Inflatable membrane apparatus and process for transferring a coating onto a surface of a lens blank

1. An inflatable membrane apparatus for transferring a transferable coating onto a lens blank, the apparatus comprising:

a fluid accumulator having an upper and a lower face and a fluid entrance, said lower face being partly formed by an inflatable membrane;

a trunconical part projecting outwardly from the lower face of the accumulator, wherein the greater base of the trunconical part is closed by the lower face, and wherein the smaller base of the trunconical part forms a circular opening; and

a flexible carrier for receiving the transferable coating thereon and configured to be disposed between the inflatable membrane and the lens blank;

where the inflatable membrane apparatus is configured such that, as pressurized fluid is introduced into the accumulator, deformation of the inflatable membrane is guided by the trunconical part to urge the transferable coating against the lens blank.

2. The inflatable membrane apparatus of claim 1 , wherein the height of the trunconical part is between 10 mm and 50 mm.

3. The inflatable membrane apparatus of claim 1 , wherein the taper of the trunconical part is between 10° and 90°.

4. The inflatable membrane apparatus of claim 1 , wherein at least a portion of the inflatable membrane and at least a portion of the upper face of the accumulator is transparent.

5. A process for transferring a coating from a flexible carrier and onto a geometrically defined surface of a lens blank, the process comprising:

depositing an amount of curable glue on at least one of said geometrically defined surface and said coating;

placing the lens blank and the flexible carrier in front of an inflatable membrane of an inflatable membrane apparatus comprising:

a fluid accumulator having an upper and a lower face and a fluid entrance, said lower face being partly formed by the inflatable membrane; and

a trunconical part projecting outwardly from the lower face of the accumulator, wherein the greater base of the trunconical part is closed by the lower face, and wherein the smaller base of the trunconical part forms a circular opening; and

introducing fluid into the accumulator such that the inflatable membrane urges the flexible carrier against the lens blank, thereby coupling the coating and the geometrically defined surface via the glue, where deformation of the inflatable membrane is guided by the trunconical part.

6. The process of claim 5 , wherein the flexible carrier comprises a polycarbonate material.

7. The process of claim 5 , wherein the flexible carrier has a thickness of between 0.3 mm and 5.0 mm.

8. The process of claim 5 , wherein the geometrically defined surface of the lens blank comprises an optical surface.

9. The process of claim 5 , wherein the geometrically defined surface of the lens blank has a root mean square roughness (Sq) of between 10 −3 micrometers and 1 micrometer.

10. The process of claim 5 , comprising:

curing the glue;

wherein the thickness of the glue after curing is less than 100 micrometers.

11. The process of claim 5 , wherein a pressure applied by the inflatable membrane to the flexible carrier is between 5 psi and 50 psi.

12. The process of claim 5 , wherein the coating comprises at least one of the following: an anti-reflection coating layer, an anti-abrasion coating layer, an impact resistant coating layer, a photochromic coating layer, a dyeing coating layer, a polarized coating layer, and a printed layer.

13. The process of claim 12 , wherein the coating has a thickness of less than 50 micrometers.

14. The process of claim 5 , wherein the lens blank comprises a semi-finished lens including a coating.

15. The process of claim 5 , wherein the geometrically defined surface of the lens blank comprises a spherical surface, and the base curvature of the flexible carrier (BC) and the base curvature of the spherical surface (BL) fulfill the following relationships:

0< BC−BL< 1.5.

16. The process of claim 5 , wherein the geometrically defined surface of the lens blank comprises a toric surface, and the base curvature of the flexible carrier (BC) and the base curvatures of the toric surface (BLR, BLr) fulfill the following relationships:

BLR<BLr and

a) if BLr−BLR≦3.5, then 0<BC−BLR<3 and |BC−BLr|<1, or

b) if BLr−BLR>3.5, then BLR<BC<BLr.

17. A process for transferring a coating from a flexible carrier and onto a geometrically defined surface of a lens blank, the process comprising:

placing the lens blank and the flexible carrier in front of an inflatable membrane of an inflatable membrane apparatus comprising:

a fluid accumulator having an upper and a lower face and a fluid entrance, said lower face being partly formed by the inflatable membrane; and

a trunconical part projecting outwardly from the lower face of the accumulator, wherein the greater base of the trunconical part is closed by the lower face, and wherein the smaller base of the trunconical part forms a circular opening; and

introducing fluid into the accumulator such that the inflatable membrane urges the flexible carrier against the lens blank, thereby transferring the coating from the flexible carrier and onto the geometrically defined surface of the lens blank, where deformation of the inflatable membrane is guided by the trunconical part.

18. The inflatable membrane apparatus of claim 1 , wherein, without pressurized fluid within the accumulator, said inflatable membrane is flat.

19. The inflatable membrane apparatus of claim 1 , wherein the inflatable membrane is configured to extend through the circular opening of the smaller base of the trunconical part when the fluid accumulator is pressurized.

20. The inflatable membrane apparatus of claim 1 , wherein the flexible carrier is separable from the inflatable membrane.