JP2006251017A - Hybrid lens and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a hybrid lens which has an improved adhesive force between a glass lens substrate and a resin layer and to provide a manufacturing method of the hybrid lens. <P>SOLUTION: The hybrid lens is provided with the glass lens substrate 2 and the resin layer 3 which is adhesively formed on either side surface of an incident surface and an outgoing surface, or on both side surfaces of the glass lens substrate 2. Further, the hybrid lens has an engagement part on which the glass lens substrate 2 and the resin layer 3 are engaged with each other and, on the engagement part, a resin composition which forms the resin layer 3 is integrally engaged and hardened with the glass lens substrate 2. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a hybrid lens in which a resin layer is formed on one side of a glass lens substrate and a method for manufacturing the same. Specifically, the present invention relates to a hybrid lens having improved adhesion between a glass lens substrate and a resin layer, and a method for manufacturing the hybrid lens.

  As a so-called hybrid lens in which a resin layer is formed on one surface of a glass lens substrate, a resin layer is formed on one surface of the glass lens substrate, and this resin layer is adjacent to one surface of the glass lens substrate. There has been proposed a composite optical member that is continuously formed on the other surface (the end surface of the glass lens base material) (see Patent Document 1).

Japanese Patent Laid-Open No. Sho 63-110410

  In the composite optical member described in Patent Document 1, since the resin layer covers the other surface (the end surface of the glass lens substrate) adjacent to one surface of the glass lens substrate, the resin layer accompanying the temperature change Although it can cope with the expansion / contraction force of the lens, it is a great obstacle to use the end surface of the glass lens base material in order to eliminate lens positioning or lens eccentricity.

  The objective of this invention is providing the hybrid lens which improved the adhesive force of a glass lens base material and a resin layer, and its manufacturing method, without coat | covering the end surface of a glass lens base material with a resin layer.

The hybrid lens of the present invention is a hybrid lens comprising a glass lens substrate and a resin layer formed in close contact with one or both of the entrance surface and the exit surface of the glass lens substrate. An engaging portion for engaging the glass lens substrate and the resin layer with each other is provided outside the optical effective diameter of the joint surface of the glass lens substrate with the resin layer. The resin composition forming the resin layer is integrally cured with the glass lens substrate.
According to the present invention, the glass lens substrate and the resin layer are integrally formed and joined by the engaging portions that engage with each other, that is, they are joined by physical means formed on each. Thus, the adhesion between the glass lens substrate and the resin layer can be improved. In addition, since the engaging portion is provided outside the optical effective diameter, the optical characteristics are not affected. The optical effective diameter described here represents the maximum optical diameter formed by the peripheral rays as shown in FIG. The present invention also includes a double-sided hybrid lens in which resin layers are formed on both the entrance surface and the exit surface of the glass lens substrate.

In the hybrid lens according to the aspect of the invention, the engaging portion may be a concave portion formed on one of the bonding surfaces of the glass base material and the resin layer, and the other of the glass lens base material and the resin layer. It is preferable that the projection is formed integrally with the joint surface and is fitted to the recess.
If comprised in this way, since a glass lens base material and a resin layer are comprised from a crevice and a convex part fitted to this, even if big external force acts in the joint surface direction of both, It is possible to prevent the two from shifting.

In the hybrid lens of the present invention, it is preferable that the convex portion and the concave portion are formed in an annular shape.
If configured in this way, even when the resin layer receives an external force due to an external factor such as a temperature change, the external force can be uniformly dispersed, so that it is possible to prevent a concentrated stress from being applied to a part, Durability can be improved.

In the hybrid lens according to the aspect of the invention, it is preferable that the concave portion is formed in a dovetail shape in which the maximum width dimension at the back of the opening is larger than the maximum width of the opening.
If comprised in this way, since the recessed part is formed in the dovetail shape where the largest dimension in an opening part back part is larger than the largest dimension in an opening part, fitting with a recessed part and a convex part is hard to remove | deviate. Therefore, in particular, the bonding force between the glass lens substrate and the resin layer can be further increased with respect to the external force in the direction intersecting the bonding surface.

The hybrid lens manufacturing method of the present invention includes a glass lens substrate and a hybrid provided with a resin layer formed in close contact with one or both of the incident surface and the exit surface of the glass lens substrate. A method for manufacturing a lens, the glass lens base material forming step for forming a glass lens base material having a recess outside the effective optical diameter of the joint surface with the resin layer, and the entrance surface and the exit surface of the glass lens base material The transfer mold is placed in a state where one or both surfaces of the transfer mold are opposed to each other, and a cavity is formed by winding an adhesive tape around the glass lens substrate and the entire side surface of the transfer mold, and the glass lens base And a resin layer molding step of forming a resin layer by injecting and curing a resin between a material and the transfer mold.
According to this hybrid lens manufacturing method, a hybrid lens can be obtained simply by forming a glass lens substrate having a recess and then laminating a resin layer on the surface of the glass lens substrate on which the recess is formed. it can. At this time, since the resin constituting the resin layer is cured in a state of entering the recess of the glass lens base material, that is, an anchor effect can be expected at this portion, the adhesion between the glass lens base material and the resin layer is expected. A hybrid lens with a high value can be easily manufactured.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
<Description of Hybrid Lens of First Embodiment>
FIG. 1 is a cross-sectional view showing the hybrid lens of this embodiment.
The hybrid lens 1 of the present embodiment includes a glass lens substrate 2 and a resin layer 3 formed on one of the incident surface and the exit surface of the glass lens substrate 2 (the exit surface in the present embodiment). It has.

The glass lens substrate 2 is a lens that is mirror-polished into a spherical surface on which the entrance surface 22 and the exit surface 21 are easily polished, and may be a convex lens or a concave lens. A glass lens substrate 2 shown in FIG. 1 shows a lens lens that is used as the most objective concave lens of a projection lens for a liquid crystal projector. The emission surface 21 is formed on the convex surface side of the glass lens substrate 2 and constitutes a bonding surface in contact with the resin layer 3. The entrance surface 22 is formed in a concave spherical shape and has a larger curvature than the exit surface 21. The material of the glass is determined in consideration of the refractive index and dispersibility.
A recess 23 is formed outside the optically effective diameter of the exit surface 21 of the glass lens substrate 2. Here, a concave portion 23 having a depth of 100 μm or less is formed in an annular shape on the exit surface 21 of the glass lens substrate 2, which is outside the optical effective diameter and is 100 μm or more inside the end surface of the glass lens substrate 2. Has been.
The recess 23 is formed in a dovetail shape having a maximum dimension at the back of the opening that is larger than the maximum dimension at the opening. In this embodiment, the width dimension is formed in a trapezoidal cross-sectional shape that gradually increases from the opening toward the back of the opening.

The resin layer 3 has a cemented surface 31 in contact with the emission surface 21 of the glass lens substrate 2 formed in a concave spherical surface, and a side surface 32 opposite to this surface formed in an aspherical shape. Outside the optically effective diameter of the joint surface 31, a convex portion 33 that fits into the concave portion 23 formed in the glass lens substrate 2 is formed in an annular shape.
The convex portion 33 is formed in a shape that fits into the concave portion. In this embodiment, it is formed in a trapezoidal cross section.

<Description of Manufacturing Method of Hybrid Lens of First Embodiment>
FIG. 2 is a process diagram showing a method for manufacturing a hybrid lens. The manufacturing method of the hybrid lens in this embodiment includes (a) a mold processing step, (b) a mold assembly step, (c) a monomer preparation step, (d) an injection step, (e) a curing step, and (f) separation. A mold process, and (g) an annealing process.
In addition, in the (a) mold processing step, a glass lens base material forming step for forming the glass lens base material 2 having the recesses 23 outside the optically effective diameter of the joint surface with the resin layer 3 is executed. Further, in (b) mold assembly process, (c) monomer preparation process, (d) injection process, and (e) curing process, the resin layer 3 is laminated and formed on the surface of the glass lens substrate 2 having the recesses 23. A layer forming process is performed.

(A) Mold Processing Process As shown in FIG. 3, the glass lens base 2 and the upper mold 5 necessary for molding the hybrid lens are selected and necessary pretreatment is performed.
As shown in FIG. 1, the glass lens substrate 2 is formed with a recess 23 having a width of about 20 μm and a depth of about 30 μm in an annular shape over the entire circumference outside the optically effective diameter of the emission surface 21 forming the resin layer 3. ing. For the purpose of washing the glass lens substrate 2 with the recesses 23 and improving the adhesion of the resin layer 3 to the emission surface 21, a liquid containing about 3 to 10% of a silane coupling agent is applied and heated and fired. To do. The silane coupling agent needs to be applied as uniformly as possible to the emission surface 21, and is preferably performed using a spin coating device using a spin coater, a dipping device with a controlled pulling speed, or the like. The silane coupling agent will be described later.
The upper mold 5 is made of glass and has a transfer surface 51 for transferring an aspherical shape and an outer surface 52 facing the transfer surface 51. The transfer surface 51 is mirror-polished and the outer surface 52 is formed into a flat surface.
The outer diameters of the glass lens base 2 and the upper mold 5 are substantially the same, and both have a circumferential side surface. It is preferable that the transfer surface 51 of the upper mold 5 is cleaned and a release agent is applied in advance. By applying a release agent to the transfer surface 51, the upper mold 5 can be easily detached from the resin layer 3 after molding.

(B) Mold Assembly Process As shown in FIG. 4, the glass lens substrate 2 is held horizontally with the emission surface 21 of the glass lens substrate 2 facing up, and the transfer surface 51 of the upper mold 5 that is a transfer mold is positioned below. Then, the glass lens substrate 2 is held opposite to the exit surface 21 of the glass lens substrate 2 with a predetermined distance. And the adhesive tape 6 is wound over the glass lens base material 2 and the side surface of the upper mold 5, and it is wound more than one round to form a region where the adhesive tape 6 overlaps. As a result, the cavity 7 surrounded by the emission surface 21, the transfer surface 51, and the adhesive tape 6 is formed, and the hybrid lens mold 8 can be assembled.
The adhesive tape 6 has a structure in which an adhesive layer is formed on a tape base material. The tape base material is polyolefin such as polyethylene and polypropylene, polyvinyl halide such as polyvinyl chloride and polyvinylidene chloride, polyester such as polyethylene terephthalate, polybutylene terephthalate and polyethylene naphthalate, polyamides, polyimides and polycarbonates. Etc. are used. As the pressure-sensitive adhesive, acrylic, rubber, silicone or the like is used. A pressure-sensitive adhesive that does not dissolve in the resin composition or inhibits polymerization is selected.
The width of the adhesive tape 6 is not limited as long as the gap between the glass lens base material 2 and the upper mold 5 can be sealed while these gaps can be sealed.
The glass lens substrate 2 and the upper mold 5 are arranged to face each other, and an adhesive tape 6 is adhered to these side surfaces to seal the gap between the glass lens substrate 2 and the upper mold 5, thereby hybrid lens mold 8. The method of sealing the adhesive tape can form a thick cavity more easily and simply than the method of holding the glass lens substrate 2 and the upper mold 5 using a conventional sleeve or mold.

（式中、Ｒ¹は水素またはメチル基、ｍは０〜４の整数、ｎは１〜１６の整数を表す。）
（Ｂ）１分子中に（メタ）アクリロイルオキシ基を２個以上有するウレタンポリ（メタ）アクリレートあるいはエポキシポリ（メタ）アクリレート
（Ｃ）一般式（II）で示されるモノ（メタ）アクリレート化合物

（式中、Ｒ²は水素またはメチル基、Ｒ³は炭素原子数が５〜１６の脂環式炭化水素基を表す。）
の中、少なくとも１種のラジカル重合性モノマー (C) Monomer preparation process The resin composition which comprises the resin layer 3 is prepared. As the resin composition, a resin composition in which a radical polymerizable monomer and a silane coupling agent are mixed at a specific ratio can be used.
The radical polymerizable monomer used in the present invention is characterized by being composed of the following polymerizable monomer mixtures (A) to (C).
(A) Di (meth) acrylate compound represented by the general formula (I)

(In the formula, R ¹ represents hydrogen or a methyl group, m represents an integer of 0 to 4, and n represents an integer of 1 to 16.)
(B) Urethane poly (meth) acrylate having two or more (meth) acryloyloxy groups in one molecule or epoxy poly (meth) acrylate (C) mono (meth) acrylate compound represented by general formula (II)

(Wherein R ² represents hydrogen or a methyl group, and R ³ represents an alicyclic hydrocarbon group having 5 to 16 carbon atoms.)
Among these, at least one radical polymerizable monomer

  Specific examples of the di (meth) acrylate compound represented by the general formula (I), which is the first component of the composition described above, include ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, and triethylene glycol di Di (meth) acrylate compounds of polyethylene glycol such as (meth) acrylate, tetraethylene glycol di (meth) acrylate, pentaethylene glycol di (meth) acrylate, and nonaethylene glycol di (meth) acrylate; propylene glycol di (meth) acrylate , Dipropylene glycol di (meth) acrylate, tripropylene glycol di (meth) acrylate, tetrapropylene glycol di (meth) acrylate, nonapropylene glycol di (meth) acrylate, etc. Polypropylene glycol di (meth) acrylate compound; butylene glycol di (meth) acrylate, dibutylene glycol di (meth) acrylate, tributylene glycol di (meth) acrylate, tetrabutylene glycol di (meth) acrylate, nonabutylene glycol di ( Di (meth) acrylate compounds of polybutylene glycol such as (meth) acrylate; 1,3-butylene glycol di (meth) acrylate, 1,6-hexamethylene glycol di (meth) acrylate, 1,14-tetradecamethylene glycol di Examples include (meth) acrylate, neopentyl glycol di (meth) acrylate, and di (meth) acrylate compounds of caprolactone adducts of neopentyl glycol hydroxypivalate.

  The urethane poly (meth) acrylate having two or more (meth) acryloyloxy groups in one molecule as the second component of the composition described above includes (meth) acrylate containing a hydroxyl group and two in the molecule. The urethanation reaction product with the isocyanate compound which has the above isocyanate group is mentioned. In addition, as an epoxy poly (meth) acrylate having two or more (meth) acryloyloxy groups in one molecule, an epoxy compound having two or more glycidyl groups in the molecule and (meth) acrylic acid or in the molecule Examples thereof include a glycidyl group ring-opening reaction product with a compound having a (meth) acryloyloxy group and a carboxyl group. This second component is a component that imparts heat resistance that is insufficient with only the di (meth) acrylate compound as the first component.

  Specific examples of the polyisocyanate compound having a polyisocyanate group having at least two isocyanate groups in the molecule include aliphatic, aromatic or alicyclic isocyanates such as tetramethylene diisocyanate, hexamethylene diisocyanate, 2,2, 4-trimethylenehexamethylene diisocyanate, cyclohexane diisocyanate, isophorone diisocyanate, tolylene diisocyanate, xylylene diisocyanate, 1,3-bis (α, α'-dimethylisocyanate methyl) benzene, diphenylmethane diisocyanate, m-phenylene diisocyanate, dicyclohexylmethane diisocyanate , Naphthalene diisocyanate, biphenyl diisocyanate and the like. From a compound having at least two isocyanate groups in the molecule obtained by the reaction of these isocyanates with a compound having at least two active hydrogen atoms such as amino group, hydroxyl group, carboxyl group, or a trimer of the diisocyanate compounds. Pentamers can also be used. Moreover, as an epoxy compound (epoxy compound having at least two glycidyl groups in the molecule) used for the above-described ring-opening reaction, 1,6-hexanediol diglycidyl ether, ethylene glycol diglycidyl ether, diethylene glycol diglycidyl ether, Triethylene glycol diglycidyl ether, tetraethylene glycol diglycidyl ether, nonaethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, dipropylene glycol diglycidyl ether, triethylene glycol diglycidyl ether, tetraethylene glycol diglycidyl ether, nonapropylene Glycol diglycidyl ether, neopentyl glycol diglycidyl ether, neopentyl glycol Roxypivalate ester diglycidyl ether, trimethylolpropane diglycidyl ether, trimethylolpropane triglycidyl ether, glycerol diglycidyl ether, glycerol triglycidyl ether, diglycerol triglycidyl ether, pentaerythritol diglycidyl ether, pentaerythritol tetraglycidyl ether, Dipentaerythritol pentaglycidyl ether, dipentaerythritol hexaglycidyl ether, sorbitol tetraglycidyl ether, diglycidyl ether of tris (2-hydroxyethyl) isocyanurate, diglycidyl ether of tris (2-hydroxyethyl) isocyanurate, tris (2 -Hydroxyethyl) isocyanurate trigly Aliphatic epoxy compounds such as fatty acid epoxy compounds such as diether, diglycidyl ether of isophoronediol, diglycidyl ether of 1,4-bis (hydroxymethyl) cyclohexane, diglycidyl ether of bis-2,2-hydroxycyclohexylpropane Resorcin diglycidyl ether, bisphenol A, bisphenol F, bisphenol A diglycidyl ether obtained by condensation of bisphenol S and epichlorohydrin, bisphenol F diglycidyl ether, bisphenol S diglycidyl ether, tetrabromobisphenol A diglycidyl ether, bis ( 3,5-dimethyl-4-hydroxyphenyl) sulfone, bis (3-methyl-4-hydroxyphenyl) sulfone, bis (3-phenyl-4-) Hydroxyphenyl) and epichlorohydrin condensates, 2,6-xylenol dimer and epichlorohydrin condensates, orthophthalic acid diglycidyl ester, phenol novolac polyglycidyl ether, cresol novolac polyglycidyl ether, and the like.

Examples of the compound to be reacted with these epoxy compounds include acrylic acid and methacrylic acid, and carboxyl group-containing (meth) acrylate obtained by reacting hydroxyethyl (meth) acrylate with acid anhydrides such as o-phthalic anhydride. And carboxyl group-containing (meth) acrylate obtained by reacting a compound having two or more carboxyl groups in the molecule such as glycidyl (meth) acrylate and adipic acid.
The reaction between the epoxy compound and the carboxyl group-containing (meth) acrylate is performed, for example, by mixing the two and adding a tertiary amino compound such as dimethylaminoethyl methacrylate or a quaternary amine salt such as benzyltrimethylammonium chloride as a catalyst. It is carried out by heating to ~ 110 ° C.

  In the present invention, urethane poly (meth) acrylate or epoxy poly (meth) acrylate can be used singly or in combination of two or more, but the colorless and transparent of the hybrid lens obtained by curing, heat resistance From the viewpoint of properties, isophorone diisocyanate, 2,2,4-trimethylhexamethylene diisocyanate, dicyclohexylmethane diisocyanate, xylylene diisocyanate, 1,3-bis (α, α'-dimethylisocyanate methyl) benzene, tolylene diisocyanate or naphthalene diisocyanate And urethane poly (meth) acrylate, which is an adduct of 2-hydroxypropyl (meth) acrylate, 1,6-hexanediol diglycidyl ether, diethylene glycol diglycidyl ester Ether, trimethylolpropane diglycidyl ether, trimethylolpropane triglycidyl ether, glycerol triglycidyl ether, triglycidyl tris (2-hydroxyethyl) isocyanurate, 2,2-bis (4-glycidyloxycyclohexyl) propane, bisphenol A It is particularly preferable to use epoxy poly (meth) acrylate, which is a reaction product of diglycidyl ether, bisphenol S diglycidyl ether or tetrabromobisphenol A diglycidyl ether and acrylic acid or methacrylic acid.

The mono (meth) acrylate compound represented by the general formula (II), which is the third component of the composition described above, improves the surface accuracy during lens molding that cannot be obtained by using only the first component and the second component. It is a component that exerts an effect.
Specific examples of mono (meth) acrylate compounds include cyclopentyl (meth) acrylate, cyclohexyl (meth) acrylate, trimethylcyclohexyl (meth) acrylate, norbornyl (meth) acrylate, isobornyl (meth) acrylate, adamantyl (meth) acrylate, di cyclopentenyl (meth) acrylate, tricyclo (5,2,1,0 ^2,6) decane-8-yl (meth) acrylate are particularly preferred.

The silane coupling agent that is a resin composition used in the present invention is a component that imparts adhesion between the glass lens substrate and the resin layer.
Examples of the silane coupling agent in the present invention include vinyltrichlorosilane, vinyltriethoxysilane, vinyltris (β-methoxyethoxy) silane, γ-gridoxypropyltrimethoxysilane, γ-methacryloxypropyltrimethoxysilane, N-β ( Aminoethyl) γ-aminopropyltrimethoxysilane, N-β (aminoethyl) γ-aminopropyldimethoxysilane, γ-chloropropyltrimethoxysilane, γ-mercaptopropyltrimethoxysilane, γ-aminopropyltriethoxysilane, etc. Although used, other silane coupling agents may be used depending on the nature of the organic polymer that is the resin layer to be bonded to the glass substrate.

  The optimal content of the components (A) to (C) in the hybrid lens resin composition of the present invention is (A) 30 to 90 parts by weight, (B) 5 to 50 parts by weight, and (C) 5 to 40 parts by weight. Furthermore, it is 0.05-10 weight part of silane coupling agents. If the component (A) is less than 30 parts by weight, sufficient impact resistance cannot be obtained for the lens, heat resistance corresponding to environmental temperature changes is insufficient, and water absorption cannot be suppressed. On the other hand, when it exceeds 90 parts by weight, the decrease in surface hardness is extremely undesirable. Preferably 50-80 weight part is good. Further, when the component (B) is less than 5 parts by weight, sufficient heat resistance cannot be imparted, and when it exceeds 50 parts by weight, the viscosity of the composition becomes high and workability by casting is deteriorated. The amount is preferably 10 to 30 parts by weight. Further, when the component (C) is less than 5 parts by weight, sufficient surface accuracy cannot be obtained, and when it exceeds 40 parts by weight, the heat resistance of the lens is undesirably lowered. The amount is preferably 10 to 30 parts by weight. The silane coupling agent is a component that adheres the base glass and the resin layer during curing molding. If the content of the silane coupling agent is more than 10 parts by weight, there is a possibility of gelation in the resin composition, and there is a risk that the pot life of the resin composition will be reduced. There is also concern about the deterioration of workability. Preferably, 3 to 5 parts by weight is good.

The resin composition for a hybrid lens of the present invention may be blended with additives such as an antioxidant, an anti-yellowing agent, an ultraviolet absorber, a dye, and a pigment as long as necessary without impairing the effects of the present invention. good.
Examples of the polymerization initiator used for curing the resin composition for a hybrid lens of the present invention include (a) 2-hydroxy-2-methyl-1-phenylpropan-1-one, methylphenylglyoxylate, 2 , 4,6-trimethylbenzoyldiphenylphosphine oxide and the like, (b) organic peroxidation such as benzoyl peroxide, t-butylperoxyisobutyrate, t-butylperoxy-2-ethylhexanoate Products, (c) azo compounds such as 2,2′-azobis (isobutyronitrile), 2,2′-azobis (2,4-dimethylvaleronitrile), and the like. Among these polymerization initiators, it is more preferable to use a photopolymerization initiator because the curing speed is high and room temperature curing is possible. These polymerization initiators may be used in one or a mixture of two or more, and a co-catalyst and a sensitizer may be added to improve the curing rate. The blending ratio of the polymerization initiator is usually 0.005 to 5 parts by weight with respect to 100 parts by weight of the total monomer components.
The resin composition for a hybrid lens of the present invention can be produced by mixing and stirring a radical polymerizable monomer component and a silane coupling agent by a conventional method, and further adding various additives as necessary.

(D) Injection step As shown in FIG. 5, the overlapping part of the adhesive tapes 6 is peeled off to form a small opening to the cavity 7 and from this opening through a thin injection tube 9 such as an injection needle. The ultraviolet curable resin composition previously adjusted in the monomer preparation step is injected into the cavity 7, and the peeled adhesive tape 6 is attached again to seal the cavity 7.

(E) Curing Step As shown in FIG. 6, the ultraviolet curable resin composition in the cavity 7 is irradiated with ultraviolet rays from both sides through a double-sided mold (glass lens substrate 2 and upper mold 5). An ultraviolet irradiation source such as a high-pressure mercury lamp or a metal halide lamp is disposed on both sides of the mold (glass lens substrate 2 and upper mold 5), or a glass upper mold 5 and a glass lens substrate 2 using a reflecting mirror. The ultraviolet curable resin composition in the internal cavity 7 is irradiated with ultraviolet rays through both of the above, and the ultraviolet curable resin composition is almost completely cured.
The irradiation time of ultraviolet rays may be 50 to 300 seconds, the environmental temperature may be room temperature, or may be performed in a heated atmosphere up to 120 ° C. The irradiation intensity of ultraviolet rays is about 50 to 150 mW on one side, and when irradiating from both sides, the irradiation intensity is preferably substantially equal. The irradiation amount of ultraviolet rays is not particularly limited, but is about 1 to 500 J / cm ² .

(F) Mold release step As shown in FIG. 7, after curing and molding are sufficiently performed, a force is applied so that a wedge is accurately driven between the upper mold 5 and the resin layer 3, and the resin layer 3 and The upper die 5 that is joined is detached. In this mold release process, if the warming is applied locally, for example, by applying hot air to the upper layer 5 and the surface layer of the resin layer 3, the force applied to the wedge can be reduced.

(G) Annealing step This step is intended to reduce polymerization strain. Heat treatment for about 30 minutes to 2 hours in a temperature atmosphere slightly lower than the glass transition point of the cured product (resin layer 3) of the ultraviolet curable resin composition, preferably in a temperature atmosphere lower by 2 to 3 ° C than the glass transition point. The polymerization strain can be reduced by carrying out the process.

In the method for producing a hybrid lens described in the present invention, the glass lens substrate 2 is applied to the resin composition 9 after the silane coupling agent is applied to the bonding surface of the glass lens substrate 2 to the resin layer 3 in advance. It is characterized by strengthening the bonding between the glass lens substrate 2 and the resin layer 3 at the same time as curing the resin by mixing a silane coupling agent which is a component for imparting adhesion between the resin layer 3 and the resin layer 3. . As described above, it is possible to increase the adhesive strength with the glass lens substrate 2 by increasing the content of the silane coupling agent in the resin composition. Defects such as a drop in mold release become large, and practicality at the time of mass production is low in practice.
A silane coupling agent is applied to the surface of the glass lens substrate 2, and further, Si—O groups are firmly bonded onto the surface of the glass lens substrate 2 by heating and baking at 100 ° C. to 120 ° C. The silane coupling agent has at least two different functional groups having different reactivity in one molecule.
The alkoxysilyl group (Si—OR) of the silane coupling agent is hydrolyzed by water or moisture to form a silanol group, and this silanol group and the inorganic surface form a Si—O—Si bond by a condensation reaction. On the other hand, the reactive group X- is bonded or compatibilized with an organic group to form a strong bond with the resin layer. The required coating amount of the silane coupling agent to be applied to the surface of the glass lens substrate 2 can be obtained by the following formula, but it should be adjusted and used in consideration of the type and concentration of the dilution solvent, the coating method, and the like. preferable.
Silane coupling agent treatment amount (g)
= Surface area (m ² ) of adhesive surface with resin layer of base glass / Minimum coverage area of silane coupling agent (m ² / g)

The hybrid lens made based on the manufacturing method described in the present invention is used as, for example, a lens, a prism, a diffraction grating, and the like, but when applied as an aspheric lens, an excellent effect can be obtained. That is, since higher aberration correction capability can be obtained as compared with the conventional hybrid lens, the number of lenses can be further reduced, and a small and light optical system can be realized.
Furthermore, the optical lens element having the above-described hybrid lens as a constituent element can exhibit the most excellent effect when applied as an aspheric lens for a projector, but in addition, a still camera, a video camera, The present invention can also be applied to optical components such as those interchangeable lenses, spectacle lenses, telescopes, binoculars, microscopes, optical disk / magneto-optical disk reading pickup lenses.

The resin layer of the hybrid lens of the present invention can be formed by a molding die whose molding surface is an inverted shape of the above resin shape.
As a material of the mold of the present invention, a general mold material can be used, but in particular, a lens having a thick resin layer or a lens having a large difference in resin layer thickness (so-called strong uneven thickness) is molded. In order to prevent optical distortion, it is necessary to use a glass mold obtained by grinding optical glass such as S-3 (manufactured by Shot Co., Ltd.) or BK7 and irradiate ultraviolet rays from both the upper and lower surfaces of the resin layer. Also preferred.

<Description of Hybrid Lenses of Second to Fourth Embodiments>
8-10 is sectional drawing which shows the hybrid lens of 2nd-4th embodiment.
The hybrid lenses of the second to fourth embodiments are different from the hybrid lens 1 of the first embodiment in the shapes of the recesses 23 and the projections 33.
As shown in FIG. 8, the recess 23A of the second embodiment is formed such that, of the recess inner walls, the outer inner wall is formed in parallel with the end surface of the glass lens substrate 2, and the inner inner wall gradually inclines away from the outer inner wall. The cross section is formed in a right triangle shape.
As shown in FIG. 9, the concave portion 23 </ b> B of the third embodiment bends in a direction in which the concave inner walls (outer inner wall and inner inner wall) gradually move away from the opening toward the inner portion, and then gradually curves closer to each other. The cross section is formed in a circular shape.
As shown in FIG. 10, the recess 23C of the fourth embodiment is formed such that the inner walls of the recess (outer inner wall and inner inner wall) are parallel to the end surface of the glass lens substrate 2 and parallel to each other from the opening to the back. The cross section is formed in a rectangular groove shape.
In addition, convex part 33A-33C of 2nd-4th embodiment is formed in the shape fitted to recessed part 23A-23C.
The effects described in the first embodiment can be expected also by these shapes.

Moreover, in the above 1st-4th embodiment, although the recessed parts 23 and 23A-23C were formed in the glass lens base material 2 side, and the convex parts 33 and 33A-33C were formed in the resin layer 3 side, these are reverse. But you can. That is, the convex portions 33 and 33A to 33C may be formed on the glass lens substrate 2 side, and the concave portions 23 and 23A to 23C may be formed on the resin layer 3 side.
The positions where the concave portions 23, 23 </ b> A to 23 </ b> C and the convex portions 33, 33 </ b> A to 33 </ b> C are formed may be any as long as they are 100 μm or more inside from the end surface of the glass lens substrate 2, but close to the end surface of the glass lens substrate 2. If it is too large, the end face may be damaged.
Moreover, if the depth of the recessed parts 23 and 23A-23C is also 100 micrometers or less, the depth dimension according to the width | variety of the recessed parts 23 and 23A-23C can be selected.

EXAMPLES Hereinafter, although an Example demonstrates this invention, this invention is not limited to these Examples.
In the following examples, the resin layer was irradiated with light (ultraviolet rays) from both the glass lens substrate side and the mold side, and a transparent glass mold made of optical glass was used as the mold. However, the present invention is not limited to this, and for example, a metal mold may be used as a mold and irradiation may be performed only from the transparent glass lens substrate 2 side.
The present invention can also be applied to a double-sided hybrid lens in which resin layers are formed on both the entrance surface and the exit surface of a glass lens substrate, and a resin layer is formed on both surfaces of the lens substrate using a mold. And a method of manufacturing a double-sided hybrid lens. Further, in the present invention, a hybrid lens may be formed by fitting a concave portion of a glass lens substrate prepared in advance and a convex portion of a resin layer.
The abbreviations of the monomers are as follows.
9BGDM: Nonabutylene glycol dimethacrylate 12BGDM: Dodecabutylene glycol dimethacrylate 9EGDM: Nonaethylene glycol dimethacrylate UDM1: Urethane dimethacrylate obtained by reacting isophorone diisocyanate and 2-hydroxypropyl methacrylate UDA2: Tolylene diisocyanate It is reacted with 2-hydroxyethyl acrylate urethane diacrylate obtained EDM1: bisphenol a diglycidyl ether and epoxy dimethacrylate obtained by reacting a methacrylic acid TCDM: tricyclo (5,2,1,0 ^2,6) decane -8-yl methacrylate CHM: cyclohexyl methacrylate MTS: γ-methacryloxypropyltrimethoxysilane MDS: γ Methacryloxypropyl methyl dimethoxy silane

<Example 1>
9 BGDM (Mitsubishi Rayon Co., Ltd .: trade name Icure M-70) 65 parts by weight, UDA2 (Mitsubishi Rayon Co., Ltd .: trade name Diabeam U-12) 10 parts by weight, TCDM (Hitachi Chemical Industry Co., Ltd.) : Product name FA-513MS) 22 parts by weight, MTS (manufactured by GE Toshiba Silicone Co., Ltd .: trade name Organosilane TSL-8730) 5 parts by weight, bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide ( Ciba Specialty Chemicals Co., Ltd .: trade name IRGACURE 819) 500 ppm, t-butyl peroxyisobutyrate (Nippon Yushi Co., Ltd .: trade name Perbutyl IB) 1200 ppm were mixed and stirred well at room temperature. And deaerated for 15 minutes under reduced pressure to 40 mmHg.

  On the other hand, a mirror-finished glass lens substrate having an outer diameter of 100 mm (optical effective diameter of 96 mm) and a curvature of 120 mm is placed on a grinding machine, and is ground using a grinding wheel over the entire circumference of the lens at a radius of 49 mm from the lens center. A recess having a diameter of 20 μm and a depth of 20 μm was ground. Further, a trace amount of hydrofluoric acid was dropped along the recess and left for 3 minutes. Thereafter, a large amount of running water was washed to wash away hydrofluoric acid. The shape of the recess formed in this way was observed to be 30 μm wide and 40 μm deep and slightly wider as it goes deeper from the opening. Next, a 5% MTS alcohol solution was applied to the adhesive surface with the resin layer, and then placed in an oven at 125 ° C. and baked for about 20 minutes to perform the base processing.

A glass lens base material having the above-described composition as a base, and a glass upper die having an outer diameter of 100 mm, which is mirror-finished into an aspherical shape and has a release agent applied to the transfer surface, with a center thickness of 0.5 mm The mixture was poured into a hybrid lens mold that was combined so that the maximum resin layer thickness was 5 mm.
Next, ultraviolet rays were irradiated from both sides of the mold for 200 seconds using a UV irradiation device having an irradiation intensity of 100 mW. A hybrid lens in which a resin layer having a predetermined shape was in close contact with the glass lens substrate was obtained. Similarly, a resin composition prepared in the same manner as the resin composition shown above is molded into a disk-shaped flat plate having a thickness of 2 mm and an outer diameter of 80 mm, cut into a size necessary for measurement, and used as a test piece, and subjected to thermal analysis. The glass transition temperature (Tg) of the resin measured with an apparatus system TMA-60 (manufactured by Shimadzu Corporation) was 84.6 ° C.
Next, ultraviolet rays were irradiated from both sides of the mold for 200 seconds using a UV irradiation device having an irradiation intensity of 100 mW. Thereafter, the upper die of the aspherical shape was released and annealed by heating at 135 ° C. for 1 hour. The lenses thus produced were evaluated by the following evaluation methods and are shown in Table 1.

Injection workability: The degree of difficulty when injecting the monomer mixture into the mold was determined.
・: Easy to inject.
Δ: Slightly difficult to inject.
X: Difficult to inject.
Transferability: The transferability of the lens surface from which the mold was released was visually determined.
○: Transferability is good.
Δ: Some problem in transferability.
X: Transferability is poor.
Appearance: The resin layer and the antireflection film were visually observed for cracks, corrosion, bubbles, peeling, and significant color change.
Solvent resistance: The surface of the antireflection film was rubbed 10 times with a lens cleaning paper (Ozu Paper Industry Co., Ltd., trade name: Dasper) soaked with an alcohol-based organic solvent, and the appearance was visually observed. Those with no change were considered good.
Surface accuracy: The surface shape of the optical lens was measured using a 3D shape measuring machine UA3P manufactured by Matsushita Electric Industrial Co., Ltd. A sample having a shape accuracy of 3 μm or less was evaluated as ◯, a sample having a shape accuracy of more than 3 μm and less than 10 μm was evaluated as Δ, and a sample having a shape accuracy of 10 μm or more as x.
-Preparation of test piece: A resin composition prepared in the same manner as the resin composition shown in the examples was molded into a disk-shaped flat plate having a thickness of 2 mm or 5 mm and an outer diameter of 80 mm, cut into a size required for measurement, and tested. It was a piece.
-Refractive index measurement: The refractive index at 25 degreeC of the test piece created above was measured using the Abbe refractometer.

・ Temperature cycle test: The lens obtained by curing and molding is placed in a small environmental testing machine (SH-220 type manufactured by Tabai Espec Co., Ltd.), left at a low temperature of −30 ° C. for 2 hours and then at a high temperature of 80 ° C. The operation of leaving for 2 hours is taken as 1 cycle and repeated 10 cycles. After the endurance test, the following items were evaluated. The evaluation results are shown in Table 1.
(I) Appearance: It was visually observed whether cracks, corrosion, bubbles, peeling, and significant color changes were observed in the resin layer and the antireflection film. Those with no change were considered good.
(Ii) Solvent resistance: The surface of the antireflection film was rubbed 10 times with a lens cleaning paper (Ozu Paper Industry Co., Ltd., trade name: Dasper) soaked with an alcohol-based organic solvent, and the appearance was visually observed. Those with no change were considered good.
(Iii) Adhesion: The operation of adhering an adhesive tape (manufactured by Nichiban Co., Ltd .: trade name Cello Tape CT-12) to the surface of the antireflection film and peeling it was repeated three times, and the appearance was visually observed. Those with no change were considered good.

High-temperature and high-humidity storage test: A lens obtained by curing and molding is placed in a constant temperature and humidity chamber (PGL-2SM type manufactured by Tabai Espec Co., Ltd.) and left in a constant temperature and humidity environment of 60 ° C. and 90% for 7 days. . After the endurance test, the following items were evaluated, and the evaluation results are shown in Table 1.
(I) Appearance: It was visually observed whether cracks, corrosion, bubbles, peeling, and significant color change were observed in the resin layer and the antireflection film. Those with no change were considered good.
(Ii) Adhesiveness: The operation of adhering an adhesive tape (manufactured by Nichiban Co., Ltd .: trade name Cellotape CT-12) to the surface of the antireflection film and peeling it was repeated three times, and the appearance was visually observed. Those with no change were considered good.

<Comparative Example 1>
A lens was manufactured and evaluated in the same manner as in Example 1 except that a glass lens base material without forming a recess was used. The results are shown in Table 1.
<Contrast between Example 1 and Comparative Example 1>
In the appearance and adhesion of the high-temperature and high-humidity storage test, both results were good in Example 1 and bad in Comparative Example 1, and it can be seen that Example 1 is superior.

  The present invention is used as an optical component such as a still camera, a video camera, an interchangeable lens thereof, a spectacle lens, a telescope, a binocular, a microscope, and an optical disk / magneto-optical disk reading pickup lens in addition to a projection lens for a liquid crystal projector. Can do.

1 is a cross-sectional view showing a hybrid lens according to a first embodiment of the present invention. The flowchart which shows the manufacturing process of the hybrid lens of embodiment same as the above. The figure which shows the process of the shaping | molding die of embodiment same as the above. The figure which shows the type | mold assembly process of embodiment same as the above. The figure which shows the injection | pouring process of embodiment same as the above. The figure which shows the hardening process of embodiment same as the above. The figure which shows the mold release process of embodiment same as the above. Sectional drawing which shows the hybrid lens concerning 2nd Embodiment of this invention. Sectional drawing which shows the hybrid lens concerning 3rd Embodiment of this invention. Sectional drawing which shows the hybrid lens concerning 4th Embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Hybrid lens, 2 ... Glass lens base material, 3 ... Resin layer, 21 ... Output surface (joining surface), 23, 23A-23C ... Concave part, 31 ... Joining surface, 33, 33A-33C ... Convex part.

Claims (5)

A hybrid lens comprising a glass lens substrate and a resin layer formed in close contact with either one or both of the incident surface and the exit surface of the glass lens substrate,
Outside the optical effective diameter of the joint surface of the glass lens base material with the resin layer, the glass lens base material and the resin layer have an engaging portion that engages with each other,
The hybrid lens, wherein the resin composition forming the resin layer is engaged and cured integrally with the glass lens substrate in the engagement portion. The hybrid lens according to claim 1,
The engaging portion is integrally formed on a concave portion formed on one of the bonding surfaces of the glass base material and the resin layer and on the other bonding surface of the glass lens base material and the resin layer. And a convex portion that fits into the concave portion. The hybrid lens according to claim 2,
The hybrid lens, wherein the convex part and the concave part are formed in an annular shape. In the hybrid lens according to claim 2 or 3,
The hybrid lens according to claim 1, wherein the concave portion is formed in a dovetail shape having a maximum width dimension at the back of the opening that is larger than a maximum width of the opening. A method of manufacturing a hybrid lens comprising a glass lens substrate and a resin layer formed in close contact with either one or both of the entrance surface and the exit surface of the glass lens substrate,
A glass lens substrate forming step of forming a glass lens substrate having a recess outside the optically effective diameter of the bonding surface with the resin layer;
The transfer mold is placed in a state where the transfer mold faces one or both of the entrance surface and the exit surface of the glass lens substrate, and an adhesive tape is applied to the entire circumference of the side surface of the glass lens substrate and the transfer mold. A method of manufacturing a hybrid lens, comprising: a resin layer forming step of forming a resin layer by winding and forming a cavity, injecting and curing a resin between the glass lens base material and the transfer mold .

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