JP2014142440A - Method of manufacturing polarizing lens - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a polarizing lens, which can suppress occurrence of aberrations due to deformation of a polarizing lens.SOLUTION: The method of manufacturing a polarizing lens includes steps of: heating a polarizing film; subjecting the heated polarizing film to curved-surface machining; disposing the polarizing film subjected to the curved-surface machining, between a first mold and a second mold facing the first mold; injecting a polymerizable composition between the first mold and the polarizing film subjected to the curved-surface machining and between the second mold and the polarizing film subjected to the curved-surface machining; and polymerizing the polymerizable composition to cure it. In the heating step, the polarizing film is heated at a temperature equal to or higher than 105°C and lower than 150°C.

Description

  The present invention relates to a method for manufacturing a polarizing lens.

  2. Description of the Related Art Conventionally, a polarizing plastic lens (hereinafter also referred to as a polarizing lens) that blocks light in a predetermined polarization direction is known (see, for example, Patent Document 1). The lens described in Patent Document 1 is a polarizing plastic lens in which a polarizing polyvinyl alcohol film is sealed as a polarizing film inside the lens. It is manufactured by injecting a polymerizable composition around the polarizing film and then heating and polymerizing and curing. The polarizing film used in Patent Document 1 is used after being dried in a temperature range of 25 ° C. to 100 ° C. before injection of the polymerizable composition so as not to generate bubbles that can be detected with the naked eye in the lens. I have to.

Special table 2007-523768 gazette

  However, a polarizing lens in which a polarizing film is sealed inside the lens has a problem in that the polarizing plastic lens is deformed after polymerization and curing of the lens substrate by heating, and as a result, aberration occurs in the polarizing lens. Japanese Patent Application Laid-Open No. H10-228561 does not describe that the polarizing lens is deformed or has aberration.

  An object of the present invention is to provide a method for manufacturing a polarizing lens capable of suppressing the deformation of the polarizing lens and the occurrence of aberrations.

  One aspect of the present invention is to heat a polarizing film, process a curved surface of the heated polarizing film, and a first mold and a second mold facing the first mold Disposing the curved film with the curved surface in between, the polarizing film after the curved processing with the first mold and the polarizing film after the curved processing with the second mold And injecting a polymerizable composition between, and polymerizing and curing the polymerizable composition, and the heating comprises heating the polarizing film to 105 ° C. or more and less than 150 ° C. It is a manufacturing method of a polarized lens, which is heating at a temperature.

  According to this aspect, the polarizing film is heated at a temperature of 105 ° C. or higher and lower than 150 ° C., and the heated polarizing film is processed into a curved surface. Then, a polymerizable composition is injected between the first mold and the curved polarizing film and between the second mold and the curved polarizing film. As a result of intensive studies, the present inventors have found that the polarizing lens is deformed when the polarizing film is contracted or deformed by heating for polymerization. The polarizing film can be contracted in advance by heating the polarizing film at a temperature of 105 ° C. or higher and lower than 150 ° C. before the curved surface processing. Thereby, when superposing | polymerizing the polymerizable composition by heating and making it harden | cure, it can suppress that a polarizing film shrink | contracts. Therefore, it can suppress that a polarizing lens deform | transforms by shrinkage | contraction of a polarizing film, and an aberration arises.

  The said aspect WHEREIN: It is preferable to heat the said polarizing film at the temperature of 120 to 130 degreeC.

  When the polarizing film is heated at a temperature of 120 ° C. or higher and 130 ° C. or lower, the polarizing film can be sufficiently contracted, and defects such as discoloration are hardly generated in the polarizing film. Therefore, it is possible to manufacture a polarizing lens with less aberration and good appearance.

  In the above aspect, the curved surface processing includes absorbing moisture to the heated polarizing film, and processing the curved polarizing film after absorbing moisture using a glass mold having a curved surface. Preferably, the method further comprises holding the curved film processed polarizing film on the curved surface of the glass mold and drying the polarizing film.

  By drying the curved polarizing film, it is possible to suppress the generation of bubbles due to moisture in the polarizing film when the polymerizable composition is polymerized and cured. Since the hygroscopic polarizing film is swollen, it shrinks when dried. Therefore, when the polarizing film is dried without being held in the glass mold, the shape of the polarizing film may change from the shape obtained by the curved surface processing. On the other hand, according to this aspect, since the polarizing film is held and dried by the glass mold used for processing the curved surface of the polarizing film, the polarizing film is hardly deformed to a shape different from the shape of the glass mold. Therefore, since it can suppress that the shape of the curved film processed polarizing film changes with drying, a polarizing lens with a more favorable external appearance can be manufactured.

Sectional drawing of the polarizing lens which concerns on this embodiment. (A) (B) Sectional drawing of the polarizing film used for the plastic lens which concerns on this embodiment. The flowchart explaining the manufacturing method of the plastic lens which concerns on this embodiment. (A) (B) (C) (D) The schematic diagram which shows the manufacturing method of the plastic lens which concerns on this embodiment. (A) (B) The schematic diagram which shows the manufacturing method of the plastic lens which concerns on this embodiment. The schematic diagram which shows the manufacturing method of the plastic lens which concerns on this embodiment. The schematic diagram which shows the manufacturing apparatus of the plastic lens which concerns on this embodiment. (A) (B) The schematic diagram which shows the manufacturing method of the plastic lens which concerns on this embodiment. The schematic diagram which shows the manufacturing method of the plastic lens which concerns on this embodiment.

An embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a cross-sectional view of a polarizing lens according to the present embodiment. The polarizing lens 100 in FIG. 1 is a plastic semi-finished lens (hereinafter referred to as a plastic lens 100). “Semi-finished lens” means that one of the object-side surface and the eyeball-side surface constituting the lens is completed, and the other surface is polished according to the prescription of the wearer to complete the lens. It is a lens that can be created. In the present embodiment, a lens obtained by polishing the plastic lens 100 according to the prescription is referred to as a “finished lens”. The finished lens includes both a lens that has been processed into a shape that matches the shape of the spectacle frame and a lens that has not been processed into a shape that matches the shape of the frame. The “object-side surface” of the lens refers to a surface on the target side that is visually recognized by the wearer when the lens is worn as eyeglasses among the surfaces constituting the lens. The “eye-side surface” of the lens refers to a surface on the eyeball side of the wearer when the lens is worn as eyeglasses among the surfaces constituting the lens.

<Lens configuration>
As shown in FIG. 1, the plastic lens 100 is a plastic lens for spectacles, and has a configuration in which a polarizing film 14 is provided between a first lens base 110 and a second lens base 120. . The first lens substrate 110 is provided on the object side of the plastic lens 100 with respect to the polarizing film 14, and the second lens substrate 120 is provided on the eyeball side of the plastic lens 100 with respect to the polarizing film 14. Yes. Therefore, the surface of the first lens substrate 110 opposite to the surface facing the polarizing film 14 is the object-side surface 111 of the plastic lens 100, and faces the polarizing film 14 of the second lens substrate 120. The surface opposite to the surface is a surface 121 on the eyeball side of the plastic lens 100.

  The first lens substrate 110 and the second lens substrate 120 preferably have a refractive index of 1.50 or more, and more preferably have a refractive index of 1.60 or more. Examples of the material of the first lens substrate 110 and the second lens substrate 120 include acrylic resin, thiourethane resin, thioepoxy resin, methacrylic resin, allyl resin, episulfide resin, and polycarbonate resin. . Among these, thiourethane resins and thioepoxy resins are preferable from the viewpoint of thinning. In addition, it is preferable that the 1st lens base material 110 and the 2nd lens base material 120 are the same materials. Further, the first lens base 110 and the second lens base 120 may be colored.

  The resin of the first lens substrate 110 and the second lens substrate 120 is obtained by polymerizing and curing a polymerizable composition. Examples of the polymerizable composition include compounds having allyl groups, acrylic groups, methacryl groups, isocyanate groups, hydroxyl groups, mercapto groups, epoxy groups, episulfide groups, amino groups, allyl groups, and combinations of these compounds. . For example, a composition containing a polyisocyanate compound or polyisothiocyanate compound having two or more isocyanate groups or isothiocyanate groups in one molecule and a polythiol compound having two or more mercapto groups in one molecule is used. Moreover, you may use a thioepoxy compound.

FIG. 2 is a cross-sectional view of the polarizing film 14 used in the plastic lens 100 according to this embodiment.
As shown in FIGS. 2 (A) and 2 (B), the polarizing film 14 of this embodiment is a single layer (FIG. 2 (A)) or a multilayer (FIG. 2) having a resin layer made of polyvinyl alcohol (PVA). 2 (B)). The resin layer of PVA is obtained by uniaxially stretching a PVA film impregnated with iodine or a dichroic dye, and has a polarizing property. The multilayer polarizing film 14 is obtained by laminating triacetyl cellulose (TAC) as a protective layer on one side of a PVA resin layer or on both sides as shown in FIG. PVA is a material having excellent transparency, heat resistance, affinity with iodine or dichroic dye as a dyeing agent, and orientation during stretching. In addition, as the single-layer polarizing film 14, a polarizing film using polyethylene terephthalate (PET) can be used instead of PVA.

  The thickness of the polarizing film 14 is preferably about 10 μm to 500 μm. If the thickness is less than 10 μm, the rigidity becomes weak and handling becomes difficult. On the other hand, when the thickness exceeds 500 μm, since the rigidity is strong, it is difficult to obtain a predetermined curvature when the polarizing film is curved.

<Lens manufacturing method>
A method for manufacturing the plastic lens 100 of the present embodiment will be described with reference to the drawings.
FIG. 3 is a flowchart for explaining a manufacturing process of the plastic lens 100 according to this embodiment. 4 to 9 are schematic views showing a method for manufacturing the plastic lens 100 according to this embodiment. Hereinafter, it demonstrates along the flowchart of FIG.

  First, as shown in FIG. 4A, a film body 10 (polarized film before curved surface processing) obtained by cutting a PVA film into a rectangle is heated at a temperature of 105 ° C. or higher and lower than 150 ° C. (step S300). By heating at a temperature of 105 ° C. or higher and lower than 150 ° C., the film body 10 can be contracted (FIG. 4A). Since the degree of shrinkage of the uniaxially stretched polarizing film 14 varies depending on the direction, the shape changes from the shape before heating when heat is applied. Therefore, if the polarizing film 14 is not heated in advance, the polymerizable composition injected between the first mold 16 and the polarizing film 14 and between the second mold 18 and the polarizing film 14 is heated. Thus, the polarizing film 14 is deformed in the polymerizable composition by heat during polymerization and curing. As a result, the cured first lens base 110 and second lens base 120 are deformed by being pulled by the polarizing film 14, so that aberration is generated in the obtained plastic lens 100. In this embodiment, since the film body 10 is preliminarily contracted by heating, the shrinkage of the film body 10 during polymerization can be suppressed, and as a result, the occurrence of aberration in the plastic lens 100 can be suppressed.

  The temperature which heats the film body 10 is 105 degreeC or more and less than 150 degreeC. When the heating temperature is lower than 105 ° C., the shrinkage of the film body 10 becomes insufficient, and when the polymerizable composition is heated and polymerized and cured, the polarizing film 14 is further shrunk, and the obtained plastic lens 100 may be deformed. Moreover, when the heating temperature is 150 ° C. or higher, the film body 10 is discolored, and the appearance of the plastic lens 100 using the polarizing film 14 formed from the film body 10 may be deteriorated. In order to sufficiently contract the polarizing film 14 and suppress discoloration, it is more preferable to heat at a temperature of 120 ° C. or higher and 130 ° C. or lower.

  Examples of the heating method of the film body 10 include placing the film body 10 in a hot air circulation oven heated to the above temperature and applying hot air. There is no restriction | limiting in particular in heating time, Although it should just heat until the film body 10 fully shrink | contracts, it is preferable to set it as about 30 minutes or more and 5 hours or less. If the heating time is too short, the film body 10, that is, the polarizing film 14 formed from the film body 10 is not sufficiently contracted, and the plastic lens 100 may be deformed. If the heating time is too long, the film body 10 may be discolored and the appearance of the plastic lens 100 may be deteriorated.

  Next, the heated film body 10 is made to absorb moisture (step S302). Inclusion of moisture increases the flexibility of the film body 10 and facilitates curved surface processing. Water absorption is performed by, for example, using an oven capable of adjusting the humidity and appropriately adjusting the humidity and temperature in accordance with the properties of the film body 10.

  Subsequently, the film body 10 is processed into a curved surface (step S304). The curved surface processing is performed by known press means, vacuum forming, or the like. In this embodiment, as shown in FIGS. 4B and 4C, two curved surfaces 12 are formed on the film body 10 by using the glass mold 60 and pressing the film body 10. The glass mold 60 has a curved surface 61 corresponding to the curvature (or shape) of the curved surface 12 to be formed. The curvature (shape) of the curved surface 61 is transferred to the film body 10 by bringing at least a part of the film body 10 into contact with the curved surface 61 of the glass mold 60 and pressing with a pressing means. The curvature of the curved surface 12 of the film body 10 is set according to the base curve (the curvature of the object-side surface 111) of the plastic lens 100 (see FIG. 1) to be manufactured. For example, the curvature of the curved surface 12 may be increased as the base curve is increased. The curvature of the curved surface 12 is different from the base curve of the plastic lens 100 as long as the finished lens can be manufactured (polishing of the semi-finished lens) even if the curvature is the same as the base curve of the plastic lens 100. Also good. In addition, when the finished product lens has a surface shape other than a spherical surface, such as a progressive lens or an aspheric lens, the curved surface 12 may have a surface shape that matches the surface shape of the finished product lens. In the present embodiment, the base curve is divided into several stages, and the curved surface 12 having a different curvature is set for each stage.

  Once the curved surface of the film body 10 is processed, the film body 10 is dried (step S306). By removing the moisture from the film body 10, it is possible to prevent bubbles from being generated in the plastic lens 100 due to a reaction between the moisture in the film body 10 and the polymerizable composition. For drying, a general apparatus such as a hot air circulating oven, a vacuum drying furnace, a desiccator or the like can be used. In this embodiment, drying was performed using a vacuum drying furnace under conditions of a temperature of 80 ° C. and a pressure of 30 Torr (30 Torr≈3999.67 Pa). As a result of investigation, if the heating (step S300) is performed under the above-described conditions, even if the temperature when the moisture is absorbed and then heated again (drying, step S306) is lower than 105 ° C. The inventors have found that the deformation of the plastic lens 100 is suppressed. By drying at a temperature lower than 105 ° C., deterioration of the film body 10 due to heat can be suppressed.

  In the present embodiment, heating (drying) is performed as it is without separating the glass mold 60 and the film body 10. That is, the curved film processed polarizing film (film body 10) is held by the curved surface 61 of the glass mold 60 and heated. Only the film body 10 which is separated from the glass mold 60 and is processed to be curved may be heated, but the shape of the film body 10 may be changed from the shape obtained by the curved surface processing. Since the water-absorbed film body 10 is swollen, it shrinks by drying. Since the film body 10 can be contracted along the shape of the glass mold 60 by being held by the glass mold 60, the curvature and shape of the curved surface 12 are more increased than when heating without using the glass mold 60. Can be molded with high accuracy.

  The glass mold 60 used for drying and the glass mold 60 used for curved surface processing may be the same or different as long as the shape and size of the curved surface 61 are the same. That is, the curved film body 10 may be separated from the glass mold 60 and placed on the glass mold 60 for drying. However, in order to improve processing efficiency and maintain processing accuracy, it is preferable to use the glass mold 60 used for the curved surface processing as it is for drying. In the present embodiment, when the film body 10 is dried, the polarizing film after being curved and cut along the broken line K in FIG. 4D while leaving the film body 10 around each curved surface 12. Get 14.

  The diameter of the polarizing film 14 obtained by cutting the film body 10 is preferably smaller than the inner diameters of the first mold 16 and the second mold 18. For example, the diameter of the polarizing film 14 in this embodiment is preferably about 2 mm smaller than the inner diameter of the first mold 16. Thereby, when the polymerizable composition that is the raw material of the lens base material is injected into a matrix 48 (see FIG. 8B) described later, the polymerizable composition wraps around both sides of the polarizing film 14, The polymerizable composition can be smoothly injected into the matrix 48.

  Next, the polarizing film 14 (dried polarizing film 14) after the curved surface processing is disposed between the first mold 16 and the second mold 18 (step S308). In this embodiment, the adhesive 20 is applied to a part of one mold (16 or 18), and the polarizing film 14 is fixed. The other mold (16 or 18) is disposed on the side opposite to the one mold with respect to the polarizing film 14, and is fixed with a tape 46 to form a mother die 48 (see FIG. 8B).

  The first mold 16 is used to form one of the object-side surface 111 and the eyeball-side surface 121 of the plastic lens 100. The second mold 18 is used to form a surface different from the surface formed by the first mold 16 among the object-side surface 111 and the eyeball-side surface 121. In the present embodiment, the object-side surface 111 is formed by the first mold 16, and the eyeball-side surface 121 is formed by the second mold 18. In this embodiment, the finished lens is obtained by polishing the eyeball side surface 121 of the plastic lens 100 in accordance with the prescription. Therefore, the concave surface 16a of the first mold 16 (the surface facing the second mold 18) is a curved surface that matches the shape of the object-side surface of the finished product lens. The shape of the convex surface 18a (the surface facing the first mold 16) of the second mold 18 is arbitrary as long as a finished lens can be produced by polishing, but in this embodiment, it is a spherical surface.

  The material of the first mold 16 and the second mold 18 is not particularly limited as long as it can withstand the heat at the time of polymerizing the polymerizable composition, and may be inorganic or organic. . When the polarizing film 14 is fixed using the adhesive 20, it is preferable to select materials for the first mold 16 and the second mold 18 in consideration of the properties of the adhesive 20. In this embodiment, since the ultraviolet curable resin adhesive 20 is used, crown glass, which is a heat-resistant material with little deterioration due to ultraviolet rays, is used.

  Hereinafter, step S308 will be described more specifically. FIG. 5A is a plan view of the first mold 16 according to the present embodiment as viewed from below (the eyeball side of the plastic lens 100 to be manufactured). FIG. 5B is a cross-sectional view of the first mold 16 according to the present embodiment. 5A and 5B show a state where the adhesive 20 is applied to the first mold 16. In this specification, “plan view”, “plan view”, and the like mean a state viewed from the optical axis direction of the lens.

  First, the adhesive 20 is applied to the concave surface 16 a of the first mold 16. The first mold 16 according to the present embodiment has a circular shape in plan view, and has a flat peripheral edge (that is, the curvature is substantially zero). The adhesive 20 is applied to the peripheral portion of the concave surface 16a of the first mold 16 at a plurality of locations using a known method such as a dispenser. For example, it is applied to three or four places. In the example shown in FIGS. 5A and 5B, four adhesives 20 are applied at equal intervals.

  The adhesive 20 is preferably a material that hardly alters the polarizing film 14 or chemically reacts with the polymerizable composition. For example, ultraviolet curable resin and thermosetting resin are mentioned. In this embodiment, an ultraviolet curable resin adhesive is used as the adhesive 20. The ultraviolet curable resin is a synthetic resin containing a prepolymer, a monomer, a photopolymerization initiator, and an additive, and has a property of changing from a liquid to a solid when irradiated with ultraviolet rays. The type of the ultraviolet curable resin is not particularly limited, but an appropriate one can be selected in consideration of compatibility with the polarizing film 14 and the polymerizable composition. In this embodiment, an ultraviolet curable epoxy resin is used.

In the present embodiment, the adhesive 20 is applied to the first mold 16 using the discharge device 22.
FIG. 6 is a view showing a method for applying the adhesive 20 to the first mold 16, and FIG. 7 is a view showing a discharge device 22 for applying the adhesive 20. The discharge device 22 of the present embodiment includes a main body 24 having a motor (not shown) built therein, a rotary shaft 26 connected to the main body 24 and driven by the motor, and a table 28 connected to the rotary shaft 26. . A rod 32 is further connected to the main body 24. A syringe 36 is attached to the rod 32 via a slider 34. The viscous adhesive 20 is discharged from the needle 38 at the tip of the syringe 36 at a constant discharge amount by pneumatic control by a dispenser device in the main body 24 (not shown). The needle 38 of this embodiment discharges the adhesive 20 downward in the direction in which gravity acts.

  A flexible pad 30 is disposed on the table 28. When the first mold 16 is mounted on the table 28, the pad 30 contacts the convex surface 16b of the first mold 16 (surface facing the concave surface 16a). The pad 30 only needs to be capable of stably holding the first mold 16. For example, a ring-shaped pad 30 (shown in cross section in the drawing) shown in FIG. 6 may be used. The discharge device 22 may have a configuration in which a plurality of tables 28 and syringes 36 are provided and the adhesive 20 can be applied to the plurality of first molds 16 with a single discharge device 22. Moreover, as long as the adhesive agent 20 can be apply | coated to several places of the 1st mold 16 to desired height, the structure of the discharge apparatus 22 can be changed suitably.

  The first mold 16 is mounted on the table 28, and the position of the syringe 36 is adjusted by the slider 34 so that the needle 38 is disposed at a position facing the peripheral edge of the concave surface 16 a of the first mold 16. The table 28 is rotated to rotate the first mold 16 in the circumferential direction. When the position where the adhesive 20 in the first mold 16 is to be applied reaches below the needle 38, the dispenser device is driven to drive the needle 38. The adhesive 20 is discharged from the front end of the adhesive to the peripheral edge of the concave surface 16a. The height of the adhesive 20 varies depending on the amount of the discharged adhesive 20. Therefore, the distance between the polarizing film 14 and the concave surface 16a can be adjusted by adjusting the discharge amount of the adhesive 20. It is preferable that the adhesives 20 applied to the respective positions of the concave surface 16a have substantially the same height. It is possible to vary the height of the adhesive 20 for each application position.

Next, the polarizing film 14 is fixed to the first mold 16 to which the adhesive 20 is applied, and the mother die 48 is formed.
8A, 8B, and 9 are schematic views illustrating a method for manufacturing the plastic lens 100 according to the present embodiment. FIG. 8A is a view showing a method for fixing the polarizing film 14 to the first mold 16, and FIG. 8B is a view showing a method for forming the mother die 48. FIG. 9 is a schematic view for injecting a polymerizable composition into the matrix 48.

  As shown to FIG. 8 (A), the polarizing film 14 and the 1st mold 16 are made to approach. Either one of the polarizing film 14 and the first mold 16 may be moved or both may be moved. The convex surface of the curved surface 12 of the polarizing film 14 and the concave surface 16a of the first mold 16 are opposed to each other and approached. When the curved surface 12 of the polarizing film 14 is not a spherical surface, positioning is performed so that the shape of the curved surface 12 and the shape of the concave surface 16a of the first mold 16 are in an appropriate direction.

  When the polarizing film 14 and the first mold 16 are properly positioned, the concave surface 16a of the first mold 16 and the polarizing film 14 are brought close to the distance below the height of the adhesive 20, and the adhesive is applied to the polarizing film 14. 20 is brought into contact. Subsequently, the ultraviolet irradiation device 40 is driven to irradiate the adhesive 20 with ultraviolet rays from the irradiation lamp 44 to solidify the adhesive 20. Thereby, the polarizing film 14 and the 1st mold 16 are adhere | attached. The time for irradiating the ultraviolet rays is several seconds to several tens of seconds depending on the type of the adhesive 20. For example, ultraviolet rays are irradiated at 500 mW for 15 seconds. The adhesive 20 may not be completely solidified as long as the polarizing film 14 is fixed (if it is not peeled off in the subsequent steps). When the adhesive 20 is a material other than the ultraviolet curable resin, an apparatus or a method for solidifying the adhesive 20 can be used instead of the ultraviolet irradiation device 40.

  Next, the second mold 18 is placed on the concave surface of the polarizing film 14 (opposite to the surface facing the first mold 16) so that the distance between the first mold 16 and the second mold 18 is a predetermined distance. Side surface). That is, the polarizing film 14 is disposed between the first mold 16 and the second mold 18 facing the first mold 16. The predetermined distance here is a distance necessary for molding the plastic lens 100. The second mold 18 is the same as the first mold 16 except that the second mold 18 is a curved surface used to mold the eyeball-side surface 121 of the plastic lens 100 on which the convex surface 18a is molded.

  Next, as shown in FIG. 8 (B), a tape 46 having an adhesive layer on one side is placed around the side surfaces of the first mold 16 and the second mold 18 arranged at a predetermined distance from each other. Wrap a little more. At this time, the first mold 16 and the second mold 18 are held by the fixed pad 52. The fixed pad 52 is rotationally driven by a rotating shaft 54 connected to a motor device (not shown).

  The material of the tape 46 is not particularly limited. In view of ease of use and economy, it is preferable to use a plastic adhesive tape. For example, a base material made of polypropylene and a polyethylene terephthalate pressure-sensitive adhesive tape and an acrylic, natural rubber-based, or silicon-based pressure-sensitive adhesive can be used in combination. The tape 46 may be provided with an injection hole (not shown) for injecting a polymerizable composition.

  Returning to the description of FIG. As shown in FIG. 9, a polymerizable composition is injected into the assembled matrix 48 (step S310). A polymerizable composition is injected between the first mold 16 and the polarizing film 14 and between the second mold 18 and the polarizing film 14 from the injection hole using an injector or the like. A polymerizable composition may be injected between the first mold 16 and the polarizing film 14 and between the second mold 18 and the polarizing film 14. When the polarizing film 14 smaller than the inner diameters of the first and second molds 16 and 18 is used, the polymerizable composition moves through the gap between the polarizing film 14 and the tape 46 as described above. The polymerizable composition can be wrapped around from one mold side to the other mold side.

  Next, the polymerizable composition filled in the matrix 48 is polymerized and cured (step S312). Polymerization hardening is performed by putting the mother mold 48 filled with a polymerizable composition into a heating furnace and heating it. The heating temperature is preferably 0 ° C. or higher and 150 ° C. or lower, more preferably 10 ° C. or higher and 130 ° C. or lower. Preferably, the temperature rises over 5 hours to 50 hours, more preferably 10 hours to 25 hours to polymerize the polymerizable composition. For example, the temperature is maintained at 30 ° C. for 7 hours, and then the temperature is raised to a temperature of 30 ° C. or more and 120 ° C. or less over 15 hours.

  When the heat treatment is completed, the polymerizable composition is cured, and the plastic lens 100 in which the polarizing film 14 is incorporated is obtained. The mother mold 48 is taken out of the heating furnace, the tape 46 is peeled off, the first mold 16 and the second mold 18 are separated from the plastic lens 100, and the plastic lens 100 (semi-finish lens) shown in FIG. ).

  The plastic lens 100 is preferably heated (annealed) after being taken out of the matrix 48. By releasing the stress accumulated in the plastic lens 100 in the process up to the polymerization curing by heat, it is possible to suppress the plastic lens 100 from being deformed by the stress later.

  The eyeball side surface 121 of the plastic lens 100 is polished according to the prescription of the spectacle wearer to obtain a finished product lens. The finished lens after polishing may be further subjected to surface treatment such as application of a primer, a hard coat, and an antireflection film, and water / oil repellent treatment. By processing the finished lens in accordance with the shape of the spectacle frame, the spectacles having the polarizing lens can be manufactured by attaching the lens to the spectacle frame.

  It should be noted that the present invention can be embodied with the following modifications.

  The object to which the adhesive 20 is applied in the above embodiment is not limited to the first mold 16 and may be applied to the polarizing film 14. Alternatively, the adhesive 20 may be applied to the second mold 18 (mold for forming the eyeball-side surface 121).

  In the said embodiment, although the material of the 1st and 2nd molds 16 and 18 was glass, you may use resin. Resin is easily deteriorated compared to glass, but is inexpensive and easy to mold. Therefore, it is suitable for use in molding a small amount of sample product, for example.

  In the above embodiment, the mother die 48 is assembled using the tape 46, but a gasket may be used instead of the tape 46.

  The shapes of the first mold 16 and the second mold 18 are not limited to the shapes used in the above embodiment. Further, the finished lens may be a single focus lens, a progressive power lens or a multifocal lens.

  Next, examples will be described. In the following, the same components as those in the above embodiment are denoted by the same reference numerals as those in the above embodiment, and the description thereof is omitted.

<Example 1>
A commercially available PVA dichroic dye-based polarizing film (film body 10) was heated at a temperature of 120 ° C. for 0.5 hours using a hot-air circulating oven. The heated film body 10 was made to absorb moisture, and a curved surface was processed into a spherical shape using a glass mold 60. Subsequently, the film body 10 was cut into an appropriate size (polarizing film 14) and dried under conditions of a temperature of 80 ° C. and a pressure of 30 Torr for 24 hours. The radius of curvature of the dried polarizing film 14 was 130.4 mm. The dried polarizing film 14 was placed between the first mold 16 and the second mold 18, and the mother die 48 was assembled using the tape 46. The shape of the concave surface 16a of the first mold 16 and the convex surface 18a of the second mold 18 was spherical, and the radius of curvature was 130.4 mm. The diameters of the first and second molds 16 and 18 were 80 mm.

  Next, 49.3 g of m-xylylene diisocyanate and 50.7 g of 4,8, 4,7 or 5,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane were mixed. The mixture was sufficiently stirred to prepare a uniform mixed solution. To this mixed solution, 0.085 g of an internal mold release agent “ZEREC UN” (manufactured by Stepan) and 1.3 g of an ultraviolet absorber “SEESORB701P” (manufactured by Sipro Kasei Co., Ltd., “SEESORB” is a registered trademark) are added. Then, it was sufficiently stirred and dissolved. Next, 0.03 g of dibutyltin dichloride is added as a curing catalyst, and after sufficiently stirring and dissolving, deaeration is performed for 60 minutes under a vacuum of 5 mmHg to prepare a polymerizable composition for a lens substrate. did. The prepared polymerizable composition was poured into a matrix 48, heated in an air polymerization furnace from 30 ° C. to 120 ° C. over 21 hours, and cured by polymerization to have a refractive index of 1.67 and an Abbe number of 32. A plastic lens 100 (semi-finished lens) was obtained.

<Lens evaluation>
The obtained plastic lens 100 was evaluated according to the following criteria. Other examples and comparative examples were evaluated in the same manner. The evaluation results are shown in Table 1.

Lens Deformation For the plastic lens 100 produced in Example 1, the curvature radius measuring device “FOCOVISON” (manufactured by Automation & Robotics) is used to determine the maximum curvature radius (Rmax) and minimum curvature radius (Rmin) of the convex geometric center of the plastic lens 100. ). The difference between Rmax and Rmin (Rmax−Rmin) was used as an index of lens deformation (aberration) and evaluated as follows. The convex geometric center is an intersection of a perpendicular passing through the center of the circle of the plastic lens 100 in plan view and the object-side surface 111.
Rmax-Rmin is 0 mm or more and less than 3 mm: ○
3 mm or more and less than 4 mm: △
4 mm or more: ×
It was.

-Discoloration of polarizing film The presence or absence of discoloration of the polarizing film 14 in the plastic lens 100 was confirmed visually.
No discoloration: ○
Discoloration that does not change the hue as compared with the polarizing film 14 before processing is seen: Δ
Discoloration clearly different in hue compared with the polarizing film 14 before processing: x
It was.

-Comprehensive evaluation Neither the deformation | transformation of the plastic lens 100 nor the discoloration of the polarizing film 14 had x determination, and what was (triangle | delta) determination was set to (circle) and x which has at least 1 determination. A case in which both evaluation items were ○ was rated as ◎.

<Example 2>
A plastic lens 100 was produced in the same manner as in Example 1 except that the polarizing film 14 was heated for 2 hours.

<Examples 3 to 5>
A plastic lens 100 was produced in the same manner as in Example 2 except that the polarizing film 14 was heated at the temperature shown in Table 1.

<Example 6>
A commercially available polarizing film (indicated as TAC / PVA in Table 1) in which a protective layer of TAC was formed on both sides of a PVA dichroic dye polarizing film was used instead of the PVA dichroic polarizing film. A plastic lens 100 was produced in the same manner as in Example 2.

<Example 7>
A plastic lens 100 was produced in the same manner as in Example 6 except that the polarizing film 14 was heated at a temperature of 140 ° C.

<Comparative Example 1>
A plastic lens 100 was produced in the same manner as in Example 1 except that the polarizing film 14 was used without being heated.

<Comparative Examples 2-4>
A plastic lens 100 was produced in the same manner as in Example 1 except that the polarizing film 14 was heated under the conditions shown in Table 1.

<Comparative Examples 5 and 6>
A plastic lens 100 was produced in the same manner as in Example 6 except that the polarizing film 14 was heated at the temperature shown in Table 1.

  As shown in Table 1, in Examples 1 to 5 and Comparative Example 4 in which the PVA polarizing film 14 was heated at a temperature of 105 ° C. or higher, the deformation of the lens was Δ or ○ (Rmax−Rmin is 0 mm or more and less than 4 mm). Met. On the other hand, in Comparative Example 1 in which the PVA polarizing film 14 was not heated, and in Comparative Examples 2 and 3 in which the PVA polarizing film 14 was heated at a temperature of 100 ° C. or less, the deformation of the lens was x (Rmax−Rmin is 4 mm or more). Although the heating time differs between Example 1 and Example 2, the deformation of the lens is ◯ in both cases. In Comparative Examples 2 and 3, heating is performed for a longer time than in Examples 1 to 5, but the deformation of the lens is x. Further, similar results were obtained from Examples 6 and 7 and Comparative Examples 5 and 6 using the TAC / PVA polarizing film 14. Therefore, it can be seen that the deformation of the lens is suppressed by heating the polarizing film 14 at a temperature of 105 ° C. or higher. When Rmax−Rmin is less than 4 mm, that is, when the deformation of the lens is Δ or ○, the aberration generated in the plastic lens 100 is at a level that can withstand actual use. When the deformation of the lens is x, the aberration is not sufficiently suppressed and is not suitable for actual use. Therefore, it is possible to suppress the occurrence of aberration in the plastic lens 100 by heating the polarizing film 14 at a temperature of 105 ° C. or higher.

  Among Examples 1 to 7 and Comparative Examples 4 and 6 in which the polarizing film 14 was heated at a temperature of 105 ° C. or higher, in Example 4 heated at 105 ° C., the deformation of the lens was Δ. Since all the other examples and comparative examples heated at a temperature of 120 ° C. or higher are deformed, it can be seen that the aberration can be more reliably suppressed by heating at a temperature of 120 ° C. or higher.

  Of Examples 1 to 7 and Comparative Examples 4 and 6 in which the polarizing film 14 was heated at a temperature of 105 ° C. or higher, in Comparative Examples 4 and 6 heated at a temperature of 150 ° C., the discoloration of the polarizing film 14 was x and 140 ° C. In Examples 5 and 7 heated at a temperature, the discoloration of the polarizing film 14 was Δ. It is considered that the polarizing film 14 has deteriorated because the heating temperature was too high. Accordingly, the heating temperature is preferably less than 150 ° C, and more preferably 130 ° C or less. By setting the temperature to less than 150 ° C., appearance defects due to discoloration can be made difficult to occur. By setting the temperature to 130 ° C. or lower, it is possible to obtain the plastic lens 100 with better appearance.

  In each of the above examples, the polarizing film 14 was heated and then curved. It has been clarified that once the polarizing film 14 is heated, aberrations occurring in the plastic lens 100 can be suppressed even if the polarizing film 14 is subjected to moisture absorption after the heating. That is, it became clear that the timing of heating can be made before the curved surface processing.

  From the above, by heating the polarizing film 14 at a temperature of 105 ° C. or higher and lower than 150 ° C., it is possible to obtain the plastic lens 100 in which aberration is suppressed and color change is small. By heating the polarizing film 14 at a temperature of 120 ° C. or higher and 130 ° C. or lower, it is possible to obtain the plastic lens 100 with smaller aberration and less discoloration.

  DESCRIPTION OF SYMBOLS 10 ... Film body, 12 ... Curved surface, 14 ... Polarizing film, 16 ... First mold, 16a ... Concave surface, 16b ... Convex surface, 18 ... Second mold, 18a ... Convex surface, 20 ... Adhesive, 22 ... Discharge device , 24 ... Main body, 26 ... Rotating shaft, 28 ... Table, 30 ... Pad, 32 ... Rod, 34 ... Slider, 36 ... Syringe, 38 ... Needle, 40 ... Ultraviolet irradiation device, 44 ... Irradiation lamp, 46 ... Tape, 48 ... Matrix, 52 ... Fixed pad, 54 ... Rotating shaft, 60 ... Glass mold, 61 ... Curved surface, 100 ... Plastic lens (polarizing lens), 110 ... First lens substrate, 111 ... Object side surface, 120 ... Second lens substrate, 121... Eyeball side surface.

Claims (3)

Heating the polarizing film;
Processing the curved surface of the heated polarizing film;
Disposing the curved film with the curved surface between a first mold and a second mold facing the first mold;
Injecting a polymerizable composition between the first mold and the polarizing film after the curved surface processing, and between the second mold and the polarizing film after the curved surface processing;
Polymerizing and curing the polymerizable composition;
Including
The heating is to heat the polarizing film at a temperature of 105 ° C. or more and less than 150 ° C.,
A manufacturing method of a polarizing lens. Heating the polarizing film is heating the polarizing film at a temperature of 120 ° C. or higher and 130 ° C. or lower.
The manufacturing method of the polarizing lens of Claim 1. The curved surface processing is
Absorbing the heated polarizing film; and
Processing the polarizing film after absorbing moisture using a glass mold having a curved surface,
Further comprising holding and drying the curved film of the polarizing film on the curved surface of the glass mold,
The manufacturing method of the polarizing lens of Claim 1 or Claim 2.

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