Method of forming an anti-reflective coating on an eyeglass lens

Abstract

Methods of coating a lens mold are described. One or more methods may include coupling a mold to a mold holder of an eyeglass lens mold coating apparatus. The mold holder may be rotatably coupled to a transport device of the mold coating apparatus. The mold may be moved to a coating process unit. The mold may be rotated while a coating composition is applied to the casting face of the mold. The mold with the coating composition applied may be moved to a curing process unit. Activating light may be applied to the coating composition to initiate curing of the coating composition.

1 - 471 . (canceled)  
   
   
       472 . A method of forming an antireflective coating stack on a lens, comprising: 
 providing an eyeglass lens mold;    coupling the eyeglass lens mold to a rotatable mold holder of an eyeglass lens mold coating apparatus, wherein the mold holder is coupled to a transport device of the coating apparatus;    moving the eyeglass lens mold into a desired operational relationship with a coating process unit;    rotating the eyeglass lens mold while applying a first mold coating composition to a casting face of the eyeglass lens mold;    moving the eyeglass lens mold into a desired operational relationship with a curing process unit;    applying activating light to the first mold coating composition to cure the first mold coating composition;    moving the eyeglass lens mold into a desired operational relationship with the coating process unit;    rotating the eyeglass lens mold while applying a second mold coating composition over the cured first mold coating composition on the casting face of the eyeglass lens mold;    moving the eyeglass lens mold into a desired operational relationship with a curing process unit;    applying activating light to the second mold coating composition to cure the second mold coating composition; wherein the first mold coating composition comprises a refractive index lower than the second mold coating composition when both compositions are cured; and    casting an eyeglass lens using at least the coated eyeglass lens mold.    
   
   
       473 . The method of  claim 472 , wherein moving the eyeglass lens mold is controlled by a controller.  
   
   
       474 . The method of  claim 472 , wherein coupling the eyeglass lens mold to the rotatable mold holder is controlled by a controller.  
   
   
       475 . The method of  claim 472 , wherein rotating the eyeglass lens mold is controlled by a controller.  
   
   
       476 . The method of  claim 472 , wherein applying a coating composition to the eyeglass lens mold is controlled by a controller.  
   
   
       477 . The method of  claim 472 , wherein applying activating light is controlled by a controller.  
   
   
       478 . A method of forming an antireflective coating stack on an eyeglass lens, comprising: 
 providing an eyeglass lens mold;    coupling the eyeglass lens mold to a rotatable mold holder of an eyeglass lens mold coating apparatus, wherein the mold holder is coupled to a transport device of the eyeglass lens mold coating apparatus;    forming an antireflective coating stack on the casting surface of the eyeglass lens mold; and    casting an eyeglass lens using at least the coated eyeglass lens mold.    
   
   
       479 . The method of  claim 478 , wherein coupling the eyeglass lens mold to the rotatable mold holder is controlled by a controller.  
   
   
       480 . The method of  claim 478 , wherein forming an antireflective coating stack on the casting surface of the eyeglass lens mold is controlled by a controller.  
   
   
       481 . The method of  claim 478 , wherein coupling the mold to the rotatable mold holder comprises inserting the mold into a vacuum chuck of the mold holder.  
   
   
       482 . The method of  claim 478 , wherein forming an antireflective coating stack on the casting surface of the eyeglass lens mold comprises rotating the lens mold while applying at least one mold coating composition.  
   
   
       483 . The method of  claim 478 , wherein forming an antireflective coating stack on the casting surface of the eyeglass lens mold comprises rotating the lens mold at a predetermined rotation while applying at least one mold coating composition.  
   
   
       484 . The method of  claim 478 , wherein forming an antireflective coating stack on the casting surface of the eyeglass lens mold comprises rotating the lens mold at between about 200 rpm and about 2000 rpm while applying at least one mold coating composition.  
   
   
       485 . The method of  claim 478 , wherein applying at least one coating layer of the antireflective coating stack to the casting surface of the mold comprises dispensing at least one coating composition from a coating applicator of a coating process unit onto the casting surface of the mold while the mold is rotating to form a uniform coating layer.  
   
   
       486 . The method of  claim 478 , wherein applying at least one layer of the antireflective coating stack to the casting face of the mold comprises selecting a coating to be applied and controlling one or more process parameters based on the coating selected.  
   
   
       487 . The method of  claim 478 , wherein applying at least one layer of the antireflective coating stack to the casting surface of the mold comprises selecting a coating to be applied and controlling the rate of rotation of the mold based on the coating selected.  
   
   
       488 . The method of  claim 478 , wherein applying at least one layer of the antireflective coating stack to the casting surface of the mold comprises selecting a coating to be applied and controlling a delay time after application of the coating and before curing of the coating based on the coating selected.  
   
   
       489 . The method of  claim 478 , wherein applying at least one layer of the antireflective coating stack comprises applying activating light pulses to a coating composition applied to the casting surface of the eyeglass lens mold.  
   
   
       490 . The method of  claim 478 , wherein applying at least one layer of the antireflective coating stack comprises applying activating light pulses to a coating composition applied to the casting surface of the eyeglass lens mold and rotating the mold between one or more activating light pulses.  
   
   
       491 . The method of  claim 478 , wherein at least one coating layer of the antireflective coating stack is less than about 1000 nm thick.  
   
   
       492 . The method of  claim 478 , wherein at least one coating layer of the antireflective coating stack is less than about 500 nm thick.  
   
   
       493 . The method of  claim 478 , further comprising cleaning the eyeglass lens mold before applying the antireflective coating stack.  
   
   
       494 . The method of  claim 493 , wherein cleaning the eyeglass lens mold comprises: 
 moving the mold into a desired operational relationship with a cleaning process unit; and    rotating the eyeglass lens mold while applying a cleaning fluid to the casting face of the eyeglass lens mold.    
   
   
       495 . The method of  claim 493 , further comprising rotating the eyeglass lens mold after cleaning to facilitate drying of the eyeglass lens mold.  
   
   
       496 . The method of  claim 493 , further comprising applying a drying agent the eyeglass lens mold after cleaning to facilitate drying of the eyeglass lens mold.  
   
   
       497 . The method of  claim 493 , further comprising applying a chemical drying agent to the eyeglass lens mold after cleaning the eyeglass lens mold.  
   
   
       498 . The method of  claim 497 , wherein the chemical drying agent comprises isopropyl alcohol.  
   
   
       499 . The method of  claim 478 , further comprising receiving input comprising eyeglass lens information.  
   
   
       500 . The method of  claim 499 , further comprising selecting at least one eyeglass lens mold to coat based on the received input, wherein at least one selected eyeglass lens mold is usable for forming an eyeglass lens substantially conforming to the eyeglass lens information.  
   
   
       501 . The method of  claim 499 , wherein the eyeglass lens information comprises an identification of at least one coating desired to be present on a lens substantially conforming to the eyeglass lens information.  
   
   
       502 . The method of  claim 499 , further comprising determining one or more operating parameters of an eyeglass lens mold coating apparatus based on the eyeglass lens information.  
   
   
       503 . The method of  claim 502 , wherein at least one operating parameter determined based on the eyeglass lens information are selected from the group consisting of: mold rotation time during a cleaning process, mold rotation rate during the cleaning process, and dispense time of a cleaning fluid during the cleaning process.  
   
   
       504 . The method of  claim 502 , wherein at least one operating parameter determined based on the eyeglass lens information is selected from the group consisting of: mold rotation time during coating, mold rotation rate during coating, a coating composition applied, and amount of coating composition dispensed during coating.  
   
   
       505 . The method of  claim 502 , wherein at least one operating parameter determined based on the eyeglass lens information is selected from the group consisting of: mold rotation time during a mold drying process, mold rotation rate during the mold drying process, and selection of a drying agent applied during the mold drying process.  
   
   
       506 . The method of  claim 502 , wherein at least one operating parameter determined based on the eyeglass lens information is selected from the group consisting of: mold rotation time during curing, intensity of activating light applied, duration of application of activating light, flash rate of activating light source, and flash duration of activating light source.  
   
   
       507 . The method of  claim 478 , further comprising moving the mold along a travel path of the transport device while applying at least one mold coating composition of at least one coating layer of the antireflective coating stack to ensure a uniform coating on the casting face of the mold.  
   
   
       508 . The method of  claim 478 , further comprising rotating the mold for a predetermined period of time after applying at least one mold coating composition of at least one coating layer of the antireflective coating stack to promote drying of the coating composition.  
   
   
       509 . The method of  claim 478 , further comprising promoting evaporation of a coating composition of at least one coating layer of the antireflective coating stack solvent before applying activating light to at least one coating composition.  
   
   
       510 . The method of  claim 478 , further comprising decoupling the mold from the mold holder at a transfer station after applying at least one coating layer of the antireflective coating stack.  
   
   
       511 . The method of  claim 510 , further comprising coupling the mold to a second rotatable mold holder at the transfer station.