Abrasion resistance for patterned lens
A patterned lens with abrasion resistance having a base layer hard coat and a top hard coat. The base layer hardcoat may be formed on a film or sheet and used in molding the patterned lens. The top hard coat may be applied after molding.
1 . A method of forming a patterned lens having improved abrasion resistance, comprising:
providing a film or sheet comprising a polymeric material and having a first surface coated with an abrasion resistant coating;
placing the film or sheet into a lens mold such that the coated surface faces a mold cavity;
injecting a thermoplastic into the lens mold behind the film or sheet to form a lens; and
replicating one or more optical features from the lens mold into the film or sheet and the abrasion resistant coating.
2 . The method of claim 1 , wherein the optical features comprise a plurality of microlenses.
3 . The method of claim 1 , wherein the abrasion resistant coating is partially cured before injection molding.
4 . The method of claim 3 , further comprising fully curing the abrasion-resistant coating after injection molding using heat, ultraviolet light, or visible light.
5 . The method of claim 3 , further comprising curing the coating.
6 . The method of claim 1 , wherein the film or sheet is composed of polycarbonate.
7 . The method of claim 1 , wherein the abrasion resistant coating comprises a material selected from the group consisting of siloxanes, acrylates, and urethanes.
8 . The method of claim 7 , wherein a second abrasion resistant coating applied to the formed lens is applied via spin coating.
9 . The method of claim 1 , further applying an abrasion resistant coating to the formed lens.
10 . The method of claim 1 , wherein a thickness of the film or sheet is between 0.1-2.0 millimeters and wherein a thickness of the coating is between 0.5-20 microns.
11 . The method of claim 1 , wherein the thermoplastic comprises nylon.
12 . The method of claim 1 , wherein the coated film or sheet is formed into a wafer prior to insertion into the mold.
13 . A method of forming a patterned lens having improved abrasion resistance, comprising:
providing a film or sheet comprising a polymeric material and having a first surface coated with a first abrasion resistant coating;
placing the film or sheet into a lens mold such that the coated surface faces the mold cavity;
injecting a thermoplastic into the mold behind the film or sheet to form a lens;
replicating one or more optical features from the mold into the abrasion resistant coating and film;
and applying a second abrasion resistant coating to the formed lens.
14 . The method of claim 13 , wherein the second coating is applied to the first coating via spin coating.
15 . The method of claim 13 , wherein a thickness of the second coating is less than a thickness of the first coating.
16 . The method of claim 13 , wherein the film or sheet is comprised of a wafer.