Bi-Layer Adhesive for Lens Lamination

Abstract

A bi-layer adhesive and a method for laminating a film onto an optical article utilizing the bi-layer adhesive are described. A method for laminating the film onto an optical article and the bi-layer adhesive for use in the method are also described. The bi-layer adhesive includes a latex adhesive layer and an HMA layer sequentially disposed on the film and dried to form a solid layer of uniform thinness throughout to provide optical quality. Various types of films may be employed to provide an optical function. Following optional pre-treatment steps, the bi-layer adhesive is coated on to the film. An optical hot press technique is used to deliver heat and pressure over a short period of time to form a functionally-enhanced optical article with high adhesive strength.

1 . A functionalized optical element comprising:
 an optical base element; and   a functionalized layered structure glued directly to the optical base element, the functionalized layer structure incorporating at least one functional layer to form a functionalized optical element, the functionalized layer structure as the functionalized optical element further comprising a bi-layer adhesive structure, the bi-layer adhesive structure comprising:
 a layer of latex adhesive disposed on a surface of said functionalized layered structure and bonding strongly to the at least one functional layer; and 
 a layer of hot melt adhesive (HMA) disposed between the layer of latex adhesive and the optical base element, a polymer for forming the layer of HMA comprising only a thermoplastic polymer, 
 the bi-layer adhesive structure forming a uniformly thin bi-layer of an optical quality permanently bonding the functionalized layered structure on the optical base element while maintaining optical quality, each of the layer of latex adhesive and the layer of HMA comprising a different adhesive to address disparate material properties of the least one functional layer and the optical base element. 
   
     
     
         2 . The functionalized optical element of  claim 1 , wherein said layer of latex adhesive comprises a material selected from the group consisting of an acrylic latex, a (meth)acrylic latex, a polyurethane latex, a core/shell latex, and combinations thereof. 
     
     
         3 . The functionalized optical element of  claim 2 , wherein said layer of latex adhesive comprises a dry, solid layer of between 0.5 microns and 10 microns thick with a substantially uniform thickness throughout to provide the optical quality. 
     
     
         4 . The functionalized optical element of  claim 2 , wherein said layer of latex adhesive comprises a dry, solid layer of between 1.0 microns and 5.0 microns thick with a substantially uniform thickness varying by less than 0.3 microns to provide the optical quality. 
     
     
         5 . The functionalized optical element of  claim 1 , wherein said layer of HMA is formed from a starting material selected from one or more of a group consisting of a UV curable HMA, a UV curable monomer, a thermal curable HMA, and a thermal curable monomer. 
     
     
         6 . The functionalized optical element of  claim 1 , wherein said layer of HMA further comprises one or more of an HMA polymer, and a colloid. 
     
     
         7 . The functionalized optical element of  claim 1 , wherein said layer of HMA is formed from a polyurethane HMA. 
     
     
         8 . The functionalized optical element of  claim 7 , wherein the layer of HMA comprises a dry, solid layer between 1.0 microns and 20 microns with a substantially uniform thickness throughout to provide the optical quality. 
     
     
         9 . The functionalized optical element of  claim 8 , wherein the layer of HMA comprises a dry, solid layer between 1.5 microns and 10 microns with a substantially uniform thickness varying by less than 0.3 microns to provide the optical quality. 
     
     
         10 . The functionalized optical element of  claim 1 , wherein the functionalized layered structure includes one or more layers selected from the group consisting of: an optical function layer; an optical structured layer; a Fresnel lens structure; a performance function layer; a polarizing layer; a photochromic layer; a hard coat layer; a top coat layer; an anti-fog layer; an anti-smudge layer; an anti-reflective layer; and an anti-static layer. 
     
     
         11 . The functionalized optical element of  claim 1 , wherein the functionalized layered structure includes one of a polarizing film, a TAC/PVA/TAC polarizing film and a PET polarizing film. 
     
     
         12 . The functionalized optical element of  claim 1 , wherein the optical base element is a thermoplastic optical base element selected from the group consisting of a finished lens, a semi-finished lens, a PAL lens, an afocal lens, a plano lens, a unifocal lens, and a multifocal lens. 
     
     
         13 . The functionalized optical element of  claim 1 , wherein the optical base element is a thermoset optical base element selected from the group consisting of a finished lens, a semi-finished lens, a PAL lens, an afocal lens, a plano lens, a unifocal lens and a multifocal lens. 
     
     
         14 . The functionalized optical element of  claim 1 , wherein the optical base element is a polycarbonate lens, wherein the functionalized layered structure includes a polarizing film, wherein the layer of latex adhesive is a polyurethane latex adhesive, and wherein the layer of HMA is a polyurethane HMA, which collectively form a laminated polarized ophthalmic lens. 
     
     
         15 . (canceled) 
     
     
         16 . The functionalized optical element of  claim 1 , wherein the optical base element has a base curve, and prior to bonding with the functionalized layer structure, the functionalized layered structure has a curve that is close to the base curve. 
     
     
         17 . The functionalized optical element of  claim 1 , wherein the functionalized layered structure includes at least one treated surface. 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . The functionalized optical element of  claim 1 , wherein said layer of latex adhesive is a polyurethane latex adhesive dried to a final dry thickness of between 1.0 microns and 5.0 microns, said layer of HMA is a polyurethane HMA dried to a final dry thickness of between 1.5 microns and 10 microns, and the bi-layer adhesive structure has the optical quality and uniform thickness varying by less than 0.3 microns. 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         26 . The functionalized optical element of  claim 1 , wherein the optical base element is a polycarbonate lens, and the functionalized layered structure includes a polarizing film which collectively form a laminated polarized ophthalmic lens. 
     
     
         27 . The functionalized optical element of  claim 1 , wherein the layer of latex adhesive is formed from a thermoset material. 
     
     
         28 . The functionalized optical element of  claim 1 , wherein the bi-layer adhesive structure provides both good dry adhesion and good wet adhesion to the functionalized optical element when formed with the optical base element and the functionalized layered structure. 
     
     
         29 . The functionalized optical element of  claim 1 , wherein the bi-layer adhesive structure is a structure operable with film lamination, in which film lamination is utilized to form the functionalized optical element, the bi-layer adhesive being less susceptable to defects from the film lamination as compared with a comparative functionalized optical element formed without the bi-layer structure.