Method for producing laminated photochromic lenses

A method for producing laminated photochromic lenses by forming a sandwich consisting of a photochromic layer, a primer layer and an adhesive layer between a support lens and a front lens comprising:

• providing an injection molding machine with inserts secured within their respective sleeves so that force exerted on the inserts by a molding material is transferred to a mold clamp;
• injecting thermoplastic molding material in one shot to force a mold open and coining an ultra thin front lens with an integral bifocal region as the mold begins to close, wherein the ultra thin front lens has a substantially uniform thickness of less than 0.8 mm outside the bifocal region;
• solidifying a liquid photochromic solution in situ onto a single vision (SV) support lens without pressure to form a photochromic layer directly on a SV support lens surface in the absence of an intermediate layer;
• coating a primer layer directly onto the photochromic layer;
• applying an adhesive layer to be directly in contact with the primer layer and the ultra thin front lens;
• and
• laminating said ultra thin front lens onto said primer layer with adhesive and compressive pressure, whereby the shape of the ultra thin front lens can be deflected up to 0.5 base curves to completely conform to the shape of the SV support lens surface.