CN100408316C - 可充气膜设备和将涂层转移到透镜毛坯的表面上的方法 - Google Patents

可充气膜设备和将涂层转移到透镜毛坯的表面上的方法 Download PDF

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CN100408316C
CN100408316C CNB2006100012644A CN200610001264A CN100408316C CN 100408316 C CN100408316 C CN 100408316C CN B2006100012644 A CNB2006100012644 A CN B2006100012644A CN 200610001264 A CN200610001264 A CN 200610001264A CN 100408316 C CN100408316 C CN 100408316C
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coating
lens blank
lens
inflatable membrane
much
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CN1799819A (zh
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P·江
F·O·阿迪勒
Y·Y·图尔沙尼
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Essilor International Compagnie Generale dOptique SA
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/0073—Optical laminates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B29C63/16—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material applied by "rubber" bag or diaphragm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/22—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using layers or sheathings having a shape adapted to the shape of the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1406—Ultraviolet [UV] radiation
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/545—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles one hollow-preform being placed inside the other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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Abstract

本发明涉及一种可充气膜设备(10)，其包括：具有上面和下面以及流体入口(12)的流体聚集器(11)，其中所述下面通过可充气膜(14)而部分形成，以及截锥形部件(15)，其从聚集器的下面向外突出，并且它的较大基底由至少部分可充气膜(14)封闭，它的较小基底形成圆形开孔，从而，当将加压流体被引入聚集器(11)中时，可充气膜(14)的变形通过截锥形部件来导向。

Description

可充气膜设备和将涂层转移到透镜毛坯的表面上的方法
本申请是于2002年7月1日提交的、发明名称为“将涂层转移到透镜毛坯的表面上的方法”的中国发明专利申请的分案申请。
背景技术
本发明涉及一种改进的可充气膜设备和一种将涂层转移到透镜毛坯的至少一个表面上的改进工艺或方法，该工艺或方法可在短时间内完成，并且透镜毛坯没有任何变形的危险。
本领域中常见的实践是，用几种涂层涂覆眼科透镜的至少一面，以赋予成品透镜以额外或改进的光学或机械性能。
因此，通常的做法是将通常由有机玻璃材料制成的眼科透镜的至少一个面从透镜的该面开始顺序地涂覆上抗冲击涂层(抗冲击底漆)、耐划痕涂层(硬质涂层)、抗反射涂层和任选的疏水面漆。也可将其它涂层如偏光涂层、光致变色涂层或染色涂层施涂在眼科透镜的一个或两个面上。
已经建议了各种涂覆眼科透镜面的工艺和方法。
US 4,061,518公开了一种制造含有复现涂层的制品的方法，该涂层上具有耐久性介电罩面层，该方法包括如下步骤：在模板(master)的光学抛光表面上形成防粘层、保护涂层和反光涂层，将预定量的环氧树脂胶粘剂施涂在支承浇注件的面上，之后通过将该模板的涂层面施于环氧树脂胶粘剂上而将该涂层从该模板上转移到支承浇注件上，在热作用下固化该环氧树脂胶粘剂并撤去模板。支承浇注件优选为铝铸件。所述方法特别适于制造镜子。
WO 99/24243公开了一种制造热塑性透镜的方法，包括如下步骤：将具有按照要求所需的透镜特性的层压层/涂层置于预热的透镜毛坯和预热的半模之间，对所述半模施压，使其相向运动以压缩透镜毛坯，从而均匀地将所述层压层/涂层施于其上，且在其中不产生任何折痕或裂纹。
在该方法中，对透镜模施压，使其相向运动挤压透镜毛坯，以立刻在几分钟内将透镜毛坯和任何包括在其中的层压层减少至含有所需涂层的成品透镜尺寸。实际上，将透镜毛坯和并置的层压层于预定的程序速率下压缩，从而将透镜毛坯压缩并使其扩展到模腔中，结果层压层/涂层均匀地施于其上。
为了获得最终透镜的所需几何形状，必须小心控制毛坯的扩展，因而还必须小心控制加热和压缩。
US 5,512,371公开了一种复合塑料的光学质量透镜，它包括光学质量材料的塑料透镜预制件和与所述塑料透镜预制件部分相连接的固化的塑料连接部分；其中所述固化的塑料连接部分具有比所述塑料透镜预制件更高的耐划痕性和更低的色差。
这种透镜通过将透镜组合物倾倒在由模具和透镜预制件定界的模塑腔中并然后将所述透镜组合物固化而获得。
根据US 5,512,371中的一个优选实施方案，可通过将涂层从模具上转移到所得透镜上而在所得透镜上提供涂层。
US 5,512,371的目的是显著改变和改善通常由双酚A聚碳酸酯制成的塑料透镜预制件的机械性能。整个所得透镜的性能如磨边和色差尤其认为通过固化的连接部分而显著改变。这些结果仅仅对厚度范围总体上与预制件相同或甚至比预制件高的固化连接部分才可获得，其中考虑到最终所得透镜的通常中心厚度如本领域所公知的那样一般大于1mm。
若情况不是这样，则由固化部分产生的改变将对复合透镜的性能如色差和磨边没有显著影响。
WO 93/21010也涉及复合透镜的制造，它得到最小厚度为100μm且典型厚度为0.5-1.5mm的预制件。
一般而言，难以制造和处理厚度小于500μm的预制件。
基于上述因素，显而易见的是，即使未具体提及，但US 5,512,371的固化连接部分的厚度一般为约0.5mm或更高。
根据US 5,512,371中所描述的制造方法，将树脂倒在模具中，并将聚碳酸酯透镜预制件置于充满所述树脂的模具的上端，轻轻施压，挤出过剩的树脂，直到获得足够厚度的载体。
装配透镜/预制件/模具通过树脂材料的毛细管作用和透镜预制件的重量而保持在一起。
WO 97/35216公开了一种将多层涂层转移到透镜表面上的方法，包括如下步骤：
-提供聚合物薄膜底材，该底材柔韧、可延展，并且含有一个涂覆有可转移的多层涂层的面；
-将经涂覆的膜底材置于包括膜变形元件的设备中；
-在膜底材和透镜表面之间滴一滴胶粘剂；
-促使该膜对该透镜的表面仿形；以及
-固化，将多层涂层粘结在透镜表面上。
在该方法中，伸展薄膜底材，使之与透镜的表面符合，从而将多层涂层伸展。实际上，应当避免伸展，因为这引起多层涂层的各层撕裂和/或破裂的危险，尤其是无机层如常规的抗反射层。
发明概述
本发明的目的是提供一种用于将涂层从载体上转移到透镜毛坯的至少一个表面上的工艺或方法的可充气膜设备，该方法工艺或不会引起透镜毛坯的任何变形，并且对于每种规定的最终透镜几何形状不必使用特定的模具。
本发明的另一目的是提供一种使用上述可充气膜设备将涂层从载体上转移到透镜毛坯的至少一个表面上的工艺或方法。
根据上述目的和将提及并且将在下面变得显而易见的那些目的，根据本发明提供的可充气膜设备包括：
-具有上面和下面以及流体入口的流体聚集器，其中所述下面通过可充气膜而部分形成，以及
-截锥形部件，其从聚集器的下面向外突出，并且它的较大基底由至少部分可充气膜封闭，它的较小基底形成圆形开孔，
从而，当将加压流体引入聚集器中时，可充气膜的变形通过截锥形部件来导向。
本发明还涉及一种使用本发明的可充气膜设备将涂层从至少一个载体上转移到透镜毛坯的至少一个几何限定表面上的工艺或方法，其包括如下步骤：
-提供具有至少一个几何限定表面的透镜毛坯；
-提供具有内表面和外表面的韧性载体，该内表面含有涂层；
-在所述透镜毛坯的所述几何限定表面上或在所述涂层上沉积预定量的可固化粘胶；
-使透镜毛坯和载体相向移动，以使涂层与可固化粘胶接触或使可固化粘胶与透镜毛坯的几何限定表面接触，由此形成包括透镜毛坯、可固化粘胶和涂覆载体的组装体；
-将组装体置于可充气膜设备的前面，使载体面向可充气膜；
-使可充气膜充气，促使韧性载体挤压透镜毛坯，由此在载体的外表面上施以压力，使得固化后的最终粘胶层的厚度小于100μm；
-将所述粘胶固化；以及
-撤去载体，以回收在其几何限定表面上粘结有涂层的透镜毛坯。
对于预定量，指的是足以获得涂层向透镜毛坯的转移和粘结的粘胶量。
在本发明方法的一个实施方案中，预定量的可固化粘胶可以本身位于涂层的外层中，尤其是待转移涂层的抗冲击底涂层中。这可以是该抗冲击底涂层包含可UV聚合的(甲基)丙烯酸酯单体的情形。它也可以是耐磨层，尤其当没有底涂层转移到毛坯上时。
它还可以是抗反射涂层的外层，尤其当仅该抗反射涂层被转移时。当然在这种情况下，抗反射涂层以液体形式沉积。
在本发明方法的另一实施方案中，可在沉积预定量的可固化粘胶之前将粘性的底涂层沉积在毛坯上。
当然，可将预定量的可固化粘胶以任何合适的形式如以滴状或层状形式沉积。
对于透镜毛坯或模具的几何限定表面，指的是光学表面，即具有所需几何形状和光滑度的表面，或者具有所需几何形状但可能仍旧具有一定粗糙度的表面，如经磨削和细磨但尚未抛光成所需几何形状的表面。表面粗糙度Sq一般为10-3μm至1μm，优选为10-3μm至0.5μm，最优选为10-3μm至0.1μm。
对于光学表面，指的是透镜毛坯或模具的经磨削、细磨和抛光或者模塑成所需几何形状和光滑度的表面。
本发明方法的重要特征是，涂层向透镜毛坯的几何限定表面上的转移是在毛坯无任何显著压缩和进而毛坯的几何形状没有任何变形危险、尤其是该毛坯的几何限定表面没有任何变形危险的情况下进行。
然而，施加在载体外表面上的压力优选基本保持至少直到粘胶胶凝。压力的保持可通过使用置于载体外表面上的可充气膜来进行。
优选所施加的压力为5-50Psi(0.35-3.5kgf/cm2)，更尤其为0.3-3kgf/cm2。
最优选的压力范围为5-20Psi(0.35-1.40kgf/cm2)。
使用上述方法，可将涂层顺序地或同时转移到透镜毛坯的几何限定的前表面和后表面上。也可将该涂层仅转移到透镜毛坯的单侧上，优选转移到后侧(或背侧)上。
韧性涂层载体或支承体可简单地是由合适材料如塑料材料制成的支承薄膜，例如聚碳酸酯膜。涂层载体优选是由任何合适的材料制成的模具，优选由塑料材料、特别是热塑性材料、尤其是聚碳酸酯制成的模具。
模具的工作表面可具有根据一定图案组织的突纹，换句话说，该工作表面可微结构化，并且可向最终透镜提供具有由该微结构引入的性能(例如抗反射性能)的光学表面。
获得微结构化模具的各种技术公开在WO 99/29494中。
模具或载体可通过使用已知方法如表面磨削、热成型、真空热成型、热成型/压缩、注塑、注塑/压塑而获得。
当使用韧性模具时，唯一必须的是提供具有如下表面的模具：它的几何形状与待向其上转移涂层的透镜毛坯的光学表面的总体形状相仿，或为凹形或为凸形，但该表面不必严格对应于待涂覆的透镜毛坯表面的几何形状。因此，相同的模具可用于将涂层转移到其表面具有不同特定几何形状的透镜毛坯上。一般而言，韧性模具具有两个平行的主表面，因而具有均匀的厚度。
韧性模具的含有涂层的表面优选呈球形。
韧性模具的厚度一般为0.2-5mm，优选为0.3-5mm。更优选的是，韧性模具由聚碳酸酯制成，在这种情况下其厚度为0.5-1mm。
发明人已发现，若满足对模具和透镜毛坯的基础曲率的特定要求，则本发明的最佳实施方案得以实现。
在本专利申请中，当提到模具的基础曲率时，指的是模具工作表面的基础曲率，也就是说含有待转移到透镜或透镜毛坯上的涂层的表面的基础曲率。
同样，透镜或透镜毛坯的基础曲率指的是涂层将从上述模具上向其转移的表面的基础曲率。
在本申请中，基础曲率具有如下定义：
-对于球形表面，具有曲率半径R，
基础曲率(或基数)＝530/R(R以mm计)；
这种定义在本领域中十分经典，
-对于复曲面，有两个曲率半径，一个按上式计算，两个基础曲率BR，Br，其中BR＜Br。
对于向透镜或透镜毛坯的球形后侧的涂层转移，为了避免变形，尤其当使用韧性模具时，韧性模具(前侧)的基础曲率(BC)必须稍微高于涂层待转移到其上的透镜或透镜毛坯的几何限定表面的基础曲率(BL)。然而，BC不应当太高，以避免在转移过程中涂层破裂，或者在该转移后光功率的公差超出Z801。
一般而言，对于球形透镜或透镜毛坯，透镜或透镜毛坯的基础曲率BL和韧性模具的基础曲率BC应当满足如下关系：
0＜BC-BL＜1.5，
优选
0.2＜BC-BL＜1。
对于向透镜或透镜毛坯(圆柱形透镜或透镜毛坯)的呈复曲面的后侧的涂层转移，其中该复曲面具有两条半径为R和r且R＞r的主要子午线，可计算分别对应于定义该复曲面的半径R和r的两个基础曲率BLR和BLr。
透镜的基础曲率BLR和BLr和韧性模具的基础曲率满足如下关系：
BLR＜BLr
并且
a)若BLr-BLR≤3.5
则0＜BC-BLR＜3且
|BC-BLr|＜1
优选
0.2＜BC-BLR＜2.5且
|BC-BLr|＜0.5
b)若BLr-BLR＞3.5
则BLR＜BC＜BLr。
优选的是，当使模具和毛坯相向移动时，涂层与可固化粘胶之间的接触或可固化粘胶与透镜毛坯的几何限定表面之间的接触分别发生在涂覆的模具的中心区域或透镜毛坯的几何限定表面的中心区域。
尤其在韧性模具的情况下，模具的凸起前面的曲率半径可小于待涂覆毛坯的凹表面。因此，将压力施加在中心处，然后使模具变形以与毛坯表面相符。粘胶层从毛坯的中心开始而形成，这避免了在最终固化的粘胶层中捕捉气泡。当使用具有比待涂覆的毛坯凸表面更大的曲率半径的模具凹表面时，情况也是这样。
如前所述，从韧性模具的转移使用可充气膜来进行。
可充气膜可由任何弹性体材料制成，该材料在用合适的流体施压来促使韧性模具挤压透镜或透镜毛坯并使之符合透镜或透镜毛坯的表面几何形状时能充分变形。
可充气膜可由任何合适的弹性体材料制成。一般而言，可充气膜的厚度为0.50mm-5.0mm，伸长率为100-800％，邵氏A硬度为10-100。
若将粘胶热固化，则可充气膜的材料应当选择耐受固化温度的材料。
若将粘胶进行UV固化，则应当选择透明材料，例如透明的硅橡胶或其它透明橡胶或胶乳：优选将UV光线从模具侧辐射。
通过可充气膜施于模具上的压力优选为30kPa-150kPa，并且取决于透镜或透镜毛坯以及韧性模具的尺寸和曲率。当然，该压力需要在韧性模具和透镜或透镜毛坯上保持，直到粘胶或胶粘剂充分固化，从而获得涂层与透镜或透镜毛坯的足够粘结。
透镜毛坯可以是这样的透镜，它的一个或两个面都被表面磨削或浇注成所需几何形状。(仅一个面被表面磨削或浇注成所需几何形状的透镜称为半成品透镜)。
优选透镜毛坯的第一个表面具有渐进功率，第二个表面具有非渐进功率，但优选球形或复曲面形，根据本发明方法在其上进行涂层转移。优选渐进面为毛坯的前面。
透镜毛坯也可为半成品透镜，其中该透镜的一个面，优选该透镜的前面已经用合适的涂层(抗反射涂层、硬质涂层等)预处理，该透镜的其余面，优选背面利用本发明的转移法涂覆。透镜毛坯可为偏光透镜。
透镜毛坯可在应用本发明方法之前进行预处理。
该预处理可为物理处理如等离子体处理，或化学处理如溶剂处理或NaOH处理。
转移的涂层可包含光学领域中常用的任何涂层或涂层堆叠，例如抗反射涂层、耐磨涂层、抗冲击涂层、偏光涂层、光致变色涂层、光电涂层、电-光致变色涂层、染色涂层、印刷层如标识或两种或更多种这些涂层的堆叠。
根据本发明的优选实施方案，包含如下的涂层堆叠被转移到透镜毛坯的几何限定表面上：
-任选的疏水面漆；
-抗反射堆叠，它一般包含无机材料如金属氧化物或硅石；
-硬质涂层，它优选包含一种或多种环氧硅烷的水解产物和一种或多种无机填料如胶态二氧化硅；
-任选的冲击强度底漆，优选为聚氨酯胶乳或丙烯酸系胶乳；
其中堆叠中的每一涂层都按照上述顺序沉积在载体上。
本发明方法感兴趣的是转移包含“面漆、抗反射涂层、硬质涂层和底漆”的整个堆叠。
一般而言，抗反射涂层或堆叠的厚度为80nm-800nm，优选为100nm-500nm。
硬质涂层的厚度优选为1-10μm，优选为2-6μm。
底漆的厚度优选为0.5-3μm。
通常而言，待转移涂层的总厚度为1-500μm，但优选低于50μm，更优选低于20μm，或者甚至更好为10μm或更低。
粘胶或胶粘剂可以是任何可固化的粘胶或胶粘剂，优选是能促进涂层与毛坯的光学表面粘结而又不削弱成品透镜的光学性能的可热固化的或可光固化的、尤其是可UV固化的粘胶或胶粘剂。
一些添加剂如光致变色染料和/或颜料可包含在该粘胶中。
尽管优选将液体粘胶或胶粘剂分散在中心处，但可以以无规方式进行分散，首先通过旋转涂覆而展开，或者使用精密分散阀喷雾。对于均匀的层分布，这意味着粘胶或胶粘剂层的厚度变化一旦固化就对最终透镜的光功率没有影响了。
可固化的粘胶或胶粘剂可以是聚氨酯化合物、环氧化合物、(甲基)丙烯酸酯化合物如聚二(甲基)丙烯酸乙二醇酯、乙氧基化的双酚A二(甲基)丙烯酸酯。
用于可固化粘胶或胶粘剂的优选化合物是丙烯酸酯化合物如聚二丙烯酸乙二醇酯、乙氧基化的双酚A二丙烯酸酯，各种三官能丙烯酸酯如(乙氧基化的)三羟甲基丙烷三丙烯酸酯和三(2-羟乙基)异氰脲酸酯。
单官能丙烯酸酯如丙烯酸异冰片酯、丙烯酸苄酯、丙烯酸苯基硫乙基酯也适合。
上述化合物可单独或联合使用。
优选固化时粘胶层具有均匀的厚度。适合的粘胶可从Loctite Company市购。
如前所述，固化后的最终粘胶层的厚度小于100μm，优选小于80μm，最优选小于50μm，通常为1-30μm。
透镜毛坯可由任何适于制造光学透镜的材料制成，但优选由塑料材料制成，尤其是由如下超高指数材料制成：二甘醇双-烯丙基碳酸酯(来自PPGINDUSTRIES的
Figure C20061000126400151
)、聚碳酸酯(PC)、聚氨酯、聚硫氨酯、环硫化物，它们任选含有光致变色化合物。
通过本发明方法得到的最终透镜具有非常好的光学质量，并且它们没有干涉条纹或具有非常少的干涉条纹。
附图简述
由下文的详细描述并结合附图，本发明的前述和其它目的、特征和优点将对本领域熟练技术人员而言变得显而易见，其中：
-图1A-1C是将涂层转移到透镜毛坯的光学表面上的本发明方法第一实施方案的主要步骤示意图；以及
-图2A-2C是将涂层同时转移到透镜毛坯的两个光学表面上的本发明方法第二实施方案的主要步骤示意图；以及
-图3A和3B是使用本发明的新型可充气膜设备将涂层转移到透镜毛坯的光学表面上的本发明方法第三实施方案的主要步骤示意图。
优选实施方案详述
现在参见附图并尤其参见图1A-1C，将具有凹表面2的透镜毛坯1置于支承元件3上，使其凹表面2朝上。然后，将预先测定的可UV固化粘胶滴4沉积在透镜毛坯1的表面2上。将预先涂覆有所述涂层6的具有凸光学表面的韧性模具5置于支承元件7上，使其带有光学涂层的表面朝下。
涂层6在韧性模具5表面上的沉积可通过光学领域常用的任何沉积法来进行，例如真空沉积、旋转涂覆、刷涂、浸涂等。当然，沉积法取决于沉积在韧性模具5表面上的涂层的性质。
之后，使支承元件3、7相向移动，以使涂层6与可UV固化的粘胶滴4接触，并对与涂层反向的模具的外表面施压，使得可UV固化的粘胶滴展开在透镜毛坯1的表面2和涂层6上。然而，所施加的压力应当仅仅足以展开该粘胶滴以得到最终固化粘胶膜的所需厚度，但又不足以使透镜毛坯1发生任何变形。
如图1B中所示，然后将由透镜毛坯1、粘胶膜4、涂层6和模具5形成的装配件放入用于UV固化粘胶膜4的装置中。在将UV固化膜4固化之后，撤去模具5，回收含有粘结在其凹表面2上的涂层6的毛坯1，如图1C所示。
现在参见图2A-2C，这些图显示了与图1A-1B所述类似的方法，但其中透镜毛坯1的两个表面都通过本发明的转移法涂覆了涂层。
如图2A中所示，将其凹面预先涂覆有光学涂层9的韧性模具8，例如厚度为1mm的由聚碳酸酯制成的模具，置于支承元件3上。然后，将预先测定的可UV固化的粘胶滴10沉积在涂层9上。然后，将透镜毛坯1置于模具8上，使其凸表面2’与粘胶滴10接触。然后，将预先测定的可UV固化的粘胶滴沉积在透镜毛坯1的凹表面2上。将其凸表面预先涂覆有光学涂层6的韧性模具5，例如厚度为1mm的聚碳酸酯模具，置于支承元件7上。然后，使支承元件3、7相向移动，以使涂层6与粘胶滴4接触，并对模具之一的至少一个外表面施压，以展开粘胶滴4和10，形成粘胶膜。如上所述，所施加的压力必须仅仅足以展开该粘胶滴并在固化后形成具有所需厚度的粘胶膜，但又不足以使透镜毛坯1产生任何变形。
之后，将由模具、光学涂层、粘胶膜和透镜毛坯形成的装配件放入用于UV固化粘胶膜4、10的UV固化装置中。
在粘胶膜的固化完成之后，撤去模具5和8，并回收具有粘结到透镜毛坯1的两个表面上的光学涂层5、6的成品透镜，如图2C所示。
图3A和3B是本发明方法第三实施方案的示意图，其中涂层的转移使用利用本发明的可充气膜设备而促使挤压透镜毛坯表面的韧性模具或载体来进行。
图3A显示在对膜施压和充气之前的透镜毛坯、韧性载体和可充气膜，然而图3B显示对膜施压和充气之后的透镜毛坯、韧性载体和可充气膜。
尽管下面将作出有关胶粘剂的UV固化的描述，但可使用与使用可热固化胶粘剂时类似的设备和方法。
参见图3A，将透镜毛坯1例如复曲面透镜毛坯置于透镜毛坯的载体上，使其几何限定表面1a朝外。
将透明的液体胶粘剂滴3沉积在透镜毛坯1的几何限定表面1a的中心处。
将在其一个面上沉积有可转移涂层5的薄韧性载体4，例如球形载体，置于胶粘剂滴3上，使得可转移涂层5与胶粘剂滴3接触。韧性载体4的基础曲率稍微高于透镜毛坯1的几何限定表面1a的基础曲率。
将整个装配件置于可充气膜设备10的前面。
可充气膜设备10包括流体聚集器11，例如带有流体港12的空气聚集器，例如与加压流体源相连的空气港(未示出)，用于在聚集器中引入加压流体以及从聚集器中对加压流体抽真空。聚集器10的上面包括透光部件13，例如透UV的石英玻璃部件，然而聚集器10的下面包括与透明的石英玻璃13配准的透明可充气膜14。
如图3A所示，设备10还包括用于在充气过程中横向引导可充气膜14的导向装置15。更具体而言，该导向装置包括截锥形部件或漏斗15，其从聚集器10的下面向外突出，并且它的较大基底由可充气膜封闭，它的较小基底是圆形开孔，其直径至少等于韧性载体4的基础直径，但优选稍微大一些(至多大5mm)。
一般而言，漏斗高度为10-50mm，优选为10-25mm，并且锥度为10-90°，优选为30-50°。
最后，将光源如UV光源16置于聚集器10的后面，但位于透明石英板13的前面。
一般而言，放置包括透镜毛坯支座2、透明毛坯1、胶粘剂滴3和韧性载体4的装配件，使得韧性载体4的边缘位于漏斗15的较小基底开孔的边缘平面之内，或者与其相隔，但距离不超过50mm，优选不超过20mm。
如图3B所示，将加压流体如加压空气从外部源(未示出)经由入口12引入聚集器11中。聚集器中的压力增加使可充气膜14充气，并且由于膜导向装置15，膜14均匀地促使韧性载体挤压透镜毛坯，同时均匀地展开胶粘剂3。
胶粘剂然后进行UV固化。
在固化步骤完成之后，将透镜毛坯1从支座2中卸下来，并移走韧性载体4，以回收其几何限定表面1a含有转移的涂层5的透镜毛坯1。
当然，在热固化法的情况下，不需要光源和聚集器上面的透明部件。
在这种情况下，可充气膜也不必是透明的。该设备在其它方面相同。
使用刚描述的漏斗型设备，获得良好的涂层转移，同时具有满足theAmerica Optical Laboratory Standard(ANSI Z80.1-1987)的就功率、圆柱、棱镜和变形而言的良好光学质量。
膜导向装置(漏斗)在如下方面非常重要，使膜以良好形状和方向膨胀，以通过透镜毛坯在韧性载体上施加均匀压力，而在载体和透镜毛坯边缘上无任何额外压力。
下列实施例将阐述本发明方法。
附着力试验
干附着力试验通过用刀片从涂层中切取一系列的间隔1mm的10条线，然后与第一系列呈直角切取第二系列的间隔1mm的10条线，形成交叉图案。在用空气流对交叉图案吹风除去划线过程中形成的任何灰尘之后，将透明玻璃纸带施加在交叉图案上，使劲往下压，然后以垂直于涂层表面的方向迅速拉离。然后再将新鲜带的施用和除去重复两次。然后，将透镜进行着色，以确定粘结的百分比，其中着色区域表示粘结失败。
实施例1-6
将如上所述的包含疏水面漆层、抗反射涂层、耐磨涂层和冲击和/或粘结增强层的HMC涂层沉积在不同韧性载体的凸表面上，并利用如图3A和3B所定义的工艺和设备转移到透镜的几何限定的后侧表面上。
所用材料、设备和工艺条件定义如下：
1)韧性模具(载体)：
-聚碳酸酯(厚度：0.5mm)
基础曲率(BC)：6、8或11，
韧性模具的直径(外围)：68mm。
2)透镜：
-外径为70mm的透镜，后侧的基础曲率如下表III所示，
-功率如下表III所示。
3)液体胶粘剂：
可UV固化的液体胶粘剂：来自DYMAX Corporation的OP-21。
4)可充气膜设备
-膜：透明的硅橡胶膜，厚度为1.6mm，硬度计硬度为40A，拉伸强度为5516kPa，以及伸长率为250％，
-空气压力：施于模具上的压力为10psi。
5)UV固化
-光强度：145mW/cm2；
-固化时间：40秒。
结果给出在表I中。
表I
HMC膜从薄HMC-PC载体(0.5mm)上转移到不同弯曲透镜前后的光学性能对照
  实施例   透镜功率   圆柱   BL或BL<sub>R</sub>-BL<sub>r</sub>   BC   BST之前的透镜功率   BST之后的透镜功率   BST之前的圆柱   BST之后的圆柱   BST之前的棱镜   BST之后的棱镜   总体ISO性能Z80.1
  1   (+)4.00   0   5.405.40   6   4.01   3.93   -0.04   -0.09   0.63   0.64   良好
  2   (+)3.00   -2   5.707.70   8   3.02   3.03   -1.98   -2.02   0.21   0.46   良好
  3   (+)1.00   -2   6.208.20   8   0.97   1.02   -1.93   -1.94   0.14   0.05   良好
  4   (-)1.00   -2   6.608.50   8   -1.01   -1.02   -2.05   -2.05   0.12   0.02   良好
  5   (-)3.00   0   7.707.70   8   -2.99   -2.94   -0.03   -0.05   0.37   0.31   良好
  6   (-)4.00   -2   8.5010.50   11   -4.06   -4.04   -1.93   -1.99   0.86   0.30   良好
BST：后侧转移
实施例7
重复实施例1-6，但用聚碳酸酯透镜代替功率为-2.00至+2.00的CR-39透镜。在涂层转移之后，所得透镜的光学和HMC膜质量与实施例1-6相同。
实施例8
重复实施例1-6，但用光致变色透镜代替CR-39透镜。在涂层转移之后，所得透镜的光学和HMC膜质量与实施例1-6相同。
实施例9-18和对比例1-2
在下列条件下重复实施例1-6的工序：薄PC载体：
a)HMC薄载体的制备：首先，通过表面磨削下表IV所示的PC毛坯来制备不同尺寸且厚度为0.5mm的基础曲线载体。该PC载体由非UV吸收剂PC材料制成。该载体的外径为68mm。然后这些载体用保护涂层、AR涂层、硬质涂层和胶乳底涂层涂覆，制成用于后侧涂层转移方法的HMC前面涂覆的载体。
b)透镜毛坯的制备：将外径为70mm的HMC前面涂覆的PC SF(半成品)透镜在后面表面磨削成不同功率，使之具有不同后侧基础曲率或基底，如同一表所示。
c)BST：将透镜用肥皂和水洗涤，干燥，然后将少量UV丙烯酸系胶粘剂滴在该透镜的后侧上，并将HMC载体置于该粘胶上。之后，将UV漏斗型聚集器设备置于该载体顶部上。将膜以69kPa的恒定压力充气，使HMC载体变形，并展开该粘胶液体，以与透镜的后侧曲率相匹配，然后从顶部(载体侧)辐射UV光达40秒。在UV固化之后，缓缓移动含有HMC载体堆叠的透镜，以除去边上过剩的粘胶，然后对载体吹以空气，以除去堆叠在透镜后侧上的HMC。通过HUMPHERY 350 Power，检测所得的因BST法在后侧上含有HMC的透镜的光学质量和变形。结果给出在表II中。
表II
 实施例   PC透镜功率   PC透镜圆柱   BLBL<sub>R</sub>≈BL<sub>r</sub> BC/HMC载体基底   BST之前的功率   BST之后的功率   BST之前的圆柱   BST之后的圆柱  BST之后的光的畸变
 9   +2.00   0   3.6 4.1   +2.04   +2.02   0.04   0.06  良好
 10   +2.00   2.00   3.6≈5.5 5.5   +2.04   +2.11   1.99   2.05  良好
 11   +1.00   0   4.5 5.5   +0.99   +0.94   0.03   0.01  良好
 12   +1.00   2.00   4.5≈6.3 6.1   +1.02   +1.06   1.98   1.94  良好
 13   -1.00   0   5.2 5.7   -0.98   -1.00   0.02   0.07  良好
 14   -1.00   2.00   5.2≈7.0 7.5   -1.02   -0.92   1.96   2.03  良好
 15   -2.00   0   5.1 6.1   -2.05   -1.95   0.02   0.05  良好
 16   -2.00   2.00   5.1≈6.9 6.5   -2.00   -1.93   1.99   2.01  良好
 17   -3.00   0   6.0 6.5   -2.92   -2.95   0.02   0.04  良好
 18   -3.00   2.00   6.0≈7.8 7.5   -2.90   -3.03   2.02   1.96  良好
 对比例1   +1.00   2.00   4.5≈6.3 4.5   +1.05   2.03   2.03   3.07  NG
 对比例2   0.00   0   5.5 4.5   0.00   1.00   0.00   0.45  NG
对比例1-2：载体基础曲率小于透镜后侧的基础曲率；
NG：不好。
上述实施例的模具的HMC预涂层如下，但在实施例5中，未使用硬质涂层和底涂层。
实施例9-18中的HMC前面涂覆的PC SF在HMC沉积的步骤2和3之后获得，但每层的沉积以相反顺序(底漆/硬质涂层/AR涂层)，即正常顺序进行。
步骤1：保护和防粘涂层
保护和防粘涂层的组成如下：
  组分   重量份数
  PETA LQ(季戊四醇的丙烯酸酯)   5.00
  Dowanol PnP   5.00
  Dowanol PM   5.00
  正丙醇   5.00
  1360(聚硅氧烷六丙烯酸酯，Radcure)   0.10
  Coat-O-Sil 3503(反应性流动添加剂)   0.06
  光引发剂   0.20
将PC模具用肥皂水清洁，并用压缩空气干燥。然后用上述保护涂层组合物通过旋转涂覆来涂覆模具的凸表面，其中以600rpm的施涂速率持续3秒，以1200rpm的干燥速率持续6秒。使用Fusion System H+灯以1.524m/min(5英尺/分钟)的速率将该涂层固化。
步骤2：抗反射(AR)涂层
在沉积保护涂层之后，将PC模具按如下真空涂覆：
A.标准真空AR处理：真空AR处理在标准的箱式涂布机中使用熟知的真空蒸发工艺来进行。下列为一种在模具上获得VAR的工序：
1.将其表面上已经施涂保护涂层的模具放入标准的箱式涂布机中，并将该室泵抽至高真空水平。
2.使用热力蒸发技术，将疏水涂层(Chemical＝Shin Etsu KP801M)沉积在模具的表面上，至厚度为2-15nm。
3.然后，以与正常顺序相反的顺序沉积由高和低指数材料的内层堆叠组成的介电多层AR涂层。该沉积的详细情况如下：
交替的低和高指数层的光学厚度给出在下表中：
  低指数   103-162nm
  高指数   124-190nm
  低指数   19-37nm
  高指数   37-74nm
B.在四层抗反射堆叠的沉积结束时，沉积物理厚度为1-50nm的薄SiO2层。该层将促进氧化物抗反射堆叠与后来将沉积在涂覆模具上的清漆硬质涂层之间的粘结。
步骤3：硬质涂层(HC)&胶乳底涂层
硬质涂层的组成如下：
  组分   重量份数
  Glymo   21.42
  0.1N HCl   4.89
  胶态二氧化硅   30.50
  甲醇   29.90
  双丙酮醇   3.24
  乙酰丙酮化铝   0.45
  偶联剂   9.00
  表面活性剂FC-430(3M公司)   0.60
底漆的组成如下：
  组分   重量份数
  聚氨酯胶乳W-234   35.0
  去离子水   50.0
  2-丁氧基乙醇   15.0
  偶联剂   5.00
在于步骤1和2中沉积保护涂层和AR涂层之后，将PC模具用HC溶液以600rpm/1200rpm进行旋转涂覆，并于80℃下预先固化10分钟，然后用胶乳底漆溶液以相同速率再次旋转涂覆，并于80℃下后固化1小时。
偶联剂是组成如下的预缩合溶液：
 组分   重量份数
 GLYMO(环氧丙氧基丙基三甲氧基硅烷)   10
 丙烯酰氧基丙基三甲氧基硅烷   10
 0.1N HCl   0.5
 乙酰丙酮化铝   0.5
 双丙酮醇   1.0

Claims (23)

1. 可充气膜设备(10)，包括：
-具有上面和下面以及流体入口(12)的流体聚集器(11)，其中所述下面通过可充气膜(14)而部分形成，以及
-截锥形部件(15)，其从聚集器的下面向外突出，并且它的较大基底由至少部分可充气膜(14)封闭，它的较小基底形成圆形开孔，
从而，当将加压流体引入聚集器(11)中时，可充气膜(14)的变形通过截锥形部件来导向。
2. 如权利要求1所述的可充气膜设备(10)，其中所述截锥形部件(15)的高度为10-50mm。
3. 如权利要求1或2所述的可充气膜设备，其中所述截锥形部件(15)的锥度为10-90°。
4. 如权利要求3所述的可充气膜设备，其中所述截锥形部件(15)的锥度为30-50°。
5. 如权利要求1或2所述的可充气膜设备，其中所述膜(14)是透光膜，并且所述聚集器的上面包括与所述可充气膜(14)配准的透明部件(13)。
6. 一种使用如权利要求1所定义的设备将涂层(5)转移到透镜毛坯(1)的至少一个几何限定表面(10)上的方法，包括如下步骤：
-提供具有至少一个几何限定表面(10)的透镜毛坯(1)；
-提供具有内表面和外表面的韧性载体(4)，该内表面含有涂层(5)；
-在所述透镜毛坯(1)的所述几何限定表面(10)上或在所述涂层(5)上沉积一定量的可固化粘胶(3)；
-使透镜毛坯(1)和载体(4)相向移动，以使涂层与可固化粘胶接触或使该可固化粘胶与透镜毛坯的几何限定表面接触，形成组装体；
-将组装体置于可充气膜设备(10)的前面，使载体面向可充气膜；
-使可充气膜(14)充气，促使韧性载体(4)挤压透镜毛坯(1)，由此在载体的外表面上施以压力，使得固化后的最终粘胶层的厚度小于100μm；
-将所述粘胶固化；以及
-撤去载体，以回收在其几何限定表面上粘结有涂层的透镜毛坯(1)，其中可固化粘胶的量是足以获得涂层向透镜毛坯的转移和粘结的粘胶量。
7. 如权利要求6所述的方法，其中所述韧性载体(4)由聚碳酸酯制成。
8. 如权利要求7所述的方法，其中所述韧性载体的厚度为0.3-5mm。
9. 如权利要求6-8中任一项所述的方法，其中所述透镜毛坯(1)的几何限定表面(10)为光学表面。
10. 如权利要求6-8中任一项所述的方法，其中所述透镜毛坯(1)的几何限定表面(10)的粗糙度Sq为10-3至1μm。
11. 如权利要求6-8中任一项所述的方法，其中所述最终固化粘胶层的厚度小于80μm。
12. 如权利要求11所述的方法，其中所述最终固化粘胶层的厚度小于50μm。
13. 如权利要求12所述的方法，其中所述最终固化粘胶层的厚度为1-30μm。
14. 如权利要求6-8中任一项所述的方法，其中所施加的压力为5-50Psi。
15. 如权利要求6-8中任一项所述的方法，其中所述涂层(5)包含抗反射涂层、耐磨涂层、抗冲击涂层、光致变色涂层、染色涂层、偏光涂层、印刷层或两种或更多种这些涂层的堆叠。
16. 如权利要求15所述的方法，其中所述涂层的厚度低于50μm。
17. 如权利要求6-8中任一项所述的方法，其中所述透镜毛坯(1)是其一个面已经具有涂层的半成品透镜。
18. 如权利要求17所述的方法，其中所述已经具有涂层的面是透镜的前面和位于该透镜后表面中的几何限定表面(1a)，对于后者，涂层转移到它的上面。
19. 如权利要求6-8中任一项所述的方法，其中所述透镜毛坯(1)的几何限定表面(10)是后面的球形表面，并且该韧性载体的基础曲率(BC)和该透镜毛坯的球形表面的基础曲率(BL)满足如下关系：
0＜BC-BL＜1.5。
20.如权利要求19所述的方法，其中
0.2＜BC-BL＜1。
21. 如权利要求6-8中任一项所述的方法，其中所述透镜毛坯(1)的几何限定表面(10)是后面的圆柱形表面，并且该韧性载体的基础曲率(BC)和所述透镜毛坯的圆柱形表面的基础曲率(BLR，BLr)满足如下关系：
BLR＜BLr
并且
a)若BLr-BLR＜3.5
则0＜BC-BLR＜3且
|BC-BLr|＜1
b)若BLr-BLR＞3.5
则BLR＜BC＜BLr
其中上述下标R和r分别表示所述圆柱形表面所代表的复曲面具有的两条主要子午线的半径，其中R＞r，进而BLR和BLr分别为具有半径R和r的曲面的基础曲率。
22. 如权利要求21所述的方法，其中在a)中：
0.2＜BC-BLR＜2.5且|BC-BLr|＜0.5。
23. 一种使用如权利要求1所定义的设备将涂层(5)转移到透镜毛坯(1)的几何限定表面(10)上的方法，包括如下步骤：
-提供具有至少一个几何限定表面(10)的透镜毛坯(1)；
-提供具有内表面和外表面的韧性载体(4)，该内表面含有涂层(5)和在所述涂层上沉积的一定量的可固化粘胶(3)；
-使透镜毛坯(1)和载体(4)相向移动，以使可固化粘胶与透镜毛坯的几何限定表面接触，形成组装体；
-将组装体置于可充气膜设备(10)的前面，使载体面向可充气膜；
-使可充气膜(14)充气，促使韧性载体(4)挤压透镜毛坯(1)，由此在载体的外表面上施以压力，使得固化后的最终粘胶层的厚度小于100μm；
-将所述粘胶固化；以及
撤去载体，以回收在其几何限定表面上粘结有涂层的透镜毛坯(1)，其中可固化粘胶的量是足以获得涂层向透镜毛坯的转移和粘结的粘胶量。
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