JP2009113353A - Manufacturing method of semi-finish lens, semi-finish lens and manufacturing method of plastic lens - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a semi-finish lens, which is formed of a resin material having thermoplasticity and has a first surface excellent in shape accuracy, to provide the semi-finish lens, and to provide a manufacturing method of a plastic lens, which uses the semi-finish lens as a starting material and in which a second surface is worked into a desired shape. <P>SOLUTION: The manufacturing method of the semi-finish lens 1, which has the first surface 1A optically finished and the second surface 1B to be post-worked, comprises: a base material forming process of obtaining an optical base material 10 of which one surface is made to be an optical surface 10A optically finished; a releasing process of detaching a mold from the optical base material 10; a coating layer forming process of disposing a coating layer 2 cured at a temperature of glass transition temperature of the optical base material 10 or less on the optical surface 10A of the optical base material 10; and an annealing process of heating the optical base material 10 at a temperature of the glass transition temperature of the optical base material 10 or more. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a semi-finished lens, a semi-finished lens manufactured by this manufacturing method, and a method for manufacturing a plastic lens using a semi-finished lens as a raw material.

Conventionally, plastic lenses are widely used for optical elements such as eyeglass lenses, camera lenses, and pickup lenses.
A plastic lens is generally manufactured by cast molding or injection molding. The lens manufactured by such a method has a finish lens having an optical surface on both the first surface and the second surface, and only the first surface has an optical surface, and the second surface is later formed into a desired shape. There is a semi-finished lens in which the lens is thickened in advance on the premise that it will be processed.
In particular, in a spectacle lens that manufactures thousands of types of lenses according to customer prescriptions, a semi-finished lens may be used because a desired lens can be obtained simply and in a short time only by processing the second surface. Many.

However, since the semi-finished lens is formed thick on the second surface side, internal stress due to heating, cooling, polymerization shrinkage and the like during molding tends to remain as compared with the finish lens.
The semi-finished lens in which the internal stress remains is gradually deformed in a direction to release or relieve the internal stress, and the shape accuracy of the first surface that should have the optical surface is lowered.
When the shape accuracy of the first surface is insufficient, sufficient optical accuracy as a lens cannot be obtained even if the second surface is processed in a later step.
Therefore, it is essential to anneal the semifinished lens at a temperature equal to or higher than its glass transition point (Tg) to release the remaining internal stress and obtain a first surface with high shape accuracy.

  On the other hand, Patent Documents 1 to 3 and the like have proposed a polymerizable composition that gives a resin material having a refractive index (nd) of 1.7 or more, in order to form a plastic lens having a high refractive index and excellent optical characteristics. It has been attracting attention as a base material composition.

JP 2006-169190 A (pages 3 to 8) JP 2006-83313 A (pages 4 to 10) JP 2006-182908 A (pages 4 to 10)

However, the resin material obtained by polymerizing the polymerizable composition described in Patent Documents 1 to 3 has thermoplastic properties. For this reason, if a plastic lens formed of these resin materials is subjected to an annealing treatment at a temperature exceeding the Tg of the resin material, the plastic lenses may be deformed and the shape accuracy of the first surface and the second surface may be lost. is there.
In particular, since an annealing treatment after molding is essential for a semi-finished lens, it is substantially possible to obtain a semi-finished lens having a high refractive index and high shape accuracy using the polymerizable composition described in Patent Documents 1 to 3. It was impossible.
Such a problem is not limited to the resin materials described in Patent Documents 1 to 3, but is common to resin materials having thermoplasticity. That is, it has been generally impossible to form a semi-finished lens with high shape accuracy using a thermoplastic resin material.

  An object of the present invention is to produce a semi-finished lens having a first surface that is formed of a thermoplastic resin material and has excellent shape accuracy, a semi-finished lens having a first surface that has excellent shape accuracy, and the semi-finish To provide a method of manufacturing a plastic lens using a lens as a raw material and having a second surface processed into a desired shape.

  A method for producing a semi-finished lens according to the present invention is a method for producing a semi-finished lens having a first surface optically finished and a second surface that is post-processed into a desired shape. After injecting the base material composition into the base material, the base material composition is polymerized to obtain an optical base material that is optically finished on one side, and the base material forming step. A mold release step for removing the mold from the obtained optical substrate, and a coating material that cures at a temperature below the glass transition point of the optical substrate on the optical surface of the optical substrate removed from the mold. After coating, a coating layer forming step for curing the coating material to form a coating layer, and annealing for heating the optical substrate on which the coating layer is formed at a temperature equal to or higher than the glass transition point of the optical substrate. Process And TMA (Thermomechanical Analyzer) is used to perform thermomechanical analysis of the optical substrate under the conditions of a load of 50 g, a needle probe with a diameter of 1 mm, an initial temperature of 25 ° C., and a heating rate of 10 ° C./min. The amount of change in the thickness of the optical substrate at the measurement temperature of the glass transition point of the optical substrate + 10 ° C. is 10% or more of the thickness of the optical substrate at the initial temperature.

According to this invention, in the base material forming step, the optical base material is formed of a material having a large amount of deformation at the measurement temperature (Tg + 10 ° C.), that is, a material having thermoplasticity.
In the coating layer forming process, a coating material that cures at a temperature equal to or lower than the glass transition point (Tg) of the optical substrate is applied to the optical surface of the optical substrate removed from the mold in the release process, and the coating material is cured. To form a coating layer.
In the annealing step, the optical substrate on which the coating layer is formed is heated at a temperature equal to or higher than Tg of the optical substrate.

  Here, since the coating layer is formed of a coating material that cures at a temperature equal to or lower than the Tg of the optical substrate, the optical substrate is heated to the Tg or higher when the coating material is cured on the optical surface of the optical substrate. It will not be done. Therefore, in the coating layer forming step, the possibility that the optical substrate having thermoplasticity is deformed is low.

And even if the hardened coating layer is heated more than Tg of an optical base material, the shape can be maintained, without softening.
That is, in the annealing step, the optical substrate is softened, but the coating layer provided on the optical surface of the optical substrate is not softened.
Since the coating layer prevents deformation of the optical base material and the optical surface softened by heating at Tg or higher, a semi-finished lens having a first surface with high shape accuracy can be obtained.
Therefore, according to the method for producing a semi-finished lens of the present invention, it is possible to obtain a semi-finished lens having a first surface which is formed of a thermoplastic resin material and has excellent shape accuracy.

In the present invention, the coating material is “cured at a temperature below the glass transition point of the optical substrate” means that the temperature applied from the outside when the coating material is cured is Tg or less of the optical substrate. Means.
For example, when the coating material is cured by heat polymerization, the heat applied from the outside needs to be Tg or less of the optical substrate.
In addition, for example, when the coating material is cured by irradiation with energy such as ultraviolet rays, it is necessary to adjust the temperature of the coating material during polymerization to be equal to or lower than the Tg of the optical substrate.

  In the method for producing a semi-finished lens according to the present invention, the base material composition preferably contains a compound represented by the following formula (1).

In formula (1), M is a Sn atom, Si atom, Zr atom, Ti atom, or Ge atom. R ₁ is an alkylene group having 1 to 4 carbon atoms, X ₁ is an S atom or an O atom, and n is an integer of 0 to 4. Y is any of the following formula (1-1), formula (1-2), or formula (1-3).

The compound represented by the general formula (1) has an optical substrate having a high refractive index and excellent optical properties, but has a problem that deformation occurs in the annealing process because it has thermoplasticity.
On the other hand, in the manufacturing method of the present invention, the coating layer formed on the optical surface of the optical base material prevents deformation of the optical base material and the optical surface in the annealing step. A semi-finished lens having excellent optical characteristics can be produced.

In the semifinished lens manufacturing method of the present invention, it is preferable that the coating layer forming step also serves as a step of forming a deformation preventing layer on the optical surface of the optical base material.
In this invention, since the coating layer which is a deformation preventing layer is formed on the optical surface of the optical base material, it is possible to prevent the optical base material and the optical surface from changing in shape in the annealing step. Thereby, a semi-finished lens formed of a resin material having thermoplasticity and having a first surface with excellent shape accuracy can be obtained.

In the method for producing a semi-finished lens of the present invention, it is preferable that in the coating layer forming step, the coating layer is also formed on a surface facing the optical surface of the optical substrate.
In this invention, since the coating layer is formed on the opposing surface in addition to the optical surface of the optical substrate, the deformation of the optical substrate in the annealing process can be prevented more reliably.

The semi-finished lens of the present invention is manufactured by the above-described method for manufacturing a semi-finished lens.
Since the semi-finished lens of the present invention is manufactured by the above-described manufacturing method, it has a first surface excellent in shape accuracy while being formed of a resin material having thermoplasticity.
In particular, a semi-finished lens using a compound represented by the above formula (1) has a high refractive index, high shape accuracy, and excellent optical characteristics.

  The plastic lens manufacturing method of the present invention includes a polishing step of polishing the second surface of the semi-finished lens manufactured by the above-described method of manufacturing a semi-finished lens, and the polishing step of the semi-finished lens after the polishing step. A second coating layer forming step of applying a second coating material that cures at a temperature equal to or lower than the glass transition point of the optical substrate to the two surfaces, and curing the second coating material to form a second coating layer; and And a baking step of baking the semi-finished lens at a temperature equal to or higher than the glass transition point of the optical substrate after the post-coating layer forming step.

According to the present invention, in the polishing step, the second surface of the semi-finished lens manufactured by the above-described method for manufacturing a semi-finished lens is polished to obtain a desired shape optically finished.
In the post-coating layer forming step, a second coating material that cures at a temperature equal to or lower than the Tg of the optical substrate is applied to the second surface side of the semi-finished lens, and the second coating material is cured to form the second coating layer. To do.
In the firing step, the semi-finished lens is fired at a temperature equal to or higher than Tg of the optical substrate.

  Here, since the second coating layer is formed of the second coating material that is cured at a temperature equal to or lower than the Tg of the optical substrate, when the second coating material is cured on the second surface side of the semi-finished lens, The substrate is not heated above its Tg. Therefore, in the post-coating layer forming step, the possibility that the optical substrate having thermoplasticity is deformed is low.

And even if the hardened 2nd coating layer is heated more than Tg of an optical base material, it can maintain the shape, without softening.
That is, in the firing step, the optical substrate is softened, but the second coating layer provided on the second surface side of the semi-finished lens is not softened. Further, the coating layer provided on the optical surface of the optical base material is not softened.
Therefore, since the coating layer and the second coating layer prevent deformation of the optical base material softened by heating of Tg or more, a plastic lens having the first surface and the second surface with high shape accuracy can be obtained.
Therefore, according to the plastic lens manufacturing method of the present invention, a plastic lens having a high shape accuracy in which the second surface is processed into a desired shape using a semi-finished lens formed of a thermoplastic resin material as a raw material is obtained. be able to.

In the present invention, it is preferable that the post-coating layer forming step also serves as a step of forming a deformation preventing layer on the second surface side of the semi-finished lens.
In the present invention, since the second coating layer which is a deformation preventing layer is formed on the second surface side of the semi-finished lens, it is possible to prevent the shape change of the optical substrate in the firing step. As a result, a plastic lens having a high shape accuracy in which the second surface is processed into a desired shape using a semi-finished lens formed of a thermoplastic resin material as a raw material can be obtained.

In the present invention, the post-coating layer forming step includes a primer layer forming step of forming a primer layer on the second surface of the semi-finished lens, and a hard coat layer on the surface of the second surface or the primer layer. It is preferable that both the hard coat layer forming step and the antireflection layer forming step of forming an antireflection layer on the second surface, the surface of the hard coat layer, or the surface of the primer layer are used.
In this invention, the post-coating layer forming step serves as at least one of the primer layer forming step, the hard coat layer forming step, and the antireflection layer forming step, thereby shortening the step after the firing step. Thus, a simplified method for manufacturing a plastic lens can be provided.

In the plastic lens manufacturing method of the present invention, it is preferable that in the post-coating layer forming step, the second coating layer is also formed on the first surface side of the semi-finished lens.
In this invention, since the coating layer is formed on the first surface side in addition to the second surface side of the semi-finished lens, the deformation of the optical base material in the firing step can be prevented more reliably.

  In the present invention, in the coating layer forming step, a coating layer formed from a material that cures at a temperature equal to or lower than the Tg of the optical substrate is formed on the optical surface of the thermoplastic optical substrate. Even when the annealing process at the above temperature is performed, the optical substrate can be prevented from being deformed by the presence of the coating layer, and the first surface is excellent in shape accuracy while being formed of a thermoplastic resin material. A semi-finished lens can be obtained.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The semi-finished lens, the plastic lens, and the manufacturing method thereof according to the present invention are not limited to the following embodiments.
FIG. 1 is a cross-sectional view showing a schematic configuration of a semi-finished lens and a plastic lens according to each embodiment of the present invention.
FIG. 2 is a flowchart showing a method for manufacturing a semi-finished lens.
3 to 5 are schematic views showing a method for manufacturing a semi-finished lens.
6 to 9 are flowcharts showing Embodiments 1 to 4 of the plastic lens manufacturing method, respectively.
FIG. 10 is a flowchart showing an outline of the polishing process.
FIG. 11 is a schematic cross-sectional view illustrating an annealing process according to an example.

[Semi finish lens and plastic lens]
FIG. 1A shows a semi-finished lens 1 of the present embodiment.
In the present embodiment, the semi-finished lens 1 is for an eyeglass lens. However, the present invention is not limited to a semi-finished lens for eyeglass lenses.
In FIG. 1A, a semi-finished lens 1 includes an optical base 10 and a coating layer 2 formed on the optical surface 10A and the opposing surface 10B of the optical base 10, and is optically finished first. It has a surface 1A and a second surface 1B that is post-processed into a desired shape.

FIG. 1B shows a plastic lens 100 of the present embodiment.
In the present embodiment, the plastic lens 100 is a spectacle lens. However, the present invention is not limited to the spectacle lens.
1B, a plastic lens 100 includes the semi-finished lens 1 described above, and a second coating layer 3 formed on the first surface 1A and the polished surface 1C of the semi-finished lens 1.
Here, the polished surface 1 </ b> C is a surface obtained by polishing the second surface 1 </ b> B of the semifinished lens 1.
The surface of the second coating layer 3 may include a layer P indicated by a two-dot chain line.

Here, when a thermomechanical analysis of the optical substrate 10 was performed using TMA under the conditions of a load probe of 50 g, a diameter of 2 mm, an initial temperature of 25 ° C., and a temperature increase rate of 10 ° C./min, The amount of change in the thickness of the optical substrate 10 at a measurement temperature of 10 Tg + 10 ° C. is 10% or more of the thickness of the optical substrate 10 at the initial temperature.
That is, the optical substrate 10 has thermoplasticity.

  The optical substrate 10 is preferably formed from a substrate composition 11 containing a compound represented by the general formula (1).

In General formula (1), M is a Sn atom, Si atom, Zr atom, Ti atom, or Ge atom. R ₁ is an alkylene group having 1 to 4 carbon atoms, X ₁ is an S atom or an O atom, and n is an integer of 0 to 4. Y is one of the following formulas (1-1), (1-2), or (1-3).

In general, the plastic lens 100 has a primer layer, a hard coat layer, and an antireflection layer laminated on the surface of the semifinished lens 1 from the inside to the outside. May be omitted.
The second coating layer 3 of this embodiment is at least one of a primer layer, a hard coat layer, and an antireflection layer.
That is, the second coating layer 3 is drawn in a single layer structure in FIG. 1B, but has a single layer structure or a multilayer structure composed of a plurality of layers.
The coating layer 2 can also have a single layer structure or a multilayer structure. The coating layer 2 may be any one of a primer layer, a hard coat layer, and an antireflection layer, or a combination thereof.
The coating layer 2 and the second coating layer 3 are for preventing deformation of the optical substrate 10 and are formed by curing a coating material that cures at a temperature equal to or lower than the Tg of the optical substrate 10.
In addition, the coating layer 2 and the 2nd coating layer 3 may be formed from the same coating material, and may be formed from a different coating material.

As the 2nd coating layer 3 and the layer P, the structure shown below is mentioned, for example.
“Configuration 1”
The second coating layer 3 has a two-layer structure including a primer layer and a hard coat layer. The layer P is an antireflection layer.
“Configuration 2”
The second coating layer 3 has a single layer structure composed of a hard coat layer. The layer P is an antireflection layer.
“Configuration 3”
The second coating layer 3 has a three-layer structure including a primer layer, a hard coat layer, and an antireflection layer. The layer P is not formed.
“Configuration 4”
The second coating layer 3 has a multilayer structure composed of an antireflection layer in which a plurality of inorganic layers are laminated. The layer P is not formed.

The primer layer is made of, for example, urethane resin.
The hard coat layer is formed of, for example, a silicone material or an acrylic material.
The antireflection layer has a single layer structure or a multilayer structure composed of a plurality of layers. Examples of the antireflection layer having a multilayer structure include a structure in which layers made of SiO ₂ and layers made of ZrO ₂ or TiO ₂ are alternately stacked.

[Method of manufacturing semi-finished lens]
FIG. 2 is a flowchart showing a method for manufacturing the semi-finished lens 1 of the present embodiment.
As shown in FIG. 2, the manufacturing method of the semi-finished lens 1 of this embodiment includes a base material forming step S100, a mold releasing step S104, a coating layer forming step S105, and an annealing step S106.

[Base material forming step and mold releasing step]
The base material forming step S100 is a step of polymerizing a base material composition containing the compound represented by the formula (1) to form an optical base material 10 having an optical surface 10A whose one surface is optically finished. It is.
As shown in FIG. 2, the base material forming step S100 includes a raw material preparation step S101 for preparing a base material composition, and a glass mold injection step S102 for injecting the base material composition obtained in the raw material preparation step S101 into a glass mold. And a curing step S103 for polymerizing and curing the base material composition injected into the glass mold.
The mold release step S104 is a step of removing the glass mold from the optical base material 10 obtained in the base material forming step S100.

FIG. 3 is a schematic diagram illustrating an example of the base material forming step S100 and the release step S104.
FIG. 3A is a cross-sectional view of the molding glass mold 20 used in the base material forming step S100.
The molding glass mold 20 includes a pair of glass molds 21 and 22 arranged to face each other with a gap therebetween, and an adhesive tape 23 wound around the outer peripheral surfaces of the pair of glass molds 21 and 22. , 22 and an adhesive tape 23 to form a cavity 24.
The cavity 24 is formed so as to form the optical substrate 10 having a power of about -3D.

FIG. 3B is a cross-sectional view of the molding glass mold 20 in the glass mold injection step S102.
In the glass mold injection step S102, as shown in FIG. 3B, the base material composition 11 obtained in the raw material preparation step S101 is injected into the cavity 24 using the injection nozzle 25.
FIG. 3C is a cross-sectional view of the molding glass mold 20 in the curing step S103.
In the curing step S103, as shown in FIG. 3C, the base material composition 11 in the molding glass mold 20 is polymerized and cured by means such as heating and ultraviolet irradiation to form the optical base material 10.
FIG. 3D is a cross-sectional view of the optical substrate 10 in the mold release step S104.
In the release step S104, as shown in FIG. 3D, the adhesive tape 23 is removed from the pair of glass molds 21 and 22 and the optical substrate 10, and the glass molds 21 and 22 are separated from the optical substrate 10, The optical substrate 10 is taken out.

[Coating layer forming process]
The coating layer forming step S105 is a step of forming the coating layer 2 by applying a predetermined coating material to the optical surface 10A and the facing surface 10B of the optical substrate 10 and then curing the coating material.
The coating layer forming step S105 can be performed by a wet process such as an immersion method or a dry process such as a vacuum deposition method.
4 and 5 are schematic views showing an example of the coating layer forming step S105.

[Coating layer formation process by immersion method]
FIG. 4 is a schematic perspective view showing the immersion apparatus 30 used in the coating layer forming step S105 by the immersion method.
The immersion device 30 includes a tank 34 and an elevating unit 31.
A coating composition L is accommodated in the tank 34.
The elevating part 31 has a rod 32 and a gripping tool 33 connected to the rod 32. The raising / lowering part 31 has a structure which raises / lowers in the direction of the arrow shown in FIG.
The gripping tool 33 grips the outer peripheral surface portion of the optical substrate 10.

In the coating layer forming step S <b> 105, first, with the gripping tool 33 gripping the outer peripheral surface portion of the optical base material 10, the elevating part 31 is lowered and the optical base material 10 is immersed in the coating composition L in the tank 34. .
After the immersion, the optical substrate 10 is pulled up from the tank 34 by raising the elevating unit 31. Thereby, it will be in the state by which the coating composition L was apply | coated to the optical base material 10. FIG.
Subsequently, the coating composition L applied to the optical substrate 10 is cured by means such as heating or ultraviolet irradiation. Thereby, the coating layer 2 is formed on the surface of the optical substrate 10.
The pulling speed, curing means, conditions, etc. can be determined as appropriate.

In such a coating layer forming step S105, when a primer layer is formed as the coating layer 2, as the coating composition L, for example, a primer composition made of urethane resin or the like can be used.
Moreover, when forming a hard-coat layer as the coating layer 2, as the coating composition L, the hard-coat composition which consists of a silicone type material, an acrylic material, etc. can be utilized, for example, When forming an antireflection layer, In addition, a silicone-based antireflection layer composition can be used.

[Coating layer formation process by vacuum evaporation]
FIG. 5 is a schematic cross-sectional view showing the vacuum vapor deposition apparatus 40 used in the coating layer forming step S105 by the vacuum vapor deposition method.
The vacuum vapor deposition device 40 is a so-called electron beam vacuum vapor deposition device, and includes a vacuum container 41, an exhaust device 42, a gas supply device 43, and a pressure gauge 44.

The vacuum container 41 includes evaporation sources 46 and 47 in which the coating composition L is set as an evaporation material, a filament 48 that heats and dissolves the evaporation material of the evaporation sources 46 and 47, and a substrate on which the optical substrate 10 is supported. A material support base 45 and a heater 49 for heating the optical substrate 10 are provided.
In addition, the vacuum vessel 41 includes a cold trap for removing moisture remaining in the vacuum vessel 41, an irradiation device that ionizes and accelerates a gas such as oxygen, and irradiates the optical substrate 10 as necessary. A management device or the like for managing the film thickness may be provided.
For example, as an evaporation material when an antireflection layer is formed as the coating layer 2, SiO ₂ , ZrO ₂ , or TiO ₂ that is an inorganic substance can be used.

The evaporation sources 46 and 47 are crucibles in which a vapor deposition material is set, and are arranged at the lower part in the vacuum vessel 41.
In the coating layer forming step S105, the thermoelectrons generated when the filament 48 generates heat are accelerated and deflected by an electron gun, and are evaporated by irradiating the vapor deposition material set in the evaporation sources 46 and 47.
Here, the deposition rate can be appropriately adjusted by changing the current value of the electron beam.
As other methods for evaporating the vapor deposition material, there is a so-called resistance heating vapor deposition method in which a vapor deposition material is melted and vaporized by energizing a resistor such as tungsten, or a method of irradiating the vaporization material with a high energy laser beam. Available.

The base material support base 45 is a support base for supporting a predetermined number of optical base materials 10, and is disposed in the upper part of the vacuum container 41 facing the evaporation sources 46 and 47.
The base material support 45 preferably has a rotation mechanism in order to ensure the uniformity of the coating layer 2 formed on the optical base material 10 and to improve mass productivity.

The heater 49 is composed of, for example, an infrared lamp, and is disposed on the upper part of the substrate support 45.
The heater 49 heats the optical substrate 10 to remove gas or moisture from the optical substrate 10 to ensure the adhesion of the coating layer 2 formed on the surface of the optical substrate 10.
In addition to the infrared lamp, a resistance heater or the like can be used as the heater 49. However, when the material of the optical substrate 10 is plastic or resin, it is preferable to use an infrared lamp.

The exhaust device 42 is a device that exhausts the inside of the vacuum vessel 41 to a high vacuum, and includes a turbo molecular pump and a pressure control valve that keeps the pressure inside the vacuum vessel 41 constant.
The gas supply device 43 includes a gas cylinder containing a gas such as Ar, N ₂ , and O ₂ and a flow rate control device that controls the flow rate of the gas. The gas built in the gas cylinder is introduced into the vacuum vessel 41 via the flow rate control device.

The pressure gauge 44 detects the pressure in the vacuum vessel 41.
Based on the pressure value detected by the pressure gauge 44, the pressure control valve of the exhaust device 42 is controlled by a control signal from a control unit (not shown), and the pressure in the vacuum vessel 41 is maintained at a predetermined pressure value. Be drunk.
Examples of the pressure adjustment method include a method of changing the conductance of the exhaust port, a method of changing the amount of gas introduced, and the like.
For example, the flow rate control device of the gas supply device 43 can adjust the pressure in the vacuum vessel 41 by changing the amount of gas introduced.
Further, when vapor deposition is performed at the residual pressure after exhaust without particularly adjusting the pressure, the refractive index may change, so that the film thickness needs to be adjusted. If pressure control is not performed, the pressure may change significantly during vapor deposition.

[Annealing process]
The annealing step S106 is a step of heating the optical base material 10 on which the coating layer 2 is formed at a temperature equal to or higher than Tg of the optical base material 10.
The annealing step S106 can be performed using a heating device such as an electric furnace, and the semi-finished lens 1 is completed by the annealing step S106.

[Plastic lens manufacturing method]
6 to 9 are flowcharts showing a method for manufacturing the plastic lens 100 according to the first to fourth embodiments of the present invention.

[First Embodiment]
FIG. 6 is a flowchart showing a method for manufacturing the plastic lens 100 of the first embodiment.
In the present embodiment, the method for manufacturing the plastic lens 100 includes a polishing step S201, a post-coating layer forming step S202, and a baking step S203.

[Polishing process]
The polishing step S201 is a step of polishing the second surface 1B of the semi-finished lens 1 to obtain a desired optically finished shape.
FIG. 10 shows a schematic configuration of the polishing step S201. Note that the polishing step S201 shown in FIG. 10 is an example, and the present invention is not limited to this.
As shown in FIG. 10, the polishing process includes a layout process, a blocking process, a shape creation process, a mirror finish process, a deblocking process, a cleaning process, and an inspection process.

  In the layout process, the semi-finished lens 1 is provided with a positioning mark for setting on the block jig. This layout process is necessary for toric processing and prism processing of a multifocal lens whose vertical direction is determined, and can be omitted in the case of a single focus lens having no directionality.

  Next, in the blocking step, as shown in FIG. 10A, the second surface 1B of the semi-finished lens 1 is placed on a block jig 50 for attachment to a numerically controlled machine tool through a block material 60 such as a low melting point metal. And glue. At this time, it arrange | positions so that the positioning mark attached | subjected to the semifinished lens 1 may become a predetermined position with respect to the block jig | tool 50. FIG.

Next, a shape creation process is performed. This shape creation step is a step of creating a lens surface shape based on the prescription of the eyeglass lens by cutting out the second surface 1B of the semi-finished lens 1.
In some cases, the final optical surface may be obtained in the shape creation process. However, if there are fine irregularities on the surface, a mirror finishing process for smoothing the irregularities on the surface is performed after the shape creation process.

The shape creation process includes an outer diameter machining process, an approximate machining surface rough cutting process, a finishing machining process, and a chamfering process.
The outer diameter machining step is a step for cutting an unnecessary outer peripheral portion by cutting and reducing it to a predetermined outer diameter, and is also a step for shortening the rough cutting step and the finishing step.
The approximate machining surface rough cutting step is a rough cutting step in which an approximate surface shape that approximates a desired lens surface shape is quickly created, and the semi-finished lens 1 having a considerable thickness is quickly sharpened to a predetermined thickness.
The finish cutting step is a step of precisely creating a desired lens surface shape by machining from an approximate surface shape.
The chamfering process is a process of chamfering the edge because the edge of the lens after the finishing process is sharp and dangerous, and is easy to chip.

  The outer diameter machining step is usually performed before the approximate machining surface rough cutting step, but may be performed before or after the finishing machining step. The outer diameter processing step is not performed when the outer diameter of the semi-finished lens 1 matches the prescription diameter. Further, chamfering may not be necessary. Furthermore, when the shape of the semi-finished lens 1 is very close to the lens surface shape based on the prescription data of the eyeglass lens, the rough surface process is omitted, and the lens surface shape based on the prescription data of the eyeglass lens can be obtained only by the direct finishing process. There is a case.

  As an apparatus for performing the shape creation process, a dedicated cutting apparatus can be used for each process. In each process, the type of cutting tool (cutting tool) and the movement of the cutting tool are different from each other. By using a dedicated cutting device, it is possible to perform cutting with an optimal cutting tool under optimal cutting conditions. Therefore, efficient and efficient cutting can be performed.

In the outer diameter machining step, a dedicated numerically controlled outer diameter machining cutting device (not shown) can be used.
The block jig 50 is set on the chuck of this apparatus, and the outside diameter machining data is input to the numerically controlled outside diameter machining cutting apparatus. Alternatively, the outer diameter processing data is requested to the host computer via the communication line, the data is transmitted, and the data is stored in the internal storage device.
The numerically controlled outer diameter machining cutting device controls the position of the cutting tool with respect to the Y axis direction and the radial direction of the workpiece (X axis) while rotating the workpiece on the Y axis based on the outer diameter machining data, thereby providing a semi-finished lens 1. A semi-finished lens 12 is manufactured by applying a cutting tool to the side surface of the lens and cutting the outer diameter to a predetermined diameter as shown in FIG.

In the approximate machining surface rough cutting process, a dedicated numerically controlled machine tool can be used.
The block jig 50 is set on the chuck of this apparatus, and approximate rough surface machining data is directly input to the numerically controlled cutting apparatus or transmitted through a host computer to store the data.
The numerically controlled cutting device controls the relative positions of the workpiece and the cutting tool in the X-axis direction and the Y-axis direction, and creates a rough surface of a free-form surface, a spherical surface, or a toric surface shape based on rough machining data of the approximate machining surface. .
In the approximate machining surface rough cutting step, as shown in FIG. 10C, a semi-finished lens 13 having a rough surface with a surface roughness R _max of 100 μm or less can be obtained.

In the finishing process, for example, using the same device as the numerically controlled cutting apparatus described above, the finishing tool is used to precisely perform the rough cutting surface to the desired final lens surface shape based on the finishing machining data under the finishing cutting conditions. To cut.
In the finish cutting step, as shown in FIG. 10D, a semi-finished lens 14 having a surface roughness R _max of about 0.1 to 10 μm can be obtained.

In the chamfering process, a dedicated numerically controlled chamfering cutting device (not shown) can be used.
The block jig 50 is set on the chuck of this apparatus, and chamfering data is input to the chamfering cutting apparatus. Alternatively, the chamfering data is requested from the host computer via the communication line, the data is transmitted, and the data is stored in the internal storage device.
The numerically controlled chamfer cutting apparatus chamfers the edge of the processed surface of the semi-finished lens 14 by applying a bite to the end edge of the semi-finished lens 14 while rotating the semi-finished lens 14 based on the chamfering data.
In the chamfering process, as shown in FIG. 10E, the chamfered semi-finished lens 15 can be obtained.

After the shape creation process, if necessary, a mirror finishing process is performed to smooth the surface irregularities.
In the above-described finishing, the surface roughness R _max can be processed to about 0.1 to 10 μm, and the final optical surface having a surface roughness R _max of about several tens of nm is finished in the mirror finishing process.
In the case of polishing the concave surface of a single focus lens or the concave surface of a multifocal lens having a progressive surface on the convex surface, the mirror finishing process is a spherical surface or a toric surface, so a polishing method using a conventional processing dish may be adopted. it can.

On the other hand, when a complicated curved surface is polished like the inner surface of an inner surface progressive multifocal lens, the conventional polishing method using a processing dish cannot be adopted as described above.
For polishing a complicated curved surface such as such an inner surface progressive multifocal lens, it is preferable to use a scanning polishing tool 70 as shown in FIG.
The copying polishing tool 70 is attached to the housing 72 so that a rubber sheet 71 having a hemispheric shape and flexibility forms a sealed space between the rubber sheet 71 and the housing 72, and pressure gas or liquid is press-fitted into the sealed space. The rubber sheet 71 has a structure capable of applying pressure so as to keep the rubber sheet in a hemispherical shape.
A polishing cloth such as a non-woven fabric is attached to the surface of the rubber sheet 71, and the polishing liquid is supplied between the rubber sheet 71 and the semi-finished lens 15 while rotating and swinging the casing 72 and pressing it against the semi-finished lens 15. To polish.

  In this copying polishing tool 70, the rubber sheet 71 contacts the surface of the semifinished lens 15 with a uniform pressure, so that the rubber sheet 71 remains on the surface of the semifinished lens 15 even if the surface of the semifinished lens 15 is a complicated curved surface. It can be uniformly polished following the shape. Therefore, it is particularly suitable for polishing a free curved surface such as the inner surface of an inner surface progressive multifocal lens.

A numerically controlled polishing machine can be used for polishing a complicated curved surface.
Based on the NC machining data calculated in advance from the design shape of the lens, relative positioning of the polisher head and the workpiece is performed, and any part of the surface of the polisher head is aligned with the normal direction at the machining point of the workpiece. Then, the polisher head is strongly pressed and polished from that direction.
Thereby, it is possible to polish the final optical surface without breaking the curved surface shape created in the shape creation step.

The semi-finished lens 16 having both optical surfaces as final optical surfaces is completed by the mirror finishing process.
After that, since the block jig 50 becomes unnecessary, as shown in FIG. 10 (G), a deblocking process for removing the finish lens 16 from the block jig 50 is performed, and a cleaning process is performed to remove further adhered dirt. Finally, the inspection is performed and the polishing step S201 is completed.
By such a polishing step S201, the semi-finished lens 1 having the polished surface 1C as shown in FIG. 1B is formed.

[Post-coating layer forming step]
In the post-coating layer forming step S202, a predetermined second coating material is applied to the first surface 1A side and the second surface 1B side (that is, the polishing surface 1C side) of the semi-finished lens 1, and then the second coating material is applied. This is a step of forming the second coating layer 3 by curing.
In this embodiment, as the post-coating layer forming step S202, a primer layer forming step S202A for forming a primer layer on the first surface 1A and the polished surface 1C of the semifinished lens 1, and a hard coat layer on the formed primer layer. The hard coat layer forming step S202B to be formed is performed.
The primer layer forming step S202A and the hard coat layer forming step S202B can be performed by the same method as the above-described coating layer forming step S105. For this reason, detailed description is omitted.

[Baking process]
The firing step S203 is a step of heating the semi-finished lens 1 on which the second coating layer 3 is formed at a temperature equal to or higher than Tg of the optical substrate 10.
The firing step S203 can be performed using a heating device such as an electric furnace, as in the annealing step S106.
[Antireflection layer forming step]
The antireflection layer forming step S204 is a step of forming an antireflection layer on the hard coat layer after the baking step S203.
Antireflection layer formation process S204 can be implemented by the method similar to above-mentioned coating layer formation process S105. For this reason, detailed description is omitted.
The plastic lens 100 is completed by this antireflection layer forming step S204.
The plastic lens 100 manufactured by the manufacturing method of the present embodiment includes the above-described “Configuration 1”.

[Second Embodiment]
FIG. 7 is a flowchart showing a method for manufacturing the plastic lens 100 of the second embodiment.
This embodiment differs from the first embodiment described above in that the post-coating layer forming step S202 does not include the primer layer forming step S202A. Since each process is the same as that of the first embodiment, detailed description thereof is omitted.
The plastic lens 100 manufactured by the manufacturing method of this embodiment includes the above-described “Configuration 2”.

[Third Embodiment]
FIG. 8 is a flowchart showing a method for manufacturing the plastic lens 100 of the third embodiment.
In the present embodiment, the post-coating layer forming step S202 includes an antireflection layer forming step 202C in addition to the primer layer forming step S202A and the hard coat layer forming step 202B, and the antireflection layer forming step 204 is not performed. This is different from the first embodiment.
The antireflection layer forming step 202C is the same as the above-described antireflection layer forming step 204, and the other steps are the same as those in the first embodiment, and thus detailed description thereof is omitted.
The plastic lens 100 manufactured by the manufacturing method of the present embodiment includes the above-described “Configuration 3”.

[Fourth Embodiment]
FIG. 9 is a flowchart showing a method for manufacturing the plastic lens 100 of the fourth embodiment.
This embodiment is different from the above-described third embodiment in that the post-coating layer forming step S202 does not include the primer layer forming step S202A and the hard coat layer forming step 202B. Since each process is the same as that of the first embodiment, detailed description thereof is omitted.
The plastic lens 100 manufactured by the manufacturing method of the present embodiment includes the “configuration 4” described above.

  Below, this invention is demonstrated in detail using Examples 1-9 of this embodiment. However, the present invention is not limited to these examples.

[Example 1]
In Example 1, the semi-finished lens 1 was manufactured by the following manufacturing method.

[Raw material preparation step S101]
First, the base material composition 11 is prepared by the following procedure.
30 g of tetrakis (2,3-epithiopropylthio) tin (hereinafter referred to as “Sn-1”) and 0.3 g of SEESORB701 (manufactured by Sipro Kasei Kogyo) as an ultraviolet absorber were added and stirred thoroughly. Mix.
Further, 0.1 g of N, N dimethylcyclohexylamine is added as a polymerization catalyst, and the mixture is deaerated for 15 minutes while stirring under a reduced pressure of 1.5 kPa or less.
Thereby, the base material composition 11 containing the compound shown by the said Formula (1) is obtained.

[Glass mold injection step S102]
The base material composition 11 thus obtained is injected into the cavity 24 of the molding glass mold 20 using the injection nozzle 25.
Here, the molding glass mold 20 is configured to provide an optical substrate 10 having a convex surface with a design curvature radius of 200 mm, a concave surface with a design curvature radius of 100 mm, a center thickness of 5 mm, and a diameter of 80 mm.

[Curing step S103]
Next, the glass substrate 20 for molding and the base material composition 11 are heated from 30 ° C. to 120 ° C. over 20 hours, and the base material composition 11 is polymerized and cured to form the optical base material 10.

[Release step S104]
The adhesive tape 23 is removed from the pair of glass molds 21 and 22 and the optical substrate 10, the glass molds 21 and 22 are separated from the optical substrate 10, and the optical substrate 10 is taken out.
Here, it was confirmed that the optical substrate 10 has a frequency of about -3D.
In addition, two mirror-finished glass flat plates were used, and a plastic plate having a thickness of 2 mm was prepared using the base material composition 11 as a raw material under the same conditions as described above. This was cut out with a diamond cutter and used as a sample of the optical substrate 10.
Using TMA, a sample was subjected to thermomechanical analysis under the conditions of a 50 g load, a 1 mm diameter needle probe, an initial temperature of 25 ° C., and a heating rate of 10 ° C./min. From the substrate composition containing Sn-1 The Tg of the formed optical substrate 10 was 110 ° C., and the amount of change in the thickness of the sample at Tg + 10 ° C. (ie, 120 ° C.) of the optical substrate 10 was 30% or more of the thickness of the sample at the initial temperature. .
In addition, when the refractive index of the sample with respect to the D-line of 589.3 nm was measured using an Abbe refractometer at a temperature of 20 ° C., it was nd = 1.794.

[Coating layer forming step S105]
Subsequently, the coating layer 2 is formed on the optical surface 10 </ b> A and the facing surface 10 </ b> B of the optical substrate 10. In this example, after the primer layer was formed, the hard coat layer was formed, and the primer layer and the hard coat layer were used as the coating layer 2.
The formation process of each layer is demonstrated below (refer FIG. 4).

[Formation of primer layer]
91.8 g of water is added to 220 g of methyl alcohol and mixed with sufficient stirring. After stirring and mixing, composite fine particle sol mainly composed of titanium oxide, tin oxide and silicon oxide (rutile type crystal structure, methanol dispersion, total solid concentration 20% by weight, manufactured by Catalyst Kasei Kogyo Co., Ltd., trade name “OPTRAIQUE 1120Z ”, Hereinafter referred to as“ Optlake 1120Z ”), and mixed by stirring. After stirring and mixing, 77 g of aqueous polyester (manufactured by Ito Optical Co., Ltd.) is added and mixed by stirring. 0.1 g of a silicone-based surfactant (trade name “L-7604” manufactured by Nihon Unicar Co., Ltd.) is added and mixed by stirring for 2 hours. Thereby, a primer composition is obtained as the coating composition L for forming the primer layer.
This primer composition was applied to the surface of the optical substrate 10 under the condition of a pulling speed of 200 mm / min using the dipping device 30 shown in FIG. Then, the heat processing for 30 minutes were performed at 80 degreeC, and the primer layer was formed in the surface of the optical base material 10. FIG.

[Formation of hard coat layer]
67.1 g of γ-glycidoxypropyltrimethoxysilane is added to 62.5 g of butyl cellosolve, and the mixture is sufficiently stirred. Thereafter, 30.7 g of 0.1 mol / liter hydrochloric acid is added dropwise with stirring, and the mixture is further stirred for 4 hours. Thereafter, the silane hydrolyzate is obtained by aging all day and night. To this silane hydrolyzate, 325 g of Optolake 1120Z and 12.5 g of glycerol diglycidyl ether (manufactured by Nagase Kasei Co., Ltd., trade name “Denacol EX-313”) are added. Thereafter, 1.36 g of iron (III) acetylacetonate and 0.15 g of a silicone surfactant (manufactured by Nippon Unicar Co., Ltd., trade name “L-7001”, hereinafter referred to as “L-7001”), phenolic oxidation Add 0.26 g of an inhibitor (trade name “ANTAGE CRYSTAL” manufactured by Kawaguchi Chemical Co., Ltd.) and stir for 4 hours. Thereafter, the hard coat composition α is obtained as the coating composition L by aging for a whole day and night.
This hard coat composition α was applied to the surface of the optical substrate 10 after the primer layer forming step using the dipping apparatus 30 shown in FIG. 4 under the condition of a pulling rate of 200 mm / min. Thereafter, a heat treatment was performed at 80 ° C. for 30 minutes to form a hard coat layer α on the primer layer of the optical substrate 10.
Thereby, the coating layer 2 which consists of a primer layer and the hard-coat layer (alpha) was formed.

[Annealing step S106]
The optical base material 10 on which the coating layer 2 was formed was heated to 125 ° C., which is a temperature equal to or higher than Tg (110 ° C.) of the optical base material 10, and held for 3 hours. The semi-finished lens 1 is completed by this annealing step S106.
An outline of the annealing step S106 of this embodiment is shown in FIG.
In the annealing step S106 of the present embodiment, as shown in FIG. 11, on the glass mold 26 having a convex shape along the facing surface 10B of the optical substrate 10, the facing surface 10B side is down, The optical base material 10 on which the coating layer 2 was formed was installed. In this state, the optical substrate 10 was heated by an electric furnace and kept at a high temperature.
By using the glass mold 26, the deformation of the optical substrate 10 can be more reliably prevented.
The annealing step S106 is not limited to the method using the glass mold 26. For example, the annealing step S106 is an optical in which the coating layer 2 is formed on a ring-shaped jig formed in the same shape as the periphery of the optical substrate 10. You may implement in the state which has arrange | positioned the base material 10. FIG.

[Example 2]
A semi-finished lens 1 was produced in the same manner as in Example 1 except that no primer layer was formed.
[Example 3]
A semi-finished lens 1 was produced in the same manner as in Example 1 except that the hard coat composition β prepared as follows was used and the hard coat layer β was formed instead of the hard coat layer α.
Add 1200 parts by weight of γ-glycidoxypropyltrimethoxysilane to 1000 parts by weight of butyl cellosolve and stir well, then add 300 parts by weight of 0.1 mol / liter hydrochloric acid and continue stirring all day and night to obtain a silane hydrolyzate. . 30 parts by weight of L-7001 was added to the silane hydrolyzate and stirred for 1 hour, and then 7300 parts by weight of a composite fine particle sol mainly composed of titanium oxide (OPTRAIK 1120Z) was added and mixed with stirring for 2 hours. Next, 20 parts by weight of iron (III) acetylacetonate is added and stirred for 1 hour, followed by filtration with a 2 μm filter to obtain a hard coat composition β as the coating composition L.
Using this hard coat composition β, a hard coat layer β is obtained in the same manner as in Example 1.

[Example 4]
In the raw material preparation step S101, tetrakis (3-oxetanylthio) tin (hereinafter referred to as “Sn-2”) is used instead of Sn-1, and 0.3 g of trifluoromethanesulfonic acid in addition to N, N dimethylcyclohexylamine. A semi-finished lens 1 was produced in the same manner as in Example 1 except that was added as a polymerization catalyst.
In this example, the sample of the optical substrate 10 had a refractive index nd = 1.754. Moreover, when the thermomechanical analysis was implemented like Example 1, Tg of the optical base material 10 is 110 degreeC, and the variation | change_quantity of the thickness of the sample in Tg + 10 degreeC (namely, 120 degreeC) of the optical base material 10 is It was 30% or more of the thickness of the sample at the initial temperature.
[Example 5]
A semi-finished lens 1 was manufactured in the same manner as in Example 2 except that the same raw material preparation step S101 as in Example 4 was performed.

[Example 6]
In the raw material preparation step S101, tetrakis (2,3-epoxy-1-propylthio) tin (hereinafter referred to as “Sn-3”) is used, and 0.015 g of trifluoromethanesulfonic acid is added to N, N dimethylcyclohexylamine. A semi-finished lens 1 was produced in the same manner as in Example 1 except that it was blended as a polymerization catalyst.
In this example, the sample of the optical substrate 10 had a refractive index nd = 1.758. Moreover, when the thermomechanical analysis was implemented like Example 1, Tg of the optical base material 10 is 110 degreeC, and the variation | change_quantity of the thickness of the sample in Tg + 10 degreeC (namely, 120 degreeC) of the optical base material 10 is It was 30% or more of the thickness of the sample at the initial temperature.
[Example 7]
A semi-finished lens 1 was produced in the same manner as in Example 2 except that the same raw material preparation step S101 as in Example 6 was performed.

[Example 8]
A semi-finished lens 1 is manufactured in the same manner as in Example 1 except that in the base material forming step S100, a commercially available PMMA (polymethyl methacrylate) pellet is processed into a lens shape by an injection molding method to obtain an optical base material 10. did.
When a thermomechanical analysis was performed on the sample of the optical substrate 10 prepared from the PMMA pellets in the same manner as in Example 1, the Tg of the optical substrate 10 was 110 ° C., and Tg + 10 ° C. of the optical substrate 10 (ie, The amount of change in the thickness of the sample at 120 ° C. was 50% or more of the thickness of the sample at the initial temperature.
[Example 9]
A semi-finished lens 1 was produced in the same manner as in Example 2, except that the same base material forming step S100 as in Example 8 was performed.

[Example 10]
A semi-finished lens 1 was manufactured in the same manner as in Example 1 except that in the base material forming step S100, a commercially available Pst (polystyrene) pellet was processed into a lens shape by an injection molding method to obtain the optical base material 10.
When a thermomechanical analysis was performed on the sample of the optical substrate 10 prepared from the Pst pellets in the same manner as in Example 1, the Tg of the optical substrate 10 was 95 ° C., and Tg + 10 ° C. of the optical substrate 10 (ie, The amount of change in the thickness of the sample at 105 ° C. was 50% or more of the thickness of the sample at the initial temperature.
[Example 11]
A semi-finished lens 1 was produced in the same manner as in Example 2 except that the same base material forming step S100 as in Example 10 was performed.

In Examples 1 to 11 described above, the Tg of the optical substrate 10 is 110 ° C. and 95 ° C.
Here, since the heat treatment in the coating layer forming step S105 is 80 ° C., it is Tg or less of the optical substrate 10. Moreover, since the temperature of annealing process S106 is 125 degreeC, it exceeds Tg of the optical base material 10. FIG.

[Comparative Example 1]
The semi-finished lens 1 was manufactured in the same manner as in Example 1 except that the annealing step S106 was performed without forming the coating layer forming step S105 and without forming the coating layer 2.
[Comparative Example 2]
In the coating layer forming step S105, when the hard coat layer α is formed, the semifinished lens 1 is the same as in Example 1 except that the hard coat composition α is not mixed with iron (III) acetylacetonate. Manufactured.
[Comparative Example 3]
A semi-finished lens 1 was a plastic lens made of a thermosetting resin (manufactured by Seiko Epson, trade name: Seiko Super Sovereign (SSV), refractive index: 1.67).
When a thermomechanical analysis was performed on a sample made of the same thermosetting resin as this lens in the same manner as in Example 1, the Tg of the sample was 100 ° C., and the sample at Tg + 10 ° C. (ie, 110 ° C.) The amount of change in thickness was about 0.01% of the thickness of the sample at the initial temperature.

[Evaluation of semi-finished lens]
The semi-finished lenses 1 of Examples 1 to 11 and Comparative Examples 1 to 3 described above were evaluated by the following evaluation method. The evaluation items were the degree of curing of the coating layer 2 and the degree of deformation of the optical substrate 10.
Hereinafter, an evaluation method for each evaluation item will be described.

[Evaluation of curing]
By touching the optical base material 10 after the coating layer forming step S105 by hand, the degree of curing of the coating layer 2 was evaluated in the following three stages.
○: The coating layer 2 is not sticky or does not collapse.
X: The coating layer 2 is sticky, or at least a part of the coating layer 2 is easily removed from the optical substrate 10.
-: The coating layer 2 is not formed.

[Evaluation of deformation]
The deformation of the optical substrate 10 after the annealing step S106 (that is, the deformation of the optical substrate 10 after completion of the semi-finished lens 1 when compared with the shape of the optical substrate 10 before the annealing step S106) is visually observed. The evaluation was divided into the following three stages.
A: The optical substrate 10 is not deformed.
○: The optical substrate 10 is hardly deformed.
X: The optical substrate 10 is significantly deformed.
The above evaluation results are shown in Table 1 below.

As is clear from Table 1, the semi-finished lenses 1 of Examples 1 to 11 manufactured by the manufacturing method of the present invention are excellent in the degree of curing of the coating layer 2 for preventing deformation, and are annealed at Tg or more of the optical substrate 10. Even in step S106, no deformation has occurred.
In contrast, in the semi-finished lens 1 of Comparative Example 1 in which the coating layer 2 is not formed, deformation occurred due to the annealing step S106.
Further, in the semi-finished lens 1 of Comparative Example 2 in which the coating layer forming step S105 was performed with a hard coat composition not containing iron (III) acetylacetonate, the coating layer 2 was not sufficiently cured, and the annealing step S106 was performed. Deformation was also seen.
Since the semi-finished lens 1 of Comparative Example 3 is formed of a thermosetting resin, no deformation occurs even in the annealing step S106. However, compared with the semi-finished lenses 1 of Examples 1 to 11, the refractive index is low and the optical characteristics as a lens are inferior.

[Effects of Embodiment]
Therefore, according to each above-mentioned embodiment, the following outstanding operations and effects can be obtained.
In the coating layer forming step S105, the coating layer 2 is formed by the coating material that cures at a temperature equal to or lower than the Tg of the optical base material 10. Therefore, when the coating material is cured, the optical base material 10 is heated to the Tg or higher. There is nothing to do. Accordingly, in the coating layer forming step S105, the possibility that the optical substrate 10 having thermoplasticity is deformed is low.
And even if the hardened coating layer 2 is heated to Tg or more of the optical substrate 10, it can maintain its shape without softening.
That is, in the annealing step S106, the optical substrate 10 is softened, but the coating layer 2 provided on the optical surface 10A of the optical substrate 10 is not softened.
Since the coating layer 2 prevents the deformation of the optical substrate 10 and the optical surface 10A softened by heating at Tg or higher, the semi-finished lens 1 having the first surface 1A with high shape accuracy can be obtained.
Therefore, according to the method for manufacturing the semifinished lens 1 of the present invention, it is possible to obtain the semifinished lens 1 which is formed of a thermoplastic resin material and has the first surface 1A having excellent shape accuracy.

  In each of the above-described embodiments, since the optical substrate 10 is formed using the substrate composition containing the compound of the formula (1), a semi-finish that has a high refractive index, high shape accuracy, and excellent optical characteristics. A lens can be manufactured.

  In each of the above-described embodiments, the coating layer forming step S105 also serves as a step of forming a deformation preventing layer on the optical surface 10A of the optical substrate 10. That is, since the coating layer 2 that is a deformation preventing layer is formed on the optical surface 10A of the optical base material 10, it is possible to prevent changes in the shapes of the optical base material 10 and the optical surface 10A in the annealing step S106. Thereby, the semifinished lens 1 which is formed of a resin material having thermoplasticity and has the first surface 1A having excellent shape accuracy can be obtained.

  In each of the above-described embodiments, the coating layer 2 is also formed on the facing surface 10B facing the optical surface 10A of the optical substrate 10 in the coating layer forming step S105. Therefore, the optical substrate 10 of the optical substrate 10 in the annealing step S106 is more surely formed. Deformation can be prevented.

In each of the above-described embodiments, in the post-coating layer forming step S202, the second coating material 3 is formed by the second coating material that is cured at a temperature equal to or lower than the Tg of the optical substrate 10, and thus the second coating material is cured. When making it, the optical base material 10 is not heated more than the Tg. Therefore, in the post-coating layer forming step S202, the possibility that the optical substrate 10 having thermoplasticity is deformed is low.
And even if the hardened 2nd coating layer 3 is heated more than Tg of the optical base material 10, it can maintain the shape, without softening.
That is, in the baking step S203, the optical substrate 10 is softened, but the second coating layer 3 provided on the second surface 1B side of the semifinished lens 1 is not softened. Further, the coating layer 2 provided on the optical surface 10A of the optical substrate 10 is not softened.
Therefore, since the coating layer 2 and the second coating layer 3 prevent deformation of the optical substrate 10 softened by heating of Tg or more, it is possible to obtain the plastic lens 100 having the first surface and the second surface with high shape accuracy. it can.
Therefore, according to the manufacturing method of the plastic lens 100 of the present invention, a plastic lens with high shape accuracy in which the second surface is processed into a desired shape using the semi-finished lens 1 formed of a thermoplastic resin material as a raw material. 100 can be obtained.

  In each of the above-described embodiments, the post-coating layer forming step S202 also serves as a step of forming a deformation preventing layer on the second surface 1B side of the semifinished lens 1. That is, since the second coating layer 3 that is a deformation preventing layer is formed on the second surface 1B side of the semi-finished lens 1, the shape change of the optical substrate 10 can be prevented in the firing step S203. As a result, it is possible to obtain a plastic lens 100 having high shape accuracy in which the second surface is processed into a desired shape using the semi-finished lens 1 formed of a thermoplastic resin material as a raw material.

  In each of the above-described embodiments, the post-coating layer forming step S202 serves as at least one of the primer layer forming step S202A, the hard coat layer forming step S202B, and the antireflection layer forming step S202C. Later steps are shortened. Thus, a simplified method for manufacturing the plastic lens 100 can be provided.

  In each of the above-described embodiments, the second coating layer 3 is also formed on the first surface 1A side of the semifinished lens 1 in the post-coating layer forming step S202. Deformation of the optical substrate 10 in the firing step S203 can be prevented more reliably.

Note that the present invention is not limited to the above-described embodiments, and modifications, improvements, and the like within a scope in which the object of the present invention can be achieved are included in the present invention.
For example, in each of the above-described embodiments, the optical substrate 10 has a shape having a concave surface and a convex surface. However, in the present invention, the optical base material 10 may have a shape having two flat surfaces, and a combination of a flat surface, a concave surface, and a convex surface. The shape may have two concave or convex surfaces, or may have a concave and flat surface and a convex and flat surface.

  The present invention can be used as a method for manufacturing a semi-finished lens, a semi-finished lens, and a plastic lens using a semi-finished lens as a raw material.

1 is a cross-sectional view showing a schematic configuration of a semi-finished lens and a plastic lens according to an embodiment of the present invention. The flowchart figure which shows the manufacturing method of the semi finish lens concerning embodiment of this invention. Schematic which shows the base-material formation process and mold release process concerning embodiment of this invention. The schematic perspective view which shows the immersion apparatus used for the coating layer formation process concerning embodiment of this invention. The schematic sectional drawing which shows the vacuum evaporation system used for the coating layer formation process concerning embodiment of this invention. The flowchart figure which shows the manufacturing method of the plastic lens concerning 1st Embodiment of this invention. The flowchart figure which shows the manufacturing method of the plastic lens concerning 2nd Embodiment of this invention. The flowchart figure which shows the manufacturing method of the plastic lens concerning 3rd Embodiment of this invention. The flowchart figure which shows the manufacturing method of the plastic lens concerning 4th Embodiment of this invention. The flowchart figure which shows the outline of the grinding | polishing process concerning embodiment of this invention. The schematic sectional drawing which shows the annealing process which concerns on the Example of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Semi finish lens, 1A ... 1st surface, 1B ... 2nd surface, 2 ... Coating layer, 3 ... 2nd coating layer, 10 ... Optical base material, 10A ... Optical surface, 10B ... Opposite surface, 11 ... Base material Composition: 20 ... Glass mold for molding, 21, 22 ... Glass mold, 23 ... Adhesive tape, 24 ... Cavity, 25 ... Injection nozzle, 26 ... Glass mold, 30 ... Dipping device, 31 ... Lifting unit, 32 ... Rod, 33 ... Grasping tool, 34 ... Tank, 40 ... Vacuum deposition device, 41 ... Vacuum container, 42 ... Exhaust device, 43 ... Gas supply device, 44 ... Pressure gauge, 45 ... Base material support, 46, 47 ... Evaporation source, 48 ... Filament, 49 ... Heater, 100 ... Plastic lens, L ... Coating composition, P ... Layer

Claims (9)

A method of manufacturing a semi-finished lens having an optically finished first surface and a second surface that is post-processed into a desired shape,
After injecting the base material composition into the mold, the base material composition is polymerized, and a base material forming step for obtaining an optical base material that is optically finished on one side;
A mold release step of removing the mold from the optical substrate obtained in the substrate forming step;
Coating that coats a coating material that cures at a temperature below the glass transition point of the optical substrate on the optical surface of the optical substrate removed from the mold, and then cures the coating material to form a coating layer A layer forming step;
An annealing step of heating the optical substrate on which the coating layer is formed at a temperature equal to or higher than the glass transition point of the optical substrate;
With
When TMA (Thermomechanical Analyzer) was used for thermomechanical analysis of the optical substrate under the conditions of a 50 g load, a 1 mm diameter needle probe, an initial temperature of 25 ° C., and a heating rate of 10 ° C./min, The method for producing a semi-finished lens, characterized in that the amount of change in the thickness of the optical substrate at the glass transition point of the substrate + 10 ° C. is 10% or more of the thickness of the optical substrate at the initial temperature. . In the manufacturing method of the semi-finished lens according to claim 1,
The said base material composition contains the compound represented by following formula (1). The manufacturing method of the semifinished lens characterized by the above-mentioned.

(In Formula (1), M is a Sn atom, Si atom, Zr atom, Ti atom, or Ge atom. R ₁ is an alkylene group having 1 to 4 carbon atoms, and X ₁ is an S atom or It is an O atom, and n represents an integer of 0 to 4. Y is any of the following formula (1-1), formula (1-2), or formula (1-3).
In the manufacturing method of the semi-finished lens according to claim 1 or 2,
The method for producing a semi-finished lens, wherein the coating layer forming step also serves as a step of forming a deformation preventing layer on the optical surface of the optical substrate. In the method of manufacturing a semi-finished lens according to any one of claims 1 to 3,
In the coating layer forming step, the coating layer is also formed on a surface facing the optical surface of the optical base material. A method for producing a semi-finished lens, comprising:   A semi-finished lens manufactured by the method for manufacturing a semi-finished lens according to any one of claims 1 to 4. A polishing step of polishing the second surface of the semi-finished lens manufactured by the method of manufacturing a semi-finished lens according to claim 1;
After the polishing step, a second coating material that cures at a temperature not higher than the glass transition point of the optical substrate is applied to the second surface side of the semi-finished lens, and the second coating material is cured to form a second coating material. A post-coating layer forming step of forming two coating layers;
After the post-coating layer forming step, a firing step of firing the semi-finished lens at a temperature equal to or higher than the glass transition point of the optical substrate;
A method of manufacturing a plastic lens, comprising: In the manufacturing method of the plastic lens of Claim 6,
The post-coating layer forming step also serves as a step of forming a deformation preventing layer on the second surface side of the semi-finished lens. In the manufacturing method of the plastic lens of Claim 6 or Claim 7,
The post-coating layer forming step includes
A primer layer forming step of forming a primer layer on the second surface of the semi-finished lens;
A hard coat layer forming step of forming a hard coat layer on the second surface or the surface of the primer layer;
An antireflection layer forming step of forming an antireflection layer on the second surface or the surface of the hard coat layer or the surface of the primer layer;
A plastic lens manufacturing method characterized by also serving as at least one of the following. In the manufacturing method of the plastic lens in any one of Claim 6 thru | or 8,
In the post-coating layer forming step, the second coating layer is also formed on the first surface side of the semi-finished lens.