Gradient Photochromic Lens with Interference Coating

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Solution Overview

Problem

Existing methods for producing gradient photochromic lenses with anti-reflection properties are either unsatisfactory, require complex processes, or result in uniform tinting and potential delamination issues, while conventional anti-reflection coatings inhibit photochromic effects by rejecting UV light.

Innovation Solution

A photochromic optical article with a substrate and an interference coating of gradient thickness, designed to reflect UV wavelengths, providing a gradient photochromic tint and anti-reflective properties using conventional vacuum technology, without UV absorbers, allowing for industrial-scale production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional anti-reflection coatings are applied to photochromic lenses, then anti-reflective properties and improved contrast are achieved, but photochromic effects are inhibited due to UV light rejection

Engineering Contradiction:

Improveanti-reflection coating compatibilityVSAvoidphotochromic effect activation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The interference coating is designed with spatially varying thickness to create different optical functions in different regions. The coating reflects UV light selectively while allowing visible light transmission, providing both anti-reflection properties and photochromic activation without requiring separate coating layers.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the optical parameters of the coating by precisely controlling its thickness to be in the range of 50-200 nm. This specific thickness range enables the coating to reflect UV wavelengths while transmitting visible light, resolving the contradiction between anti-reflection performance and photochromic activation.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If gradient photochromic lenses are produced using existing methods, then gradient tint distribution is achieved, but the processes are complex and require multiple steps

Engineering Contradiction:

Improvegradient tint distributionVSAvoidmanufacturing process steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the anti-reflection coating and gradient tint formation into a single interference coating layer. This merging of functions eliminates the need for separate gradient photochromic layers and anti-reflection coatings, significantly simplifying the manufacturing process while maintaining gradient tint distribution.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The interference coating performs multiple functions simultaneously: it provides anti-reflection properties, creates gradient tint distribution, and allows photochromic activation. This multi-functionality reduces the number of manufacturing steps required compared to conventional methods that use separate layers for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If uniform photochromic coating is applied, then simple manufacturing is achieved, but gradient photochromic effect is lost

Engineering Contradiction:

Improvecoating application simplicityVSAvoidgradient photochromic distribution

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The gradient thickness profile of the interference coating is established during the deposition process itself, before the photochromic effect is activated. This preliminary structuring of the coating thickness enables the gradient photochromic effect to emerge naturally when UV light activates the photochromic molecules, without requiring complex post-processing.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables the creation of lenses with graded photochromic effects and high transparency in the visible range, while maintaining anti-reflective properties, using conventional equipment and processes, thus overcoming previous limitations in lens manufacturing.

Implementation Method 1

an interference coating having a specific gradient thickness providing for a gradient reflectance

Methodology Applied

Scientific EffectInterference: Interference

Implementation Method 2

They include photochromic dyes which are able to darken and thus protect the eye from intense light when exposed to UV light

Methodology Applied

Scientific EffectPhotochromism: Photochromism

Data Source

PatentUS9678363B2Optical article with gradient photochromism

Publication Date: 2017.06.13 ESSILOR INTERNATIONAL(COMPAGNIE GENERALE D OPTIQUE)

AI summary

The present invention is drawn to an optical article comprising: (a) a photochromic substrate comprising at least one photochromic dye, and (b) an interference coating having a specific gradient thickness providing for a gradient reflectance. It also pertains to a process for making such an optical article.