Abstract: A process for producing a photochromic eyewear lens. In one embodiment at least a layer of modified photochromic poly(urea-urethane) is formed by combining photochromic material and the reaction product of a polyurethane pre-polymer and a mixture of diethyltoluene diamine and one or more polyols, plus catalyst. The mixture comprises both NH2 and OH reactive groups, with at least 0.04 equivalent weights of OH reactive species available for reaction with each 1.0 equivalent weight of excess NCO reactive species available in the pre-polymer. The lens comprising the modified photochromic poly(urea-urethane) can exhibit faster fade-back rates and better photochromic performance than lenses with non-modified poly(urea-urethane).

Abstract: The present invention is a photochromic eyewear lens product comprising photochromics material(s) and selective filtering agent(s) that selectively attenuate a portion of the blue light spectral region between 400 nm and 500 nm. The selective attenuation preferably comprises a maximum reduction in transmittance in the filtered region of about 10-25% T relative to at least one adjacent spectral region when the lens product is in the rest state, and a maximum reduction in transmittance that is measurably less than the transmittance of at least one adjacent region of the visible spectrum when the lens product has darkened in the activated state.

Abstract: A process for producing a photochromic eyewear lens. In one embodiment at least a layer of modified photochromic poly(urea-urethane) is formed by combining photochromic material and the reaction product of a polyurethane pre-polymer and a mixture of diethyltoluene diamine and one or more polyols, plus catalyst. The mixture comprises both NH2 and OH reactive groups, with at least 0.04 equivalent weights of OH reactive species available for reaction with each 1.0 equivalent weight of excess NCO reactive species available in the pre-polymer. The lens comprising the modified photochromic poly(urea-urethane) can exhibit faster fade-back rates and better photochromic performance than lenses with non-modified poly(urea-urethane).

Abstract: The present invention describes composite constructed ophthalmic lenses comprising at least two layers of optical materials that provide a composite structure over a practical vision zone of the lens product, are identifiably disparate from each other, and are integrally bonded to each other such that the adhesion of the first layer to the second layer exceeds a ranking of at least 3 when tested according to specified tests. In a preferred embodiment, one layer comprises thermoplastic polycarbonate and the second layer comprises polyurea-urethane material and one or more additives. The first layer may comprise a polarizer. The composite lens may also comprise coatings or other components.

Abstract: The present invention is embodied in an eyewear lens with at least two controlled, limited visible light blocking filters that attenuate its transmittance spectrum. More specifically, in the present invention, the eyewear lens attenuates limited amounts of light in at least two visible wavelength regions via controlled, limited blocking filters, wherein the overall luminous transmittance is at least 75%. The at least two controlled, limited blocking filters have their peak blocking wavelengths in the region of 410-500 nm and 530-620 nm, respectively. In a preferred embodiment, the minimum transmittance that occurs within the 410-500 nm region is ?55% and the minimum transmittance that occurs within the 530-620 nm region is ?65%. In another preferred embodiment, the eyewear lens comprises an anti-reflective coating on its inner surface (the eye-side of the lens).

Abstract: The present invention describes ophthalmic lens products comprising a multilayer wafer and an injection-molded polycarbonate inner portion. The multilayer wafer includes a dyed, photochromic or polarized layer between a tinted inner layer and an outer polymeric layer. The inner layer may be solid or gradient-tinted. The polycarbonate inner portion of the lens product is directly fused to the tinted inner layer of the multilayer wafer during injection molding. The invention further describes a method to produce a gradient-tinted polarized polycarbonate eyewear lens product by obtaining a multilayer wafer having an outer layer, an inner polycarbonate layer, and a polarized layer between the inner and outer layers, applying a gradient tint to the wafer's inner layer, placing the gradient tinted wafer within an injection-molding cavity, and injecting molten polycarbonate directly against the wafer's gradient-tinted layer to form the inner portion of the lens product and to fuse it to the wafer.

Abstract: The invention relates to an apparatus for comparatively demonstrating the optical properties of eyewear lenses, particularly dispersion. The apparatus includes an illumination source that provides output of shorter wavelength visible light and longer wavelength visible light, a target that creates an image on the light path, a test lens made of eyewear lens material that is illuminated by the light path from the target, and a detector that displays the image acted upon and transmitted through the test lens. The test lens can be interchangeably replaced with another test lens, for comparison of each lens' optical properties. Alternate configurations include multiple light paths, for simultaneous viewing of images through different test lenses.

Abstract: Optical-quality polarized parts and methods for manufacturing the optical parts are disclosed. The optical-quality polarized parts comprise a high impact, lightweight, high optical quality polyurethane construct and a polarizer bonded to the construct. The construct may be a lens substrate wherein the polarizer is integrally bonded at or near the front surface of the lens substrate. A sidefill gasket may be used to support and position the polarizer within a mold cavity for reproducibly forming the optical part. The polarizer may comprise a polyethylene terephthalate film or a laminated polyvinyl alcohol film or wafer. The polarized optical part- has improved impact resistance over conventional thermoset resin parts, as well as better optical properties than similarly impact-resistant polycarbonate constructs.

Abstract: An improved method is disclosed, for forming a wafer into a complex, curved shape, for use in an optical part. The method includes a step of moving the wafer into contact with a molding surface having a predetermined non-cylindrical, aspheric curved shape, to form the wafer into a corresponding shape. The step of moving is sufficient, by itself, to form the wafer into the desired non-cylindrical, aspheric curved shape, without the need for additional forming steps.

Abstract: A method is disclosed for pre-conditioning inserts for improved replication during injection molding. The pre-conditioned inserts provide improved bonding with the injection-material and improved replication of complex molding surfaces. The pre-conditioning of the inserts comprises placing the insert in position against the molding surface, followed by heat-soaking the insert. Heat-soaking can be accomplished using infrared energy, preferably broadband infrared energy or energy that is preferentially absorbed by the insert.

Abstract: Modifications to the surface of polyvinyl alcohol-based films are disclosed that result in improved adhesion to optical materials. Specifically, the surface chemistry of the polyvinyl alcohol-based film is altered to include fluorine bonds, which surprisingly improve direct adhesion of the film to materials such as optical thermoset resins, without the use of additional coatings or multilayer sandwich construction. Embodiments of this invention for incorporation of polarizer films in thermoset resin lenses are described. A method of exposing the film to indirect, reduced-pressure plasma to achieve these surface modifications, and an exemplary holder for the film during such processing, are disclosed.

Abstract: Optical-quality polarized parts and methods for manufacturing the optical parts are disclosed. The optical-quality polarized parts comprise a high impact, lightweight, high optical quality polyurethane construct and a polarizer bonded to the construct. The construct may be a lens substrate wherein the polarizer is integrally bonded at or near the front surface of the lens substrate. A sidefill gasket may be used to support and position the polarizer within a mold cavity for reproducibly forming the optical part. The polarizer may comprise a polyethylene terephthalate film or a laminated polyvinyl alcohol film or wafer. The polarized optical part has improved impact resistance over conventional thermoset resin parts, as well as better optical properties than similarly impact-resistant polycarbonate constructs.

Abstract: A polyurea/urethane material and method for making it provides for improved optical parts. The material allows for ease of manufacture of parts having good optical properties, high hardness, low density, and good impact resistance. The method provides for related manufacturing advantages.

Abstract: An eyewear lens provides for selective spectral performance in response to varying light conditions, including both changes in intensity and spectral distribution. The lens responds selectively to both ultraviolet and visible light, and exhibits different spectral transmittance characteristics under different lighting conditions, to provide for better vision for a wearer. In addition to this active response, the lens also may include a polarizer to further control light and to minimize the glare that interferes with clear vision.

Abstract: Methods for improved adhesion of an optical coating to a polarizing film incorporated onto an optical-quality plastic construct are disclosed. Preferred methods include treating a surface of the film by mechanical and/or chemical means and applying an optical coating to the treated film for effecting a coated, polarized optical-quality plastic part. Such mechanical and chemical means include exposing the polarizing film to a caustic solution at a concentration greater than or equal to 10%, roughening the surface of the film in a uniform manner, and utilizing plasma exposure to peen the surface and then chemically modify it.

Abstract: An optical-quality part such as an ophthalmic lens is provided having a PET polarizing film integrally bonded thereto and, optionally, a hard coating integrally bonded to either the PET polarizing film or to the optical construct containing the PET polarizing film. In a preferred construction, the lens material or film may be surface treated, either physically and/or chemically, for integrally bonding the film to the lens material. Similarly, in another preferred construction, the film may be physically and/or chemically surface treated for integrally bonding a hard coating to the PET film.

Abstract: An optical-quality plastic part is provided having a PET polarizing film formed to contour with the optical requirements of the plastic construct without jeopardizing its optical, mechanical or cosmetic properties.

Abstract: An optical-quality plastic part is provided having a PET polarizing film integrally bonded thereto and, optionally, a hard coating integrally bonded to the PET polarizing film. In a preferred construction, the film may be surface treated, either physically and/or chemically, for integrally bonding the film to the optical-quality plastic material. Similarly, in another preferred construction, the film may be physically and/or chemically surface treated for integrally bonding a hard coating to the PET film. In either construction, the treatment may be effected by light irradiation.

Abstract: Unique side-fill mold assembly and method for making a lens wherein the mold assembly includes a gasket having a plurality of side port holes which allow filling of the mold assembly with a thermosetting resin and allow egress of air trapped within the mold assembly.

Abstract: An optical-quality part such as an ophthalmic lens is provided having a PET polarizing film integrally bonded thereto and, optionally, a hard coating integrally bonded to either the PET polarizing film or to the optical construct containing the PET polarizing film. In a preferred construction, the lens material or film may be surface treated, either physically and/or chemically, for integrally bonding the film to the lens material. Similarly, in another preferred construction, the film may be physically and/or chemically surface treated for integrally bonding a hard coating to the PET film.