WO2024116139A1

WO2024116139A1 - Coated optical substrates

Info

Publication number: WO2024116139A1
Application number: PCT/IB2023/062124
Authority: WO
Inventors: Vitaly Krakov; Ilan Hidana; Matias SAMETBAND; Claudio Rottman; Shalom Lampert
Original assignee: Flo Optics Ltd.
Priority date: 2022-12-01
Filing date: 2023-12-01
Publication date: 2024-06-06
Also published as: GB2625055A8; GB202218049D0; GB2625055A

Abstract

An ophthalmic article and methods of producing such an article, the article including an ophthalmic substrate having an ophthalmic surface; and an ophthalmic construction; said ophthalmic construction including: (a) a polymeric recipience layer having a first surface fixedly attached to said ophthalmic surface, and a second surface disposed opposite the first surface; said polymeric recipience layer including a polymer; (b) photochromic dye, disposed within said polymeric recipience layer; and (c) an overcoat layer, coating said polymeric recipience layer, and fixedly attached to the second surface; wherein the ultimate elongation of said polymer is within a range of 250% to 900%; wherein the thickness (Toc) of said ophthalmic construction is defined by the shortest normal distance between said ophthalmic substrate and the exterior surface of the ophthalmic construction disposed distally to said ophthalmic substrate, and wherein Toc is at most 50 micrometers (μm).

Description

COATED OPTICAL SUBSTRATES

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to coated optical and ophthalmic apparatus, such as a lens, having at least one layer of photochromic coating, and to methods of producing such optical and ophthalmic apparatus.

Coated optical substrates often contain at least one photochromic colorant such as a photochromic dye. Such dyes typically change color — reversibly — in response to ultraviolet light, usually turning clear in the absence of sunlight or other source of ultraviolet light. In this photochromic transition, the photochromic dye undergoes a reversible photochemical reaction in which an absorption band in the visible part of the electromagnetic spectrum changes in strength or wavelength. For practical use, optical coatings containing photochromic dyes must satisfy numerous performance criteria, conditions and constraints.

The present inventors have recognized a need for improved optical and ophthalmic apparatus having at least one layer of photochromic coating, as well as a need for improved methods of producing such optical and ophthalmic apparatus.

SUMMARY OF THE INVENTION

According to some teachings of the present invention there is provided method of producing an optical article, the method comprising: (a) applying a wet recipience layer on an optical surface of an optical substrate; (b) after the wet recipience layer has dried to form a dried recipience layer, applying at least one photochromic dye containing ink onto the dried recipience layer; and (c) after the at least one photochromic dye containing ink has at least partially penetrated the upper surface of the dried recipience layer, and after the ink has at least partially dried to form a photochromic dye containing recipience layer, applying a first polymer formulation on the photochromic dye containing recipience layer to form an overcoat layer.

According to some teachings of the present invention there is provided an ophthalmic article, the article including an ophthalmic substrate having an ophthalmic surface; and an ophthalmic construction; said ophthalmic construction including: (a) a polymeric recipience layer having a first surface fixedly attached to said ophthalmic surface, and a second surface disposed opposite the first surface; said polymeric recipience layer including a polymer; (b) photochromic dye, disposed within said polymeric recipience layer; and (c) an overcoat layer, coating said polymeric recipience layer, and fixedly attached to the second surface; wherein the ultimate elongation of said polymer is within a range of 250% to 900%; wherein the thickness (Toc) of said ophthalmic construction is defined by the shortest normal distance between said ophthalmic substrate and the exterior surface of the ophthalmic construction disposed distally to said ophthalmic substrate, and wherein Toc is at most 50 micrometers (μm).

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. Throughout the drawings, like-referenced characters are used to designate like elements.

In the drawings:

Figure 1 provides a schematic block diagram of a method of treating an optical surface, according to aspects of the present invention;

Figure 2A provides optional steps for the schematic block diagram of Figure 1, in which a wet hardcoat layer is applied on the exposed, dried overcoat layer;

Figure 2B provides an optional step for either of the above-mentioned schematic block diagrams, in which the photochromic dye containing ink is dried to form the photochromic dye containing recipience layer;

Figure 2C provides an optional step for any of the above-mentioned schematic block diagrams, in which a first surface of the ophthalmic substrate is pre-treated to form the ophthalmic surface; Figure 2D provides an optional step for the schematic block diagram of Figure 2C, in which the pre-treatment of Figure 2C includes applying a primer to the surface of the ophthalmic substrate, wherein the primer is dried to obtain a dried primer layer;

Figure 2E provides an optional step for any of the above-mentioned schematic block diagrams, in which the application of the photochromic dye onto the dried recipience layer (step 106) is performed for at least two photochromic dye containing inks;

Figure 3 is a schematic cross-sectional view of an optical substrate having an optical construction fixedly attached to a broad surface thereof, according to aspects of the present invention, shown at a time tl after jetting of the photochromic ink;

Figure 3A is a schematic cross-sectional view of the optical construction of Figure 3, shown at a subsequent time t2;

Figure 3B is a schematic cross-sectional view of the optical construction of Figure 3, shown at a time t3 subsequent to t2;

Figure 4 is a schematic cross-sectional view of an optical substrate having an optical construction fixedly attached to a broad surface thereof, the optical construction further including a primer layer and a hardcoat layer, according to further independent features of the present invention; and

Figure 5 is a schematic cross-sectional view of an optical substrate having an optical construction fixedly attached to both the top and bottom broad surfaces thereof.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The principles and operation of the optical constructions according to the present invention may be better understood with reference to the drawings and the accompanying description.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. Coated optical substrates often contain at least one photochromic dye.

For practical use in optical coatings, the properties of the photochromic material must satisfy numerous performance criteria, conditions and constraints, a nonexhaustive list of which includes: providing a noticeable, major change in color; intrinsic rate of color change (in both directions); minimal residual color; thermal stability under ambient conditions for both states of the photochromic dye; sufficient efficiency of the photochromic change with respect to the amount of light absorbed (“quantum yield”); minimal or sufficient non-overlapping of the active absorbance bands of the two states; long-term stability of the photochromic reversibility (“fatigue resistance”): photochromic materials become less reversible over time, due to photodegradation, photooxidation, and other processes.

There exist sundry technological challenges in producing coated optical substrates, more particularly, coated optical substrates whose coating contains a photochromic dye, and yet more particularly, coated optical substrates whose coating contains two or more photochromic dyes.

The technological challenges may also relate to various stringent performance criteria for the coated optical construction, such as the overall kinetics of the color change, residual color, uniformity of the color change, and the physical and chemical durability of the coated optical construction over the long term.

In addition, the surrounding coating must provide a suitable chemical environment for the dyes (e.g., polarity, pH).

One aspect of the present invention pertains to a method of applying a plurality of formulations to an optical substrate, some of which formulations may be applied before or after the photochromic ink formulations.

The inventors have found that applying a plurality of optical coatings to an optical substrate involves a variety of technological hurdles. Some of these relate to optical substrates, which tend to be highly smooth, and substantially non-absorbent. Optical substrates are generally transparent, and may require a high degree of transparency from the plurality of optical coatings. Moreover, the refractive index of each coating, or of all the coatings together, is constrained to be similar to that of the optical substrate. Haze due to light scattering (e.g., caused by microscopic imperfections or textures) must be kept within acceptable limits. The plurality of optical coatings must satisfy mechanical criteria such as hardness and/or scratch resistance. Each of the plurality of coatings must also be relatively inert to the other coatings in contact therewith. Moreover, since the coatings may be applied successively, at least one of the applied wet, or uncured, formulations may contact, and interact with, a previously applied coating. This may be particularly problematic in the case of successive applications of different photochromic ink formulations and of other formulations applied before or after the photochromic ink formulations.

The curing time of each coating or layer should be reasonable (at most minutes or hours), and the curing temperature should be sufficiently low so as not to damage the optical substrate, nor to damage any previously applied coatings or materials.

The adhesion to the optical or ophthalmic substrate and resistance to peeling or cracking of the coating or coatings may also be crucial to obtaining a viable coated lens such as a coated ophthalmic lens.

Above and beyond all of the above, the inventors have found that attaining sufficient photochromic color density, while being a significant technological feature for such coated lenses, may be difficult to obtain. Moreover, attaining sufficient photochromic color density may require a thick layer of photochromic dye, which may, among other things, appreciably compromise the mechanical integrity of the coatings.

The inventors have found that poor photochromic color density may stem from various constraints in formulating the photochromic formulations. The solubility of the photochromic dye may be disadvantageously low in a wide variety of conventional solvents. In addition, the inventors have found that such low solubility may be compounded and exacerbated by the presence of a polymeric material (e.g., a resin) within the photochromic formulation. Firstly, it becomes necessary to find a solvent medium in which both the photochromic dye and the polymer have reasonably-high solubility. Secondly, the solubilization of the polymer may appreciably reduce the solubility of the photochromic dye within the solvent medium.

The inventors have discovered that it is possible to form a polymeric recipience layer on the optical surface that can receive and absorb high concentrations of photochromic dye. The photochromic ink may be applied to the top surface of this recipience layer, and the ink (typically as ink drops such as inkjetted ink drops) may penetrate the top surface and become fully immersed within the recipience layer.

This process relaxes the constraint on photochromic ink that the ink must contain relatively high concentrations of polymer, thereby allowing the concentration of photochromic dye within the photochromic ink to be appreciably increased. This, in turn, may serve to further improve the reception of the photochromic dye within the recipience layer, yielding even further improvements in the optical density provided by the photochromic dye received and absorbed within the recipience layer of the present invention.

It is well known in the art of lens coating that coating materials need to be hard in order to withstand abrasion, scratching and the like. The recipience layer of the present invention may be substantially softer than materials typically utilized for lens coatings. This may be particularly disadvantageous, from a mechanical standpoint. However, the inventors have found that this deficiency may be largely mitigated or overcome by the high optical density achieved, per unit thickness of recipience layer, which may greatly reduce the overall required thickness of the polymeric layer containing the photochromic dye.

Some teachings of the present invention pertain to a method of treating an ophthalmic (or more generally, an optical) surface. As schematically presented in Figure 1, the method includes providing an ophthalmic substrate having an ophthalmic surface (step 102). Typically, the ophthalmic substrate is a lens, and the ophthalmic surface is a surface of the lens. While the lens may be a glass lens, more typically the lens is a polymeric lens, e.g., a thermoplastic polymeric lens.

Typically, the optical surface is a curved optical surface, such as a curved lens surface.

As used herein in the specification and in the claims section that follows, the term “SAGITTA”, or “SAG”, with reference refers to the convex curvature of an optical substrate, represents the physical distance between the vertex (the highest point of the convex curvature) along the curved surface of the optical substrate and the center point of a line drawn perpendicular to the curved surface from one edge of the optical substrate to the other. The SAG may be measured, or determined according to the following established equation:

wherein R is the radius of curvature of the optical surface and D is the diameter thereof. The term SAG number is used herein as the absolute value of the SAG (SAG number = |SAG|) so as to properly represent the challenges of concave surfaces, e.g., the inwardly-facing broad surface of a lens.

In some embodiments, the SAG number of the optical substrate is at least 0.5mm, at least 1mm, at least 2mm, at least 3.5mm, or at least 5mm.

The method further includes applying a first recipience layer on the ophthalmic surface (step 104).

In some embodiments, the first recipience layer is an untreated or raw recipience layer such as a wet recipience layer, an uncured or at least partially uncured recipience layer.

In some embodiments, the applying of the wet recipience layer is by spin coating.

In some embodiments, the applying of the wet recipience layer is by dip coating.

In some embodiments, the applying of the wet recipience layer is by slit coating.

In some embodiments, the applying of the wet recipience layer is by die coating.

In some embodiments, the applying of the wet recipience layer is by stamp coating.

In some embodiments, the applying of the wet recipience layer is by spraying.

In some embodiments, the applying of the wet recipience layer is by jetting.

In some embodiments, and as discussed in greater depth hereinbelow, this jetting is performed by inkjetting.

In some embodiments, and as discussed in greater depth hereinbelow, this jetting is performed by a microvalve such as a single-nozzle microvalve.

In some embodiments, the wet recipience layer has an average thickness within a range of 1 to 120 micrometers (μm), 1 to 100 μm, 2 to 100 μm, or 4 to 70μm, and more typically, within a range of 1 to 70μm, 1.5 to 50μm, 1.5 to 40μm, 5 to 70μm, 5 to 50 μm, 7 to 70μm, 7 to 50 μm, 10 to 70μm, 12 to 50 μm, 12 to 70μm, 12 to 60 μm, 15 to 70 μm, 15 to 50 μm, 18 to 70 μm, 18 to 60 μm, 20 to 70 μm or 20 to 50 μm.

The method further includes, after the wet recipience layer has dried to form a dried recipience layer, applying or depositing (e.g., printing and/or jetting) at least one photochromic dye containing ink onto the dried recipience layer (step 106).

The dried or fully dried recipience layer may be somewhat soft with respect to conventional lens coatings.

In some embodiments, the dried or fully dried recipience layer has a hardness of at most 40 Shore D. In the specification and claims, all Shore hardness values are measured according to ASTM D2240.

In some embodiments, the dry, dried or fully dried recipience layer has a Konig hardness, measured in seconds, of at most 100, at most 95, or at most 90. In the specification and claims, all Konig hardness values are measured according to ASTM D4366-95.

In some embodiments, this Konig hardness is at least 10.

In some embodiments, this Konig hardness is at least 15.

In some embodiments, this Konig hardness is within a range of 20 to 95, 20 to 90, 20 to 85, 20 to 80, 20 to 75, 20 to 70, 20 to 65, or 20 to 60.

In some embodiments, this Konig hardness is within a range of 10 to 100, 10 to 95, 15 to 95, 15 to 90, 15 to 85, 15 to 80, 15 to 75, 15 to 70, 15 to 65, 15 to 60, or 15 to 55.

In some embodiments, this Konig hardness is at least 25.

In some embodiments, this Konig hardness is at least 30.

In some embodiments, this Konig hardness is at least 35.

In some embodiments, this Konig hardness is at least 40.

In some embodiments, the dried or fully dried recipience layer has an ultimate elongation within a range of 100% to 2,000%. More typically, the ultimate elongation is within a range of 150% to 1200%, 200% to 1200%, 200% to 1000%, 250% to 800%, 250% to 600%, 300% to 1000%, 300% to 800%, or 300% to 600%.

In the specification and claims, all ultimate elongation values are measured according to ASTM D638. In some embodiments, the dried or fully dried recipience layer has a pencil hardness of at most 4H. More typically, the pencil hardness of the dried recipience layer is within a range of 2B to 3H, 2B to 2H, B to 3H, B to 2H, HB to 3H, or HB to 2H.

In the specification and claims, all pencil hardness values are measured according to ASTM D3363.

In some embodiments, the ophthalmic substrate or lens may be coated or precoated with a hardcoat, and the recipience layer may applied directly on top of this coating.

In some embodiments, a primer may first be applied to this hardcoat, prior to the application of the recipience layer, in order to enhance adhesion of the recipience layer to the substrate.

The applying or depositing (e.g., printing and/or jetting) of the at least one photochromic dye containing ink onto the dried recipience layer (step 106) may be performed utilizing various technologies.

In some embodiments, the applying or depositing of the at least one photochromic dye containing ink includes coating.

In some embodiments, the coating includes spin coating.

In some embodiments, the applying or depositing of the wet recipience layer is by dip coating.

In some embodiments, the applying or depositing of the wet recipience layer is by slit coating.

In some embodiments, the applying or depositing of the wet recipience layer is by die coating.

In some embodiments, the applying or depositing of the wet recipience layer is by stamp coating.

In some embodiments, the applying or depositing of the at least one photochromic dye containing ink includes spraying.

In some embodiments, the applying or depositing of the at least one photochromic dye containing ink includes printing. In some embodiments, in the applying or depositing of the at least one photochromic dye containing ink, the at least one photochromic dye containing ink is applied or deposited onto the dried recipience layer as ink drops.

In some embodiments, the applying or depositing of the ink drops is performed by printing.

In some embodiments, the depositing of the ink drops is performed according to a digital pattern.

In some embodiments, the depositing of the ink drops is performed according to a pre-determined pattern.

In some embodiments, the applying of the wet recipience layer is by jetting.

In some embodiments, the depositing of the ink drops is performed by ink-jet printing.

In some embodiments, the ink-jet printing is by drop-on-demand.

In some embodiments, the ink-jet printing is continuous (CIJ).

In some embodiments, the jetting is performed by a microvalve such as a singlenozzle microvalve. The microjetting of the ink formulation onto the optical/ophthalmic substrate may be performed utilizing various microjetting technologies, all of which utilize a microvalve.

The microvalve may be a component within a microvalve system.

In some embodiments, the microvalve is piezo-actuated (e.g., using a Nordson Pulse Jet Valve, a Vermes MDS 1560 Series, or a Techcon 9800 series);

In some embodiments, the microvalve is electromagnetically actuated (e.g., using a solenoid valve). The fluid or dispersion flows through the microvalve directly. When a current is applied through the valve coil, a mobile anchor attached to a valve ball is magnetically pulled by the magnetic field of a stationary anchor. The microvalve opens, discharging a portion of the medium. When no current is applied, the microvalve is closed, as a closing spring acts on the mobile anchor associated with the valve ball.

Exemplary microvalves of this type are manufactured by Fritz Gyger AG and by the Lee company. In some embodiments, the microvalve is electro-pneumatically actuated. Exemplary microvalves of this type are the Liquidyn® P-Jet Series, manufactured by Nordson.

The photochromic dye containing ink and the recipience layer are adapted to one another, to allow the photochromic dye containing ink to at least partially penetrate, and typically, fully penetrate, the upper surface of the dried recipience layer.

In some embodiments, the ink and the recipience layer are adapted to one another, to allow the photochromic dye containing ink to at least partially penetrate, and typically, fully penetrate, the upper surface of the dried recipience layer within 10 minutes, and more typically, within 3 minutes, within 1 minute, or within 20 seconds.

In some embodiments, the ink and the recipience layer are adapted to one another, to allow the photochromic dye containing ink to at least partially penetrate, and typically, fully penetrate, the upper surface of the dried recipience layer essentially in substantially instantaneous fashion.

Figure 3 is a schematic cross-sectional view of an optical article 303 in which an optical construction 350 is fixedly attached to a broad surface 301 of an optical substrate 302, according to aspects of the present invention, shown at a time tl after jetting of the photochromic ink. The layer of optical construction 350 that is immediately above optical substrate 302 is recipience layer 304, which has a thickness Tree. Figure 3 schematically shows the partial penetration of an ink drop 307 with respect to the upper surface 305 of recipience layer 304.

In some embodiments, the ink and the recipience layer are adapted to one another, to allow the photochromic dye containing ink to fully penetrate the upper surface of the dried recipience layer within 10 minutes, and more typically, within 3 minutes, within 1 minute, or within 20 seconds.

Figure 3 schematically shows the complete penetration of ink drops such as ink drop 312 with respect to the upper surface 305 of recipience layer 304. The chemical and physical compatibility of the photochromic ink solvents to the recipience layer, along with the relative softness of the polymer matrix, materially contribute to this process.

In particular, the inventors have found that the solvent characteristics may be cardinal to the process. Solvents having relatively low rates of evaporation may evaporate slowly with respect to the penetration of the solvent into the recipience layer, causing pooling or flooding. Solvents having relatively high rates of evaporation may evaporate sufficiently fast so as to raise the ink viscosity and fixate the dye with respect to the polymeric recipience layer. However, the rapid evaporation may cause an appreciable portion of the dye to disadvantageously remain on the surface, reducing absorption efficacy and causing scattering. Moreover, even the portion of dye that penetrates the surface is immediately fixated (disadvantageous “pixelization”), such that a continuous layer of photochromic dye cannot be achieved.

The inventors have discovered, however that by combining solvents having relatively high rates of evaporation with those having particularly low rates of evaporation, that suitable penetration into the recipience layer can be achieved, while — at the same time — fixating the photochromic dye in a predictable fashion. The solvent having the low rate of evaporation contributes to the dye not drying out above the surface, and, surprisingly, enables controlled diffusion of the dye within the ink vehicle, within the recipience layer. This occurs both in the X-Y plane and in the Z-direction, towards the lens surface, resulting in a continuous, fairly homogeneous layer of photochromic dye within the recipience layer.

This also allows a surprisingly-high loading of photochromic dye within the recipience layer, on a per volume or per weight basis. Significantly, since the softness of the recipience layer is mechanically disadvantageous, this further allows for a higher optical density and thus, a much thinner recipience layer per unit of photochromic dye

With reference again to Figure 3, Figure 3 further shows a first set of photochromic ink drops (photochromic ink #1) such as ink drop 316, and a second set of photochromic ink drops (photochromic ink #2) such as ink drop 317.

In some embodiments, photochromic ink (or dye) #1 is deposited onto recipience layer 304 based on a digital or pre-determined pattern or array. Similarly, photochromic ink (or dye) #2 may be deposited onto recipience layer 304 based on a digital or pre-determined pattern or array.

In some embodiments, the photochromic ink or dye may be deposited in drop- on-drop fashion onto recipience layer 304. Such an operation may produce “columns” of ink (or dye) drops such as ink (or dye) column 330 of photochromic ink #1 and ink (or dye) column 340 of photochromic ink #2. It is noted that, as schematically shown in column 340, the ink drops may not be deposited exactly one on top of the other, such that the width of the column may be appreciably larger than the width of the individual drops.

Ink columns (or “pillars”) such as ink column 330 and ink column 340 may be advantageous in that they maintain separation between different photochromic dyes having different properties (e.g., activation and fading kinetics). Such ink columns advantageously allow high photochromic dye densities per unit (viewing) area. Such ink columns yet further advantageously allow high photochromic dye densities per unit area within a single layer of the ophthalmic medium (in this case, the “recipience layer”). All these advantages notwithstanding, the inventors have discovered that such “pixelization” of the different photochromic dyes using drop-on-drop jetting may disadvantageously affect the optical or ophthalmic properties of the optical construction. For example, such ink columns may produce a “slitting” type of effect, which may be deleterious for many ophthalmic products and applications. At the very least, the color density may be appreciably non-homogeneous, detracting from optical quality.

The inventors have further discovered that by applying a large number of drop- on-drops, a portion of the drops do not serve to thicken the columns, rather, they “flood” the recipience layer in between the columns, for example, ink drop 322 of photochromic ink #1 and ink drop 308 of photochromic ink #2. In some cases, such ink drops may fail to fully penetrate the upper surface 305 of the recipience layer, as ink drops 310 and 311 schematically demonstrate. The inventors have surprisingly discovered that in applying such a large number of drop-on-drops, the optical or ophthalmic properties of the optical construction may actually be improved. The advantages of the pixelization may remain substantially intact, while the deleterious “slitting” effect may be appreciably reduced or mitigated.

Thus, in some embodiments, at least 4 ink drops or at least 6 ink drops are applied in a drop-on-drop fashion. More typically, at least 8, at least 10, at least 12, at least 15, at least 18, at least 20, at least 22, at least 25, at least 28, at least 30, at least 32, or at least 35, are applied in a drop-on-drop fashion. The number of ink drops applied in such drop-on-drop fashion may be at most 100, and more typically, at most 80, at most 70, at most 60, at most 50, or at most 45. The inventors have further discovered that along with various features of the present invention (e.g., recipience layer characteristics, ink solvents and solvent combinations, and printing strategies such as drop-on-drop), high DPI may further mitigate the deleterious effects of slitting. The DPI may be at least 200, at least 250, or at least 300, and typically, at most 2400, or at most 1800.

The inventors have found that photochromic dye disposed above upper surface 305 of the recipience layer may be deleterious to the optical or ophthalmic properties of the optical construction. However, the inventors have further discovered that by applying an overcoat layer 306 on top of recipience layer 404, such exposed photochromic dye may be covered, which may somewhat mitigate some of the deleterious effects (e.g., scattering may be reduced).

The inventors have also found that various hardcoat formulations may dissolve or otherwise attack the photochromic dye containing recipience layer. However, the inventors have further discovered that by applying overcoat layer 306 on top of the outer or exposed dye containing ink layer, and effecting drying/curing as necessary, such attack may be inhibited or appreciably mitigated.

In some embodiments, the first overcoat layer is or contains a thermoplastic polymer.

In some embodiments, the first overcoat layer is or contains a thermoset polymer.

In some embodiments, the first overcoat formulation is a polymer emulsion.

In some embodiments, the first overcoat formulation is a polymer dispersion.

In some embodiments, the first overcoat formulation is a polymer solution.

In some embodiments, the first overcoat formulation includes an acrylic polymer.

In some embodiments, the first overcoat formulation includes a polyurethane.

In some embodiments, the first overcoat formulation includes a polyvinyl butyral.

In some embodiments, the material of the dry or completely cured overcoat layer has a Kbnig hardness of at least 80 (seconds). More typically, this Kbnig hardness is within a range of 80 to 180, 80 to 160, 90 to 180, 100 to 160, 100 to 150, 100 to 140, 110 to 180, 110 to 160, or 110 to 150. In some embodiments, the method further comprises, following the drying/curing of the overcoat layer, applying a second or additional overcoat layer on top of the dried first overcoat layer.

In some embodiments, the method further comprises drying/curing the second or additional overcoat layer.

In some embodiments, the dried second or additional overcoat layer may exhibit increased hardness with respect to the dried first overcoat layer (e.g., a pencil hardness of at least one grade higher).

In some embodiments, the dried second or additional overcoat layer may exhibit increased a lower coefficient of linear thermal expansion (CTE) with respect to the dried first overcoat layer.

Thus, with reference now to Figure 1 as well, the inventive method may further include, after the at least one photochromic dye containing ink has at least partially penetrated the upper surface of the dried recipience layer, and after the ink has at least partially dried to form a photochromic dye containing recipience layer, applying a first polymer formulation on top of the photochromic dye containing recipience layer to form a first overcoat layer (step 108).

The applying of the overcoat layer may be effected according to any of the application methods described hereinabove with respect to the application of the recipience layer and the application of photochromic ink. In some embodiments, the drying may be completely passive.

In some embodiments, and as shown in Figure 2B, the inventive method may further include drying the at least one photochromic dye containing ink or ink drops to form the photochromic dye containing recipience layer.

In some embodiments, the recipience layer, or the photochromic dye containing recipience layer (i.e., after the printing of the photochromic ink), after complete drying/curing, has a thickness or an average thickness within the range of 0.6μm to 30μm or 0.8μm to 30μm, and more typically, within a range of 1 to 20μm, 1 to 15μm, 1 to 12μm, 1 to 10μm, 1 to 8μm, 1 to 7μm, 1 to 6μm, 1 to 5μm, 1.5 to 15μm, 1.5 to 12μm, 1.5 to 10μm, 1.5 to 8μm, 1.5 to 7μm, 1.5 to 6μm, 1.5 to 5μm, 1.5 to 4μm, 1.5 to 3.2μm, 2 to 12μm, 2 to 10μm, 2 to 8μm, 2 to 7μm, 2 to 6μm, 2 to 5μm, 2 to 4μm, 2 to 3.2μm, 3 to 12μm, 3 to 10μm, 3 to 8μm, 3 to 6μm, 4 to 10μm, 4 to 8μm, 4 to 7μm, 4.5 to 10μm, 4.5 to 8μm, 4.5 to 7μm, 5 to 10μm, 5 to 8μm, 5 to 7μm, or 6 to 10μm.

With reference now to Figures 3A and 3B, Figure 3A is a schematic cross- sectional view of the optical construction of Figure 3, shown at a subsequent time t2, and Figure 3B is the same schematic cross-sectional view, shown at a time t3 subsequent to t2.

As described hereinabove, the solvent having the low rate of evaporation contributes to the dye not drying out above the surface, and, surprisingly, enables controlled diffusion of the dye within the ink vehicle, within the recipience layer. This occurs both in the X-Y plane, as the material in the drops expand and make X-Y contact with one another, and in the Z-direction (see “deep” drops 309 and 317) , towards the lens surface, resulting in a continuous, fairly homogeneous layer of photochromic dye within the recipience layer.

With regard to the overcoat, in some embodiments, the applying or depositing of the first polymer formulation is performed after the ink drops have fully penetrated the upper surface of the dried recipience layer.

The first overcoat layer may be disposed above, and fixedly attached to, the polymeric, photochromic dye containing recipience layer.

In some embodiments, the first overcoat layer, as a wet layer, has a thickness or an average thickness within a range of 1.5 to 70μm micrometers (μm) or within a range of 2.5 to 70μm, and more typically, within a range of 4 to 70μm, 5 to 70μm, 5 to 50 μm, 5 to 40 μm, 5 to 30 μm, 7 to 50μm, or 7 to 30μm.

In some embodiments, the first overcoat layer, as a dry layer, has a thickness or an average thickness within a range of 1 to 15μm or within a range of 1 to 12μm, and more typically, within a range of 1 to 10μm, 1 to 8μm, 1 to 7μm, 1 to 6μm, 1.5 to 8μm, 1.5 to 6μm, 1.5 to 5pm, 1.5 to 4pm, 2 to 8μm, 2 to 6pm, 2 to 5pm, or 2 to 4pm.

In some embodiments, the material of the dry or cured overcoat layer has a Kbnig hardness of at least 100 (seconds). More typically, this Kbnig hardness is within a range of 100 to 150, 100 to 140, 100 to 130, 110 to 150, or 110 to 130.

Figure 2A provides optional blocks for the schematic block diagram of Figure 1, in which a wet hardcoat layer is applied on the exposed, dried overcoat layer. An exemplary optical construction obtained is shown schematically in Figure 4. Figure 2C provides an optional block for any of the above-mentioned schematic block diagrams, in which a first or upper surface of the ophthalmic substrate is pretreated (e.g., a surface energy treatment) to form the ophthalmic surface.

In some embodiments, the surface energy treatment includes a corona treatment.

In some embodiments, the surface energy treatment includes a plasma treatment.

In some embodiments, the surface energy treatment includes an electron beam treatment.

In some embodiments, the surface energy treatment includes an electrical discharge treatment.

In some embodiments, the pre-treatment of the lens surface includes an etching treatment.

In some embodiments, the etching treatment includes laser etching.

In some embodiments, the etching treatment includes chemical etching.

Figure 2D provides an optional block for the schematic block diagram of Figure 2C, in which the pre-treatment of Figure 2C includes applying a primer (or wet primer layer) to the surface of the ophthalmic substrate (lens surface). This primer is subsequently dried, or allowed to dry, to obtain a dried primer layer. An exemplary optical construction obtained is shown schematically in Figure 4.

In some embodiments, the primer pre-treatment is directed to facilitate wetting of the wet recipience layer with respect to the lens surface.

In some embodiments, the primer pre-treatment is directed to facilitate adherence of the wet recipience layer with respect to the lens surface.

In some embodiments, the primer is a polymeric primer.

In some embodiments, the polymeric primer is in the form of a waterborne emulsion (e.g., an acrylic emulsion).

In some embodiments, the polymeric primer is in the form of a solution (e.g., a polyurethane resin solution).

In some embodiments, the wet primer layer has at least one of a thickness and an average thickness within a range of 0.3 to 10μm, 0.3 to 5μm or 0.3 to 3μm, and more typically, within a range of 0.3 to 2.5μm, 0.3 to 2μm, 0.4 to 2μm, 0.4 to 1.5μm, 0.5 to 2μm, 0.5 to 1.8μm, 0.5 to 1.5μm, or 0.5 to 1.2μm.

In some embodiments, the dried or dry primer layer has at least one of a thickness and an average thickness within a range of 0.3 to 4μm or within a range of 0.3 to 2.5μm, and more typically, within a range of 0.3 to 2 μm, 0.3 to 1.5μm, 0.4 to 2μm, 0.4 to 1.5μm, 0.5 to 2μm, 0.5 to 1.8μm, 0.5 to 1.5μm, or 0.5 to 1.2μm.

Figure 2E provides an optional block for any of the above-mentioned schematic block diagrams, in which the application of the photochromic dye onto the dried recipience layer (step 106) is performed for at least two photochromic dye containing inks.

Figure 4 is a schematic cross-sectional view of an optical article 403 in which an optical construction 450 is fixedly attached to a broad surface 401 of an optical substrate 402. Optical construction 450 further includes an optional primer layer 440 disposed between broad surface 401 and photochromic-dye-containing recipience layer 404. The thickness of primer layer 440 is designated as Tp. Above recipience layer 404 may be disposed an overcoat layer 406, substantially as described hereinabove. The thickness of overcoat layer 406 is designated as Tov. Above overcoat layer 406 may be disposed a hardcoat layer 420, according to further independent features of the present invention. The thickness of hardcoat layer 420 is designated as Thl.

In some embodiments, above hardcoat layer 420 may be disposed a second or top hardcoat layer 430, having a thickness Thl.

The entire thickness of optical construction 450 (and 350 in Figure 3) is designated as Toc. This thickness is meant to include any additional layers making up the optical construction, including anti-glare, anti-wetting, anti -reflective, super hydrophobic and super hydrophilic anti-fog, polarized layer, mirror coating, and blue light layers.

In some embodiments, the one or more hardcoat layers (Thl, Thl), prior to drying/curing, have at least one of a wet thickness and an average wet thickness within a range of 1 to 6μm or within a range of 1 to 5μm, and more typically, within a range of 1 to 4.5μm, 1 to 4μm, 1 to 3.5μm, 1.2 to 3.5μm, 1.2 to 3μm, or 1.5 to 3μm.

In some embodiments, the dry hardcoat layers (Thl, Thl) have at least one of a thickness Th and an average thickness (Thl-a, Thl-a) within a range of 0.8 to 5.5μm or within a range of 0.8 to 5μm, and more typically, within a range of 0.8 to 4μm, 0.8 to 3.5μm, 1 to 3.5μm, 0.8 to 3 μm, 1 to 3μm, or 1.2 to 3μm.

With regard to the entire thickness Toc of optical constructions 303 and 403, in some embodiments, the dry optical construction has an average thickness within the range of 5 to 60μm, and more typically, within a range of 7 to 50μm, 7 to 40μm, 7 to 35μm, 7 to 30μm, 7 to 25μm, 7 to 20μm, 7 to 18pm, or 7 to 15pm.

With reference now to Figure 5, Figure 5 is a schematic cross-sectional view of an optical article 503 in which an optical construction 550 has a first (top, or outwardly- facing) optical construction 550 fixedly attached to the top broad surface 501 of optical substrate 502, and a second, opposite (bottom, or internally-facing) optical construction 580 fixedly attached to the bottom broad surface 581 of optical substrate 502.

It will be evident to those of skill in the art that an optical article such as optical article 503 may be constructed to (i) solely have a top optical construction, (ii) solely have a bottom optical construction, or (iii) have both top and bottom optical constructions. It will be further evident that the bottom optical construction may have any or all structural features shown and/or described with respect to optical constructions 350 and 450. Typically, bottom broad surface 581 is concave.

EXAMPLES

Reference is now made to the following examples, which together with the above description, illustrate the invention in a non-limiting fashion.

Materials

Lens Materials

• polycarbonate, a thermoplastic polymer

• Trivex® (PPG), a urethane-based thermoset polymer

• CR-39® (PPG), a thermoset polymer made from allyl di glycol carbonate

Photochromic Dyes:

• Reversacol Amazon Green (James Robinson Specialty Ingredients Ltd.): a photochromic dyestuff in powder form;

• Reversacol Midnight Gray (James Robinson Specialty Ingredients Ltd.): a photochromic dyestuff in powder form;

• Reversacol Leather Brown (James Robinson Specialty Ingredients Ltd.): a photochromic dyestuff in powder form; • Reversacol Com Yellow (James Robinson Specialty Ingredients Ltd.): a photochromic dyestuff in powder form.

Solvents

High evaporation rate/ high vapor pressure at 25°C

• Dowanol™ PMA Glycol Ether (propylene glycol monomethyl ether acetate)

• Methyl Ethyl Ketone (2-butanone or MEK) (Shell Chemicals)

• Dowanol™ PM Glycol Ether (propylene glycol mono methyl ether)

Low evaporation rate/ low vapor pressure at 25°C

• Dowanol™ TPM Glycol Ether (tri-propylene glycol monomethyl ether, or TPM) (Dow), CAS 25498-49-1)

• PPH (Ph-O-CH2-CHMe-OH, CAS 770-35-4)

• Eastman™ DB Acetate (2-(2 -butoxy ethoxy) ethyl acetate, or DBA, CAS 124- 17-4)

• TPnB (Tripropylene glycol n-butyl ether, 55934-93-5)

• DOWANOL™ dipropylene glycol n-propyl ether, or DPnP, (CAS 29911-27-1)

• acetone glycerol (ALDRICH, 2, 2-dimethyl- 1,3 -di oxolane-4-m ethanol, CAS 100-79-8)

• butyl carbitol (CAS 112-34-5)

• Butyl CELLOSOLVE™ EGBE (ethylene glycol monobutyl ether, CAS 111-76- 2), DOW

• Hexyl CELLOSOLVE™ (diethylene glycol mono butyl ether, or n- hexylglycol), DOW

• DOWANOL™ dipropylene glycol monomethyl ether, or DPM

• Augeo®SL 191 racemic mixture (+/-)-2,2-dimethyl-4-hydroxymethyl-l,3- dioxolane.

Coating Materials for Recipience Laver Formulations:

PUD-water based o Alberdingk®U-3251 — Highly flexible, solvent-free, aliphatic polyester polyurethane dispersion (Alberdingk Boley) o Alberdingk®U-9150 Aqueous aliphatic polyester polycarbonatepolyurethane dispersion (TPU) (Alberdingk Boley) o Alberdingk®U-6100VP — Aqueous colloidal, anionic, low viscous dispersion of an aliphatic polyester-polyurethane without free isocyanate groups (Alberdingk Boley) o Lubrijet™ T800 — Waterborne aliphatic polyurethane dispersion designed for inkjet (Lubrizol) o Lubrijet™ N240 — Waterborne acrylic colloidal dispersion polymer for inkjet printing (Lubrizol) o Lubrijet™ T340 — Aqueous acrylic emulsion polymer (Lubrizol) o Alberdingk APU-10610 — Solvent-free, self-crosslinking, aliphatic polyester polyurethane, acrylic hybrid dispersion (Alberdingk Boley) o Eternacoll UW-5502D-C1 — Waterborne polyurethane dispersions (UBE).

Acrylic polymer emulsions o JONCRYL® 2136-A —Waterborne acrylic emulsion o JONCRYL® 2121 —Waterborne acrylic emulsion o JONCRYL® 659-A —Waterborne acrylic emulsion

Thermoplastic Resins o Pearlcoat™ DIPP 119 — Aromatic poly caprolactone copolyester-based thermoplastic polyurethane (TPU) (Lubrizol) o Pearlbond™ 360 — Polyether based thermoplastic polyurethane (TPU) (Lubrizol) o SETALUX® 2127 XX-60 Thermoplastic acrylic resin having good adhesion to plastics (Allnex) o Laropal A-81 — Thermoplastic aldehyde resin (BASF) o Evatane® 33-45 — random ethylene-vinyl acetate copolymer (SK Functional Polymer). o Evatane® 33-400 — random ethylene-vinyl acetate copolymer (SK Functional Polymer).

Thermoset Resins o UV curable acrylic monomers and oligomers s BR-744SD — Difunctional aliphatic polyester urethane acrylate oligomer (DYMAX) s SR-610 Polyethylene glycol 600 diacrylate ( Arkema) . BR-3641AJ — Aliphatic polyether urethane acrylate oligomer (DYMAX) . SR506E (isobornyl acrylate, CAS&5888-33, IBOA)

Monofunctional acrylic monomer (Arkema) . SR484 (octyldecyl acrylate, CAS# 4813-57-4 Monofunctional acrylate monomer with hydrophobic backbone (Arkema) o Self-crosslinking polymer emulsions . Bondthane™ UD-610 Soft self-crosslinking aliphatic polyurethane dispersion (BPI) . Bondthane™ UD-615 — Self-crosslinking aliphatic polyurethane dispersion (BPI).

Properties of Various Recipience Layer Coating Materials:

¹The above-provided polymers passed haze transparency tests ASTM 1003, ISO 13468 Ink and Recipience Laver Formulation Additives

• BYK®3760, Polyether-modified polydimethylsiloxane (BYK, Germany) — Silicone-containing surface additive for solvent-borne, aqueous and UV systems, reduces surface tension and increases surface slip

• BYK®333, Wetting agent, Silicone-containing surface additive for solvent-free, solvent-borne and aqueous coating systems; strong surface tension reducer

• BYK®358, Leveling agent, Surface additive on polyacrylate-basis for solvent- borne and solvent-free coating and thermoset systems to improve leveling

• BYK® 346 wetting additive

• BYK®044 defoamer

• BYK®024 defoamer

• EFKA® FL 3277 Leveling agent, fluorocarbon-modified polyacrylate

• EFKA®SL 3035 Leveling agent, organically modified polysiloxane that may be suitable for water and solvent based coatings

• EFKA®SL 3200 Leveling agent, silicone-based solvent-free slip and leveling agent; suitable for aqueous, solvent-based and UV formulations

• EFKA®FL 3778 Leveling agent, acrylic copolymer.

Additives for U V Th ermoset Polymers

ADDITOL® TPO (Diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide, CAS# 75980-60-8) — Radical photoinitiator that can be used alone or in combination with other photoinitiators. (Allnex)

CN3715 —Monofunctional acrylated amine synergist for use in UV/LED and EB curing applications. (Arkema).

Primers and Overcoats

Acrylic polymer emulsions: o Joncryl®1532 - waterborne acrylic emulsion offering excellent adhesion to a wide variety of substrates including plastics (BASF); Primer o Joncryl®1534 - waterborne acrylic emulsion offering excellent adhesion to a wide variety of substrates including plastics (BASF); Primer o Joncryl®2110 - waterborne acrylic emulsion primer Styrene Acrylate copolymer (BASF); Primer o Joncryl®9530-A waterborne acrylic emulsion self-crosslinking polymer designed for use in topcoats and primers; Overcoat o Joncryl®617-A - waterborne acrylic polymer emulsion film forming overprint varnish formulations. (BASF); Overcoat o SETALUX® 17-7202 is an acetoacetate functional acrylic resin that is combined with a ketimine resin (SETALUX® 10-1440) for primer; Overcoat o SETALUX® 17- 1246 is a fast-dry thermoplastic acrylic resin solution which provides an excellent balance of hardness, adhesion and film toughness together with clarity and transparency; Overcoat.

PU polymer emulsions: o ALBERDINGK ' APU 10600 Self-crosslinking acrylic, PES/PC- polyurethane hybrid dispersion (Alberdingk Boley); Overcoat o Bondthane™UD-620 — Self-crosslinking polyurethane is ideally suited for hard, clear or pigmented coatings for rigid plastics (BPI); Overcoat.

Resin Solvent Based Solutions: o Versamid®PUR 1010 Thermoplastic aliphatic polyurethane resin solution in an alcohol/acetate solution (BASF); Primer o Laroflex®HS-9000 - High molecular weight polyester resin solution in n-propanol (BASF); Primer.

Hardcoat Laver:

• CrystalCoat™TC-3000 . Polysiloxane-based tintable abrasion resistant hardcoat (SDC); refractive index is 1.49

• CrystalCoat™MP-1154D . Polysiloxane-based abrasion resistant hardcoat (SDC); refractive index is 1.49

• CrystalCoat™MP-2020B — Highly cross-linkable, abrasion resistant hardcoat SDC); refractive index is 1.49

• NANOMYTE®SR-100 Polysiloxane-based 2-component liquid coating

(NEI); provides abrasion and scratch resistance to plastic substrates

• NANOMYTE®SR-100RT Poly siloxane-based single component liquid coating (NEI); provides abrasion and scratch resistance to plastic substrates.

Equipment

• Coating Equipment o Printer: Dimatix Materials Printer DMP-2831 equipped with a 10 pL Dimatix Materials Cartridge (Fujifilm Dimatix™ Inc) o Spin coater: MUTECH pCoater (Mutech Microsystems SAS) o UV LED Curing System (Lamp): FJ100 Gen 2, 395nm, 12W/cm²

(Phoseon Technology) o Thermal Curing System: Venticell ECO Forced air oven (MMM) o Surface Activation: Corona Treatment Device Electrical Surface

Treatment HF SpotTEC Single (Tantec).

• Testing Equipment o Spectrophotometer: Cary 4000 UV-Vis. double-beam spectrophotometer, ISO/ EN 8980-3:2013 (Agilent) o Light Transmittance and Haze Measuring Meter: TH-100, ASTM D1003/D1044 (Hangzhou CHN Spec Technology Co., Ltd.) o Thickness measurements: ThetaMetrisis layer thickness analyzer.

Example 1: Corona Surface Treatment Procedure

The head of the corona treatment device (Tantec) was set at 1cm from the surface of the ophthalmic lens and was activated for 10 seconds. The process was performed twice before various coating materials were applied on the ophthalmic lens.

Example 2: Procedure for Primer Application using Spin-Coating

The ophthalmic lens was attached to the vacuum chuck of the spin coating apparatus. The spinning of the ophthalmic lens was performed at a spinning speed of 3000 rpm, an acceleration of 1000 rpm/sec, for 10 seconds.

Example 3: Procedure for Application of Recipience Layer using Spin-Coating

The ophthalmic lens was attached to the vacuum chuck of the spin coating apparatus. The spinning of the ophthalmic device was performed at a spinning speed of 800 rpm, an acceleration of 500 rpm/sec, for 10 seconds. The spin-coating operation may be repeated as necessary, following drying/curing, in order to produce thicker recipience layers.

Example 3A: Procedure for Application of Overcoat using Spin-Coating

The ophthalmic lens was attached to the vacuum chuck of the spin coating apparatus. The spinning of the ophthalmic device was performed at a spinning speed of 1800 rpm, an acceleration of 800 rpm/sec, for 10 seconds. The spin-coating operation may be repeated as necessary, following drying/curing, in order to produce thicker recipience layers. Example 3B: Procedure for Application of Hardcoat using Spin-Coating

The ophthalmic lens was attached to the vacuum chuck of the spin coating apparatus. The spinning of the ophthalmic device was performed at a spinning speed of 1500 rpm, an acceleration of 500 rpm/sec, for 10 seconds.

Example 4: Optimization of the Ink- Jetting Parameters

The Dimatix™ print head was pre-heated to 40°C. The drop characteristics were then optimized for each photochromic ink using a stroboscope mounted on the printer (camera and light source synchronized with the jetting frequency). The waveform was optimized for each photochromic ink, jetted at a frequency of 0.5-3 kHz. The distance between the printhead and the substrate was 0.6-1.0 mm. The jetting typically resulted in a drop (dot) size of about 50 micrometers (on the test substrate). The resolution was set at 300 dots per inch (dpi).

Example 5 A: Jetting of a Photochromic Ink onto the Recipience Layer

An optical construction having photochromic functionality was prepared by printing (by means of the Fujifilm Dimatix™ Inkjet printer) an ink-jet compatible ink containing a photochromic dye onto a recipience layer covered lens substrate, preferably utilizing the ink-jetting optimization technique of Example 5 A. The optical construction was prepared by ink-jetting an array of ink drops containing the photochromic dye such that the distance between the center of a first drop to the center of the adjacently jetted drop was about 85 micrometers. This distance can be adjusted as desired. To control the viscosity at jetting and the spreading of the drops, both the printhead and the substrate were heated to 40°C.

Example 5B: Jetting of Multiple Photochromic Inks onto the Recipience Layer

An optical construction having dual photochromic functionality was prepared by printing (by means of the Fujifilm Dimatix™ Inkjet printer) two different inks, each ink containing a different photochromic dye, preferably utilizing the ink-jetting optimization technique of Example 5 A. The optical construction was prepared in a two-step process in which an array of ink drops containing the first dye was printed such that the drops were disposed whereby the distance between the center of a first drop to the center of the adjacently jetted drop was 100 micrometers. To control the viscosity at jetting and the spreading of the drops, both the printhead and the substrate were heated to 40°C.

The second dye was added to the layer by jetting drops of the second ink containing the second dye between the drops of the first array of drops. The drops of the second ink were printed at the same general conditions described above, but were jetted so as to be disposed at a distance of 50 micrometers from the drops of the first ink, measured from the center of the ink drop of the first ink to the center of the ink drop of the second ink.

Example 6: Jetting of Photochromic Inks onto the Recipience Layer: Photochromic Color Intensity

Using the procedure of Example 5 A and the method of Example 5B, multiple photochromic ink drops of two or more photochromic inks were applied to various lenses coated with the recipience formulations provided hereinbelow to produce an optical construction having a photochromic dye(s) containing recipience layer. In some cases a single pass of ink-jet ink was applied, but typically, 2-80 passes, and more typically, 5-50 passes of photochromic ink were applied, as arrays, in a drop-on-drop fashion. Drying was then performed at 60°C for 60 minutes.

EXAMPLE 7

30 grams of TPM were mixed with 67.8 grams of PMA in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.2 grams of surfactant BYK®-333 were added to the solvent mixture while mixing. 2 grams of Reversacol Midnight Gray dye were then added while mixing. Mixing was continued for another 20 minutes at 60°C to produce the photochromic ink, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 8

30 grams of TPM were mixed with 67.8 grams of PMA in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.2 grams of surfactant BYK®-358 were added to the solvent mixture while mixing. 2 grams of Reversacol Leather Brown dye were then added while mixing. Mixing was continued for another 20 minutes at 60°C to produce the photochromic ink, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 9

30 grams of TPM were mixed with 20 grams of EB and 47.5 grams of PMA in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA®-3277 were added to the solvent mixture while mixing 2 grams of Reversacol Amazon Green dye were added while mixing. Mixing was continued for another 20 minutes at 60°C to produce the photochromic ink, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 10

30 grams of TPM were mixed with 20.65 grams of PMA, 47 grams of MEK in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.35 grams of surfactant EFKA®SL 3200 were added to the solvent mixture while mixing 2 grams of Reversacol Corn Yellow dye were added while mixing. Mixing was continued for another 20 minutes at 60°C to produce the photochromic ink, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 11

30 grams of Augeo SL-191 were mixed with 67.9 grams of PMA in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.1 grams of surfactant BYK®-358 were added to the solvent mixture while mixing 2 grams of Reversacol Amazon Green dye were added while mixing. Mixing was continued for another 20 minutes at 60°C to produce the photochromic ink, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 12

30 grams of Augeo SL-191 were mixed with 67.7 grams of PM in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.3 grams of surfactant EFKA®-3778 were added to the solvent mixture while mixing. 2 grams of Reversacol Amazon Green dye were then added, while mixing, and the mixing was continued for another 20 minutes at 60°C to produce the photochromic ink, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 13

30 grams of n-hexylglycol were mixed with 25 grams of PMA, 42.8 grams of MEK in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.2 grams of surfactant BYK®-3760 were added to the solvent mixture while mixing. 2 grams of Reversacol Midnight Gray were then added, while mixing, and the mixing was continued for another 20 minutes at 60°C to produce the photochromic ink, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 14

30 grams of DPnP were mixed with 67.9 grams of PM in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.1 grams of surfactant BYK®-346 were added to the solvent mixture while mixing 1 gram of Reversacol Midnight Gray dye and 1 gram of Reversacol Amazon Green dye were added while mixing. Mixing was continued for another 20 minutes at 60°C to produce the photochromic ink, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 14A

65 grams of Joncryl®1532 were mixed with 20 grams of water in a 200ml glass beaker equipped with a magnetic stirrer. Then 9.5 grams of EB solvent, 4.8 grams of DPM solvent and 0.2grams of BYK®024 were added while mixing. After mixing the components for 5 minutes, 0.5 grams of surfactant BYK®-346 were added to the mixture and the mixing was continued for another 10 minutes at 30°C.

EXAMPLE 14B

70 grams of Joncryl®1534 were mixed with 15 grams of water in a 200ml glass beaker equipped with a magnetic stirrer. Then 9.5 grams of EB solvent, 4.8 grams of DPM solvent and 0.2grams of BYK®024 were added while mixing. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA®3200 were added to the mixture and the mixing was continued for another 10 minutes at 30°C.

EXAMPLE 15

8 grams of Evatane® 33-45 were mixed with 46 grams of xylene and 46 grams of toluene in a 200ml glass beaker equipped with a magnetic stirrer for 30 minutes at room temperature.

EXAMPLE 16

8 grams of Evatane® 33-400 were mixed with 46 grams of xylene and 46 grams of toluene in a 200ml glass beaker equipped with a magnetic stirrer for 30 minutes at room temperature.

EXAMPLE 17

75 grams of Joncryl®2110 were mixed with 10 grams of water in a 200ml glass beaker equipped with a magnetic stirrer. Then 10 grams of EB, 4.5 grams of DPM and 0.25 grams of BYK®044 were added while mixing. After mixing the components for 5 minutes, 0.25 grams of surfactant BYK®346 were added to the mixture and the mixing was continued for another 10 minutes at 30°C. EXAMPLE 18

The corona surface treatment procedure was performed on a Trivex® (PPG) lens made of urethane-based pre-polymer, according to Example 1.

EXAMPLE 19

The corona surface treatment procedure was performed on a polycarbonate lens according to Example 1.

EXAMPLE 20

The corona surface treatment procedure of Example 1 was performed on a polycarbonate lens that was pre-coated with a hardcoat.

EXAMPLE 21

The corona surface treatment procedure of Example 1 was performed on a Trivex® (PPG) lens that was pre-coated with a hardcoat.

EXAMPLE 22

The corona surface treatment procedure of Example 1 was performed on a CR- 39® (PPG) lens made of poly(allyl di glycol carbonate) (PADC) that was pre-coated with a hardcoat.

EXAMPLE 23

Onto a polycarbonate lens was applied Versamid®PUR 1010 as a primer. Spin coating was effected according to Example 2, and a calculated (average) wet thickness of 2.86pm was obtained. The wet layer was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 10 minutes, to produce a primer layer having a thickness of 1.0μm.

EXAMPLE 24

Onto a polycarbonate lens was applied Laroflex®HS-9000 as a primer. Spin coating was effected according to Example 2, and a calculated wet thickness of 2.14μm was obtained. The wet layer was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 10 minutes, to produce a primer layer having a thickness of about 1.5μm.

EXAMPLE 25

Onto a polycarbonate lens was applied the Joncryl®1534 formulation of Example 14B as a primer. Spin coating was effected according to Example 2, and a calculated wet thickness of 0.65μm was obtained. The wet layer was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 10 minutes, to produce a primer layer having a thickness of about 0.2μm.

EXAMPLE 26

Onto a Trivex® (PPG) lens that had been pre-coated with a hardcoat was applied the Joncryl®1532 formulation of Example 14A as a primer. Spin coating was effected according to Example 2, and a calculated wet thickness of 1.48μm was obtained. The wet layer was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 10 minutes, to produce a primer layer having a thickness of about 0.5 μm.

EXAMPLE 27

Onto a CR-39® (PPG) lens that had been pre-coated with a hardcoat was applied the Joncryl®2110 formulation of Example 17 as a primer. Spin coating was effected according to Example 2, and a calculated wet thickness of 6.71μm was obtained. The wet layer was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 10 minutes, to produce a primer layer having a thickness of about 2.5 μm.

EXAMPLE 28

Onto the Trivex® (PPG) lens that had been corona-treated according to Example 21 was applied the Joncryl®1534 formulation of Example 14B as a primer. Spin coating was effected according to Example 2, and a calculated wet thickness of 2.6μm was obtained. The wet layer was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 10 minutes, to produce a primer layer having a thickness of about 0.8μm.

EXAMPLE 29

Onto the polycarbonate lens that had been corona-treated according to Example 20 was applied the Joncryl®1534 formulation of Example 14B as a primer. Spin coating was effected according to Example 2. The wet layer was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 10 minutes.

EXAMPLE 30

Onto the CR-39® lens that had been corona-treated according to Example 22 was applied the Joncryl®1534 formulation of Example 14B as a primer. Spin coating was effected according to Example 2. The wet layer was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 10 minutes.

EXAMPLE 31

Onto the Trivex® lens of Example 18 was applied the Joncryl®2110 formulation of Example 17 as a primer. Spin coating was effected according to Example 2. The wet layer was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 10 minutes.

EXAMPLE 32

65 grams of difunctional aliphatic polyester urethane acrylate oligomer (BR- 744D) were mixed with 30 grams of SR-610 (polyethylene glycol 600 diacrylate) in a 200ml glass beaker equipped with a magnetic stirrer. Subsequently, 5 grams of photoinitiator TPO were added and the mixing was continued for another 10 minutes at 30°C.

EXAMPLE 33

60 grams of BR-744D were mixed with 30 grams of SR-610 polyethylene glycol 600 diacrylate in a 200ml glass beaker equipped with a magnetic stirrer. Subsequently, 5 grams of photoinitiator TPO and 5 grams of CN3715 were added and the mixing was continued for another 10 minutes at 30°C.

EXAMPLE 34

50 grams of BR-3641AJ were mixed with 45 grams of SR506 (IBOA) in a 200ml glass beaker equipped with a magnetic stirrer. Subsequently, 5 grams of TPO were added as a photoinitiator, and the mixing was continued for another 10 minutes at 30°C.

EXAMPLE 35

50 grams of BR-3641AJ were mixed with 25 grams of SR506 and 20 grams of SR484 (octyl acrylate monomer) in a 200ml glass beaker equipped with a magnetic stirrer. Subsequently, 5 grams of TPO were added, and the mixing was continued for another 10 minutes at 30°C.

EXAMPLE 36

30.5 grams of TPM solvent were mixed with 55 grams of PMA solvent in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA®SL 3200 were added to the solvent mixture while mixing. 10 grams of Pearlbond™ 360 were then added while continuing to mix. Mixing was continued for another 40 minutes at 60°C to produce the recipience layer lacquer, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 37

30.5 grams of TPM solvent were mixed with 55 grams of PMA solvent in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA®SL 3035 were added to the solvent mixture while mixing. 10 grams of Pearlcoat™ DIPP 119 were then added while continuing to mix. Mixing was continued for another 40 minutes at 60°C to produce the recipience layer lacquer, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 38

10.5 grams of TPM solvent were mixed with 10 grams of PMA solvent in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA®SL 3778 were added to the solvent mixture while mixing. 70 grams of SETALUX® 2127 XX-60 were then added while continuing to mix. Mixing was continued for another 40 minutes at 60°C to produce the recipience layer lacquer, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 39

33 grams of TPM solvent were mixed with 52.5 grams of PMA solvent in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA®SL 3035 were added to the solvent mixture while mixing. 10 grams of Pearlcoat™ DIPP 119 were added while continuing to mix. Mixing was continued for another 40 minutes at 60°C to produce the recipience layer lacquer, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 40

30.5 grams of TPM solvent were mixed with 55 grams of PMA solvent in a 200ml glass beaker equipped with a magnetic stirrer. After mixing the components for 5 minutes, 0.5 grams of surfactant EFKA®SL 3035 were added to the solvent mixture while mixing. 10 grams of Laropal A-81 were added while continuing to mix. Mixing was continued for another 40 minutes at 60°C to produce the recipience layer lacquer, which was subsequently filtered with a syringe filter (0.45 micrometer).

EXAMPLE 41

Onto a polycarbonate lens was applied Alberdingk®U-3251 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 17.5μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 7μm.

EXAMPLE 41 A

Onto a polycarbonate lens was applied Alberdingk®U-3200 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 28.3μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (measured) thickness was about 8.5μm.

EXAMPLE 42

Onto a CR-39® lens was applied Alberdingk®U-3251 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 12.5μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 5μm.

EXAMPLE 42 A

Onto a CR-39® lens was applied Alberdingk®U-3251 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 5μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 2μm.

EXAMPLE 43

Onto a polycarbonate lens was applied Alberdingk®U-6100 VP as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 21.7μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 7.8μm.

EXAMPLE 44

Onto a polycarbonate lens was applied Lubrijet™ T800 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 32.3μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 10μm. EXAMPLE 45

Onto a polycarbonate lens was applied Lubrijet™ N240 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 30.0μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 12μm.

EXAMPLE 46

Onto a polycarbonate lens was applied Lubrijet™ T340 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 34.9μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (measured) thickness was about 11.5μm.

EXAMPLE 47

Onto a polycarbonate lens was applied Alberdingk APU-10610 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 16.2μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 5.5μm.

EXAMPLE 48

Onto the primed Trivex® (PPG) lens of Example 26 was applied Etemacoll UW- 5502D-C1 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 21.4 μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 7.5μm.

EXAMPLE 48A

Onto a Trivex® (PPG) lens was applied JONCRYL 2136-A as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 21.4 μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 9μm.

EXAMPLE 48B

Onto a Trivex® (PPG) lens was applied JONCRYL 2121 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 19.6 μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 10μm.

EXAMPLE 49

Onto a CR-39® lens was applied the formulation of Example 15 as a recipience layer formulation. Spin coating was effected according to Example 3, but for 5 seconds at 2000rpm (and 500rpm-s). The wet layer, having a calculated average thickness of 65μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 60 minutes. The dry (average calculated) thickness was about 5.2μm.

EXAMPLE 50

Onto a CR-39® lens was applied the formulation of Example 16 as a recipience layer formulation. Spin coating was effected according to Example 3, but for 5 seconds at 2000rpm (and 500rpm-s). The wet layer, having a calculated average thickness of 65μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 60 minutes. The dry (average calculated) thickness was about 5μm.

EXAMPLE 51

Onto the primed CR-39® lens of Example 27 was applied JONCRYL 2136-A as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 10.7 μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 4.5μm.

EXAMPLE 52

Onto a polycarbonate lens was applied JONCRYL 659-A as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 25.45μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 11.2μm.

EXAMPLE 53

Onto a polycarbonate lens was applied Alberdingk®U-3200 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer, having a calculated average thickness of 48.7 μm, was then subjected to thermal drying and curing in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes. The dry (average calculated) thickness was about 14.6μm.

EXAMPLE 54

Onto a polycarbonate lens was applied the formulation of Example 32. Spin coating was then effected according to Example 3, and the wet layer was subjected to UV curing for 10-20 seconds using the UV Curing LED.

EXAMPLE 55

Onto a polycarbonate lens was applied the formulation of Example 33. Spin coating was then effected according to Example 3, and the wet layer was subjected to UV curing for 10-20 seconds using the UV Curing LED.

EXAMPLE 56

Onto a CR-39® lens was applied the formulation of Example 34. Spin coating was then effected according to Example 3, and the wet layer was subjected to UV curing for 10-20 seconds using the UV Curing LED.

EXAMPLE 57

Onto the primed polycarbonate lens of Example 24 was applied the formulation of Example 35. Spin coating was then effected according to Example 3, and the wet layer was subjected to UV curing for 10-20 seconds using the UV Curing LED.

EXAMPLE 58

Onto a CR-39® lens was applied the Pearlbond™ 360 TPU formulation of Example 36 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes.

EXAMPLE 59

Onto a polycarbonate lens was applied the Pearlbond™ DIPP 119 formulation of Example 37 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes.

EXAMPLE 60

Onto a polycarbonate lens was applied the SETALUX® 2127 XX-60 formulation of Example 38 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes.

EXAMPLE 61

Onto a Trivex® lens was applied the Pearlcoat™ DIPP 119 formulation of Example 39 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes.

EXAMPLE 62

Onto the primed polycarbonate lens of Example 27 was applied the Laropal A- 81 formulation of Example 40 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes.

EXAMPLE 63

Onto a Trivex® lens was applied Bondthane™ UD-610, a self-crosslinking aliphatic polyurethane dispersion, as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes.

EXAMPLE 64

Onto the primed Trivex® (PPG) lens of Example 26 was applied Bondthane™ UD-615, a self-crosslinking aliphatic polyurethane dispersion, as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 10 minutes and then at 100°C for 20 minutes.

EXAMPLE 65

Onto the corona surface treated polycarbonate lens of Example 19 was applied the Pearlbond™ DIPP 119 formulation of Example 37 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes.

EXAMPLE 66

Onto the corona surface treated polycarbonate lens of Example 20 was applied the BR-3641AJ formulation of Example 34 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to UV curing for 10-20 seconds using the UV Curing LED.

EXAMPLE 67

Onto the corona surface treated Trivex® lens of Example 21 was applied the Pearlcoat™ DIPP 119 formulation of Example 39 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes.

EXAMPLE 68

Onto the primed, corona surface treated, Trivex® lens of Example 28 was applied the Pearlbond™ DIPP 119 formulation of Example 37 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes.

EXAMPLE 69

Onto the primed, corona surface treated, Trivex® lens of Example 31 was applied the BR-3641AJ formulation of Example 34 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to UV curing for 10-20 seconds using the UV Curing LED.

EXAMPLE 70

Onto the primed, corona surface treated, polycarbonate lens of Example 29 was applied the Pearlcoat™ DIPP 119 formulation of Example 39 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes.

EXAMPLE 71

Onto the primed, corona surface treated, CR-39® lens of Example 30 was applied the BR-744D formulation of Example 33 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to UV curing for 10-20 seconds using the UV Curing LED.

EXAMPLE 72

Onto the primed, corona surface treated, CR-39® lens of Example 30 was applied Bondthane™ UD-615 as a recipience layer formulation. Spin coating was effected according to Example 3. The wet layer was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. EXAMPLES 73-108: Jetting onto the Recipience Layer-covered lens

After optimizing the inkjetting parameters according to the procedure of

Example 4, the photochromic dye containing inkjet ink formulations of Examples 7 to

14 were inkjetted onto various recipience layer covered lens substrates described hereinabove.

In Examples 73 to 80 and 102C-D, a single photochromic dye containing inkjet ink formulation was inkjetted onto the recipience layer surface, according to the procedure of Example 5 A. In Examples 81 to 108, two different photochromic ink formulations were inkjetted onto the recipience layer surface, according to the procedure of Example 5B. In order to increase the intensity of the photochromic color(s), the ink-drop arrays were applied in a drop-on-drop fashion (4 to 72 drop-on- drops), according to the procedure of Example 6.

Examples 73 to 108 are summarized in the Table provided below:

It is noted that in Examples 94 and 95, haze was observed, perhaps indicating that the recipience layer was overloaded with photochromic dye.

EXAMPLE 109 Onto the coated polycarbonate lens produced in Example 76 was applied SETALUX® 17-7202 as an overcoat formulation. Spin coating was effected according to Example 3 A. The wet layer, having a calculated average thickness of 15 μm, was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. The dry (average calculated) thickness was about 7.5μm.

EXAMPLE 110

Onto the coated CR-39® lens produced in Example 93 was applied ALBERDINGK®APU 10600 as an overcoat formulation. Spin coating was effected according to Example 3A. The wet layer, having a calculated average thickness of 6.1μm, was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. The dry (average calculated) thickness was about 2.0μm.

EXAMPLE 111

Onto the primed and coated Trivex® lens produced in Example 83 was applied Bondthane™ LID-620 as an overcoat formulation. Spin coating was effected according to Example 3A. The wet layer, having a calculated average thickness of 8.8μm, was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. The dry (average calculated) thickness was about 3 μm.

EXAMPLE 112

Onto the corona-treated, primed and coated CR-39® lens produced in Example 79 was applied SETALUX®17-1246 as an overcoat formulation. Spin coating was effected according to Example 3A. The wet layer, having a calculated average thickness of 7.5μm, was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. The dry (average calculated) thickness was about 3μm.

EXAMPLE 113

Onto the primed and coated polycarbonate lens produced in Example 107 was applied Joncryl®9530-A as an overcoat formulation. Spin coating was effected according to Example 3A. The wet layer, having a calculated average thickness of 4μm, was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. The dry (average calculated) thickness was about 1.6μm.

EXAMPLE 114

Onto the coated Trivex® lens produced in Example 82 was applied Joncryl®617- A as an overcoat formulation. Spin coating was effected according to Example 3A. The wet layer, having a calculated average thickness of 6.5μm, was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. The dry (average calculated) thickness was about 3 μm.

EXAMPLE 115

Onto the coated lens produced in Example 110 was applied CrystalCoat™ TC- 3000 as a hardcoat. Spin coating was effected according to Example 3B. The wet layer, having a calculated average thickness of 11μm, was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. The dry (average calculated) thickness was about 2.2μm.

EXAMPLE 116

Onto the coated CR-39 lens produced in Example 111 was applied CrystalCoat™ MP-1154D as a hardcoat. Spin coating was effected according to Example 3B. The wet layer, having a calculated average thickness of 27.8μm, was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. The dry (average calculated) thickness was about 5μm.

EXAMPLE 117

Onto the coated Trivex® lens produced in Example 114 was applied CrystalCoat™ MP-2020B as a hardcoat. Spin coating was effected according to Example 3B. The wet layer, having a calculated average thickness of 13.6μm, was then subjected to thermal drying in a Venticell ECO forced air oven at 60°C for 30 minutes. The dry (average calculated) thickness was about 3 μm.

EXAMPLE 118: Measuring Haze & % Transmittance

After calibrating the T-100 instrument, the Target lens was measured (uncoated reference lens). In Sample mode, the coated lens was then tested. The instrument then displayed the following results of the coated and uncoated lenses: % Transmittance, A % Transmittance, Haze, and A Haze. Lower delta values between the coated and uncoated lens indicate good optical clarity/transparency.

EXAMPLE 119: Measuring Photochromic properties

Spectrophotometric studies were conducted using a Cary 4000 UV-Vis. doublebeam spectrophotometer. The light source was a UV-LED lamp (395 nm). Activation and fading properties & kinetics were characterized. In the spectrophotometric studies, the coated samples were characterized against an uncoated reference slide or lens. Spectrum data were normally collected in the range 350-700nm at a resolution of Inm. Kinetics measurements of activation and fading rates were performed at the wavelength of maximal absorbance for each photochromic dye, with a typical resolution of 0.2 seconds. The measurements were initiated while the UV-LED lamp is off. After 3-5 seconds, the UV-LED lamp was turned on for 120-180 seconds to attain maximal absorbance. The lamp was then turned off, and monitoring of the fading was conducted.

EXAMPLE 120: Photochromic Dye Density and Photochromic Dye Concentration

An exemplary photochromic dye density is calculated as follows, using the parameters of Example 80: the print density is 300dpi (Examples 4, 5 A), corresponding to about 13,924 dots/cm². The ink drops have a volume of 10 pL, and contain 2% photochromic dye. As 1pL/ cm² = 10^-5μm, the calculated thickness of dye per pass (or layer) is 0.028μm, which, assuming a specific gravity of about 1.0 for the components, corresponds to a calculated photochromic dye content per lens area of 0.028mg/cm². Example 80 has 48DoD (passes), such that the total calculated thickness of dye is 1.34μm, on a pure dye basis.

Based on the above, and upon the photochromic dye formulation, an exemplary recipience layer photochromic dye concentration may be calculated: the total calculated thickness of dye is 1.34μm, the total calculated thickness of other ink solids is 0.13 μm (Example 13), and the calculated thickness of the recipience layer is 7.5μm (Example 47). Thus, the calculated recipience layer photochromic dye concentration equals 100*1.34/(1.34 + 0.13 + 7.5), or 14.9% (volume% or weight%). Similarly, the calculated recipience layer photochromic dye concentration for Example 102B equals 100*1.34/(1.34 + 0.13 + 2.0), or 38.6%.

Continuing now with Example 102B, assuming that the recipient layer is covered with an overcoat having a thickness of 2.2 μm, followed by a hardcoat having a thickness of 2.5 μm, the calculated photochromic dye concentration for the entire optical construction (volume% or weight%) equals 100*1.34/(1.34 + 0.13 + 2.0 + 2.2 + 2.5), or 16.4%.

Additional Embodiments

Various methods and apparatus, as well as additional systems, are disclosed herein.

Additional Embodiments (or “Clauses”) 1 to 214 are provided hereinbelow.

Embodiment 1. An optical article comprising: an optical substrate having an optical surface; and an optical construction including a polymeric recipience layer having a first surface fixedly attached to the optical surface, and a second surface disposed opposite the first surface; the polymeric recipience layer including a polymer; photochromic dye, disposed within the recipience layer; and an overcoat layer, coating the recipience layer, and fixedly attached to the second surface.

Embodiment 1A. The article of Embodiment 1, wherein the optical substrate having an optical surface is an ophthalmic substrate having an ophthalmic surface.

Embodiment 2. The article of Embodiment 1 or 1A, wherein: optionally, at least one of the polymer and the polymeric recipience layer has a Kbnig hardness, measured in seconds, within a range of 20 to 100; optionally, the thickness (Toc) of the article is defined by the shortest distance or shortest normal distance between the substrate and the exterior surface of the article disposed distally to the substrate; wherein Toc is at most 175 μm; and optionally, the ultimate elongation of the polymer is within a range of 150% to 2000%. Embodiment 3. The article of Embodiment 2, wherein the Kbnig hardness of at least one of the polymer and the polymeric recipience layer is within a range of 20 to 100. Embodiment 3 A. The article of Embodiment 3, wherein the Kbnig hardness is at most 90.

Embodiment 4. The article of Embodiment 3, wherein the Kbnig hardness is at most 85.

Embodiment 5. The article of Embodiment 3, wherein the Kbnig hardness is at most 80.

Embodiment 6. The article of Embodiment 3, wherein the Kbnig hardness is at most 75.

Embodiment 7. The article of Embodiment 3, wherein the Kbnig hardness is at most 70.

Embodiment 8. The article of Embodiment 3, wherein the Kbnig hardness is at most 65.

Embodiment 9. The article of any one of Embodiments 2 to 8, wherein the Kbnig hardness is at least 30.

Embodiment 10. The article of Embodiment 9, wherein the Kbnig hardness is at least 40.

Embodiment 10 A. The article of any one of claims 1 to 10, wherein the photochromic dye disposed within the polymeric recipience layer is a first portion Pl of the photochromic dye; a second portion P2 of the photochromic dye is disposed within the optical substrate, and a third portion P3 of said photochromic dye is disposed within the overcoat layer; and wherein a dye ratio defined by P1/(P2+P3) is at least 10.

Embodiment 10B. The article of Embodiment 10A, wherein the dye ratio is at least 20.

Embodiment 10C. The article of Embodiment 10A or 10B, wherein P2 is 0.

Embodiment 10D. The article of any one of Embodiments 10A to 10C, wherein P3 is 0. Embodiment 11. The article of any one of Embodiments 2 to 10D, wherein the ultimate elongation of the polymer is within a range of 150% to 2000%.

Embodiment 12. The article of Embodiment 11, wherein the ultimate elongation of the polymer is at least 175%.

Embodiment 13. The article of Embodiment 11, wherein the ultimate elongation of the polymer is at least 200%.

Embodiment 14. The article of Embodiment 11, wherein the ultimate elongation of the polymer is at least 250%.

Embodiment 15. The article of Embodiment 11, wherein the ultimate elongation of the polymer is at least 300%.

Embodiment 16. The article of Embodiment 11, wherein the ultimate elongation of the polymer is at least 350%.

Embodiment 17. The article of Embodiment 11, wherein the ultimate elongation of the polymer is at least 400%.

Embodiment 18. The article of any one of Embodiments 2 to 17, wherein the ultimate elongation of the polymer is at most 1500%.

Embodiment 19. The article of Embodiment 18, wherein the ultimate elongation of the polymer is at most 1200%.

Embodiment 20. The article of Embodiment 18, wherein the ultimate elongation of the polymer is at most 900%.

Embodiment 21. The article of Embodiment 18, wherein the ultimate elongation of the polymer is at most 800%.

Embodiment 22. The article of Embodiment 18, wherein the ultimate elongation of the polymer is at most 700%.

Embodiment 23. The article of any one of Embodiments 2 to 22, wherein the thickness (Toc) of the article is defined by the shortest distance between the substrate and the exterior surface of the article disposed distally to the substrate, and wherein Toc is at most 60 μm.

Embodiment 24. The article of Embodiment 23, wherein Toc is at most 50 μm.

Embodiment 25. The article of Embodiment 23, wherein Toc is at most 45 μm.

Embodiment 26. The article of Embodiment 23, wherein Toc is at most 40 μm.

Embodiment 27. The article of Embodiment 23, wherein Toc is at most 35 μm.

Embodiment 28. The article of Embodiment 23, wherein Toc is at most 30 μm.

Embodiment 29. The article of Embodiment 23, wherein Toc is at most 25 μm.

Embodiment 30. The article of Embodiment 23, wherein Toc is at most 20 μm.

Embodiment 31. The article of Embodiment 23, wherein Toc is at most 15 μm.

Embodiment 32. The article of Embodiment 23, wherein Toc is at most 12 μm.

Embodiment 33. The article of Embodiment 23, wherein Toc is at most 10 μm.

Embodiment 34. The article of any one of Embodiments 23 to 33, wherein Toc is at least 4 μm.

Embodiment 35. The article of Embodiment 34, wherein Toc is at least 6 μm.

Embodiment 36. The article of Embodiment 34, wherein Toc is at least 8 μm.

Embodiment 37. The article of Embodiment 23, wherein Toc is within a range of 5 to 45 μm.

Embodiment 38. The article of Embodiment 23, wherein Toc is within a range of 6 to 35 μm.

Embodiment 39. The article of Embodiment 23, wherein Toc is within a range of 7 to 30 μm.

Embodiment 40. The article of any one of Embodiments 2 to 39, further comprising a first hardcoat layer, coating the overcoat layer, the first hardcoat layer fixedly attached to the side of the overcoat layer that faces the exterior surface of the article.

Embodiment 41. The article of Embodiment 40, the first hardcoat layer having a Kbnig hardness, measured in seconds, of at least 100.

Embodiment 42. The article of Embodiment 40, the first hardcoat layer having a Kbnig hardness, measured in seconds, of at least 110.

Embodiment 43. The article of Embodiment 40, the first hardcoat layer having a Kbnig hardness, measured in seconds, of at least 120.

Embodiment 44. The article of any one of Embodiments 40 to 43, wherein the Kbnig hardness of the first hardcoat layer is at most 160. Embodiment 45. The article of Embodiment 44, wherein the Kbnig hardness of the first hardcoat layer is at most 150.

Embodiment 46. The article of Embodiment 44, wherein the Kbnig hardness of the first hardcoat layer is at most 140.

Embodiment 47. The article of any one of Embodiments 2 to 46, wherein the thickness (Tree) of the polymeric recipience layer is within a range of 0.6 to 30μm.

Embodiment 48. The article of any one of Embodiments 2 to 47, wherein the average thickness of the polymeric recipience layer (Trec-avg) is within a range of 0.6 to 30μm. Embodiment 49. The article of Embodiment 47 or 48, wherein at least one of Tree and Trec-avg is at least 1μm.

Embodiment 50. The article of Embodiment 47 or 48, wherein at least one of Tree and Trec-avg is at least 1.5μm.

Embodiment 51. The article of Embodiment 47 or 48, wherein at least one of Tree and Trec-avg is at least 2.5μm.

Embodiment 52. The article of Embodiment 47 or 48, wherein at least one of Tree and Trec-avg is at least 3.5μm.

Embodiment 53. The article of Embodiment 47 or 48, wherein at least one of Tree and Trec-avg is at least 5μm.

Embodiment 54. The article of Embodiment 47 or 48, wherein at least one of Tree and Trec-avg is at least 6μm.

Embodiment 55. The article of Embodiment 47 or 48, wherein at least one of Tree and Trec-avg is at least 8μm.

Embodiment 56. The article of any one of Embodiments 47 to 55, wherein at least one of Tree and Trec-avg is at most 25μm.

Embodiment 57. The article of Embodiment 56, wherein at least one of Tree and Trec- avg is at most 20μm.

Embodiment 58. The article of Embodiment 56, wherein at least one of Tree and Trec- avg is at most 15μm.

Embodiment 59. The article of Embodiment 56, wherein at least one of Tree and Trec- avg is at most 12μm.

Embodiment 60. The article of Embodiment 56, wherein at least one of Tree and Trec- avg is at most 10μm. Embodiment 61. The article of Embodiment 59, wherein at least one of Tree and Trec- avg is at most 8μm.

Embodiment 62. The article of Embodiment 59, wherein at least one of Tree and Trec- avg is at most 6μm.

Embodiment 63. The article of Embodiment 47, wherein Tree of the polymeric recipience layer is within a range of 1 to 18μm.

Embodiment 64. The article of Embodiment 47, wherein Tree of the polymeric recipience layer is within a range of 1.5 to 9μm.

Embodiment 65. The article of Embodiment 48, wherein Trec-avg of the polymeric recipience layer is within a range of 1 to 18μm.

Embodiment 66. The article of Embodiment 48, wherein Trec-avg of the polymeric recipience layer is within a range of 1.5 to 9μm.

Embodiment 67. The article of any one of Embodiments 1 to 66, wherein the substrate is a lens.

Embodiment 68. The article of any one of Embodiments 1 to 67, wherein the substrate is a curved ophthalmic substrate having a SAG of at least 0.5mm.

Embodiment 69. The article of Embodiment 68, wherein the SAG is at least 1mm.

Embodiment 70. The article of Embodiment 68, wherein the SAG is at least 2mm.

Embodiment 71. The article of Embodiment 68, wherein the SAG is at least 3.5mm.

Embodiment 72. The article of Embodiment 68, wherein the SAG is at least 5mm.

Embodiment 73. The article of any one of Embodiments 68 to 72, wherein the SAG is at most 15mm or at most 12mm.

Embodiment 74. The article of any one of Embodiments 1 to 73, wherein the dried recipience layer has a pencil hardness of at most 4H.

Embodiment 75. The article of Embodiment 74, wherein the pencil hardness is at most 3H.

Embodiment 76. The article of Embodiment 74, wherein the pencil hardness is at most 2H.

Embodiment 77. The article of any one of Embodiments 74 to 76, wherein the pencil hardness is at least 2B.

Embodiment 78. The article of Embodiment 77, wherein the pencil hardness is at least B. Embodiment 79. The article of Embodiment 83, wherein the pencil hardness is at least HB.

Embodiment 80. The article of any one of Embodiments 1 to 79, wherein the substrate is or includes a thermoplastic substrate.

Embodiment 81. The article of Embodiment 80, wherein the thermoplastic substrate is or includes polycarbonate.

Embodiment 82. The article of any one of Embodiments 1 to 79, wherein the substrate is or includes a thermoset substrate.

Embodiment 83. The article of any one of Embodiments 1 to 82, wherein the overcoat layer is a hardcoat layer.

Embodiment 84. The article of Embodiment 83, wherein the hardcoat layer is an antiscratch layer.

Embodiment 85. The article of Embodiment 83 or 84, wherein the hardcoat layer is, includes, or consists essentially of amorphous silica.

Embodiment 86. The article of any one of Embodiments 1 to 82, further comprising a hardcoat layer, disposed above, and fixedly attached, to the overcoat layer.

Embodiment 87. The article of Embodiment 86, wherein the hardcoat layer is an antiscratch layer.

Embodiment 88. The article of Embodiment 86 or 87, wherein the hardcoat layer is, includes, or consists essentially of amorphous silica.

Embodiment 89. The article of any one of Embodiments 1 to 88, wherein the photochromic dye includes at least 2 photochromic dyes.

Embodiment 90. The article of any one of Embodiments 1 to 89, further comprising a primer layer adhering to both the ophthalmic surface and to the first surface of the polymeric recipience layer, and disposed therebetween.

Embodiment 91. The article of Embodiment 90, wherein the primer layer has at least one of a spot thickness and an average thickness of at most 2.5μm.

Embodiment 92. The article of Embodiment 90, wherein the primer layer has at least one of a spot thickness and an average thickness of at most 1.8μm.

Embodiment 93. The article of Embodiment 90, wherein the primer layer has at least one of a spot thickness and an average thickness of at most 1.0μm.

Embodiment 94. The article of any one of Embodiments 91 to 93, wherein at least one of the spot thickness and the average thickness is at least 0.2μm. Embodiment 95. The article of any one of Embodiments 91 to 93, wherein at least one of the spot thickness and the average thickness is at least 0.5μm.

Embodiment 96. The article of any one of Embodiments 1 to 95, further comprising an interior hardcoat layer disposed between the substrate and the polymeric recipience layer, the interior hardcoat layer adhering to the surface of the substrate.

Embodiment 97. The article of any one of Embodiments 1 to 96, wherein the calculated recipience layer photochromic dye concentration, Crecipience, is at least 3%. Embodiment 98. The article of Embodiment 90, wherein Crecipience is at least 5%.

Embodiment 99. The article of Embodiment 90, wherein Crecipience is at least 8%.

Embodiment 100. The article of Embodiment 90, wherein Crecipience is at least 12%.

Embodiment 100A. The article of Embodiment 90, wherein Crecipience is at least 18%.

Embodiment 100B. The article of Embodiment 90, wherein Crecipience is at least 24%.

Embodiment 100C. The article of Embodiment 90, wherein Crecipience is at least 30%.

Embodiment 100D. The article of any one of Embodiments 97 to 100C, wherein Crecipience IS at most 48%.

Embodiment 100E. The article of Embodiment 100D, wherein Crecipience is at most 45%, at most 42%, at most 40%, at most 37%, at most 35%, or at most 32%.

Embodiment 101. The article of any one of Embodiments 1 to 100E, wherein the calculated photochromic dye concentration for the entire optical construction, Centire, is at least 2%.

Embodiment 101A. The article of Embodiment 101, wherein Centire is at least 3.5%.

Embodiment 10 IB. The article of Embodiment 101, wherein Centire is at least 5%.

Embodiment 101C. The article of Embodiment 101, wherein Centire is at least 8%.

Embodiment 101D. The article of Embodiment 101, wherein Centire is at least 12%.

Embodiment 10 IE. The article of any one of Embodiments 101 to 10 ID, wherein Centire is at most 25%.

Embodiment 101F. The article of Embodiment 101E, wherein Centire is at most 22%.

Embodiment 101G. The article of Embodiment 10 IE, wherein Centire is at most 20%.

Embodiment 101H. The article of Embodiment 101, wherein Centire is at most 18%.

Embodiment 102. The article of any one of Embodiments 1 to 101H, wherein the total calculated thickness of dye, Td_ye, is at least 0.25 μm.

Embodiment 102A. The article of Embodiment 102, wherein Td_ye is at least 0.5 μm.

Embodiment 102B. The article of Embodiment 102, wherein Td_ye is at least 0.75μm. Embodiment 102C. The article of Embodiment 102, wherein Td_ye is at least 1.0μm. Embodiment 102C. The article of Embodiment 102, wherein Td_ye is at least 1.25μm. Embodiment 102D. The article of any one of Embodiments 102 to 102C, wherein Td_ye is at most 2μm.

Embodiment 102E. The article of Embodiment 102D, wherein Td_ye is at most 1.5 μm.

Embodiment 103. The article of any one of Embodiments 1 to 102E, wherein the haze value of the optical article, or of the optical construction, is at most 1.5%.

Embodiment 103A. The article of Embodiment 103, wherein the haze value of the optical article, or of the optical construction, is at most 1.0%.

Embodiment 103B. The article of Embodiment 103, wherein the haze value of the optical article, or of the optical construction, is at most 0.5%.

Embodiment 104 A. The article of any one of Embodiments 1 to 103B, wherein the shortest distance between the first surface and the optical surface is at most 10 μm.

Embodiment 104B. The article of Embodiment 104A, wherein this shortest distance is at most 5 μm.

Embodiment 104C. The article of any one of Embodiments 1 to 104B, wherein the polymeric recipience layer contains at most 5% or at most 2%, by weight, or is substantially devoid of a 3-dimensional network such as amorphous silica nanoparticles.

Embodiment 104D. The article of any one of Embodiments 1 to 104C, the article having a transparency of at least 90%, at least 92%, or at least 95%, according to ASTM D1746-15.

Embodiment 104E. The article of any one of Embodiments 1 to 104D, wherein the optical surface is, or includes, the top or outwardly-facing surface of the optical substrate, and wherein optionally, the top or outwardly-facing surface has convex curvature.

Embodiment 104F. The article of Embodiment 104E, wherein the bottom or inwardly- facing surface has convex curvature.

Embodiment 104G. The article of any one of Embodiments 1 to 104F, wherein the optical surface is, or includes, the bottom or inwardly-facing surface of the optical substrate, and wherein optionally, the bottom or inwardly-facing surface has concave curvature. Embodiment 104H. The article of Embodiment 104G, wherein the bottom or inwardly- facing surface has concave curvature.

Embodiment 1041. The article of any one of Embodiments 1 to 104H, wherein the optical surface includes a first, top optical surface and a second, bottom optical surface, wherein the optical construction includes a first, top optical construction and a second, bottom optical construction, and wherein the first, top optical surface is attached to the first, top optical construction and the second, bottom optical surface is attached to the second, bottom optical construction.

Embodiment 105. A method of producing an optical or ophthalmic article, the method comprising:

(a) applying a wet recipience layer on an optical surface of an optical substrate;

(b) after the wet recipience layer has dried to form a dried recipience layer, applying at least one photochromic dye containing ink onto the dried recipience layer; and

(c) after the at least one photochromic dye containing ink has at least partially penetrated the upper surface of the dried recipience layer, and after the ink has at least partially dried to form a photochromic dye containing recipience layer, applying a first polymer formulation on the photochromic dye containing recipience layer to form an overcoat layer.

Embodiment 106. The method of Embodiment 105, wherein the at least one photochromic dye containing ink is applied to the dried recipience layer as photochromic ink drops.

Embodiment 107. The method of Embodiment 106, wherein the applying of the photochromic ink drops is performed digitally.

Embodiment 108. The method of Embodiment 106 or 107, wherein the applying of the photochromic ink drops is performed according to a pre-determined pattern.

Embodiment 109. The method of any one of Embodiments 106 to 108, wherein the applying of the first polymer formulation is performed after the ink drops have fully penetrated the upper surface of the dried recipience layer.

Embodiment 110. The method of any one of Embodiments 106 to 109, wherein the applying of the ink drops is performed by printing.

Embodiment 111. The method of any one of Embodiments 106 to 110, wherein the applying of the ink drops is performed according to a digital pattern. Embodiment 112. The method of any one of Embodiments 106 to 111, wherein the applying of the ink drops is performed by jetting.

Embodiment 112A. The method of Embodiment 112, wherein the jetting of the ink drops is performed by inkjetting, such as drop-on-drop (DOD) inkjetting.

Embodiment 113. The method of any one of Embodiments 105 to 111, wherein the applying of the at least one photochromic dye containing ink includes spraying.

Embodiment 114. The method of any one of Embodiments 105 to 113, wherein the applying of the at least one photochromic dye containing ink includes printing.

Embodiment 115. The method of any one of Embodiments 105 to 114, wherein the wet recipience layer has a first thickness (spot thickness or average thickness) within a range of 1 to 120μm.

Embodiment 116. The method of Embodiment 115, wherein the first thickness is at least 1.5μm.

Embodiment 117. The method of Embodiment 115, wherein the first thickness is at least 2 μm.

Embodiment 118. The method of Embodiment 115, wherein the first thickness is at least 3 μm.

Embodiment 119. The method of Embodiment 115, wherein the first thickness is at least 5μm.

Embodiment 120. The method of Embodiment 115, wherein the first thickness is at least 7μm.

Embodiment 121. The method of Embodiment 115, wherein the first thickness is at least 10μm.

Embodiment 122. The method of Embodiment 115, wherein the first thickness is at least 12μm.

Embodiment 123. The method of Embodiment 115, wherein the first thickness is at least 15μm.

Embodiment 124. The method of Embodiment 115, wherein the first thickness is at least 20μm.

Embodiment 125. The method of Embodiment 115, wherein the first thickness is at least 25μm.

Embodiment 126. The method of Embodiment 115, wherein the first thickness is at least 30μm. Embodiment 127. The method of any one of Embodiments 115 to 126, wherein the first thickness is at most 100μm.

Embodiment 128. The method of Embodiment 127, wherein the first thickness is at most 70μm.

Embodiment 129. The method of Embodiment 127, wherein the first thickness is at most at most 50μm.

Embodiment 130. The method of Embodiment 127, wherein the first thickness is at most 40μm.

Embodiment 131. The method of Embodiment 127, wherein the first thickness is at most 30μm.

Embodiment 132. The method of Embodiment 127, wherein the first thickness is within a range of 1μm to 45μm.

Embodiment 133. The method of Embodiment 127, wherein the first thickness is within a range of 1.5 μm to 35μm.

Embodiment 134. The method of Embodiment 127, wherein the first thickness is within a range of 1.5μm to 25μm.

Embodiment 135. The method of Embodiment 127, wherein the first thickness is within a range of 1.5 μm to 18μm.

Embodiment 136. The method of Embodiment 127, wherein the first thickness is within a range of 1.5μm to 12μm.

Embodiment 137. The method of Embodiment 127, wherein the first thickness is within a range of 6 to 80μm.

Embodiment 138. The method of any one of Embodiments 105 to 137, wherein the photochromic dye containing recipience layer, after complete drying, has a second thickness (spot thickness or average thickness) within a range of 0.6μm to 30μm.

Embodiment 139. The method of Embodiment 138, wherein the second thickness is at most 20μm.

Embodiment 140. The method of Embodiment 138, wherein the second thickness is at most 10μm.

Embodiment 141. The method of Embodiment 138, wherein the second thickness is at most 7 μm. Embodiment 146. The method of any one of the above Embodiments, wherein the dried recipience layer has a transparency of at least 95%, at least 97%, or at least 99%, according to ASTM D1746-15.

Embodiment 148. The method of any one of Embodiments 105 to 147, wherein the dried recipience layer has a solubility S in the solvent of the ink drops, the solubility S being defined as:

S = Wd / (Wd + Wsolvent) wherein:

Wd is the weight of dissolved dried recipience layer;

Wsolvent is the weight of the solvent of the ink drops; and S is measured at 25C; and wherein S is at least 0.005.

Embodiment 149. The method of Embodiment 148, wherein S is at least 0.015.

Embodiment 150. The method of Embodiment 148, wherein S is at least 0.03.

Embodiment 151. The method of Embodiment 148, wherein S is at least 0.05.

Embodiment 152. The method of Embodiment 148, wherein S is at most 0.60.

Embodiment 153. The method of Embodiment 148, wherein S is at most 0.45.

Embodiment 154. The method of Embodiment 148, wherein S is at most 0.35.

Embodiment 155. The method of any one of Embodiments 105 to 154, wherein the first overcoat layer is a hardcoat.

Embodiment 156. The method of any one of Embodiments 105 to 155, further comprising, after the first overcoat layer has dried to form a dried first overcoat layer, applying a second formulation on top of the dried first overcoat layer to form a wet hardcoat layer.

Embodiment 157. The method of Embodiment 156, wherein the second formulation includes a silane or an alkoxide adapted to produce amorphous silica.

Embodiment 158. The method of Embodiment 156 or 157, further comprising: drying the wet hardcoat layer to form a dried hardcoat layer.

Embodiment 159. The method of any one of Embodiments 105 to 158, further comprising drying the at least one photochromic dye containing ink or the ink drops to form the photochromic dye containing recipience layer.

Embodiment 160. The method of any one of Embodiments 105 to 159, further comprising, prior to the providing of the ophthalmic substrate: pre-treating a first surface of the ophthalmic substrate to form the ophthalmic surface. Embodiment 161. The method of Embodiment 160, wherein the pre-treating of the first surface includes a corona treatment.

Embodiment 162. The method of Embodiment 160, wherein the pre-treating of the first surface includes a plasma treatment.

Embodiment 163. The method of Embodiment 160, wherein the pre-treating of the first surface includes an electron beam treatment.

Embodiment 164. The method of Embodiment 160, wherein the pre-treating of the first surface includes an electrical discharge treatment.

Embodiment 165. The method of Embodiment 160, wherein the pre-treating of the first surface includes an etching treatment.

Embodiment 166. The method of Embodiment 165, wherein the etching treatment includes laser etching.

Embodiment 167. The method of Embodiment 165 or Embodiment 166, wherein the etching treatment includes chemical etching.

Embodiment 168. The method of any one of Embodiments 160 to 167, wherein the pre-treating includes applying a primer to the first surface, to facilitate wetting of the wet recipience layer with respect to the first surface.

Embodiment 169. The method of any one of Embodiments 160 to 168, wherein the pre-treating includes applying a primer to the first surface, to facilitate adherence of the wet recipience layer with respect to the first surface.

Embodiment 170. The method of any one of Embodiments 160 to 167, wherein the pre-treating includes applying a primer to the first surface.

Embodiment 171. The method of any one of Embodiments 168 to 170, further comprising drying the primer to obtain a dried primer layer, the broad exposed face of the dried primer layer forming the (ophthalmic) surface.

Embodiment 172. The method of any one of Embodiments 168 to 171, wherein the applying of the primer includes application by coating.

Embodiment 173. The method of Embodiment 172, wherein the coating is spincoating.

Embodiment 174. The method of Embodiment 172, wherein the coating is dip-coating.

Embodiment 175. The method of any one of Embodiments 105 to 174, wherein after the wet recipience layer has dried to form a dried recipience layer, the applying or depositing of the at least one photochromic dye containing ink onto the dried recipience layer is performed as a drop-on-drop application of the photochromic ink drops.

Embodiment 176. The method of Embodiment 175, wherein the drop-on-drop application is performed or repeated to produce at least a first drop-on-drop ink column and a second drop-on-drop ink column, the first drop-on-drop ink column having at least 3 of the ink drops.

Embodiment 177. The method of Embodiment 176, wherein the drop-on-drop application is performed such that the first ink column contains at least 4 of the ink drops.

Embodiment 178. The method of Embodiment 176, wherein the drop-on-drop application is performed such that the first ink column contains at least 6 of the ink drops.

Embodiment 179. The method of Embodiment 176, wherein the drop-on-drop application is performed such that the first ink column contains at least 8 of the ink drops.

Embodiment 180. The method of Embodiment 176, wherein the drop-on-drop application is performed such that the first ink column contains at least 10 of the ink drops.

Embodiment 181. The method of Embodiment 176, wherein the drop-on-drop application is performed such that the first ink column contains at least 12 of the ink drops.

Embodiment 182. The method of Embodiment 176, wherein the drop-on-drop application is performed such that the first ink column contains at least 15 of the ink drops.

Embodiment 183. The method of Embodiment 176, wherein the drop-on-drop application is performed such that the first ink column contains at least 20 of the ink drops.

Embodiment 184. The method of Embodiment 176, wherein the drop-on-drop application is performed such that the first ink column contains at least 25 of the ink drops.

Embodiment 188. The method of any one of Embodiments 175 to 184, wherein the drop-on-drop application is performed such that the first ink column contains at most 60 of the ink drops. Embodiment 189. The method of Embodiment 185, wherein the drop-on-drop application is performed such that the first ink column contains at most 50 of the ink drops.

Embodiment 190. The method of Embodiment 185, wherein the drop-on-drop application is performed such that the first ink column contains at most 40 of the ink drops.

Embodiment 191. The method of Embodiment 185, wherein the drop-on-drop application is performed such that the first ink column contains at most 35 of the ink drops.

Embodiment 192. The method of Embodiment 185, wherein the drop-on-drop application is performed such that the first ink column contains at most 30 of the ink drops.

Embodiment 193. The method of any one of Embodiments 175 to 192, wherein only after all of the ink drops have at least partially dried to form the photochromic dye containing recipience layer, is performed the applying of the first polymer formulation on top of the photochromic dye containing recipience layer to form the first overcoat layer.

Embodiment 194. The method of any one of Embodiments 105 to 193, wherein the applying of the wet recipience layer is by at least one of spin coating, dip coating, slit coating, die coating, and stamp coating.

Embodiment 195. The method of any one of the previous method Embodiments, wherein the photochromic dye containing ink is a solvent-based photochromic dye containing ink.

Embodiment 196. The method of Embodiment 195, wherein, on a relative n-butyl acetate normalized 25°C evaporation rate scale (Evap_nba-norm), at least 10 weight% of the total solvent within the ink formulation has a normalized evaporation rate (Evapnorm) of at most 0.10.

Embodiment 197. The method of Embodiment 196, wherein at least 15 weight% of the total solvent within the ink formulation has an Evapnorm of at most 0.10.

Embodiment 198. The method of Embodiment 196 or 197, wherein at least 20 weight% of the total solvent within the ink formulation has an Evapnorm of at most 0.25. Embodiment 199. The method of any one of Embodiments 196 to 198, wherein at least 20 weight% of the total solvent within the ink formulation has an Evapnorm of at most 0.10.

Embodiment 200. The method of any one of Embodiments 196 to 199, wherein at least 10 weight% of the total solvent within the ink formulation has an Evapnorm of at most 0.02.

Embodiment 201. The method of any one of Embodiments 196 to 200, wherein at least 25 weight% of the total solvent within the ink formulation has an Evapnorm of at least 0.3.

Embodiment 202. The method of Embodiment 201, wherein at least 45 weight% of the total solvent within the ink formulation has an Evapnorm of at least 0.3.

Embodiment 203. The method of Embodiment 201 or 202, wherein at least 35 weight% of the total solvent within the ink formulation has an Evapnorm of at least 0.4.

Embodiment 204. The method of any one of Embodiments 201 to 203, wherein at least 60 weight% of the total solvent within the ink formulation has an Evapnorm of at least 0.25.

Embodiment 205. The method of any one of Embodiments 195 to 204, wherein at most 5 weight% of the total solvent is water.

Embodiment 206. The method of any one of the previous method Embodiments, wherein the photochromic dye containing ink has a surface tension of at most 38 mN/m. Embodiment 206A. The method of Embodiment 206, wherein the surface tension is at most 35 mN/m, at most 32 mN/m, or at most 30 mN/m.

Embodiment 206B. The method of Embodiment 206 or 206 A, wherein the surface tension is at least 20 mN/m, at least 22 mN/m, or at least 24 mN/m.

Embodiment 206C. The method of any one of the previous Embodiments, wherein at least one of the recipience layer and the photochromic dye containing recipience layer has a surface energy within a range of 20-35 or 20-33 mN/m.

Embodiment 207. The method of any one of the previous method Embodiments, wherein the first polymer formulation is a water-based polymer formulation.

Embodiment 208. The method of Embodiment 207, wherein the water-based polymer formulation includes a polyurethane.

Embodiment 209. The method of Embodiment 207, wherein the water-based polymer formulation includes a polyurethane dispersion. Embodiment 210. The method of any one Embodiments 105 to 206C, wherein the first polymer formulation is a solvent-based polymer formulation.

Embodiment 211. The method of Embodiment 210, wherein the solvent -based polymer formulation includes a polyurethane.

Embodiment 211 A. The method of any one of the previous method Embodiments, wherein the at least partial penetration of the upper surface of the dried recipience layer is at least 80%, at least 90%, or at least 95%, by weight or by volume.

Embodiment 212. The method or article of any one of the preceding Embodiments, wherein the polymer of the polymeric recipience layer is a thermoset polymer.

Embodiment 213. The method or article of any one of Embodiments 1 to 212, wherein the polymer of the polymeric recipience layer is a thermoplastic polymer.

Embodiment 213. The method or article of any one of Embodiments 1 to 212, wherein between each of the respective layers within the optical construction (between each layer of the construction and the layer disposed immediately underneath) there is a Konig hardness differential of at least 5 seconds, and more typically, 5-40, 5-35, 3-30, 5-25, or 5-20 seconds.

Embodiment 213A. The method or article of any one of Embodiments 1 to 213, wherein between each of the respective layers within the optical construction there is a delta pencil hardness of at least one hardness grade (+1) between each layer of the construction and the layer disposed immediately underneath.

Embodiment 214. The article of any one of Embodiments 1 to 104, produced by the method of any one of Embodiments 105 to 213.

As used herein in the specification and in the claims section that follows, the term “percent”, or “%”, refers to percent by weight, unless specifically indicated otherwise.

As used herein in the specification and in the claims section that follows, the terms “anti-glare”, “anti -reflectance”; “anti-fog”; “ultraviolet absorber”;

“photochromic”, and the like, unless otherwise specified, are meant as used in the art of optical substrate coatings.

As used herein in the specification and in the claims section that follows, the term “anti-scratch”, with respect to a material such as a formulation or a coating, refers to a material whose dried and cured coating exhibits a haze value of less than 6%, using the following taber abrasion properties, according to ASTM DI 004-08: CS 10 F wheel, 500g Load, 500 cycles.

Alternatively, the term “anti-scratch”, with respect to a material such as a formulation or a coating, refers to a material whose Bayer number is at least 5 or at least 6 when using ASTM F735-21.

As used herein in the specification and in the claims section that follows, the term “relative n-butyl acetate normalized 25°C evaporation rate scale” and the like may be determined using test method ASTM D3539.

As used herein in the specification and in the claims section that follows, the term “continuous”,

The term “ratio”, as used herein in the specification and in the claims section that follows, refers to a weight ratio, unless specifically indicated otherwise.

The “thickness” of a layer or a plurality of layers at a particular location is measured in the direction that is normal (N) to the lens substrate at that location.

Various types of thin-film thickness measurements are know to those of skill in the art. For example, single-spot thickness measurements may be performed by spectral reflectance or by spectroscopic ellipsometry.

In addition, mapping of thin-film surfaces and calculation of average thicknesses of such films may be performed using these techniques.

The “average thickness” of a wet layer may be determined as follows: when a volume of material vol covers a surface area of a surface having an area SA with a wet layer - the thickness of the wet layer is assumed to be vol/SA. If the weight of the materials is known, vol may be calculated by dividing by the material’s specific gravity. Typically, the specific gravity of the various coating materials may safely be approximated as 1.00. The “average thickness” of a dried film may be calculated as follows: when a volume of material vol that is x% liquid, by weight, wets or covers a surface area SA of a surface, and all the liquid is evaporated away to convert the wet layer into a dry film, the thickness of the dry film is calculated as:

VOl/pwet layer (100- x) / (SA·p_{dry layer}) where p_Wet layer is the specific gravity of the wet layer and p_dry layer is the specific gravity of the dry layer. This calculation requires a knowledge of various properties of the wet coating material of the film, e.g., the specific gravity. As mentioned above, typically, the specific gravities may be assumed to be 1.

Similarly, an average diameter of drops such as jetted or microjetted drops (Ddrop) may be calculated by weighing a large number of the jetted drops, converting the total weight into volume using the specific gravity, dividing by the number of drops, and utilizing the equation relating spherical drop diameter to sphere volume: D = (6*V/π )^1/3.

It will be appreciated by those of skill in the art that the various layers disposed on the optical or ophthalmic surface (e.g., the lens surface) of the present invention are generally of a substantially even thickness, hence, the “average thickness” may be determined by evaluating one or more spot thicknesses on the film or layer.

As used herein in the specification and in the claims section that follows, the term “average”, with respect to a dimension of a plurality of dots such as the height, length or diameter thereof, refers to the arithmetic mean of that dimension, and is calculated using the characteristic dimension for each dot in the plurality.

As used herein in the specification and in the claims section that follows, the terms “transparent” and “haze”, typically with respect to a material, e.g., a material used in a coating, or as a substrate, may be determined according to ASTM D1003-21. Utilizing ASTM D1003-21, a material having a haze measurement of less than 2% and a total transmittance (Tt) of at least 85% is considered “transparent”. More typically, the haze is at most 1.5% or at most 1.0%. More typically, Tt is at least 90% or at least

95%. Yet more typically, the haze is at most 1.0% and Tt is at least 95%.

The term “ophthalmic formulation”, is meant to be understood as used in the art of ophthalmic substrate coatings. As used herein, the term “film-forming”, typically with respect to a resin, polymer, or formulation, is meant to be understood as generally used in the art of ophthalmic substrate coatings.

As used herein, the term “wet” may be used, in context, to include uncured UV materials.

As used herein, the term “drying”, “dried”, and the like, may be used, in context, to refer to or to include the curing of UV materials.

As used herein in the specification and in the claims section that follows, the term “liquid” refers to the state of the material at 25°C.

As used herein in the specification and in the claims section that follows, the term “liquid medium” and the like refers to a medium that is liquid at its temperature of use. For example, the liquid medium in an ink-jet ink jetted at 38°C is a liquid at 38°C. A “liquid medium” is typically liquid at 25°C.

As used herein in the specification and in the claims section that follows, the term “ophthalmic” is always a subset of the term “optical”.

As used herein in the specification and in the claims section that follows, the structural features “calculated recipience layer photochromic dye concentration”, “calculated photochromic dye concentration for the entire optical construction”, “total calculated thickness of dye”, and “calculated photochromic dye content per lens area”, as well as the method feature “total calculated thickness of dye per pass”, refer to the terms as calculated in Example 120. These features may be evaluated in various ways by those of skill in the art.

As used herein in the specification and in the claims section that follows, the term “drop-on-drop” refers to a printing strategy in which two or more drops, typically 6 to 60 drops, are fired or jetted one on top of the other.

As used herein in the specification and in the claims section that follows, the condition “drop-on-drop” is fulfilled if at least one of the following holds true: (a) in practice, the overlap of a second jetted drop with respect to the first jetted drop, after impact, is at least 50 area% of the first drop; and (b) the jetting algorithm is designed for the jetting nozzle to fire the first and second drops (idealized as spheres having a center and a radius R based on the nominal drop volume) to land on the substrate at nominal positions that are within a distance of 1.5R from each other, and more typically, within a distance of 1.25R, l.OOR, 0.75R, 0.5R, or 0.25R from each other. As used herein in the specification and in the claims section that follows, the term “continuous dried layer”, “continuous layer”, or “continuous” with respect to a layer or coating, is continuous over an entirety of a region of the optical surface of optical substrate whose area is at least 0.5 cm² (and more typically, at least 1 cm², at least 2 cm², at least 4 cm², at least 10 cm², optionally, at most 100 cm² or at most 40 cm², and most typically, within a range of 0.5 to 20 cm², 0.5 to 10 cm², or 0.5 to 5 cm²). This optical surface may be on the outwardly disposed or inwardly disposed broad face of the substrate.

As used herein in the specification and in the claims section that follows, the term “continuous”, with respect to a layer or coating, signifies continuity that is recognized by the naked human eye, looking through the optical article. Alternatively, the term “continuous”, with respect to a layer or coating, signifies continuity that is verifiable by spectrophotometric means or other tools known to those of skill in the art.

In the context of the present application and claims, the phrase "at least one of A and B" is equivalent to an inclusive "or", and includes any one of "only A", "only B", or "A and B". Similarly, the phrase "at least one of A, B, and C" is equivalent to an inclusive "or", and includes any one of "only A", "only B", "only C", "A and B", "A and C", "B and C", or "A and B and C".

As used herein in the specification and in the claims section that follows, the terms “top”, “bottom”, “above”, “below”, “upper”, “lower”, “height” and “side” and the like are utilized for convenience of description or for relative orientation, and are not necessarily intended to indicate an absolute orientation in space.

It will be appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. All publications, patents and patent applications mentioned in this specification, including US Patent No. 10,310,151, are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention.

Claims

WHAT IS CLAIMED IS

1. An ophthalmic article comprising: an ophthalmic substrate having an ophthalmic surface; and an ophthalmic construction; said ophthalmic construction including:

(a) a polymeric recipience layer having a first surface fixedly attached to said ophthalmic surface, and a second surface disposed opposite the first surface; said polymeric recipience layer including a polymer;

(b) photochromic dye, disposed within said polymeric recipience layer; and

(c) an overcoat layer, coating said polymeric recipience layer, and fixedly attached to the second surface; wherein the ultimate elongation of said polymer is within a range of 250% to 900%; wherein the thickness (Toc) of said ophthalmic construction is defined by the shortest normal distance between said ophthalmic substrate and the exterior surface of the ophthalmic construction disposed distally to said ophthalmic substrate, and wherein Toc is at most 50 micrometers (μm); wherein said ophthalmic substrate is a lens; and wherein the calculated photochromic dye concentration for the entire optical construction (Centire), by weight or by volume, is at least 3.5%.

2. The ophthalmic article of claim 1, wherein Centire is at least 5%.

3. The ophthalmic article of claim 1, wherein Centire is at least 8%.

4. The ophthalmic article of any one of claims 1 to 3, wherein the calculated recipience layer photochromic dye concentration, Crecipience, is at least 12%.

5. The ophthalmic article of any one of claims 1 to 4, wherein, from a perpendicular viewing direction (Z-direction) intersecting the broad outer face of said lens, said photochromic dye disposed within said polymeric recipience layer forms a continuous dye projection.

6. The ophthalmic article of any one of claims 1 to 5, wherein said polymeric recipience layer has a thickness within a range of 1 to 6 micrometers (μm).

7. The ophthalmic article of any one of claims 1 to 6, wherein said lens has a lens curvature, expressed as SAG number, of at least 5mm.

8. The ophthalmic article of any one of claims 1 to 7, wherein said photochromic dye disposed within said polymeric recipience layer is a first portion Pl of said photochromic dye; a second portion P2 of said photochromic dye is disposed within said lens, and a third portion P3 of said photochromic dye is disposed within said overcoat layer; and wherein P1/(P2+P3) is at least 10.

9. The ophthalmic article of any one of claims 1 to 8, wherein at least one of said polymer and said polymeric recipience layer has a Konig hardness, measured in seconds, within a range of 20 to 80.

10. The ophthalmic article of any one of claims 1 to 9, wherein said ophthalmic construction further includes a hardcoat layer, disposed on and adhering to said overcoat layer.

11. The ophthalmic article of claim 10, wherein said ophthalmic construction further includes a second hardcoat layer disposed on and adhering to said first hardcoat layer.

12. A method of producing the article of any one of claims 1 to 11, the method comprising:

(a) applying a wet recipience layer on said ophthalmic surface;

(b) after said wet recipience layer has dried to form a dried recipience layer, jetting at least one photochromic dye containing ink onto said dried recipience layer; and

(c) after said at least one photochromic dye containing ink has at least partially penetrated the upper surface of said dried recipience layer, and after said ink has at least partially dried to form a photochromic dye containing recipience layer, applying a first polymer formulation on said photochromic dye containing recipience layer to form said overcoat layer.

13. The method of claim 12, wherein said jetting of said at least one photochromic dye containing ink onto said dried recipience layer, is performed as a drop-on-drop application of said photochromic ink drops.

14. The method claim 12 or 13, wherein the dried recipience layer has a solubility S in the solvent of the ink drops, the solubility S being defined as:

S = Wd / (Wd + Wsolvent) wherein:

Wd is the weight of dissolved dried recipience layer;

Wsolvent is the weight of the solvent of the ink drops; and

5 is measured at 25C; and wherein S is at least 0.03, and at most 0.45

15. The method of any one of claims 12 to 14, wherein the drop-on-drop application is performed to produce at least a first drop-on-drop ink column and a second drop-on-drop ink column, the first drop-on-drop ink column containing at least

6 of the ink drops.

16. The method of any one of claims 12 to 15, wherein, on a relative n-butyl acetate normalized 25°C evaporation rate scale (Evap_nba-norm), at least 15 weight% of the total solvent within the ink formulation has a normalized evaporation rate (Evapnorm) of at most 0.10.

17. The method of claim 16, wherein at least 20 weight% of the total solvent within the ink formulation has an Evapnorm of at most 0.25.

18. The method of claim 16 or 17, wherein at least 10 weight% of the total solvent within the ink formulation has an Evapnorm of at most 0.02.

19. The method of any one of claims 16 to 18, wherein at least 45 weight% of the total solvent within the ink formulation has an Evapnorm of at least 0.3.

20. The method of any one of claims 16 to 19, wherein at least 60 weight% of the total solvent within the ink formulation has an Evapnorm of at least 0.25.

21. The method of any one of claims 12 to 20, wherein at most 5 weight% of the total solvent is water.