JP2000061965A - Mold for ocular lens and molding apparatus for ocular lens using the same, and mold for lens blank and molding apparatus for lens blank using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain high safety, prevent damage, and reduce manufacturing costs by providing a notch in a particular portion of a male mold or a female mold. SOLUTION: A polymerizable monomer is charged into a space formed by the combination of a male mold 2 and a female mold 3 and polymerized to produce a polymer P. After the polymerization, the male mold 2 is removed. Pressure is then applied externally to the female 3 through a notch 4 and deformed, thereby producing a gap G between the polymer P and the female mold 3 to separate the polymer P from the female mold 3. The notch 4 is provided in at least one portion of the male mold 2 or the female mold 3. Molds 1 are formed by using a material having adequate elasticity such that the coupling portion 5 with the notch 4 and the peripheral portion are deformed. A high-safety ocular lens is thereby produced without a mold release agent, and further the damage occurring at the time of the mold release is prevented and the manufacturing cost is reduced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an ophthalmic lens molding die, an ophthalmic lens molding apparatus using the same, a lens blank molding die and a lens blank molding apparatus using the same. More specifically, the present invention relates to an ophthalmic lens mold for mold-polymerizing a polymerizable monomer to produce an ophthalmic lens, and an ophthalmic lens molding device using the same.

[0002]

2. Description of the Related Art Generally, an ophthalmic lens such as a contact lens and a lens blank for manufacturing an ophthalmic lens by a mold polymerization (a precursor of an ophthalmic lens such as a finished contact lens, which is called a button. In the case of obtaining a polymer), a mold is filled with a polymerizable monomer, the monomer is polymerized, and then the lens made of the obtained polymer is released.

However, since the polymer adheres to the mold during polymerization, it becomes difficult to release the polymer from the mold. Therefore, conventionally, as a method of releasing the polymer, a method of applying a release agent to the surface of the mold, a method of adding a release agent or an internal additive to the monomer mixture,
A method of applying an external force to the mold and a method depending on the material characteristics of the mold are used.

As a method of applying a release agent to the surface of a mold, for example, as described in JP-A-53-41359, a silicone resin is molded and processed, and then immersed in an organic solvent. A method for facilitating easy peeling is known. As the organic solvent, acetone, cyclohexane, ethyl acetate, trichloroethylene, methanol,
Ethanol, butanol, or a mixture thereof is used.

As another method, as described in Japanese Patent Application Laid-Open No. 9-183131, a pair of a plurality of mold pieces is formed before contacting the surface of the mold pieces with the reactive monomer mixed liquid. An effective amount of 0.0 on at least one of the optical surfaces
A method of applying a surfactant of 5 to 0.5% by weight is known.

As a method of adding a releasing agent or an internal additive to the monomer mixture, for example, JP-A-55-1 is used.
As described in Japanese Patent No. 23429, there is known a method in which a mold release agent is contained before polymerization of a monomer mixture solution, and then polymerization molding is performed. As the releasing agent, a releasing agent such as a silicone type, a phosphoric acid ester type or a phthalic acid ester type is used.

[0007] As another method, as described in JP-A-3-89314, a method in which a mold release agent is contained in a monomer mixed solution and then polymerized and molded in a mold cavity It has been known. As the release agent, a non-reactive hydrophilic polymer such as polyethylene glycol or a lipophilic compound such as oleic acid or linoleic acid is used.

Further, as still another method of the method, there are JP-A-8-318536 and JP-A-9-183.
As described in Japanese Patent No. 132, a method is known in which a mold material contains an internal additive and is polymerized and molded. As the internal additive, polyethylene, polypropylene wax, stearate, glycerol ester, amide wax, silicone or the like is used.

A method for applying an external force to the mold is shown in FIG. 11, for example, Japanese Patent Laid-Open No. 8-9937.
As described in Japanese Unexamined Patent Publication (Kokai) No. 0-52, a braking force is applied to one mold 51 to maintain it at a predetermined position, the other mold 52 is heated, and a temperature difference is provided between the pair of molds 51 and 52. Later,
Methods are known for performing gradual separation between molds. Specifically, the bending fingers 5 with respect to an axis extending in a direction perpendicular to the plane of the flange 51a of the back curved formwork 51.
The rotational axis rotation of 3 is basically intermittent or cyclically stops and progresses while changing the speed, and is only a few degrees in angle, and is gradually inclined with an inclination similar to the separating operation between the molds 51 and 52. It is sufficient to angle the flange 51a so as to provide a "wavefront" that travels in the upward direction to transmit the upward pulling motion. In effect, this allows the mold 5 to move from one end towards the opposite end as shown in FIG.
A stepwise controlled separation between 1, 52 can be provided, which facilitates the separation of the two mold parts.

As another method, the method shown in FIG.
As shown in, for example, Japanese Patent Application Laid-Open No. 8-174700, an annular peripheral flange 61 is provided around each of the front curve half mold 61 and the back curve half mold 62.
A method using a contact lens mold assembly separating device having a and 62a is known. According to this method, when releasing the pair of mold halves 61, 62, the lever finger 6 of the lever means 63 is provided between the annular peripheral flanges 61a, 62a.
3a and 63b are inserted, and the lever fingers 63a and 63b are pulled away from each other to remove the mold.

As a method based on the material characteristics of the mold, for example, a method using a mold made of fluorine-based glass is known, as described in Japanese Patent Laid-Open No. 61-106211. In this case, the adhesive force between the mold and the monomer is small, and the releasability is good.

As another method, for example, as described in Japanese Patent Application Laid-Open No. 7-195558, one of the molding surfaces of the two mold halves is placed on the outer region of the optically active area of the contact lens. A method is known in which pretreatment such as corona discharge is performed so that the contact lens adheres to the pretreated mold half when the mold is opened.

[0013]

However, the above method,
Then, since a releasing agent such as an organic solvent or a surfactant is mixed in the ophthalmic lens made of a polymer, and the releasing agent may be contained in the ophthalmic lens after molding, it may occur on the cornea. There is a problem in terms of safety when considering the use of an eye lens.

Further, the method has a problem that a large load is required when releasing the polymer from the mold. Further, due to the large load, the annular peripheral flange is broken and the ophthalmic lens made of the polymer is damaged, resulting in a poor yield rate.

On the other hand, in the method, there is a problem that the manufacturing cost of the ophthalmic lens becomes high when a mold made of an expensive material such as fluorine glass is used. In addition, there is a problem that the number of working steps is increased when pretreatment such as corona discharge is performed.

The present invention has been made to solve the above problems, and can provide a highly safe ophthalmic lens,
Provided are a mold for an ophthalmic lens capable of preventing breakage of an ophthalmic lens and further reducing the manufacturing cost, an ophthalmic lens molding device using the same, and a lens blank molding die and a lens blank molding device using the same. The purpose is to do.

[0017]

A mold for an ophthalmic lens of the present invention comprises a male mold and a female mold, and a polymerizable monomer is placed in a space formed when the male mold and the female mold are combined. A mold for an ophthalmic lens for filling to manufacture an ophthalmic lens, characterized in that a notch is provided in at least one position of the male mold or the female mold.

It is preferable that the notch has a substantially linear shape.

It is preferable that the notch has a substantially L shape.

It is preferable that the notch has a substantially T shape.

It is preferable that when the notch receives an external force, the connecting portion of the male mold and the female mold with respect to the notch and its peripheral portion are deformed.

It is preferable that when the notch receives an external force, a connecting portion of the male mold and the female mold with the notch and a peripheral portion thereof are damaged.

It is preferable that the notch is provided near a portion corresponding to the optical center of the ophthalmic lens to be manufactured or the outer diameter center of the lens blank.

An ophthalmic lens molding apparatus using the ophthalmic lens includes (a) the ophthalmic lens molding die, (b) a member for applying an external force to the notch of the ophthalmic lens molding die, and (c) the And a carrying section for carrying the eye lens forming die, which has a holding mechanism for holding a male die of the eye lens forming die.

Preferably, the retaining mechanism and the male end have complementary male and female structures so that they can engage one another.

The complementary male and female structure has a concave portion or a convex portion formed in a portion of the holding mechanism that contacts the male mold, and a convex portion or a convex portion formed in a portion of the holding mechanism that contacts the holding mechanism or It preferably comprises a recess.

The lens blank mold of the present invention is composed of a male mold and a female mold, and the space formed when the male mold and the female mold are combined is filled with a polymerizable monomer to prepare a precursor for an ophthalmic lens. A lens blank molding die for producing a lens blank that is a body, characterized in that a notch is provided in at least one position of the male mold or the female mold.

The lens blank molding apparatus of the present invention comprises:
(A) the lens blank mold, (b) a member for applying an external force to the notch of the lens blank mold, and (c)
And a carrying section for carrying the lens blank mold having a holding mechanism for holding the male mold of the lens blank mold.

[0029]

BEST MODE FOR CARRYING OUT THE INVENTION Next, with reference to the drawings, an eye lens molding die of the present invention, an eye lens molding apparatus using the same, a lens blank molding die, and a lens blank molding apparatus using the same will be described in detail. Explained. FIG. 1 is a process cross-sectional explanatory view showing a step of molding an ophthalmic lens using an ophthalmic lens molding die according to an embodiment of the present invention, FIG.
Is a process cross-sectional explanatory view showing a step of molding an ophthalmic lens using a molding die for an ophthalmic lens which is another embodiment of the present invention, and FIGS. 3 to 7 are females of the ophthalmic lens molding die of the present invention. 8 is an explanatory sectional view showing an example of a mold, FIG. 8 is an explanatory sectional view showing steps of an embodiment of the ophthalmic lens molding apparatus of the present invention, FIG. 9 is an enlarged sectional view of the holding mechanism of FIG. 8, and FIG. 10 is the present invention. FIG. 8 is a cross-sectional explanatory view showing another example of the male mold of the eye lens molding die.

A mold 1 for an ophthalmic lens (hereinafter referred to as a mold) 1 shown in FIG. 1 comprises a male mold 2 and a female mold 3,
A polymer P is obtained by filling a polymerizable monomer into a space formed when the male mold 2 and the female mold 3 are combined and polymerizing them.
To manufacture an ophthalmic lens consisting of. Further, a notch 4 is provided on the outer surface of the female die 3.

In the molding die 1, a material having an appropriate elasticity, for example, polypropylene, is formed so that the connecting portion 5 of the female die 3 with the notch 4 and its peripheral portion are deformed when the notch 4 receives an external force. , Polyacetal, polycarbonate, preferably polypropylene which is easily deformed by an external force is used.

As shown in FIG. 1, after polymer P is polymerized (step (a)), male mold 2 is removed (step (b)), and then pressure is applied from outside to female mold 3 via notch 4. By adding and deforming, a gap G is generated between the polymer P and the female mold 3, and the polymer P is separated from the female mold 3 (step (c)). Therefore, the polymer P can be released from the female mold 3 without mixing an additive such as a surfactant into the polymer P (step (d)).

In the step (b) of FIG. 1, the male mold 2
Can be separated from the polymer P by this principle using a metal member or the like. Further, in step (c) of FIG. 1, if a gap G is generated in the vicinity of the notch 4, the separation of the bonded portion between the polymer P and the female mold 3 proceeds in a chain manner starting from the gap G.

Further, the notch 4 may be used instead of deforming the female mold 3 to break it. Specifically, as shown in FIG. 2A, in the molding die 1, when the notch 4 receives an external force, the connecting portion 5 of the female die 3 with the notch 4 and its peripheral portion are damaged. A material with moderate brittleness, such as polypropylene, polyacetal, polycarbonate,
The root of the notch 4 is broken by receiving an external force.
Further, as shown in FIG. 5, even if the peripheral portion of the connecting portion 5 of the female die 3 is made thin, it is easily damaged.

As in FIG. 1, after polymerizing the polymer P and removing the male mold 2, as shown in FIG. 2A, a load is applied to the notch 4 to connect the connecting portion 5 and its peripheral portion. Is broken, a gap G is generated between the polymer P and the female mold 3, and the polymer P is separated from the female mold 3.
After that, as in the case of FIG. 1, the polymer P can be released from the female mold 3 without mixing an additive such as a surfactant into the polymer P (step (b) in FIG. 2). ). If the vicinity of the connecting portion 5 is damaged in the step (a) of FIG. 2, a larger external force is applied to the female die 3, so that many gaps G are generated. Then, the other bonded portions are separated as in the step (c) of FIG.

The notch 4 may have any shape as long as the notch portion is provided on the known eye lens and eye lens blank mold, and various shapes can be adopted. For example, as shown in FIG. 3, if the notch 4 has a substantially linear shape, a member 6 for applying an external force described later (FIG. 8C).
(Ref.) Has a merit that the gap G can be easily formed by lightly repelling the notch 4.

As shown in FIG. 4, if the notch 4 has a substantially L-shape, the member 6 catches the notch 4 so that the molding die receives a strong force to deform or damage it. Has the advantage that

Further, as shown in FIG. 6, the notch 4
Has a substantially T-shape, the member 6 hooks the notch 4 so that the molding die receives a strong force and can be deformed or damaged.

Further, as shown in FIG. 7, the notch 4
Has a substantially T shape, and the tip of the notch 4 is sharp, there is an advantage that when the member 6 hooks the notch 4, it is repelled at a predetermined position.

The notch 4 may be provided at a position outside the known ophthalmic lens such as a contact lens and the lens blank molding die (specifically, outside the female die 3). .

As shown in FIGS. 6 to 7, if the notch 4 is provided near the portion corresponding to the optical center of the ophthalmic lens or the outer diameter center of the lens blank, the notch 4 is installed. Polymer P when external force is applied to
Since the gap formed between the female mold 3 and the female mold 3 is uniform with respect to the polymer P, in other words, it can be made uniform and wide,
preferable.

The ophthalmic lens molding die configured as described above can also be applied to a lens blank molding die for producing a lens blank which is a precursor of an ophthalmic lens, and the same operational effect as described above. Can be played.

As shown in FIG. 8, an ophthalmic lens molding apparatus (hereinafter referred to as molding apparatus) using the molding die 1 is as follows.
A holding mechanism 7 for holding the molding die 1, a member 6 for applying an external force to the notch 4 of the molding die 1, and a male die 2 of the molding die 1.
And a carrying section 8 for carrying the molding die 1 provided with. Although not shown, the molding apparatus also includes a mechanism for filling the mold 1 with the polymerizable monomer and a mechanism for polymerizing the filled monomer, as in the conventional case.

The member 6 that applies an external force to the notch 4 is a member that can break the notch 4 by applying an external force to the notch 4. For example, a versatile synthetic resin such as polypropylene, polyolefin methacrylate, polyethylene, or brass. It is made of metal such as stainless steel or aluminum and ceramics, and is preferably made of metal in that the member 6 having a larger strength than the notch 4 is easily deformed or damaged.

The transport section 8 is made of brass, stainless steel, aluminum or the like. The holding mechanism 7 is provided in the lower portion of the transport unit 8 (inserted in the gap between the male die 2 and the female die 3 to hold the male die 2). 8 (b)-
(F) shows the main part of the transport unit 8 in order from the upstream side, and the transport unit 8 flows by being cured by the arrow in the figure.

When the polymer P (see FIG. 8A) inside the molding die 1 after polymerization is released from the mold using the molding apparatus configured as described above, first, as shown in FIG. 8B. As described above, the molding die 1 is fixed to the transport unit 8 by inserting the pair of holding mechanisms 7 below the transport unit 8 between the male mold 2 and the female mold 3. Then, as shown in FIG. 8C, the forming die 1 is conveyed by the conveying portion 8, and the notch 4 projecting upward from the fixing surface between the plurality of lines L flowing in parallel to the conveying portion 8 is formed. The notch 4 is provided by the member 6 that applies an external force.
Apply external force to and fold. At this time, as shown in FIG. 8D, the polymer P is released from the female mold 3 as in the case of FIG. The detached female mold 3 flows on the line L.
At this time, the polymer P is released from the female mold 3,
It is fixed to the male mold 2.

After that, as shown in FIG.
When reaching the end of the line L, the transport unit 8 transports the male mold 2 locked by the holding mechanism 7 horizontally, and at the same time, discards the female mold 3 in the dust box D. The line L flowing in parallel with the transport unit 8 may be one line instead of a plurality (two lines in FIG. 8). In this case, the member 6 is arranged at an appropriate position other than between the lines L.

Finally, as shown in FIG. 8 (f), the male die 2 is removed from the holding mechanism 7, and the flange 2a of the male die 2 is removed.
The polymer P can be easily released from the male mold 2 by bending the polymer P in a direction away from the polymer P.

If the holding mechanism 7 and the ends of the male die 2 of the molding die 1 have complementary male and female structures so that they can engage with each other, the male die 2 can be securely held by the holding mechanism 7. can do.

The complementary male and female structure is described in, for example, FIG.
As shown in FIG.
It is composed of a concave portion 9 formed in a portion that comes into contact with and a convex portion 10 formed in a portion where the male die 2 comes into contact with the holding mechanism 7. As an example opposite to FIG. 9, the concave portion 9 may be formed in the male mold 2 and the holding mechanism 7 may be provided with the convex portion 10. By providing the concave portion 9 and the convex portion 10, the male mold 2 can be reliably held by the holding mechanism 7.

In the eye lens molding apparatus configured as described above, a lens blank molding apparatus can be configured by replacing the eye lens molding die with a lens blank molding die. This lens blank molding device can also achieve the same effects as the above.

1 and 8 show a solid male mold 2 as an example, the present invention is not limited to this. As another male die, as shown in FIG. 10, a hollow male die 2 may be adopted.

In the above embodiments, the example in which the notch 4 is provided on the side of the female die 3 has been described, but the present invention is not limited to this, and the male die 2 or the female die 3 can be used. It is sufficient to provide the notch 4 at least at one place, and the notch 4 may be provided on the male mold 2 side.

[0054]

EFFECTS OF THE INVENTION According to the present invention, an ophthalmic lens made of a polymer can be released from the mold without using a releasing agent, so that an ophthalmic lens with high safety can be provided.

Moreover, since the ophthalmic lens can be released from the notch by applying a slight external force, it is possible to prevent the ocular lens from being damaged during the release. Moreover, it has excellent releasability as compared with the conventional one.

Further, since it is not necessary to make a mold with an expensive material such as fluorine glass, and pretreatment such as corona discharge is unnecessary, the manufacturing cost can be reduced.

[Brief description of drawings]

FIG. 1 is a process cross-sectional explanatory view showing a process of molding an ophthalmic lens using a mold for an ophthalmic lens which is an embodiment of the present invention.

FIG. 2 is a process cross-sectional explanatory view showing a process of molding an ophthalmic lens using an ophthalmic lens molding die which is another embodiment of the present invention.

FIG. 3 is a cross-sectional explanatory view showing an example of a female mold of the ophthalmic lens molding die of the present invention.

FIG. 4 is a cross-sectional explanatory view showing an example of a female mold of the ophthalmic lens molding die of the present invention.

FIG. 5 is a cross-sectional explanatory view showing an example of a female mold of the ophthalmic lens molding die of the present invention.

FIG. 6 is a cross-sectional explanatory view showing an example of a female mold of the ophthalmic lens molding die of the present invention.

FIG. 7 is a cross-sectional explanatory view showing an example of a female mold of the ophthalmic lens molding die of the present invention.

FIG. 8 is a process cross-sectional explanatory view showing an embodiment of the ophthalmic lens molding apparatus of the present invention.

9 is an enlarged cross-sectional view of the holding mechanism of FIG.

FIG. 10 is a cross-sectional explanatory view showing another example of the male mold of the ophthalmic lens molding die of the present invention.

FIG. 11 is a cross-sectional view showing an example of a conventional eye lens molding die.

FIG. 12 is a cross-sectional view showing another example of a conventional eye lens molding die.

[Explanation of symbols]

1 Mold 2 male 3 female 4 notches

Claims (12)

[Claims] 1. An ophthalmic lens for producing an ophthalmic lens comprising a male mold and a female mold, and filling a polymerizable monomer into a space formed when the male mold and the female mold are combined. A mold for an ophthalmic lens, wherein a notch is provided in at least one of the male mold and the female mold. 2. The mold for an ophthalmic lens according to claim 1, wherein the notch has a substantially linear shape. 3. The mold for an ophthalmic lens according to claim 1, wherein the notch has a substantially L shape. 4. The ophthalmic lens molding die according to claim 1, wherein the notch has a substantially T-shape. 5. The notch receives an external force,
The ophthalmic lens molding die according to claim 1, 2, 3 or 4, wherein a connecting portion of the male mold and the female mold with the notch and a peripheral portion thereof are deformed. 6. The notch receives an external force,
The ophthalmic lens mold according to claim 1, 2, 3 or 4, wherein a connecting portion of the male mold and the female mold with respect to the notch and a peripheral portion thereof are damaged. 7. The notch is provided near a portion corresponding to an optical center of an ophthalmic lens to be manufactured or an outer diameter center of a lens blank to be manufactured. Mold for eye lens of. 8. A method according to claim 1, 2, 3, 4, 5, 6 or 7.
An ophthalmic lens molding apparatus using the ophthalmic lens molding die according to claim 1, wherein: (a) the ophthalmic lens molding die, (b) a member that applies an external force to a notch of the ophthalmic lens molding die, )
An ophthalmic lens forming apparatus comprising: a conveying unit that conveys the ophthalmic lens forming die having a holding mechanism for holding a male die of the ophthalmic lens forming die. 9. The holding mechanism and the end of the male mold are
9. The ophthalmic lens molding device according to claim 8, which has complementary male and female structures so that they can be engaged with each other. 10. The complementary male and female structure has a concave portion or a convex portion formed at a portion of the holding mechanism that contacts the male mold, and a convex portion formed at a portion of the male mold that contacts the holding mechanism. The ophthalmic lens molding device according to claim 9, which comprises a part or a concave part. 11. A lens blank, which is a precursor of an ophthalmic lens, comprising a male mold and a female mold, and filling a polymerizable monomer into a space formed when the male mold and the female mold are combined with each other. A lens blank molding die for producing a lens blank molding die, wherein a notch is provided in at least one position of the male mold or the female mold. 12. A lens blank molding apparatus using the lens blank molding die according to claim 11, wherein a member for applying an external force to the notches of the lens blank molding die (a) and the lens blank molding die (b). And (c) a lens blank molding apparatus comprising: a carrying unit for carrying the lens blank molding die, which has a holding mechanism for holding the male mold of the lens blank molding die.