Patent ID: 8003022

Claim:
A method of forming a coated optical element, the method using a mould having first and second mould sections that will form front and back surfaces of the optical element, one of the mould sections having a casting face, the method including the steps of: (a) applying an abrasion resistant coating layer to the casting face of a mould section, the casting face being capable of imparting a desired optical configuration on a surface of the optical element; (b) treating the abrasion resistant coating layer to prevent damage to the layer during subsequent steps; (c) applying a second coating layer to the abrasion resistant coating layer to substantially cover the abrasion resistant coating layer; (d) treating the second coating layer to provide at least weak adhesion of the second coating layer to the abrasion resistant coating layer and to prevent damage to the second layer during subsequent steps; (e) filling the mould with an organic liquid material; and (f) hardening the organic liquid material so as to form the optical element adhered to the second coating layer; wherein the second coating layer is an intermediate coating layer which co-reacts with the organic liquid material and with the abrasion resistant coating layer, thereby forming the coated optical element.