical article 100 is a single-focus positive-meniscus lens blank having a first major surface 82 (the lower surface in Fig. 3B) characterized at least in part by a spherical curvature, and a second major surface 81 (the upper surface) characterized at least in part by a paraboloid curvature. According to embodiments, the rotating of the mold 120 with the curable composition 15 resident therein causes a portion of the curable composition 15 to displace, e.g., as a result of so-called centrifugal forces. The displacing of the portion of the composition 15 includes displacing radially outward away from the center of rotation 128 towards the outer perimeter. After a period of rotating, e.g. rotating at a constant speed, at least a portion of the upper surface of the composition 15 takes on a concave paraboloid shape. At the constant speed of rotation, the paraboloid shape reaches a steady state, such that in situ curing of the composition 15 during continued rotation of the mold 120 is effective to preserve the paraboloid contour in the solidified composition 15 that forms the optical article 100.

[0096] In some embodiments, the optical article 100 comprises multiple layers, and optionally one or more coatings.

[0097] In a first implementation, the optical article comprises a base-member layer and an optical layer characterized by a non-zero diopter. The optical article comprises an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm.

[0098] Referring now to Fig. 4A, a base member 34 according to embodiments is inserted in a mold and placed on the floor 130 of the mold to form a base-member layer of the optical article to be fabricated. An example of such a mold floor 130 is the one illustrated in Fig. 2A. The base member 34 is a thin, optically transparent element that can be less than 2 mm thick, or 1 mm thick, or less than 1 mm thick. The base member 34 of Fig. 4A was preferably selected to match the curvature, e.g., a spherical curvature, of the mold floor portion 130. The base member 34 is not required to have a non-zero diopter.

[0099] Fig. 4B shows an optical article 100 comprising a base member 34 and an optical layer 38. The skilled artisan will understand that Fig. 4B potentially illustrates either one of two possible arrangements of elements. In a first possible arrangement, Fig. 4B shows an optical layer 38 formed atop a base member 34 in a ‘floorless’ mold 120 such as, for example, the mold 120 of Fig. 2B, where the base member 34 acts as the floor portion. The forming of optical members 38 is suitably performed by introducing a radiation-curable composition into the mold, i.e., atop the base member 34, rotating the mold at a speed of at least 50 rpm and not more than 120 rpm so as to cause a portion of the radiation-curable composition to displace to change a contour of an upper surface of the curable composition to a concave paraboloid shape, and subjecting the curable composition to the curing radiation to solidify the composition. In a second possible arrangement, Fig. 4B illustrates an optical article 100 after it is released from the mold - regardless of whether the mold included a floor portion 130 or the base member 34 was inserted into the mold to act as a floor within the mold cavity. Following release of the optical article 100 from the mold, it can be seen that the base member 34 is part of the optical article 100, and specifically the base-member layer thereof. In embodiments, the bottom surface 82 of the optical article 100 is characterized at least in part by a convex contour. While this convex contour is typically spherical, it may also be aspherical, planar, toric, atoric, or progressive. The upper surface 81 is characterized at least in part by a concave paraboloid contour.

[0100] Having noted above that the drawings are not necessarily to scale, it is worth noting here that the gaps apparent between layers in the instant figures are only to provide sufficient clarity so that the individual layers can be identified, and in fact there are no actual gaps between layers. In general, materials are selected to ensure proper adhesion and unrefracted optical transmission between the layers.

[0101] Fig. 4C shows a coated base member 137 comprising a base member 34 and a coating 29 applied to the convex major surface of the base member 34. The coated base member 137 can be provided for use, for example, in place of the uncoated base member 34 of Figs. 4A-4B and 4C-4D.

[0102] Figs. 4D and 4E, like Fig. 4B, can be understood either as illustrating an optical article 100 formed on the base member 34 in a floorless mold, or as illustrating an optical article 100 released from a mold 120, including one with a fixed or replaceable floor portion 130. Fig. 4D shows an optical article 100 having an intermediate functional coating layer 36 applied to the upper surface of the base member 34. In embodiments, the applying of the coating layer 36 can include spinning the mold to spread the coating formulation, or alternatively can include printing, e.g., inkjet printing. The intermediate coating layer 36 generally has to be cured, e.g., by actinic radiation, by applying heat, or by drying (i.e., evaporation of a solvent), before the optical layer 38 is formed. Fig. 4E shows an optical article 100 having a rear-surface (upper surface in the mold) functional and / or protective coating layer 39 applied to the upper surface of the optical member 38. In embodiments, the applying of the coating layer 39 can include spinning the mold to spread the coating formulation, or alternatively can include printing, e.g., inkjet printing. The coating layer 39 generally has to be cured, e.g., by actinic radiation, by applying heat, or by drying (i.e., evaporation of a solvent), before the optical article 100 is removed from the mold. In some implementations, the optical article 100 includes an intermediate coating layer 36 and an upper / rear surface coating layer 39. As discussed earlier, the optical article can optionally include a coated base member 137 rather than an uncoated base member 34.

[0103] Referring now to Fig. 5A, a method is disclosed for producing an optical article 100 in a mold 120. According to the method, the optical article 100 comprises a base-member layer and an optical layer 38 characterized by a non-zero diopter. In embodiments, the optical article 100 comprises an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm. As illustrated by the flow chart in Fig. 5A, the method comprises at least the three steps SOI, S02 and S03.

[0104] Step SOI includes inserting, into the mold 120, a base member 34 comprising a major surface characterized at least in part by a convex spherical shape, the inserting being such that said major surface is facing downward. In some embodiments, the inserted base member 34 forms a floor 130 of a molding volume of the mold 120, e.g., as illustrated in Fig. 2B. In some embodiments, inserting the base member 34 includes placing the base member 34 on a floor 130 of a molding volume of the mold 120, e.g., as illustrated in Fig. 4 A. In some embodiments, the base member 34 includes, on the convex major surface, at least one protective coating and / or at least one functional coating. The protective coating can be selected from photochromic coatings, tint coatings, thermochromic coatings, UV- blocking coatings, and blue-light blocking coatings. The functional coating can be selected from photochromic coatings, tint coatings, thermochromic coatings, UV-blocking coatings, and blue-light blocking coatings. An example of a coated base member is the coated base member 137 of Fig. 4C. In some embodiments, the opposing, i.e., concave major surface of the base member 34 is coated with at least one functional coating selected from photochromic coatings, tint coatings, thermochromic coatings, UV-blocking coatings, and blue-light blocking coatings. Additionally or alternatively, the base member 34 can comprises a composition performing a function of at least one of a protective coating and a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating. In some embodiments, the base member has a maximum thickness of no more than 2 mm, or no more than 1 mm, or less than 1 mm.

[0105] Steps S02 includes forming the optical layer 38, the forming including (i) introducing a radiation-curable composition 15 into the mold 120, (ii), rotating the mold 120 at a speed of at least 50 rpm and not more than 120 rpm to cause a portion of the radiation-curable composition 15 to displace so as to change a contour of an upper surface of the curable composition 15 to a concave paraboloid shape, and (iii) subjecting the curable composition 15 to the curing radiation to solidify the composition.

[0106] Step S03 includes releasing the optical article 100 from the mold. When the optical article 100 is released from the mold 120, the base-member layer comprises the base member 34.

[0107] In some embodiments, as illustrated by the flowchart of Fig. 5B, the method can additionally include Step S05. As shown in Fig. 5B, Step S05 includes applying - before Step S02 - a functional coating, e.g., the coating layer 36 of Fig. 4D, selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0108] In some embodiments, as illustrated by the flowchart of Fig. 5C, the method can additionally include Step S06. As shown in Fig. 5C, Step S06 includes applying - after Step S02 and before Step S03, a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating, and / or a protective coating selected from a hard coat, a tintable hard coat, and a tinted hard coat. The step results in an upper coating layer 39 as illustrated schematically in Fig. 4E.

[0109] In some embodiments, applying a coating in any of the foregoing steps includes printing, e.g., printing by an inkjet printer.

[0110] In a second implementation, the optical article comprises an optical layer coated by a coating layer applied, e.g., printed, on the floor of a mold and transferred to the convex major surface of the optical layer.

[0111] Referring now to Fig. 6A, a coating layer 129 according to embodiments and comprising one or more of the functional and protective coatings described above, is applied to the upper surface 131 of a floor portion 130 of a rotating mold 120. The coating layer is applicable to the surface 131 by printing (e.g., inkjet printing), by spin-coating utilizing the motor 110, or by any other suitable coating technique. A curing element 295 such as, for example and not exhaustively, a source of curing radiation, a source of heat, or a air dryer, is provided for curing the coating layer 129.

[0112] As shown in Fig. 6B, an optical layer 38 is formed above the coated surface 131 of the floor 130 by introducing a curable composition into the mold, rotating the composition so as to form a parabolic contour on the upper surface of the composition, and curing the composition until it solidifies or mostly (e.g., >80%) solidifies. As can be seen in Fig. 6C, when the optical article 100 is released from the mold, the coating layer is released with it, such that the convex major surface is coated by the coating layer 129. Fig. 6D illustrates such an optical article that had an additional coating layer 39 applied, e.g., while still resident in the mold, by any of the coating techniques described above.

[0113] Referring now to Fig. 7A, a method is disclosed for producing an optical article 100 in a mold 120. In embodiments, the optical article 100 comprises an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm. As illustrated by the flow chart in Fig. 7A, the method comprises at least the three steps Sil, S12 and S13.

[0114] Step Sil includes applying, on a floor 130 of the mold 120, a coating layer 129 comprising at least one of a protective coating and a functional coating. In some embodiments, the applying comprises printing, e.g., by an inkjet printer. Additionally or alternatively, the applying can include spin-coating or any other suitable coating technique. In some embodiments, the coating layer consists of at least one of a protective coating selected from the group consisting of a hard coat, a tintable hard coat, and a tinted hard coat, and / or a functional coating selected from the group consisting of a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0115] In some embodiments, a hydrophobic release layer (not shown) is introduced in the mold before the applying. This can include, for example and not exhaustively, a permanent coating on the mold floor, a hydrophobic coating applied before each use of the mold, or a thin sticker that is subsequently peeled off the optical article after its release from the mold.

[0116] Step S12 includes forming an optical layer 38 over the coating layer 129, including (i) introducing a radiation-curable composition 15 into the mold 120, (ii), rotating the mold 120 at a speed of at least 50 rpm and not more than 120 rpm to cause a portion of the radiation-curable composition 15 to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape, and (iii) subjecting the curable composition to the curing radiation to solidify the composition.

[0117] Step S13 includes releasing the coated optical article 100 from the mold 120. In some embodiments, the optical article has a minimum thickness of at least 1 mm, and / or an average thickness of at least 2 mm.

[0118] In some embodiments, the floor 130 of the mold 120 is characterized at least in part by a concave spherical shape.

[0119] In some embodiments, as illustrated by the flowchart of Fig. 7B, the method additionally comprises Step S14. As shown in Fig. 7B, Step S14 includes curing the coating layer 129 using at least one of radiation, heat and drying by evaporation. Step S14, if / when carried out, is carried out after Step Sil and before Step S12.

[0120] In some embodiments, as illustrated by the flowchart of Fig. 7C, the method additionally comprises Step S15. As shown in Fig. 7C, Step S15 includes applying at least one functional coating selected from the group consisting of photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating, and / or at least one protective coating selected from the group consisting of a hard coat, a tintable hard coat, and a tinted hard coat. Step S15, if / when carried out, is carried out after Step S12 and before Step S13.

[0121] In a third implementation, the optical article comprises a base-member layer formed in the mold and an optical layer. The optical article comprises an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm.

[0122] Fig. 8A illustrates a base member 134 formed on a floor portion 130 of a mold 120. Unlike the base member 34 of Fig. 4A which is inserted into the mold and can, in some implementations act as the floor portion of the mold, the base member 134 of Fig. 8 A is formed in a rotating mold 120 by introducing a quantity of a radiation-curable base-layer composition 15 into the mold 120, rotating the mold 120 to create a concave contour on an upper surface of the base-layer composition 15, and subjecting the base-layer composition to curing radiation (from radiation source 295) to solidify the base-layer composition within the mold 120.

[0123] As shown in Fig. 8B, a second layer 138 is subsequently formed above the cured base-member layer 134 in the rotation mold 120 using similar techniques as for the basemember layer 134, the main difference being the selection of a rotation speed between 50 and 120 rpm for forming a paraboloid contour on the upper surface 81. Figs. 8C-8E illustrate various examples of optical articles 100 produced according to this third implementation in which a base layer 134 is formed from a curable composition 15 in a rotating mold 120.

[0124] In Fig. 8C, an intermediate coating layer 139, similar to intermediate coating layer 36 of Fig. 4D, comprising a functional coating, is applied between the base layer 134 and the second layer 138. As illustrated schematically in Fig. 8D, as many as three coating layers 129, 139 and 39 can be applied: A coating layer 129 can be applied to the floor 130 of the mold 120 and be configured to transfer to the convex bottom surface of the base member 134 as described above in connection with Fig. 6A. The base coating layer 129 can include a functional coating and / or a protective coating. An intermediate coating layer 139 comprising a functional coating, can be applied between the base-member layer 134 and the second layer 138 as shown in Fig. 8C.

[0125] Fig. 8E illustrates an optical article 100 built up from a base-member layer 134 and multiple additional ‘second layers’ 138. (Two such layers are shown in Fig. 8E but this is not limiting.) Each of the additional layers 138 is formed using the rotating-mold technique, and the final (uppermost) layer includes selecting a rotation speed between 50 and 120 rpm for forming a paraboloid contour on the upper surface. Corresponding intermediate coating layers 139 can optionally be applied between each pair of adjacent layers, as shown in Fig. 8E. A base coating layer 129 and / or rear (uppermost) coating layer 39 can optionally be applied as shown in Fig. 8D.

[0126] Any of the coating layers 39, 129, 134, 139 illustrated in Figs. 8A-8E can be applied by spinning the mold to spread the coating formulation, or alternatively can be applied using a printing technique, e.g., inkjet printing.

[0127] Referring now to Fig. 9A, a method is disclosed for producing an optical article 100. According to the method, the optical article 100 comprises a base-member layer 134 and a second layer 138. In embodiments, the optical article 100 comprises an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm. As illustrated by the flow chart in Fig. 9 A, the method comprises at least the two steps S21 and S22.

[0128] Step S21 includes forming a base layer 134 in a mold 120, the forming of the base layer 134 including: (i) introducing a quantity of a radiation-curable base-layer composition into the mold 120, (ii) rotating the mold at a first speed to create a concave contour on an upper surface of the base-layer composition, and (iii) subjecting the baselayer composition to a first curing radiation to solidify the base-layer composition within the mold, the solidifying being effective to preserve the concave shape. In some embodiments, the base layer 134 comprises a major surface characterized at least in part by a convex spherical shape.

[0129] Step S22 includes forming a second layer 138, the forming of the second layer 138 including: (i) while the solidified base layer 134 is disposed within the mold 120, introducing a quantity of a radiation-curable second-layer composition into the mold 120, (ii) rotating the mold 120 at a second speed of at least 50 rpm and not more than 120 rpm to cause a portion of the radiation-curable composition to displace so as to change a contour of an upper surface of the second-layer composition to a concave paraboloid shape, and (iii) subjecting the second-layer composition to a second curing radiation to solidify the second-layer composition.

[0130] In some embodiments, the first speed (of Step S21) is faster than the second speed (of Step S22). In some embodiments, the first curing radiation and the second curing radiation have different wavelengths.

[0131] In some embodiments, as illustrated by the flowchart in Fig. 9B, the method additionally comprises Step S23. As shown in Fig. 9B, Step S23 includes: applying a coating layer 129 comprising at least one of a protective coating and a functional coating on the floor 130 of the mold 120. Step S23, if / when carried out, is carried out before Step S21. In some embodiments, the coating layer 129 includes at least one of a functional coating selected from the group consisting of a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating, and a protective coating selected from the group consisting of a hard coat, a tintable hard coat, and a tinted hard coat. Additionally or alternatively, the base layer 134 can comprise a composition performing a function of at least one of a protective coating and a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0132] In some embodiments, as illustrated by the flowchart of Fig. 9C, the method additionally comprises Step S24. As shown in Fig. 9C, Step S24 includes applying at least one functional coating selected from the group consisting of photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating. Step S24, if / when carried out, is carried out after Step S21 and before Step S22.

[0133] In some embodiments, as illustrated by the flowchart of Fig. 9D, the method additionally comprises Step S25. As shown in Fig. 9C, Step S25 includes applying at least one functional coating selected from the group consisting of photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating, and / or at least one protective coating selected from the group consisting of a hard coat, a tintable hard coat, and a tinted hard coat. Step S25, if / when carried out, is carried out after Step S22 while the optical article 100 is still in the mold.

[0134] We now refer to Fig 10, in which a block diagram shows components of an apparatus 200 for fabricating an optical article 100 according to embodiments. The solid lines in Fig. 10 (and in Fig. 14) represent elements or components that are present in every implementation of the embodiments, while the dashed lines represent elements or components that may be absent in some implementations.

[0135] As previously discussed with reference to Figs. 1 and 2, the apparatus 200 comprises a powered, e.g., electrically powered, rotatable mold 120 shaped, i.e., having a volume appropriately sized and shaped to receive a quantity of the radiation-polymerizable composition 15. In some embodiments as illustrated in Fig. 2A, the mold 120 includes and, when operational, has inserted or installed therein a floor portion 130 shaped to impart a curvature to a first major surface (e.g., a bottom surface 82 as molded) of the optical article 100 formed upon the floor portion 130. In such embodiments, the floor portion 130 can be non-destructively removable, non-removable or permanently affixed to the mold 120, or integrally formed with the mold 120, e.g., formed with the wall 124 of the mold 120. In some embodiments, as illustrated in Fig. 2B, the mold 120 has no floor and a base member 34 inserted into the mold 120 serves as a floor portion.

[0136] In some embodiments, the quantity of the polymerizable composition 15 is selected in accordance with physical parameters of the specific optical article 100 being formed in the mold 120, and / or corresponding parameters of a particular layer 38, 138, 134 for example any of volume, weight, specific density, or any other parameter necessary to set the quantity of material. In some embodiments, the quantity is selected in accordance with the optical properties of the specific optical article 100 or layer 38, 138, 134 being formed in the mold 120, for example the diopter and / or refractive index of the optical article 100, and / or base curvature of the floor portion 130 or base member 34 that gets transferred to the first surface of the optical article 100. In some embodiments, the quantity of the polymerizable composition 15 supplied to the mold 120 is greater than that needed for the specific optical article 100, and the excess is drained from the mold and / or trimmed from the cured optical article 100. In either of these cases, the mold 120 is large enough to receive the delivered quantity. In In embodiments, the apparatus 200 comprises a motor 110. The motor can be disposed, for example in the housing 115 shown in Fig. 1. In some embodiments, other rotation means are used to rotate the mold 120, such as, for example, magnetic induction. The motor 110 - or alternative rotation means such as magnetic induction - is configured or configurable to cause rotation of the mold 120 at a constant speed less than 200 revolutions per minute in any of the speed ranges disclosed hereinabove. In some embodiments, the rotation speed of the motor is user- or software- selectable in increments of no more than 10 revolutions per minute.

[0137] As shown in block diagram of Fig, 10, the apparatus 200 additionally comprises a source 250 of polymerizing radiation 25. Referring now to Fig. 11, the radiation source 250 is represented graphically by a UV flashlight, but the radiation source 250 can take on any form suitable for emitting polymerizing radiation 25 according to embodiments, and can include more than one emitter. To be operational, the radiation source 250 is configured to produce radiation 25 at least at a wavelength effective to solidify the specific radiation-polymerizable composition 15. In some embodiments, the wavelength is selectable by a user and / or by control system software. The radiation source 250 is arranged, as shown in the non-limiting example of Fig. 11, to irradiate at least a portion of the upper surface of the polymerizable composition 15 - in the mold 120 - with the polymerizing radiation 25. Additionally or alternatively, the radiation source 250 can include more than radiation source, such as the emitters 250 beneath and / or on the sides of the mold 120 in the non-limiting example of Fig. 12, which shows a detail of a cross section of the mold 120 of Fig. 11. In some embodiments, irradiating the curable composition 15 from more than one angle can shorten the time needed to solidify the composition 15. It can be desirable, including for this purpose, to employ a floor portion 130 as shown, or insertable base member 34, that is transparent at least to the polymerizing wavelength of the emitters 250.

[0138] In some embodiments, an apparatus 200 additionally comprises a vessel 21 for storing a supply of a radiation-curable composition 15, as shown in block diagram of Fig. 8. The vessel 21 is arranged, e.g., appropriately sized and disposed in at least switchable fluid communication with the mold 120 to enable timely delivery of the composition 15 to the mold 120, e.g., through a fluid conveyance 35 arranged to mediate between the vessel 21 and the mold 120. The vessel 21 and fluid conveyance 35 are represented graphically in a non-limiting example of apparatus components in Fig. 13 as a simple container with a spigot. In other examples, vessels 21, fluid conveyances 35 can be more sophisticated and / or more industrialized while performing the same functions as the examples illustrated in Fig. 13. In yet another example, the vessel 21 can be a simple bottle and the corresponding fluid conveyance 37 can be a simple nozzle. In some embodiments, the fluid conveyance 35 includes a metering or measuring device 37 for metering or measuring the quantity of the composition 15 delivered to the mold 120 for each optical article 100. In some embodiments, the fluid conveyance 35 can be designed, built, and / or adjusted to supply the desired quantity without metering, for example, and without limitation, by regulating the duration of the supplying or by regulating an electrical parameter associated with the supplying. The size and quantity of the vessel(s) 21, the type and size of the fluid conveyance 35 as well as the type of metering device 37 are configurable to meet the requirements of the apparatus according to specific implementations.

[0139] We refer again to Fig. 10. In some embodiments, two or more components of the polymerizable composition 15 are mixed externally to the mold 120 and prior to the introducing of the composition 15 into the mold 120. In a non-limiting example, one of the components is a colorant. In such embodiments, an external mixer 111 can comprise, without limitation, a static mixer, a mixing tube or a mixing container, and can be provided as part of the apparatus 200. In some embodiments, pre-fabrication mixing is carried out in the mold 120. In some embodiments, regardless of whether or where the mixing is carried out, a sonication probe 112 or equivalent de-aeration device is provided as part of the apparatus 200 for de-aeration, i.e., bubble-removing, of the composition 15. In some embodiments, regardless of where the mixing is carried out, a heater 113 is provided as part of the apparatus 200 for heating the mixer 111 or mold 120, e.g., for reducing the viscosity of the composition 15 for more effective or efficient mixing.

[0140] In some embodiments, the apparatus 200 includes arrangements (not shown) for flowing an inert gas, e.g., N2, to reduce the oxygen exposure of the composition 15. In some embodiments, the rotating and / or the curing are performed in an at least partly oxygen-depleted atmosphere.

[0141] We now refer to Fig. 14, which shows a block diagram of a system 500 for fabricating an optical article 100. The system 500 comprises at least a molding assembly 220 and electronic circuitry 150. The molding assembly comprises a mold, e.g., the rotatable mold 120 of Figs. 1 and 2 surrounding a cavity 121 with a minimum diameter of 50 mm, for producing the optical article 100 from a radiation-polymerizable composition 15. The producing of the optical article in the mold 120 includes forming a paraboloid shape on a surface of the radiation-polymerizable composition 15 by rotating the mold 120, e.g., at a constant speed slower than 200 rpm. The molding assembly 220 additionally comprises an emitter 250 of polymerizing radiation 25. The emitter 250 is arranged to solidify at least a portion of the polymerizable composition 15 by irradiation. In some embodiments, the system comprises a material supply assembly 230 that comprises one or more vessels 21 storing the radiation-polymerizable composition 15, and a conveyance 35 mediating between the vessel 21 and the mold 120, for supplying the radiation- polymerizable composition 15 to the mold 120.

[0142] In embodiments, the electronic circuitry 150 comprises a control system 60 configured, e.g., programmed, to regulate operation of the molding assembly 220 in response to inputs, and a user interface 60. In some embodiments, the regulation includes operation of a material supply assembly 230. Some or all of the inputs are received through the user interface 60. Each input defines one or more parameters related to the shape of the optical article 100 and / or the composition of the optical article 100 and / or operation of the molding assembly 220 or material supply assembly 230. As shown in the block diagram of Fig. 15, an exemplary control system 50 comprises computing equipment and ancillary equipment configured for monitoring, controlling, regulating and / or actuating one or more components or sub-systems of the system 500. Depending on location customization, the control system can include any or all of (and not exhaustively): one or more computer processors 55, computer-readable storage media 58, 59, and a communications module 57. The computer-readable program storage media 58, 59 can include transient and / or transient storage, and can include one or more storage units, all in accordance with desired functionality and design choices. Some or all of the computer-readable program storage media 58, 59 can be cloud-based. In embodiments, the program storage 58 can be used for storing program instructions in firmware and / or software, for execution by the one or more processors 55; operating data and / or maintenance data relating to components of the system 500 and / or optical 100 articles produced any one or more of its sub-systems and their components can be stored in the data storage module 59. The communications module 57 can be configured to establish communications links with external computers, e.g., for software and firmware updates, database access, etc., and to interact with users via the user interface 60. In some embodiments, not all of the illustrated components of the control system 50 are provided. In some embodiments, not all of the communications arrangements are provided.

[0143] In embodiments, the electronic circuitry 150 comprises a user interface 60 configured to receive user inputs and to provide, e.g., display and / or store, information about the fabrication of optical articles 100 using the system 500. As discussed hereinabove, a user interface 60 can include a screen, e.g., a touchscreen. In some embodiments, the user interface 60, or at least the screen portion of the user interface 60, is realized in a computer program or an app for a mobile device. In some embodiments, the user interface 60 includes a communications-enabled handheld device designed to run software or preloaded-software of the interface.

[0144] Sample screenshots of an exemplary user interface 60 are shown schematically in Figs. 16A, 16B and 16C. The three illustrations are non-limiting examples of types of information exchanged through the user interface. In other examples, more technical and detailed data is input, displayed and / or adjusted, while in yet other examples, fewer options are provided the user and more decisions may be made by software of the control system 50, e.g., using machine learning and artificial intelligence.

[0145] Fig. 16A shows a screen displaying buttons that allow data entry of input parameters and / or for receiving image scans, barcode scans, and other major inputs. Fig. 16B shows another screen displaying buttons that offers the user an opportunity to check and / or adjust process parameters, including parameters based on inputs received via the screen shown in Fig. 16A. Fig. 16C shows a panel with status indicators showing the progress of the process of fabricating the optical article 100.

[0146] Referring again to the block diagram of Fig. 14, the system 500 can include, according to some embodiments, one or more additional components. A first example of an additional component is a 3D printer 205 for fabricating, e.g., a contour insert 140 or a mold 120 having a molding volume shaped to form a final optical article 100, e.g., a mold 120 comprising an integral contour insert 140. A second example of an additional component is a fluid bath 208 for cleaning, e.g., chemical cleaning or ultrasonic cleaning of the optical article 100 formed in the mold 120. The fluid bath 208 can be accompanied by a drying station (not shown). A third example of an additional component is a spin coater 209 for coating the optical article 100 formed in the mold 120. The optical article 100 can be coated with one or more coatings, including, for example (and not exhaustively), a functional coating including a colorant, a protective hard coat, an anti- reflective or antiglare coating, and / or a super-hydrophobic or antifog coating. A fourth example of an additional component is a printer 210 for adding, e.g., a tint layer or a photochromatic layer to a major surface of the optical article 100. The printer 210 is adapted to employ any appropriate technology for depositing a colorant directly or indirectly on a surface of the optical article 100 after being formed in the mold 120. A fifth example of an additional component is a quality control (QC) station 206 for final measurements and, if needed, adjustments, e.g., buffing or polishing. A sixth example of an additional component is a scanner (not shown) for measuring a shape or an internal space of an eyeglass frame, or a lensometer for assessing an existing, either or both deployed in communication with the control system 50 for transferring information needed for fabricating a new lens.

[0147] In some embodiments, an optical article such as an eyeglass lens, e.g., an eyeglass lens having a maximum dimension of at least 30mm, or an eyeglass lens blank, e.g., an eyeglass lens blank having a diameter of at least 40 mm, can include two layers having different respective refractive indexes.

[0148] Referring now to Fig. 17A, a method is disclosed for producing an optical article 100. In embodiments, the method of Fig. 17A is suitable for producing and optical article that includes two layers having different respective refractive indexes. In some embodiments, there are no layers thicker than 0.5 mm between the two layers having the two different respective refractive indexes. In some embodiments, there are no layers thicker than 0.1 mm between the two layers having the two different respective refractive indexes. Depending on the refractive index differential, an anti -reflective coating can be provided between the two layers having the two different respective refractive indexes.

[0149] According to the method, the optical article 100 comprises a base-member layer 234 and a second layer 238, shown in Figs. 18A-C. In embodiments, the optical article 100 comprises an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm. As illustrated by the flow chart in Fig. 17A, the method comprises at least the four steps S31, S32, S33 and S34

[0150] Step S31 includes introducing a radiation-curable composition 15 into a mold 120 in which resides a base layer 234 comprising a major surface 82 of the optical article 100. A base layer 234 can be an inserted, prefabricated base-layer member such as the baselayer member 34 of Figs. 4A-E, or a mold-produced base layer such as the base layer 134 of Figs. 8A-E. The base layer 234 has a first index of refraction that is uniform throughout the layer, where ‘uniform’ means having no more than a de minimis amount of variability, e.g., the amount of variability inherent in a manufacturing process, or alternatively, a variability of no more than ±1% from an average refractive index for the base layer 234, or no more than ±2%, or no more than ±5%, or no more than ±10% in local refractive index. In some embodiments, the base layer 234 has a minimum thickness of at least 0.5 mm. In some embodiments, the base layer 234 has a minimum thickness of at least 1.0 mm.

[0151] Step S32 includes rotating the mold 120, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition 15 to displace so as to change a contour of an upper surface 81 of the curable composition 15 to a concave paraboloid shape.

[0152] Step S33 includes subjecting the curable composition 15 to a curing radiation 25 during the rotating of the mold 120. According to the method, exposure to the curing radiation 25 is effective to solidify the composition 15, and form an optical layer 238, the solidifying being at least to an extent that the optical article 100 can be safely released from the mold 120 and retain its shape. By means of the curing, the solidified composition forms an optical layer 238 having a second uniform refractive index that is more than 0.1 higher or lower than the first uniform refractive index, i.e., of the base layer 234. In some embodiments, the second uniform refractive index is more than 0.15 higher or lower than the first uniform refractive index.

[0153] Step S34 includes releasing the optical article 100 from the mold, the optical article 100 including the base layer 234 and an optical layer 238 comprising the solidified composition, as illustrated schematically in Fig. 18 A. According to the method, the optical layer 238 has a non-zero diopter.

[0154] In some embodiments, a reflection mismatch can occur at the interface between the base layer 234 and the optical layer 238, In such embodiments, as illustrated by the flowchart of Fig. 17B, the method additionally can comprise Step S35. As shown in Fig. 17B, Step S35 includes applying an anti -reflective layer 237, as illustrated schematically in Fig. 18B, on an upward-facing major surface of the base layer 234 before carrying out the introducing of the radiation-curable composition 15 into the mold 120 in Step S31. In the event that a reflection mismatch will occur at the interface The anti-reflective coating can be tailored to match the refractive index of the optical layer 238.

[0155] In some embodiments, as illustrated by the flowchart of Fig. 17C, the method additionally comprises Step S36. As shown in Fig. 17C, Step S36 includes applying a functional coating 239 (other than an anti-reflective coating), as illustrated schematically in Fig. 18C, on an upward-facing major surface of the base layer 234 before carrying out the introducing of the radiation-curable composition 15 into the mold 120 in Step S31. The functional coating 239 is one selected from the group consisting of a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0156] In some embodiments, the front base layer 234 is devoid of photoinitiator residue, e.g., while the optical layer 238 has photoinitiator residue.

[0157] Both the spinning process to produce the uncured pre-polymeric optical structure and the curing of the composition in the rotating mold can result in certain structural properties. In some embodiments, the curing of the composition 15 in the rotating mold can result in certain detectable artifacts of the production process being present in the final product, i.e., in the optical layer of a finished lens or unfinished lens blank 100. An example of such a detectable artifact is a surface roughness, e.g., average surface roughness, of the upper, exposed paraboloid surface 81 being greater than a surface roughness of the bottom surface 82, i.e., the exposed major surface of the base layer 34, 134, 234, formed on the mold floor). In an example, the average roughness (Ra) of the paraboloid surface 81 is at least double the average roughness Ra of the mold-produced lower surface. Average roughness (Ra) measures the deviation of a surface from a mean height. In other examples, the average roughness of the paraboloid surface can be at least 3 times, at least 5 times, at least 10 times, at least 30 times, or at least 100 times greater than the average roughness Ra of the major surface of the base layer 34, 134, 234. In some examples, the ratio of the average roughness Ra of upper paraboloid surface to the average roughness Ra of the mold-produced lower surface can be in any one of the following ranges: 2 to 500, 2 to 100, 2 to 50, 2 to 10, 5 to 500, 5 to 100, 5 to 50, or 8 to 100. The lower surface 82 of an optical article 100 according to embodiments may have an average surface roughness (Ra) of at most 10 nm. In examples, the Ra is at most 3nm, at most 1.5nm, at most Inm, or at most 0.8nm, and at least O.lnm, at least 0.3nm. In any of these cases, the Ra may be at least 0.5nm.

[0158] The surface roughness of the at least one thin lens may be determined by means of white-light interferometry, e.g., using the Zygo™ New View™ 9000 3D optical surface profiler.

[0159] Additional examples of detectable artifacts include indications of internal material flows traceable to polymerization in a rotating mold, and bubbles. The inventors have discovered that there exists a tradeoff with respect to the viscosity of the pre-polymeric formulation: low viscosities enhance bubble removal and replace dissolved oxygen, while high viscosities may serve as a barrier for preventing oxygen to migrate into the material and inhibit the surface reaction. Fast curing times cause an increase in the rate of bubble production; this is compounded by a short time window for releasing bubbles pre-existing in the pre-polymer formulation.

[0160] The pre-polymer for use in accordance with any of the present embodiments may have at least one (and typically both) of a 25°C viscosity and a rotation viscosity (z.e., the viscosity during mold rotation, prior to curing) of at most 2000cP, at most 1200cP, at most 500cP, or at most 300cP, and more typically, at most 200cP, at most 150cP, at most lOOcP, at most 80cP, at most 60cP, at most 40cP, or at most 25cP. The pre-polymer may have at least one (and typically both) of a 25°C viscosity and a spinning viscosity of at least 3cP, at least 5cP, at least lOcP, at least 15cP, or at least 20cP.

[0161] The viscosity of the pre-polymer as well as other fluids utilized in accordance with the present invention is measured with a rotational, spindle-based viscometer such as a Brookfield rotational viscometer or the equivalent.

[0162] The pre-polymer may have a static surface tension within a range of 18 to 40 mN / m, and more typically from a range from 23 to 32 mN / m, at at least one of (a) 25°C and (b) the spinning temperature. The surface tension may be determined utilizing an instrument for drop shape analysis (e.g., a pendant drop method).

[0163] Thus, the inventors have found that despite the fact that the spinning of the prepolymer liquid within a particular rpm range may largely determine the general paraboloid shape of the pre-polymer surface, the optical quality of the surface and bulk may be mitigated to the point that the lens produced is optically unacceptable. The inventors have identified several key phenomena that appreciably detract from lens quality: interaction of oxygen with the pre-polymer, exothermicity of the curing reaction and temperature rise, and liberation of bubbles disposed within the volume of the lens during curing e.g., bubbles formed during the curing reaction). These deleterious phenomena may be significantly exacerbated by the need to cure a large, thick mass of pre-polymer: in many cases, the final lens has a minimum thickness of several millimeters, and in some areas, the thickness may be 5-6 millimeters or more. The need to effect the curing in a fairly short period of time may further exacerbate these phenomena.

[0164] The inventors have discovered how to appreciably mitigate the above-described phenomena so as to enable the production of a lens whose bulk properties are sufficiently good and whose upper or first major surface is sufficiently smooth and aberration-free for eyeglass-quality lenses. To this end, the carrying out any of the methods disclosed herein for fabrication of optical articles can include one or more of the following: utilizing an intermediate-viscosity pre-polymeric formulation; pre-heating the pre-polymeric formulation; curing the pre-polymeric formulation in an oxygen-poor environment; and reducing the thickness of the pre-polymer liquid by utilizing a pre-fabricated base-layer member that ultimately forms the base layer of the lens.

[0165] According to embodiments, the methods and systems disclosed herein are capable of producing an optical article comprising an eyeglass lens having a maximum dimension of between 30 mm and 85 mm. According to embodiments, the methods and systems disclosed herein are capable of producing an optical article comprising an eyeglass lens blank having a diameter between 40 mm and 100 mm. Optical articles can have a first (front when installed in an eyeglass frame) major surface characterized by any kind of curvature, e.g., convex spherical, convex aspherical, etc., and a second major surface (rear when installed in an eyeglass frame) characterized at least in part by a concave paraboloid shape. In some embodiments, an optical article having a non-zero refractive power through an optical axis thereof can be characterized in that at least one half of an area of the optical article has a refractive power close to the non-zero refractive power through the optical axis (e.g., within ±0.25 diopter or within ±0.125 diopter of that non-zero refractive power, or within at most ±5%, or at most ±3%, or at most ±2%, or at most ±1%, or at most ±0.5%, of that non-zero refractive power). In other words, for a ‘central’ part of the optical article(not necessarily geometrically central), the paraboloid curve is close enough to an analogous spherical curve or aspherical curve of the front major surface so that the total optical power (in diopters) is consistent throughout the ‘central’ part.

[0166] In some such embodiments, the annulus between the ‘central part’ and the outer periphery of the optical article may be characterized by a local and / or average refractive power that diverges more from the non-zero refractive power through the optical axis than the values noted above for the respective central part, as a result of the paraboloid curve being less emulative of a spherical curve as the radial distance from the optical axis increases. The ‘central part’ may have an absolute definition, e.g., 15 mm from the optical axis, or 17.5 mm from the optical axis, or 20 mm from the optical axis. Additionally or alternatively, the ‘central part’ may be defined as having a given percentage of the total area of the optical article. Such a central part can account for between 10% and 80% of the total area of the optical article. In some embodiments, the size of the central area, and / or the degree of divergence of the refractive power in the outer annulus from the non-zero refractive power at the optical axis, can be regulated by the selection of operating parameters for the processes of forming and curing the optical articles as embodied in the various methods and systems disclosed herein. We now referring now to Fig. 19, which shows a schematic cross-section of an exemplary optical article 100, fabricated at least in part in a mold in accordance with any of the embodiments disclosed herein. The optical axis 700 passes through the center of curvature of the front (convex) surface 82 at point A and through the center of curvature of the rear (concave) surface 81 at point B. The ‘central’ section of the optical article 100 as discussed above is indicated in Fig. 19 by the arrow marked Areal. In an example, the fraction of the optical article marked by Areal comprises at least one fourth of the area of an optical article 100, e.g., surrounding the optical axis 700, and has a refractive power within a small difference, e.g., ±0.125 diopter or ±0.25 diopter, from the refractive power through the optical axis 700. In another example, at least one half of the area of the optical article, e.g., surrounding the optical axis 700, has a refractive power within ±0.125 diopter or within ±0.25 diopter of the refractive power through the optical axis.

[0167] In some examples, an area at or near a periphery of the optical article (and not adjacent to said optical axis 700), e.g., up to 20% of the area of the optical article, or up to 30% or any other ratio, can have a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis 700 The area at or near the periphery is schematically marked in Fig. 19 with the arrows Area2.

[0168] Referring now to Fig. 20, a method is disclosed for producing an optical article 100 comprising an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm. The method is suitable for producing an optical article 100 with defined Areal &vA Area2 dimensions and associated ranges of diopter variation as discussed in the preceding paragraphs. As illustrated by the flow chart in Fig. 20, the method comprises at least the four steps S41, S42, S43 and S44.

[0169] Step S41 includes introducing a radiation-curable composition 15 into a mold 120 in which resides a base layer 234 comprising a major surface 82 of the optical article 100. A base layer 234 can be an inserted, prefabricated base-layer member such as the baselayer member 34 of Figs. 4A-E, or a mold-produced base layer such as the base layer 134 of Figs. 8A-E.

[0170] Step S42 includes rotating the mold 120, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition 15 to displace so as to change a contour of an upper surface 81 of the curable composition 15 to a concave paraboloid shape. Step S43 includes subjecting the curable composition 15 to a curing radiation 25 during the rotating of the mold 120. According to the method, exposure to the curing radiation 25 is effective to solidify the composition 15 and form an optical layer 238, the solidifying being at least to an extent that the optical article 100 can be safely released from the mold 120 and retain its shape.

[0171] Step S44 includes releasing the optical article 100 from the mold, the optical article 100 including the base layer 234 and an optical layer 238 comprising the solidified composition, as was illustrated schematically, e.g., in Fig. 18A. According to the method, the optical layer 238 has a non-zero diopter.

[0172] According to the method, at least one fourth of an area Areal of the optical article 100 surrounding an optical axis thereof has a refractive power within ±0.25 diopter of a refractive power through the optical axis 700, and an area Area2 adjoining a periphery of the optical article 100 comprising at 10% of the area of the optical article 100 has a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis 700. In some embodiments, the at least one fourth of the area Areal of the optical article 100 surrounding the optical axis 700 has a refractive power within ±0.125 diopter of a refractive power through the optical axis 700.

[0173] In some embodiments of the method, an average roughness (Ra) of the solidified upper surface 81 is at least 3 times greater than an average roughness (Ra) of the first major surface 82. In some embodiments, of the method, an average roughness (Ra) of the solidified upper surface 81 is at least 10 times greater than an average roughness (Ra) of the first major surface 82.

[0174] According to embodiments, the methods and systems described herein can be applied to the production of optical articles that address astigmatism in ophthalmological prescriptions.

[0175] Referring now to Fig. 21 A, a method is disclosed for producing an optical article 100 comprising an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm. The method is suitable for producing an optical article 100 that provides correction for an astigmatism. According to the method, the optical article 100 comprises a base-member layer and a second layer 338 having a non-zero diopter, shown in Fig. 22A. As illustrated by the flow chart in Fig. 21 A, the method comprises at least the three steps S51, S52 and S53.

[0176] Step S51 includes inserting, into a mold 120, a base member 334 comprising a first major surface characterized at least in part by a convex spherical shape and a second major surface characterized at least in part by a toric shape, the inserting being such that the first major surface is facing downward.

[0177] Step S52 includes forming the optical layer 338. The forming includes (i) introducing a radiation-curable composition 15 into the mold 120 (while the base member 334 is resident in the mold 120), (ii), rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition 15 to displace so as to change a contour of an upper surface 81 of the curable composition to a concave paraboloid shape, and (iii) subjecting the curable composition 15 to the curing radiation 25 to solidify the composition 15 and form an optical layer 338, the solidifying being at least to an extent that the optical article 100 can be safely released from the mold 120 and retain its shape.

[0178] Step S53 includes releasing the optical article 100 from the mold. The basemember layer of the optical article comprises the base member 334.

[0179] In some embodiments, the toric shape of the back surface of the base member 334 can be distorted by the addition of the optical layer 338 thereupon. It can be desirable, in such embodiments, to increase preservation of the toric shape effect (the astigmatism correction), by forming the optical layer 338 from a composition 15 having a different, e.g., higher or lower, refractive index than that of the base member 334. The difference in refractive indexes preserves at least a part of the toric diopter that could be lost in the interface between the two layers. In some embodiments, the base-member layer has a first uniform refractive index, and the optical layer 338 has a second uniform refractive index that is more than 0.1 higher or lower than the first uniform refractive index. In some embodiments, the base-member layer has a first uniform refractive index, and the optical layer 338 has a second uniform refractive index that is more than 0.15 higher or lower than the first uniform refractive index. In some embodiments, the base-member layer has a first uniform refractive index, and the optical layer 338 has a second uniform refractive index that is more than 0.2 higher or lower than the first uniform refractive index.

[0180] In some embodiments, the toric effect can be enhanced by applying a toric shape 339 to the upper surface of an optical article, as illustrated schematically in Fig. 22B. In some embodiments, as illustrated by the flowchart of Fig. 2 IB, the method additionally comprises Step S36. As shown in Fig. 2 IB, Step S36 includes applying a toric shape 339 to the upper surface of an optical article 100. The toric shape 339 can be applied by various techniques, including, without limitation, casting, printing and grinding. In some embodiments (not illustrated), the toric effect can be enhanced by applying a toric shape to the front surface of the base-member layer.

[0181] In an illustrative, non-limiting example, a toric shape applied to the front surface of the base-member layer has a toric diopter of 0.5 diopter, and a toric shape 339 applied to the upper (rear) surface of the optical layer 228 has a toric diopter of 2.0 diopter. In addition, the base member 334 has a toric diopter of 2.0, the effectiveness of which is reduced by approximately half in an optical article 100 comprising two layers with different refractive indexes.

[0182] In some embodiments, not all of the steps of any given method are carried out. The steps of any of the methods disclosed herein can be combined in any combination to yield a method within the scope of the invention. Inventive concepts

[0183] The embodiments include, without limitation, the following exemplary inventive concepts, some of which have been discussed in further detail hereinabove:

[0184] Inventive concept 1. A method of producing an optical article in a mold, the optical article comprising an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm, the optical article comprising a base-member layer and an optical layer characterized by a non-zero diopter, the method comprising: (a) inserting, into the mold, a base member comprising a major surface of the optical article, the inserting being such that said major surface is facing downward; (b) forming the optical layer, the forming including (i) introducing a radiation-curable composition into the mold, (ii), rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape, and (iii) subjecting the curable composition to the curing radiation to solidify the composition; and (c) releasing the optical article from the mold, the basemember layer of the optical article comprising the base member.

[0185] Inventive concept 2. The method of Inventive concept 1, wherein the inserted base member forms a floor of a molding volume of the mold.

[0186] Inventive concept 3. The method of Inventive concept 1, wherein inserting the base member includes placing the base member on a floor of a molding volume of the mold.

[0187] Inventive concept 4. The method of any one of the preceding Inventive concepts, wherein the base member includes, on said major surface, at least one of a protective coating and a functional coating selected from the group comprising photochromic coatings, tint coatings, thermochromic coatings, UV-blocking coatings, and blue-light blocking coatings.

[0188] Inventive concept 5. The method of any one of the preceding Inventive concepts, wherein the base member includes, on a major surface characterized at least in part by a concave shape, at least one functional coating selected from the group consisting of photochromic coatings, tint coatings, thermochromic coatings, UV-blocking coatings, and blue-light blocking coatings.

[0189] Inventive concept 6. The method of any one of Inventive concepts 1 to 3, wherein the base member comprises a composition performing a function of at least one of a protective coating and a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0190] Inventive concept 7. The method of any one of the preceding Inventive concepts, wherein the base member has a maximum thickness Tmax of at most 5mm.

[0191] Inventive concept 7A. The method of Inventive concept 7, wherein Tmax is at most 3.5mm.

[0192] Inventive concept 7B. The method of Inventive concept 7, wherein Tmax is at most 2.5mm.

[0193] Inventive concept 7C. The method of Inventive concept 7, wherein Tmax is at most 2mm.

[0194] Inventive concept 7D. The method of Inventive concept 7, wherein Tmax is at most 1.5mm.

[0195] Inventive concept 7E. The method of Inventive concept 7, wherein Tmax is at most 1mm.

[0196] Inventive concept 7F. The method of Inventive concept 7, wherein Tmax is at most 0.5mm.

[0197] Inventive concept 7G. The method of any one of Inventive concepts 7 to 7F, wherein Tmax is at least 0.3mm.

[0198] Inventive concept 7H. The method of any one of Inventive concepts 7 to 7E, wherein Tmax is at least 0.5mm.

[0199] Inventive concept 71. The method of any one of Inventive concepts 7 to 7E, wherein Tmax is at least 0.8mm.

[0200] Inventive concept 7J. The method of any one of Inventive concepts 7 to 7D, wherein Tmax is at least 1.2mm. Inventive concept 7K. The method of any one of Inventive concepts 7 to 7C, wherein Tmax is at least 1.7mm.

[0201] Inventive concept 7L. The method of any one of Inventive concepts 7 to 7B, wherein Tmax is at least 2.2mm.

[0202] Inventive concept 7L. The method of any one of Inventive concepts 7 to 7A, wherein Tmax is at least 2.7mm.

[0203] Inventive concept 8. The method of any one of the preceding Inventive concepts, additionally comprising: before forming the optical layer, applying a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV- blocking coating, and a blue-light blocking coating.

[0204] Inventive concept 9. The method of any one of the preceding Inventive concepts, additionally comprising: applying, above the optical layer, a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0205] Inventive concept 10. The method of any one of the preceding Inventive concepts, additionally comprising: applying, above the optical layer, a protective coating selected from a hard coat, a tintable hard coat, and a tinted hard coat.

[0206] Inventive concept 11. The method of any one of Inventive concepts 8 to 10, wherein the applying includes printing.

[0207] Inventive concept 12. The method of any one of Inventive concepts 1 to 11, wherein an optical power of the optical article is substantially the same as an optical power of the optical layer.

[0208] Inventive concept 12 A. The method of any one of the preceding Inventive concepts, wherein the base-member layer has a major surface characterized at least in part by a convex surface, the convex surface selected from the group consisting of spherical, aspherical, planar, toric, atoric, and progressive surfaces.

[0209] Inventive concept 13. An optical article obtainable by applying the method of any one of Inventive concepts 1 to 12A, the optical article comprising an eyeglass lens having a maximum dimension of between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm, the optical article comprising a base-member layer and an optical layer having a major surface characterized at least in part by a concave parabolic shape.

[0210] Inventive concept 13 A. The optical article of Inventive concept 13, the basemember layer having a major surface characterized at least in part by a convex shape. Inventive concept 13B. The optical article of Inventive concept 13 A, the convex shape being a convex spherical shape.

[0211] Inventive concept 14. The optical article of Inventive concept 13, wherein an optical power of the optical article is substantially the same as an optical power of the optical layer.

[0212] Inventive concept 15. A system for use in producing an optical article by the method of any one of Inventive concepts 1 to 12, the system comprising a rotatable mold shaped to receive the base member, a motor arranged to rotate the mold at a constant speed of at least 50 rpm and not more than 120 rpm, and a source of curing radiation arranged to irradiate at least an upper surface.

[0213] Inventive concept 16. The system of Inventive concept 15, additionally comprising at least one of an inkjet printer and a micro-jet printer.

[0214] Inventive concept 17. A method of producing a coated optical article in a mold, the optical article comprising an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm, the method comprising: (a) applying, on a floor of the mold, a coating layer comprising at least one of a protective coating and a functional coating; (b) forming an optical layer over the coating layer, the forming including (i) introducing a radiation-curable composition into the mold, (ii), rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape, and (iii) subjecting the curable composition to the curing radiation to solidify the composition; and (c) releasing the coated optical article from the mold.

[0215] Inventive concept 18. The method of Inventive concept 17, wherein the applying comprises printing.

[0216] Inventive concept 19. The method of either one of Inventive concepts 17 or 18, wherein a hydrophobic release layer is introduced in the mold before the applying.

[0217] Inventive concept 20. The method of any one of Inventive concepts 17 to 19, wherein the floor of the mold is characterized at least in part by a concave spherical shape.

[0218] Inventive concept 21. The method of any one of Inventive concepts 17 to 20, wherein the coating layer comprises a protective coating selected from the group consisting of a hard coat, a tintable hard coat, and a tinted hard coat.

[0219] Inventive concept 22. The method of any one of Inventive concepts 17 to 21, wherein the coating layer includes a functional coating selected from the group consisting of a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0220] Inventive concept 23. The method of any one of Inventive concepts 17 to 22, wherein the optical article has a minimum thickness of at least 1 mm, and / or an average thickness of at least 2 mm.

[0221] Inventive concept 24. The method of any one of Inventive concepts 17 to 23, additionally comprising, before the introducing: curing the coating layer using at least one of radiation, heat and drying by evaporation.

[0222] Inventive concept 25. The method of any one of Inventive concepts 17 to 24, additionally comprising, after the forming and before the releasing: applying at least one functional coating selected from the group consisting of photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0223] Inventive concept 26. The method of any one of Inventive concepts 17 to 25, additionally comprising, after the forming and before the releasing: applying at least one protective coating selected from the group consisting of a hard coat, a tintable hard coat, and a tinted hard coat.

[0224] Inventive concept 27. The method of either one of Inventive concepts 25 or 26, wherein the applying includes printing.

[0225] Inventive concept 28. An optical article obtainable by applying the method of any one of Inventive concepts 17 to 27, the optical article comprising an eyeglass lens having a maximum dimension of between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm, the optical article comprising an optical layer having a major surface characterized at least in part by a concave parabolic shape and an opposing major surface having a coating layer thereupon comprising at least one of a protective coating and a functional coating.

[0226] Inventive concept 29. A system for use in producing an optical article by the method of any one of Inventive concepts 17 to 27, the system comprising a rotatable mold having a floor characterized at least in part by a concave spherical shape, a motor arranged to rotate the mold at a constant speed of at least 50 rpm and not more than 120 rpm, and a source of curing radiation arranged to irradiate at least an upper surface of the radiation- curable composition in the mold.

[0227] Inventive concept 30. The system of Inventive concept 29, additionally comprising a printer. Inventive concept 31. A method of producing an optical article, the optical article comprising an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter between 40 mm and 100 mm, the optical article comprising a base-member layer and a second layer, the method comprising: (a) forming the base-member layer in a mold, the forming of the base layer including: (i) introducing a quantity of a radiation-curable base-layer composition into the mold, (ii) rotating the mold at a first speed to create a concave contour on an upper surface of the base-layer composition, and (iii) subjecting the base-layer composition to a first curing radiation to solidify the base-layer composition within the mold, the solidifying being effective to preserve the concave shape; and (b) forming the second layer, the forming of the second layer including: (i) while the solidified base layer is disposed within the mold, introducing a quantity of a radiation-curable second-layer composition into the mold, (ii) rotating the mold at a second speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition to displace so as to change a contour of an upper surface of the second-layer composition to a concave paraboloid shape, and (iii) subjecting the second-layer composition to a second curing radiation to solidify the second-layer composition.

[0228] Inventive concept 32. The method of Inventive concept 31, wherein the base layer comprises a major surface characterized at least in part by a convex shape such as a convex spherical shape.

[0229] Inventive concept 33. The method of Inventive concept 31, wherein the first speed is faster than the second speed.

[0230] Inventive concept 34. The method of either one of the Inventive concepts 31 or 32, wherein the first curing radiation and the second curing radiation have different wavelengths.

[0231] Inventive concept 35. The method of any one of Inventive concepts 31 to 34, additionally comprising, before the forming of the base layer: applying, on a floor of the mold, a coating layer comprising at least one of a protective coating and a functional coating.

[0232] Inventive concept 36. The method of Inventive concept 35, wherein the applying includes printing.

[0233] Inventive concept 37. The method of either one of Inventive concepts 35 or 36, wherein the coating layer includes at least one of a functional coating selected from the group consisting of a photochromic coating, a tint coating, a thermochromic coating, a UV- blocking coating, and a blue-light blocking coating, and a protective coating selected from the group consisting of a hard coat, a tintable hard coat, and a tinted hard coat.

[0234] Inventive concept 38. The method of any one of Inventive concepts 31 to 34, wherein the base layer comprises a composition performing a function of at least one of a protective coating and a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0235] Inventive concept 39. The method of any one of Inventive concepts 31 to 38, additionally comprising: before forming the second layer, applying a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV- blocking coating, and a blue-light blocking coating.

[0236] Inventive concept 40. The method of any one of Inventive concepts 31 to 38, additionally comprising: applying, above the second layer, a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0237] Inventive concept 41. The method of any one of Inventive concepts 31 to 39, additionally comprising: applying, above the second layer, a protective coating selected from a hard coat, a tintable hard coat, and a tinted hard coat.

[0238] Inventive concept 42. The method of any one of Inventive concepts 39 to 41, wherein the applying includes printing.

[0239] Inventive concept 43. An optical article obtainable by applying the method of any one of Inventive concepts 31 to 42, the optical article comprising an eyeglass lens having a maximum dimension of between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm, the optical article comprising a front-base optical layer having a major surface characterized at least in part by a concave parabolic shape and comprising residue of a first photoinitiator and a rear optical layer comprising residue of a second photoinitiator different from the first photoinitiator.

[0240] Inventive concept 44. The optical article of Inventive concept 43, additionally comprising, between the front-base optical layer and the rear optical layer, a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

[0241] Inventive concept 45. A system for use in producing an optical article by the method of any one of Inventive concepts 31 to 41, the system comprising a rotatable mold shaped to receive the base-layer composition, a motor arranged to rotate the mold at a constant speed of at least 50 rpm and not more than 120 rpm, and at least one source of curing radiation arranged to irradiate at least an upper surface of each of the base layer and the second layer.

[0242] Inventive concept 46. A method of producing an optical article comprising an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm, the method comprising: (a) introducing a radiation-curable composition into a mold in which resides a base layer comprising a major surface of the optical article; (b) rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape; (c) during the rotating of the mold, subjecting the curable composition to a curing radiation to solidify the composition; and (d) releasing the optical article from the mold, the optical article including the base layer and an optical layer having a non-zero diopter and comprising the solidified composition, wherein the base layer has a first uniform refractive index, and the optical layer has a second uniform refractive index that is more than 0.1 higher or lower than the first uniform refractive index.

[0243] Inventive concept 47. The method of Inventive concept 46, wherein the second uniform refractive index is more than 0.15 higher or lower than the first uniform refractive index.

[0244] Inventive concept 48. The method of either one of Inventive concepts 46 or 47, additionally comprising applying an anti -reflective layer on an upward-facing major surface of the base layer before the introducing.

[0245] Inventive concept 49. The method of any one of Inventive concepts 46 to 48, additionally comprising applying a functional coating on an upward-facing major surface of the base layer before the introducing, the functional coating selected from the group consisting of a photochromic coating, a tint coating, a thermochromic coating, a UV- blocking coating, and a blue-light blocking coating.

[0246] Inventive concept 50. The method of any one of Inventive concepts 46 to 49, wherein the base layer has a minimum thickness of at least 0.5 mm.

[0247] Inventive concept 51. The method of any one of Inventive concepts 46 to 50, wherein the released optical article comprises no layers thicker than 0.5 mm between the base layer and the optical layer. Inventive concept 52. The method of any one of Inventive concepts 46 to 51, wherein the released optical article comprises no layers thicker than 0.1 mm between the base layer and the optical layer.

[0248] Inventive concept 53. An optical article comprising an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm, the optical article comprising: (a) a front base layer having a minimum thickness of at least 0.5 mm and comprising a first major surface of the optical article; and (b) a rear optical layer having a minimum thickness of at least 1.0 mm, comprising a second major surface of the optical article, and characterized by a non-zero diopter, the second major surface characterized at least in part by a concave paraboloid shape, the rear optical layer containing residue of a photoinitiator, wherein the front base layer has a first uniform refractive index, and the rear optical layer has a second uniform refractive index that is more than 0.1 higher or lower than the first uniform refractive index.

[0249] Inventive concept 53 A. The optical article of Inventive concept 53, wherein the first major surface is characterized at least in part by a convex shape.

[0250] Inventive concept 53B. The optical article of Inventive concept 53 A, wherein the convex shape is a convex spherical shape.

[0251] Inventive concept 53C. The optical article of Inventive concept 53B, wherein the convex shape is selected from the group consisting of aspherical, planar, toric, atoric, and progressive shapes.

[0252] Inventive concept 54. The optical article of any one of Inventive concepts 53 to 53C, wherein the second uniform refractive index is more than 0.15 higher than the first uniform refractive index.

[0253] Inventive concept 55. The optical article of any one of Inventive concepts 53 to 53C, wherein the second uniform refractive index is more than 0.15 lower than the first uniform refractive index.

[0254] Inventive concept 56. The optical article of any one of Inventive concepts 53 to 55, additionally comprising, between the front base layer and the rear optical layer, an anti- reflective layer.

[0255] Inventive concept 57. The optical article of any one of Inventive concepts 53 to 56, additionally comprising, between the front base layer and the rear optical layer, a functional coating selected from the group consisting of a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating. Inventive concept 58. The optical article of any one of Inventive concepts 53 to 57, wherein the front base layer has a minimum thickness of at least 1.0 mm.

[0256] Inventive concept 59. The optical article of any one of Inventive concepts 53 to 58, wherein there are no layers thicker than 0.5 mm between the front base layer and the rear optical layer.

[0257] Inventive concept 60. The optical article of any one of Inventive concepts 53 to 59, wherein there are no layers thicker than 0.1 mm between the front base layer and the rear optical layer.

[0258] Inventive concept 61. The optical of any one of Inventive concepts 53 to 60, wherein an average roughness (Ra) of the second major surface is at least 3 times greater than an average roughness (Ra) of the first major surface.

[0259] Inventive concept 62. The optical article of any one of Inventive concepts 53 to 61, wherein an average roughness (Ra) of the second major surface is at least 10 times greater than an average roughness (Ra) of the first major surface.

[0260] Inventive concept 63. The optical article of any one of Inventive concepts 53 to 62, wherein at least one fourth of an area of the optical article surrounding an optical axis thereof has a refractive power within ±0.25 diopter of a refractive power through the optical axis, and an area adjoining a periphery of the optical article comprising at least 10% of the area of the optical article has a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis.

[0261] Inventive concept 64. The optical article of any one of Inventive concepts 53 to 63, wherein the front base layer is devoid of photoinitiator residue.

[0262] Inventive concept 65. A method of producing an optical article comprising an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm, the optical article comprising a base-member layer and an optical layer characterized by a non-zero diopter, the method comprising: (a) inserting, into a mold, a base member comprising a first major surface optionally characterized at least in part by a convex spherical shape and a second major surface characterized at least in part by a toric shape, the inserting being such that the first major surface is facing downward; (b) forming the optical layer, the forming including (i) introducing a radiation-curable composition into the mold, (ii), rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation- curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape, and (iii) subjecting the curable composition to the curing radiation to solidify the composition; and (c) releasing the optical article from the mold, the base-member layer of the optical article comprising the base member.

[0263] Inventive concept 65 A. The optical article of Inventive concept 65, wherein the first major surface is characterized at least in part by the convex spherical shape.

[0264] Inventive concept 66. The method of Inventive concept 65, wherein the basemember layer has a first uniform refractive index, and the optical layer has a second uniform refractive index that is more than 0.1 higher or lower than the first uniform refractive index.

[0265] Inventive concept 67. The method of Inventive concept 65, wherein the basemember layer has a first uniform refractive index, and the optical layer has a second uniform refractive index that is more than 0.15 higher or lower than the first uniform refractive index.

[0266] Inventive concept 68. The method of any one of Inventive concepts 65 to 67, additionally comprising applying a toric shape to the upper surface.

[0267] Inventive concept 69. A method of producing an optical article comprising an eyeglass lens having a maximum dimension between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm, the method comprising: (a) introducing a radiation-curable composition into a mold in which resides a base layer comprising a major surface of the optical article; (b) rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation-curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape; (c) subjecting the curable composition to a curing radiation to solidify the composition; and (d) releasing the optical article from the mold, the optical article including the base layer and an optical layer having a non-zero diopter and comprising the solidified composition, wherein at least one fourth of an area of the optical article surrounding an optical axis thereof has a refractive power within ±0.25 diopter of a refractive power through the optical axis, and an area adjoining a periphery of the optical article comprising at 10% of the area of the optical article has a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis.

[0268] Inventive concept 69A. The optical article of Inventive concept 69, wherein the first major surface is characterized at least in part by the convex spherical shape. Inventive concept 70. The method of Inventive concept 69, wherein the at least one fourth of the area of the optical article surrounding the optical axis has a refractive power within ±0.125 diopter of a refractive power through the optical axis.

[0269] Inventive concept 71. The method of either one of Inventive concepts 69 or 70, wherein an average roughness (Ra) of the solidified upper surface is at least 3 times greater than an average roughness (Ra) of the first major surface.

[0270] Inventive concept 72. The optical article of either one of Inventive concepts 69 or 70, wherein an average roughness (Ra) of the second major surface is at least 10 times greater an average roughness (Ra) of the first major surface.

[0271] Inventive concept 73. An optical article comprising an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm, the optical article comprising: (a) a front base layer having a minimum thickness of at least 0.5 mm and comprising a first major surface of the optical article, the first major surface optionally characterized at least in part by a convex spherical shape; and (b) a rear optical layer comprising a second major surface of the optical article, having a minimum thickness of at least 1.0 mm and characterized by a non-zero diopter, the second major surface characterized at least in part by a concave paraboloid shape, wherein at least one fourth of an area of the optical article surrounding an optical axis thereof has a refractive power within ±0.25 diopter of a refractive power through the optical axis, and an area adjoining a periphery of the optical article comprising at 10% of the area of the optical article has a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis.

[0272] Inventive concept 74. The optical article of Inventive concept 73, wherein at least one fourth of an area of the optical article surrounding an optical axis thereof has a refractive power within ±0.125 diopter of a refractive power through the optical axis, and an area adjoining a periphery of the optical article comprising at least 10% of the area of the optical article has a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis.

[0273] Inventive concept 75. The optical article of either one of Inventive concepts 73 or 74, wherein an average roughness (Ra) of the second major surface is at least 3 times greater than an average roughness (Ra) of the first major surface.

[0274] Inventive concept 76. The optical article of either one of Inventive concepts 73 or 74, wherein an average roughness (Ra) of the second major surface is at least 10 times greater an average roughness (Ra) of the first major surface. Inventive concept 77. The method of any one of the preceding Inventive concepts, wherein a processor or controller sets or selects one or more parameters based on a curvature of a front surface of the optical article and a prescription from which the optical article is produced.

[0275] Inventive concept 78. The method of Inventive concept 77, wherein the parameters include at least one of rotation speed, quantity of resin required, a desired shape, a refractive index of the composition, and a time of rotation.

[0276] Inventive concept 79. The method of either one of Inventive concepts 77 or 78, wherein the setting or selecting is to achieve a calculated radial dioptric function wherein at least one fourth of an area of the optical article surrounding an optical axis thereof has a refractive power within ±0.25 diopter of a refractive power through the optical axis, and an area adjoining a periphery of the optical article comprising at least 10% of the area of the optical article has a refractive power that is not within ±0.25 diopter of the refractive power through the optical axis.

[0277] Inventive concept 80. The method of any one of the preceding Inventive concepts, additionally comprising, prior to step (c), pre-heating the curable composition.

[0278] Inventive concept 80A. The method of any one of the preceding Inventive concepts, additionally comprising, prior to step (c), pre-heating the mold.

[0279] Inventive concept 80B. The method of Inventive concept 80 or 80 A, wherein the pre-heating is to at least 40°C.

[0280] Inventive concept 80C. The method of Inventive concept 80B, wherein the preheating is to at least 45°C.

[0281] Inventive concept 80D. The method of Inventive concept 80B, wherein the preheating is to at least 50°C.

[0282] Inventive concept 80E. The method of Inventive concept 80B, wherein the preheating is to at least 55°C.

[0283] Inventive concept 80F. The method of Inventive concept 80B, wherein the preheating is to at least 60°C.

[0284] Inventive concept 80G. The method of any one of Inventive concepts 80 to 80F, wherein the pre-heating is to at most 90°C.

[0285] Inventive concept 80H. The method of Inventive concept 80G, wherein the preheating is to at most 80°C.

[0286] Inventive concept 801. The method of Inventive concept 80G, wherein the preheating is to at most 70°C. Inventive concept 81. The method of any one of the preceding Inventive concepts, wherein the solidifying of the composition is effected within 10 minutes or within 7 minutes.

[0287] Inventive concept 81 A. The method of Inventive concept 81, wherein the solidifying is effected within 5 minutes.

[0288] Inventive concept 8 IB. The method of Inventive concept 81, wherein the solidifying is effected within 3 minutes.

[0289] Inventive concept 82. The method of any one of Inventive concepts 81 to 8 IB, wherein the solidifying of the composition is effected for a period of at least 0.5 minutes.

[0290] Inventive concept 82A. The method of Inventive concept 82, wherein the period is at least 1 minute.

[0291] Inventive concept 82B. The method of Inventive concept 82, wherein the period is at least 1.5 minutes, at least 2 minutes, at least 2.5 minutes, or at least 3.5 minutes.

[0292] Inventive concept 83. The method of any one of the preceding Inventive concepts, wherein the solidifying of the composition can be effected in a nitrogen environment, in a partial vacuum, and / or under glycerol and / or water.

[0293] Inventive concept 84. The method of any one of the preceding Inventive concepts, wherein the solidified composition is post-cured in a nitrogen environment, in a partial vacuum, and / or under glycerol and / or water.

[0294] Inventive concept 85. The method of any one of the preceding Inventive concepts, wherein the curing of the composition oxygen-poor environment characterized by a partial pressure of oxygen of at most 0.15 bar.

[0295] Inventive concept 85 A. The method of Inventive concept 85, wherein the partial pressure is at most 0.10 bar.

[0296] Inventive concept 85B. The method of Inventive concept 85, wherein the partial pressure is at most 0.06 bar.

[0297] Inventive concept 85C. The method of Inventive concept 85, wherein the partial pressure is at most 0.03 bar.

[0298] Inventive concept 85D. The method of Inventive concept 85, wherein the partial pressure is at most 0.01 bar.

[0299] Inventive concept 86. The method of any one of the preceding Inventive concepts, wherein a ratio (Rt) of average thickness of the base layer or base-member layer to an average thickness of the optical layer is at least 0.3. Inventive concept 86A. The method of Inventive concept 86, wherein Rt is at least

[0300] 0.4.

[0301] Inventive concept 86B. The method of Inventive concept 86, wherein Rt is at least 0.5.

[0302] Inventive concept 86C. The method of Inventive concept 86, wherein Rt is at least 0.6.

[0303] Inventive concept 86D. The method of Inventive concept 86, wherein Rt is at least 0.7.

[0304] Inventive concept 86E. The method of Inventive concept 86, wherein Rt is at least 0.75.

[0305] Inventive concept 86F. The method of any one of Inventive concepts 86 to 86E, wherein Rt is at most 0.9.

[0306] Inventive concept 86G. The method of Inventive concept 86F, wherein Rt is at most 0.85.

[0307] Inventive concept 86H. The method of Inventive concept 86F, wherein Rt is at most 0.8.

[0308] Inventive concept 87. The method of any one of the preceding Inventive concepts, wherein the extent of the solidifying of the composition is sufficient to attaining at least 70%, of the Rockwell-scale hardness value of the final, i.e., fully cured / polymerized material.

[0309] Inventive concept 88. The method of Inventive concept 87, wherein the Rockwellscale hardness value is at least 80% or at least 90% of the final, i.e., fully cured / polymerized material.

[0310] Inventive concept 89. The method of any one of the preceding Inventive concepts, carried out in a mold configured to rotate at a constant speed of at least 50 rpm and not more than 120 rpm and in optical communication with a source of actinic radiation, wherein at least a portion of the steps of the method are carried out and / or controlled by a control system.

[0311] The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons skilled in the art to which the invention pertains.

Claims

WHAT IS CLAIMED IS:

1. A method of producing an optical article in a mold, the optical article comprising an eyeglass lens having a maximum dimension of at least 30 mm or an eyeglass lens blank having a diameter of at least 40 mm, the optical article comprising a base-member layer and an optical layer characterized by a non-zero diopter, the method comprising: a. inserting, into the mold, a base member comprising a major surface of the optical article, the inserting being such that said major surface is facing downward; b. forming the optical layer, the forming including (i) introducing a radiation- curable composition into the mold, (ii), rotating the mold, at a speed of at least 50 rpm and not more than 120 rpm, to cause a portion of the radiation- curable composition to displace so as to change a contour of an upper surface of the curable composition to a concave paraboloid shape, and (iii) subjecting the curable composition to the curing radiation to solidify the composition; and c. releasing the optical article from the mold, the base-member layer of the optical article comprising the base member.

2. The method of claim 1, wherein the inserted base member forms a floor of a molding volume of the mold.

3. The method of claim 1, wherein inserting the base member includes placing the base member on a floor of a molding volume of the mold.

4. The method of any one of the preceding claims, wherein the base member includes, on said major surface, at least one of a protective coating and a functional coating selected from the group comprising photochromic coatings, tint coatings, thermochromic coatings, UV-blocking coatings, and blue-light blocking coatings.

5. The method of any one of the preceding claims, wherein the base member includes, on a major surface characterized at least in part by a concave shape, at least one functional coating selected from the group consisting of photochromic coatings, tint coatings, thermochromic coatings, UV-blocking coatings, and bluelight blocking coatings.

6. The method of any one of claims 1 to 3, wherein the base member comprises a composition performing a function of at least one of a protective coating and afunctional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

7. The method of any one of the preceding claims, wherein the base member has a maximum thickness of no more than 2 mm.

8. The method of any one of the preceding claims, additionally comprising: before forming the optical layer, applying a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

9. The method of any one of the preceding claims, additionally comprising: applying, above the optical layer, a functional coating selected from a photochromic coating, a tint coating, a thermochromic coating, a UV-blocking coating, and a blue-light blocking coating.

10. The method of any one of the preceding claims, additionally comprising: applying, above the optical layer, a protective coating selected from a hard coat, a tintable hard coat, and a tinted hard coat.

11. The method of any one of claims 8 to 10, wherein the applying includes printing.

12. The method of any one of claims 1 to 11, wherein an optical power of the optical article is substantially the same as an optical power of the optical layer.

13. An optical article obtainable by applying the method of any one of claims 1 to 12, the optical article comprising an eyeglass lens having a maximum dimension of between 30 mm and 85 mm or an eyeglass lens blank having a diameter of between 40 mm and 100 mm, the optical article comprising a base-member layer and an optical layer having a major surface characterized at least in part by a concave parabolic shape.

14. The optical article of claim 13, wherein an optical power of the optical article is substantially the same as an optical power of the optical layer.

15. A system for use in producing an optical article by the method of any one of claims 1 to 12, the system comprising a rotatable mold shaped to receive the base member, a motor arranged to rotate the mold at a constant speed of at least 50 rpm and not more than 120 rpm, and a source of curing radiation arranged to irradiate at least an upper surface.

16. The system of claim 15, additionally comprising at least one of an inkjet printer and a micro-jet printer.

Images