CN1124200C - 光学透镜的加压模制 - Google Patents
光学透镜的加压模制 Download PDFInfo
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Abstract
一种用于透镜的模制方法与系统,它使用了带有圆筒形屏障(201)的浮动容器(200,202)支撑的玻璃模具(204,206),此圆筒形屏障确定了一个用于置入预热后的透镜毛坯的模腔的边缘,另外透镜毛坯表面被加热,并在压力下铸造与冷却。
Description
背景技术
聚碳酸酯是一种用来制作眼部透镜的常用的材料。聚碳酸酯透镜常常通过流体树酯的喷射模制法或压力模制法来制得。传统的操作方法会使透镜留有残余应力的影响。
这些残余应力会影响透镜尺寸的稳定性,并导致其它的问题。例如,有过度应力的聚碳酸酯透镜会在贮存或佩带的过程中弯曲。这样的透镜的边缘会有不同的屈光力(焦强)。一种称为低温蠕变的现象,同样也会对透镜造成问题。
发明内容
本发明所要叙述的系统揭示了一种用于形成低应力的光学聚碳酸酯透镜的新的方法及装置。
此处所述的机器的与工艺过程,通过经控制压力及均匀的加热,同时模制这些透镜的凹面与凸面,从而形成眼部透镜。
一种较佳的方式是同时并以大致相同的压力加压顶部和底部。
另一种方式是用玻璃制的模具,目的是使模具的膨胀系数更接近于聚碳酸酯毛坯。细微颗粒状固体用挤压在模具上以加热或冷却模具。这样可以使受热及热量的扩散得以均匀。
附图说明
下面将对本发明及其实施例的这些和其他的方面结合附图加以详细说明,在附图中是:
图1为本发明系统所使用的工艺过程的总体概况的流程图;
图2为用于模制低应力的聚碳酸酯透镜的模制机器的示意图;
图3所为用于生产一般透镜的机器;以及
图4所为用于生产特定规格透镜的机器。
具体实施方式
本系统最好从一固体的聚碳酸酯树脂毛坯开始。这些毛坯是可以市场上购得的。操作流程如图1所示。在步骤110首先对树脂的毛坯进行预热。初始的预热使毛坯达到一个均匀一致的温度,此温度低于塑料的变形温度。在步骤112,通过将温度升高至塑料的玻璃转化点的温度以上,对聚碳酸酯的表面层进一步加以软化。在较佳的实施例中,预加热使毛坯的温度达到约270F,然后将温度升至305F补充加热。在此温度时,聚碳酸酯的内部温度与其外部温度是不同的。
然后,在步骤114将表面已软化的毛坯加热成形。此步骤是在将加热了的毛坯置于形成在两个玻璃模子之间的模子空腔99之中以及围绕空腔边缘有一圆筒形屏障。此外,这种结构的具体布局如图2所示,下面将结合图2对它作进一步详述。
热成型时将已加热的毛坯的外部表面与已预热的玻璃模具相接触。玻璃模具预加热的温度比毛坯外部表面的温度高。例如,此模具的温度可为390F。
在热成型以后,执行步骤116的应力校正(orientation)。此时压力增高,例如翻一倍,最好将压力增至1874.08kPa与2928.25kPa(272psi与425psi)之间。在此较高的压力下,使热成型后的透镜冷却,直至透镜达到相对稳定的温度,例如235F。然后将压力释放而得到透镜。
最好使用液化的固体热传导媒质来进行模具的加热及冷却,例如用一种非金属的经细微粉碎后的固体。这种导热媒质能够用来均匀地分布加在玻璃模具座及保持容器上的高达9301.5kPa(1350psi)的压力。这有助于避免在热成型的过程中流动的塑料所产生的下陷(undercut)。
在凹模与凸模之间的空间形成一模腔。透镜的厚度以及树脂的粘性流动率由大小可变的圆筒形屏障确定。
现对此作进一步的详述,形成初始产品的毛坯可以是,例如,由聚碳酸酯注塑而成的固体树脂毛坯。这些毛坯可以从市场上购得。典型的树脂毛坯为蝶片状,且具有两个相互之间基本平行的平坦表面。
毛坯的厚度应使其有足够树脂量来填满模腔,也不应太厚而造成树脂太多的浪费。并且,树脂的直径最好比最终形成的透镜小。例如,一直径为85mm的透镜可以由一直径75mm的树脂毛坯模制而成。
固体的毛坯在一常规的炉中预热,直至其温度低于此毛坯的变形温度。由于较佳的聚碳酸酯材料的变形温度为270F,所以预热的较佳温度为260F。在此毛坯被均匀加热后,便被转移至一温度更高的炉中,在其中,至少将毛坯一部分的温度加热至此塑料的玻璃化转变点温度以上。聚碳酸酯的玻璃化转变点温度为305F。在步骤112处,用于加热表面的适当的时间,如在370F时为7至9分钟。此时,毛坯并没有被完全加热。也就是说,毛坯表面比毛坯内部加热得更高些。
步骤114是热成型步骤。预热后的固体毛坯有一软化的表面。这个预热的毛坯被转移至此处所述的模腔中,其中玻璃模具的温度已被预加热至390F,略比补充加热的温度高。在转移过程中模具上的热量立刻被充分地切断。而模腔上的压力自其上部及下部同时增加。压力的增加使上部的压力与下部的压力基本上相匹配。较佳的是,使用浮动容器来平衡顶部与底部的负荷。
压力从最初的大约68.9kPa(10psi)逐渐开始增加,最终的压力接近689kPa(100psi)。在热成型的过程中,树脂在模腔中粘滞地流动。在透镜热成型完成以后,在步骤116处进行透镜应力校正。应力校正涉及增加压力,例如,在粘滞流动的末期将热成型压力增加一倍。一旦达到这个压力,冷却开始。较佳的用于应力校正的压力在1874.08kPa与2928.25kPa(272psi至425psi)之间。无论使用什么上限,在达到此上限后移开热源,将透镜冷却至它们的玻璃化转变点温度以下,此温度低于它们的变形温度。较佳的温度为235F。此时,完成的透镜从模腔中移开。热成型及应力校正两者混合的时间约需22至23分钟。
热成型最好使用玻璃模具进行。由于涉及过高的温度及压力,已有技术中的系统不使用玻璃模具。而本系统中由于温度和压力较低,因此可以应用玻璃模具。此外,它还有其它某些优点,包括使用此类玻璃模具可避免过度的收缩。发明人认为与已有技术的钢——聚碳酸酯系统相比,本发明的玻璃——聚碳酸酯系统热膨胀系数比较接近。
最好以液化的或细微粉碎后的固体媒质挤压玻璃模具。这也提供了一种改进的控制加热/冷却的技术。
另外一个重要的特点是,玻璃模具施加在树脂上的压力在整个冷却过程中是均匀的,持续的。在320F至235F的冷却过程中,这种特点使得应力松弛,及应力得到校正。
以此方式制造的聚碳酸酯透镜,它们具有良好的几何曲线及屈光力(焦强),优良的尺寸稳定性,低应力分布,以及出众的抗冲击强度。在以下的比较中,用本发明生产的透镜称为“校正应力的聚碳酸酯”:
测试项目 注塑的聚碳酸酯(1) 校正应力的聚碳酸酯(2)
几何曲线
球径计偏差 9至23×10-4 in 4至5×10-4in
屈光力(焦强)
焦度计读数 边缘屈光力(焦强)减弱 屈光力(焦强)一直至边缘不变
内部应力
偏振光图案 有明显的应力 应力最小化
抗冲击强度
表面硬度(4) 22~25 19~22
极端冲击力(5) 有裂缝撕裂扩展 表面变形
注:
(1)所用的是市售的聚碳酸酯眼部透镜,由Gentex及Orcolite生产。
(2)以本发明的过程生产的透镜具有优良的几何曲线,尺寸稳定性以及抗冲击强度,本发明的应力校正过程得到了这些证据的有力的支持。
计划以额外的分析测试来得到应力校正效果的证据。打算对注塑与应力校正的聚碳酸酯薄膜进行比较和评价其强度(拉伸,模量及耐撕扯性),圆形极化(偏振)红外以及激光/拉曼光谱以及X射线衍射图案。
(3)在室温下存贮一年以上时间有明显的变形。
(4)读数来自巴柏考尔门(Barber-Colman)表面痕迹检测器。
(5)以2磅钢锤连续冲击。
模制的眼部透镜其中心的一般典型值在1.5mm至5mm之间。然而,与这个典型的值不同,本发明的系统生产的聚碳酸酯眼部透镜,其厚度可薄0.4mm甚至更薄。本发明的系统可具有1.0mm边缘而几何曲线仍非常优良。然而,根据本发明,中心的厚度最好在1至4mm之间。
具有较高的屈光度的透镜可能需要相对于其中心较厚的边缘。此处所述的圆筒形屏障,确定了模腔范围。这些屈光度较高的透镜可能需要绝热以防止边缘热量的散失。
一个用来执行本发明上述过程的装置如图2所示。本系统用了两个浮动容器(floating canister)200,202。此浮动容器实际上是可以被单独控制的活塞。玻璃模具204由浮动容器200加以支撑,另一个玻璃模具206由另一个浮动容器202支撑,它们分别被支撑于浮动容器的末端。因此,玻璃模具204与206能够相向移动并相对施压。
圆筒形屏障210确定了下部容器202的模腔的边缘。此圆筒形屏障210靠在凸出部分212上,从而使模制的透镜保持在位置。
根据一最佳实施例,通过平台的活塞220与222分别加压于浮动凸模204以及凹模204上,且两者的压力相等。推进气缸,例如224,用于传递来自相关联的平台活塞220上的压力。
容器228的壁最好由不锈钢制成。类似地,推力气缸224最好包括不锈钢或其它传热部件。这些壁与气缸可以允许热通过传导物质传递。加压平板234,236最好为平坦的板材,并分别由压力P1与P2对称地驱动。
这些平板,例如234,压向一液化的热传导媒质240,以将这些媒质挤压在模具上。在一种最佳的方式中,热传导媒质为具有适当的热传导率以及可压缩的细微粉碎后的盐,金刚砂,或其它的非金属可自由流动的固体。
这些材料必需被保持在玻璃模204及加压平板234之间的空腔中。在压力平板234与壁228之间设置有一密封圈242,用以密封空腔边缘。
顶部的玻璃模204由一个固定支架244支持。下部的支架246用来保持下部的玻璃模在位。然而,当树脂处于粘滞流动状态时,树脂便可能被容纳在支架244,246下面。为了避免这种情况,需要将固体媒质240压在玻璃模204,206上。最好使用一弹簧来保持这种持续的压力。例如,为了提供一持续的压力,可以设置一个贝氏弹簧(Bellevue spring)250,以在加压板234上施加一持续压力,如9301.5kPa(1350psi)。通过在螺杆224上转动的板牙252并拧至能压向浮动容器的弹簧那一点,将弹簧设置在与螺杆224的一位置上。
圆筒形屏障210控制了粘滞流动率,从而也就控制了透镜的厚度。玻璃模204,206的外表面以及圆筒形屏障210的内表面确定了模腔99的大小。圆筒形屏障的横截面最好倾斜大约35度,以利于取出完成模制的透镜。
玻璃模204,206最好用回火的玻璃形成。这样可以改善模具对温度以及压力的抵抗力。
在操作过程中,固体的毛坯首先被预热,然后再补充加热,如上所述。将毛坯置于模腔99中,通过顶部与底部的平台活塞234,236施加基本相同的压力。施加于顶部的压力与施加于底部的压力大体相同。这些压力以相同的速率从相对方向施加。当透镜以这种方式热成型后,压力增加,温度下降。保持压力直至透镜充分地冷却能从模具上取出为止。
为了改进操作,较佳的系统使用以回火的玻璃制成的玻璃模具。虽然玻璃模具是较好的,但也可使用其它材料的模具。较好的模具材料应具有与被模制的材料相近的膨胀系数与收缩系数。另一种较佳的用于模具的材料是镍。镍由电解形成。如果液化后的固体媒质能够充分地与容器200,202保持接触进行热传递,以在金属与聚碳酸酯界面处的收缩控制的差异能够减至最小,也可选择使用其它的材料。由此,这样的系统可以防止所模制的透镜中的应力,哪怕使用金属模具也可以。金属模具的边缘最好被充分地拉紧,以排除粘滞流动树脂所产生的下陷。
另一实施例通过使眼部透镜棱镜化,可以形成一种特定规格的透镜,此处为Rx透镜。棱镜化是一种将透镜的光学中心移至一非中心的位置的技术。这里根据佩带者的需要而使用的。棱镜化后的透镜其光学中心不再在其几何中心上。对商业用的透镜确定适当的几何中心可通过使用一制成后的透镜毛坯完成。透镜毛坯的整体尺寸首先要允许其几何中心的定位可以满足特定的规格要求,然后将透镜切割及安装入一经选择的镜框中。然而,棱镜化要全部完成,还需通过磨光与抛光。
此实施例的较佳系统能够通过改变推进气缸的位置来实现额外的的棱镜化过程。图3与图4示出了在棱镜化时对推进气缸以及圆筒形屏障的操作。图3示出了具有和不具棱镜化的推进气缸,图4示出了具有和不具有棱镜化的圆筒形屏障。模制可以满足规格的透镜棱镜化的要求。一半的光学装置相对于另一半倾斜,由此,聚碳酸酯透镜的形成可以无需再对这些透镜进行磨光与抛光。
尽管,上面叙述了一些具体实施例,本领域的技术人员应认识到,从已揭示的实施例中可进行种种变化。
所有诸如此类的变化全部将被包含于下述权利要求书中。
Claims (14)
1.一种聚碳酸酯透镜的成型方法,包括:
取得一用于模制透镜的聚碳酸酯毛坯;
将聚碳酸酯毛坯预加热至一低于聚碳酸酯材料的变形点温度的特定的温度,并保续一段时间,有效地均匀加热聚碳酸酯材料;
仅将对聚碳酸酯材料外表面的温度升高至第二个较高的温度,但此温度低于聚碳酸酯材料的玻璃化转变点的温度,从而使聚碳酸酯材料表面软化;
将顶部与底部的模具预加热至第三个温度,此温度高于所述的第二个温度,以形成预热的模具;
在所述的预热的模具各自的第一表面之间加压已加热的聚碳酸酯毛坯,并且从底部加压的压力与从顶部加压的压力大致相同。
2.如权利要求1所述的一种方法,其特征在于,还包括使加热媒质相对每一个所述模具的第二表面偏置的弹簧,所述的第二表面与压在聚碳酸酯毛坯上的第一表面相对。
3.如权利要求2所述的一种方法,其特征在于,加热媒质为细微颗粒状的固体。
4.如权利要求3所述的一种方法,其特征在于,所述加压沿一直的轴线进行。
5.如权利要求3所述的一种方法,其特征在于,所述加压沿一弯曲的轴线进行。
6.如权利要求1所述的一种方法,其特征在于,还包括,在加压透镜后,使透镜在压力下冷却。
7.如权利要求1所述的一种方法,其特征在于,还包括,在加压透镜后,增加压力至1874.08kPa与2928.25kPa之间,使透镜在所述压力下冷却,并在透镜冷却后取出透镜。
8.如权利要求6所述的一种方法,其特征在于,所述的压力能有效地压缩透镜,且不会在透镜中产生应力。
9.如权利要求1所述的一种方法,其特征在于,所述的模具为玻璃模具。
10.一种模制聚碳酸酯透镜的装置,包括:
一第一玻璃模,它具有一凸的模制表面,及具有相对于所述凸的模制表面的第二表面;
一第二玻璃模,其具有一凹的模制表面,及具有避开所述凹的模制表面的第二表面;
与所述的第一与第二模具的第二表面相接触的细微颗粒状的加热媒质;
一将所述细微颗粒状的加热媒质加压至所述第二表面的弹簧元件;以及
一压力施加装置,用于向所述的第一与第二模具施加恒定的压力,用以在所述的凸面与所述的凹面间加压聚碳酸酯透镜。
11.如权利要利10所述的一种装置,其特征在于,还包括一模具支撑元件,位于在所述的模具周围的至少一个位置上,以将模具保持在位,以及还包括一装有弹簧的元件,以将加热材料压向所述模具以及将模具边缘压向所述的模具支撑元件。
12.如权利要求10所述的一种装置,其特征在于,所述的细微颗粒状的加热材料为细微粉碎的液化的固体。
13.如权利要求10所述的一种装置,其特征在于,还包括一在模制区域周围的圆筒形屏障。
14.一种聚碳酸酯透镜成型装置,包括:
一炉,其程序设定得首先加热一聚碳酸酯毛坯至低于聚碳酸酯材料变形点温度的第一温度,然后仅有效地升高加热聚碳酸酯材料外表面的温度,将外表面加热至第二个较高的温度,此温度在第一温度以上但低于聚碳酸酯材料的玻璃化转变点的温度;以及
一被加热增压的模具,被加热至比所述第二温度更高的第三温度,当所述聚碳酸酯材料的所述外表面被加热至所述第二温度后,以低于2928.25kPa的压力加压所述聚碳酸酯材料的表面。
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US09/257,231 US6162376A (en) | 1999-02-24 | 1999-02-24 | Compression molding of optical lenses |
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CN1345267A (zh) | 2002-04-17 |
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IL145042A0 (en) | 2002-06-30 |
IL145042A (en) | 2005-12-18 |
EP1178885A4 (en) | 2004-11-17 |
KR100533475B1 (ko) | 2005-12-06 |
BR0008518A (pt) | 2002-02-13 |
CA2364139C (en) | 2005-05-03 |
JP4116769B2 (ja) | 2008-07-09 |
EP1178885A1 (en) | 2002-02-13 |
KR20020011367A (ko) | 2002-02-08 |
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