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 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 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 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: 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: 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: 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: 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.