JP2020173284A - Method of manufacturing optical component - Google Patents

Abstract

To provide a method of manufacturing an optical component with superior optical properties, which allows for protecting a half mirror layer during and after manufacture.SOLUTION: An optical component manufacturing method of the present invention is for an optical component comprising: a light-transmissive lens layer; and an optical laminate comprising light-transmissive first and second base materials, and a half mirror layer located between the two base materials and designed to transmit a portion of incident light and reflect the rest. The method comprises: a half mirror layer formation step of laminating the half mirror layer on the first base material; a first bonding step of bonding the second base material onto a surface of the half mirror layer on a side opposite the first base material; and a second bonding step of melting a resin material forming the lens layer and bonding the same to the second base material on a side opposite the half mirror layer.SELECTED DRAWING: Figure 8

Description

The present invention relates to a method for manufacturing an optical component.

Various optical multilayer films are used in optical products such as eyeglasses and cameras, and devices that cause optical and visual phenomena such as display screens of display devices (see, for example, Patent Document 1).

The optical multilayer film is used as, for example, an antireflection film or a half mirror.
The optical multilayer film described in Patent Document 1 is manufactured by forming and laminating a metal thin film on the surface of a transparent base material such as a lens by, for example, a vacuum vapor deposition method. Then, by appropriately setting the thickness and material of each metal thin film, the optical multilayer film functions as an antireflection film or a half mirror.

However, the optical multilayer film disclosed in Patent Document 1 is exposed on the surface portion (outermost layer) of the optical component, and may be worn or damaged. Depending on the degree of this damage, the optical properties may deteriorate.

Further, as a configuration in which the optical multilayer film is not exposed on the surface, for example, the optical multilayer film is laminated on a transparent base material, and the laminated body is formed so that the optical multilayer film is located on the lens side. A configuration that joins the lens is conceivable. In this case, for example, a manufacturing method is conceivable in which a laminated body is arranged on the bottom surface of a jig having a recess so that the optical multilayer film faces the opposite side to the bottom surface, and the molten lens material is poured onto the laminate.

However, in such a method, when the molten material is poured, the optical multilayer film is peeled off or the optical multilayer film is deformed. At such a damaged portion of the half mirror, desired optical characteristics cannot be obtained, and the optical characteristics of the optical multilayer film are deteriorated.

JP-A-2009-058703

An object of the present invention is to provide a method for manufacturing an optical component that can protect the half mirror layer during and after manufacturing and manufacture an optical component having excellent optical characteristics.

Such an object is achieved by the present invention of the following (1) to (7).
(1) A lens layer having light transmission and
An optical laminate having a first base material and a second base material having light transmittance, and a half mirror layer located between them, which transmits a part of incident light and reflects the rest. It is a manufacturing method of an optical component for manufacturing an optical component provided with
A half mirror layer forming step of laminating the half mirror layer on the first base material,
A first joining step of joining the second base material to the surface side of the half mirror layer opposite to the first base material,
A method for manufacturing an optical component, which comprises a second joining step of melting and joining a resin material to be a lens layer on a surface side of the second base material opposite to the half mirror layer.

(2) The method for manufacturing an optical component according to (1) above, wherein in the first joining step, the half mirror layer and the second base material are joined via an adhesive layer.

(3) The method for manufacturing an optical component according to (2) above, wherein the adhesive layer contains a silylated urethane adhesive.

(4) In the second joining step, a jig having a concave portion having a curved concave surface at the bottom is used, the optical laminate is arranged on the curved concave surface, and in the arranged state, the melted state is provided in the concave portion. The method for manufacturing an optical component according to any one of (1) to (3) above, which supplies a resin material.

(5) The method for manufacturing an optical component according to any one of (1) to (4) above, wherein the melting point of the resin material is 200 ° C. or higher and 280 ° C. or lower.

(6) The method for manufacturing an optical component according to any one of (1) to (5) above, wherein the melting point of the second base material is higher than the melting point of the resin material.

(7) The method for manufacturing an optical component according to any one of (1) to (6) above, wherein the thickness of the second base material is 100 μm or more and 1000 μm or less.

According to the present invention, the half mirror layer can be protected during and after manufacturing, and an optical component having excellent optical characteristics can be manufactured.

FIG. 1 is a perspective view of sunglasses including an optical component manufactured by the method for manufacturing an optical component of the present invention. FIG. 2 is a perspective view of a sun visor including an optical component manufactured by the method for manufacturing an optical component of the present invention. FIG. 3 is an enlarged cross-sectional view of an optical laminate manufactured by the method for manufacturing an optical component of the present invention. FIG. 4 is a cross-sectional view for explaining the manufacturing method (first embodiment) of the optical component of the present invention, and is a diagram showing a preparation process. FIG. 5 is a cross-sectional view for explaining the manufacturing method (first embodiment) of the optical component of the present invention, and is a diagram showing a half mirror layer forming step. FIG. 6 is a cross-sectional view for explaining a method for manufacturing an optical component (first embodiment) of the present invention, and is a diagram showing a first joining step. FIG. 7 is a cross-sectional view for explaining a method for manufacturing an optical component (first embodiment) of the present invention, and is a diagram showing a first joining step. FIG. 8 is a cross-sectional view showing an optical component manufacturing apparatus (first embodiment) used in the second joining step of the optical component manufacturing method of the present invention. FIG. 9 is an enlarged schematic cross-sectional view showing a state in which the second joining step of the method for manufacturing an optical component of the present invention is being performed. FIG. 10 is an enlarged schematic cross-sectional view showing a state in which the lens and the optical laminate are joined by a conventional manufacturing method.

Hereinafter, a method for manufacturing an optical component of the present invention will be described in detail based on a preferred embodiment shown in the accompanying drawings.

<First Embodiment>
FIG. 1 is a perspective view of sunglasses including an optical component manufactured by the method for manufacturing an optical component of the present invention. FIG. 2 is a perspective view of a sun visor including an optical component manufactured by the method for manufacturing an optical component of the present invention. FIG. 3 is an enlarged cross-sectional view of an optical laminate manufactured by the method for manufacturing an optical component of the present invention.

In FIGS. 1 and 2, when the sunglasses and the sun visor are worn on the user's head, the eye-side surface of the lens is referred to as the back surface, and the opposite surface is referred to as the front surface. Also called. That is, in FIG. 3, the left side surface is the “front side surface” and the right side surface is the “back side surface”. Further, in FIGS. 3 to 10, the thickness direction of the optical laminate is exaggerated, but the actual dimensions are significantly different.

The optical laminate 100 is used by being laminated on the lens 4 of the sunglasses 1 (optical component) shown in FIG. 1 and the light transmitting member 7 of the sun visor 1'(optical component) shown in FIG.

As shown in FIG. 1, the sunglasses 1 includes a frame 2 worn on the user's head and a lens 3 (optical component) with an optical laminate fixed to the frame 2. In the present specification, the "lens" includes both a lens having a light-collecting function and a lens having no light-collecting function.

As shown in FIG. 1, the frame 2 is attached to the user's head, and includes a rim portion 21, a bridge portion 22, a temple portion 23 hung on the user's ear, and a nose pad portion 24. have. Each rim portion 21 has a ring shape, and is a portion on which the lens 3 with an optical laminate is mounted.

The lens 3 with an optical laminate has an optical laminate 100 and a lens 4, and the optical laminate 100 is formed on the front surface of the lens 4. As a result, the function as sunglasses can be exhibited while enjoying the advantages of the optical laminate 100 described later.

The bridge portion 22 is a portion that connects the rim portions 21. The temple portion 23 has a vine shape and is connected to the edge portion of each rim portion 21. The temple portion 23 is a portion that can be hung on the user's ear. The nose pad portion 24 is a portion that comes into contact with the user's nose when the sunglasses (optical components) are worn on the user's head. As a result, the mounted state can be stably maintained.

The shape of the frame 2 is not limited to the one shown in the figure as long as it can be worn on the user's head.

As shown in FIG. 2, the sun visor 1'has a ring-shaped mounting portion 5 mounted on the user's head and a brim 6 provided in front of the mounting portion 5. The brim 6 (optical component) has a light transmitting member 7 (base material) and an optical laminate 100 provided on the upper surface of the light transmitting member 7.

The constituent materials of the lens 4 and the light-transmitting member 7 are not particularly limited as long as they have light-transmitting properties, and are, for example, various thermoplastic resins, thermosetting resins, photocurable resins, and the like. Examples thereof include various resin materials of various curable resins, various glass materials, various crystal materials, and the like, but polycarbonate is preferable. As will be described later, the second base material 20 of the optical laminate 100 may be made of polycarbonate. In this case, the adhesion between the lens 4 or the light transmitting member 7 and the optical laminate 100 is improved. Can be enhanced.

Examples of the resin material include polyolefins such as polyethylene, polypropylene and ethylene-propylene copolymer, polyvinyl chloride, polystyrene, polyamide, polyimide, polycarbonate, poly- (4-methylpentene-1), ionomer and acrylic resin. , Polymethylmethacrylate, acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylonitrile-styrene copolymer (AS resin), butadiene-styrene copolymer, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), etc. Polyether, polyether, polyetherketone (PEK), polyetheretherketone (PEEK), polyetherimide, polyacetal (POM), polyphenylene oxide, polysulfone, polyethersulfone, polyphenylene sulfide, polyallylate, aromatic polyester (liquid crystal) Polymers), polytetrafluoroethylene, polyvinylidene fluoride, other fluororesins, epoxy resins, phenol resins, urea resins, melamine resins, silicone resins, polyurethanes, etc., or copolymers, blends, polymer alloys mainly composed of these. Etc., and one or more of these can be used in combination.

The glass material is not particularly limited as long as it has light transmittance, and examples thereof include soda glass, crystalline glass, quartz glass, lead glass, potassium glass, borosilicate glass, and non-alkali glass. Be done.

The crystal material is not particularly limited as long as it has light transmittance, and examples thereof include sapphire and quartz. The thickness of the lens 4 or the light transmissive member 7 is not particularly limited, and is preferably 0.5 mm or more and 5.0 mm or less, and more preferably 1.0 mm or more and 3.0 mm or less. .. As a result, both relatively high strength and weight reduction can be achieved at the same time.

Hereinafter, the optical laminate 100 will be described in detail. In the following, a case where the lens 4 (base material) is laminated will be typically described.

As shown in FIG. 3, the optical laminate 100 includes a first base material 10, a second base material 20, a half mirror layer 30 (optical multilayer film) provided between them, and a half mirror layer 30. It is composed of a laminate having an adhesive layer 40 provided between the second base material 20 and the second base material 20.

Further, the optical laminate 100 is a laminate in which the second base material 20, the adhesive layer 40, the half mirror layer 30, and the first base material 10 are laminated in this order. Further, the optical laminate 100 is used by being laminated on the lens 4 so that the first base material 10 is located on the opposite side of the lens 4, that is, on the front side.

Further, the optical laminate 100 has flexibility. As a result, even if the lens 4 has a curved shape, the optical laminated body 100 can be laminated following the curvature.

(1st base material and 2nd base material)
The first base material 10 and the second base material 20 have a function of supporting and protecting the half mirror layer 30.

The first base material 10 and the second base material 20 are made of a material having light transmission (visible light transmission). The constituent materials of the first base material 10 and the second base material 20 are not particularly limited, but are, for example, cyclic ether-based resins such as acrylic resins, methacrylic resins, polycarbonates, polystyrenes, epoxy resins and oxetane resins. , Polyamide, Polygonate, Polybenzoxazole, Polysilane, Polysilazane, Silicone resin, Fluorine resin, Polyurethane, Polyethylene resin, Polybutadiene, Polyisoprene, Polychloroprene, Polyester such as PET and PBT, Polyethylene succinate, Polysulfone, Poly Examples thereof include ethers, cyclic olefin resins such as benzocyclobutene resins and norbornene resins, and one or a combination of two or more of these (polymer alloy, polymer blend (mixture), copolymer). Etc.) can be used.

Among these, by using polycarbonate, the heat resistance and abrasion resistance of the optical laminate 100 can be made excellent. Further, by using a polyamide resin, impact resistance and chemical resistance can be made excellent.

The constituent materials of the first base material 10 and the second base material 20 may be the same or different.

The thicknesses of the first base material 10 and the second base material 20 may be the same or different, for example, preferably 100 μm or more and 1000 μm or less, and more preferably 200 μm or more and 900 μm or less. preferable. In particular, by setting the thickness of the second base material 20 to such a numerical value, the function of protecting the half mirror layer 30 at the time of manufacturing can be more reliably exhibited, as will be described later.

The colors of the first base material 10 and the second base material 20 may be colorless, red, blue, yellow, or any other color.

The selection of these colors is made possible by including a dye or pigment in at least one of the first base material 10 and the second base material 20. Examples of this dye include acid dyes, direct dyes, reactive dyes, basic dyes, and the like, and one or a combination of two or more selected from these can be used.

Specific examples of the dye include, for example, C.I. I. Acid Yellow 17, 23, 42, 44, 79, 142, C.I. I. Acid Red 52,80,82,249,254,289, C.I. I. Acid Blue 9,45,249, C.I. I. Acid Black 1,2,24,94, C.I. I. Food Black 1, 2, C.I. I. Direct Yellow 1,12,24,33,50,55,58,86,132,142,144,173, C.I. I. Direct Red 1,4,9,80,81,225,227, C.I. I. Direct Blue 1,2,15,71,86,87,98,165,199,202, C.I. I. Direct Black 19, 38, 51, 71, 154, 168, 171, 195, C.I. I. Reactive Red 14, 32, 55, 79, 249, C.I. I. Reactive Black 3, 4, 35 and the like can be mentioned.

(Half mirror layer)
The half mirror layer 30 is provided between the first base material 10 and the second base material 20, and has a function of transmitting a part of incident light and reflecting the rest, that is, a layer having a so-called half mirror function. Is.

The half mirror layer 30 has a high refractive index layer 31 and a low refractive index layer 32 having a refractive index lower than that of the high refractive index layer 31. In the illustrated configuration, the high refractive index layer 31 and the low refractive index layer 32 are laminated in this order from the front side (first base material 10 side).

The high-refractive index layer 31 and the low-refractive index layer 32 are thin-film vapor deposition films formed by, for example, vacuum vapor deposition such as resistance heating method and electron beam heating method (EB method), and the half mirror layer 30 is a laminate of these. The body.

Further, as the constituent materials of the high refractive index layer 31 and the low refractive index layer 32, for example, SiO ₂ , SiO, TiO ₂ , TiO, Ti ₂ O ₃ , Ti ₂ O ₅ , Al ₂ O ₃ , TaO ₂ , Ta ₂ O ₅ , NdO ₂ , NbO, Nb ₂ O ₃ , NbO ₂ , Nb ₂ O ₅ , CeO ₂ , MgO, Y ₂ O ₃ , SnO ₂ , WO ₃ , HfO ₂ , ZrO ₂ , Sc ₂ O _3, CrO , Cr ₂ O ₃ , In ₂ O ₃ , La ₂ O ₃ , CaF ₂ , MgF ₂ , Na ₃ AlF ₆ , AlF ₃ , BaF ₃ , CeF ₃ , CaF ₂ , LaF ₂ , LiF, Na ₅ Al ₃ F ₁₄ , NdF ₃ , YF _{3, and} other oxides or fluorides, and metal materials such as In, Cr, Ti, Ni, Au, Cu, Sn, Zr, and Al.

Among the above metal materials, the constituent material of the high refractive index layer 31 is preferably Cr or Zr. On the other hand, the constituent material of the low refractive index layer 32 is preferably In among the above metal materials. As a result, the refractive index of the high refractive index layer 31 can be made higher than that of the low refractive index layer 32. Therefore, as will be described later, the half mirror layer 30 has a half mirror function. Further, the bendability of the half mirror layer 30 can be improved, that is, cracks can be less likely to occur.

Among the above oxides, the constituent material of the high refractive index layer 31 is preferably Ta ₂ O ₅ , HfO ₂ , Y ₂ O ₃ , Sc ₂ O ₃ , and more preferably ZrO ₂ and CeO _2. preferable. On the other hand, among the above oxides, the constituent material of the low refractive index layer 32 is preferably, for example, SiO, SiO ₂ , MgF ₂ , CaF ₂ , Na ₃ AlF ₆ , Na ₅ Al ₃ F ₁₄ . As a result, the refractive index of the high refractive index layer 31 can be made higher than that of the low refractive index layer 32. Therefore, as will be described later, the half mirror layer 30 has a half mirror function.

As a constituent material of the half mirror layer 30, for example, a single-layer metal film such as Au, Cu, or In can be used. In the case of a single layer, the thickness of the half mirror layer 30 can be made as thin as possible, and it is possible to suppress cracks in the half mirror layer 30 during the punching process and bending process described later. it can. Further, as described above, by forming the half mirror layer 30 into a plurality of layers (multilayer film), various reflected colors can be reproduced, and the design is excellent.

The thickness (physical thickness) of the high refractive index layer 31 and the low refractive index layer 32 may be the same or different, but is preferably 1 nm or more and 200 nm or less. More preferably, it is 5.5 nm or more and 150 nm or less.

The thickness of the high refractive index layer 31 and the low refractive index layer 32 (optical thickness: with respect to a wavelength of 500 nm) is preferably 0.002 / 4λ nm or more and 0.4 / 4λ nm or less, preferably 0.003 /. It is more preferably 4λ nm or more and 0.3 / 4λnm or less.

By making the high refractive index layer 31 and the low refractive index layer 32 having such a thickness, the half mirror layer 30 can sufficiently exert the effect as a half mirror.

The total thickness of the half mirror layer 30 (the sum of the thicknesses of the high refractive index layer 31 and the low refractive index layer 32) is preferably 5 nm or more and 500 nm or less, and more preferably 7.5 nm or more and 450 nm or less. It is more preferably 10 nm or more and 400 nm or less, and particularly preferably 12 nm or more and 380 nm or less. As a result, the half mirror layer 30 can fully exert the effect as a half mirror, and can prevent the half mirror layer 30 from being cracked when it is bent and deformed.

If the total thickness of the half mirror layer 30 is too thin, the half mirror layer 30 may not be able to sufficiently exert its effect as a half mirror, and the design may be deteriorated. On the other hand, if the total thickness of the half mirror layer 30 is too thick, cracks may occur in the half mirror layer 30 when the optical laminate 100 is made to follow a curved surface having a radius of curvature of 130.8 mm or more. ..

The total thickness of the half mirror layer 30 means the average thickness of the half mirror layer 30. This average thickness can be, for example, a value obtained by exposing the cross section of the base material and using SEM or TEM.

When the total thickness of the half mirror layer 30 is thinner than 5 nm, the half mirror layer 30 cannot sufficiently exert the effect as a half mirror, and the design may be deteriorated. On the other hand, when the total thickness of the half mirror layer 30 is thicker than 500 nm, cracks may occur in the half mirror layer 30 when the optical laminate 100 is made to follow a curved surface having a radius of curvature of 130.8 mm or more. There is.

The refractive index difference (photorefractive index difference) between the high refractive index layer 31 and the low refractive index layer 32 is preferably 0.3 or more and 2 or less, and preferably 0.4 or more and 1.5 or less. More preferred. Thereby, the effect of the present invention can be obtained more remarkably.

Such a difference in refractive index can be expressed, for example, by making the constituent materials of the high refractive index layer 31 and the low refractive index layer 32 different. Thereby, the relationship of the refractive index as described above can be obtained relatively easily.

Further, it is preferable that the high refractive index layer 31 is mainly composed of Cr and the low refractive index layer 32 is mainly composed of SiO ₂ . As a result, the above-mentioned relationship of refractive index can be obtained more reliably.

Further, the difference in refractive index between the high refractive index layer 31 and the first base material 10 is preferably 0.2 or more and 1.5 or less, and more preferably 0.3 or more and 1.4 or less. As a result, the half mirror layer 30 can fully exhibit the function as the half mirror layer.

The difference in refractive index between the low refractive index layer 32 and the adhesive layer 40 is preferably 0.05 or more and 0.3 or less, and more preferably 0.1 or more and 0.28 or less. As a result, the half mirror layer 30 can fully exhibit the function as the half mirror layer.

In addition, a base layer for enhancing the adhesion thereof may be provided between the first base material 10 and the half mirror layer 30. The constituent material of the base layer is not particularly limited, and examples thereof include acrylates such as urethane acrylate, silicones, and silane coupling agents. Among these, acrylate is preferable. Thereby, the adhesion between the first base material 10 and the half mirror layer 30 can be more effectively improved.

The thickness of the base layer is preferably 0.1 μm or more and 100 μm or less, and more preferably 1 μm or more and 20 μm or less.

(Adhesive layer)
The adhesive layer 40 (bonding layer) is provided between the second base material 20 and the half mirror layer 30, and has a function of bonding the second base material 20 and the half mirror layer 30.

The adhesive layer 40 is composed of a light-transmitting adhesive. Examples of this adhesive include silicone-based, urethane resin-based, epoxy-based, polyolefin-based, chlorinated polyolefin-based, acrylic-based, cyanoacrylate-based, rubber-based, polyester-based, polyimide-based, and phenol-based adhesives. Be done. As a result, sufficient bonding strength can be ensured.

The properties of the adhesive include a method of curing a liquid adhesive by heat, UV, moisture, etc., a method of curing a liquid adhesive by adding a solvent, and then curing it by heat, UV, moisture, etc., an adhesive sheet. There is a method of bonding the two by hot melt, pressure sensitive, UV, etc.

Among these, the adhesive layer 40 is preferably composed of a silicone-based adhesive or a urethane-based adhesive. As a result, when the optical laminate 100 is punched into a desired shape and then heat-bent to be joined to the lens 4 by injection molding, deterioration of the adhesive layer 40 due to heat of the high-temperature injection resin can be prevented. You can.

Further, the adhesive layer 40 is particularly preferably composed of a silylated urethane resin-based silylated urethane adhesive. This makes it possible to prevent the generation of gas during curing. In particular, since the half mirror layer 30 has a relatively high gas barrier property, bubbles are likely to remain in the adhesive layer 40, but when a silylated urethane resin-based adhesive is used, these bubbles are prevented from remaining. be able to.

The thickness of the adhesive layer 40 is not particularly limited, and is preferably 1 μm or more and 300 μm or less, and more preferably 5 μm or more and 200 μm or less.

With such an adhesive layer 40, the second base material 20 and the half mirror layer 30 can be satisfactorily bonded to each other, and the effects of the present invention described later can be fully exhibited.

In the optical laminate 100 as described above, since the half mirror layer 30 is not exposed on the surface (upper surface or lower surface of the optical laminate 100), the half mirror layer 30 is worn or damaged. Can be prevented. Therefore, excellent optical characteristics can be exhibited for a long period of time.

The total thickness of the optical laminate 100 is not particularly limited, but is preferably 0.1 mm or more and 2.0 mm or less, and more preferably 0.12 mm or more and 1.8 mm or less. As a result, the lens 4 can be reliably followed and attached to the curved surface.

Further, when the adhesive layer 40 is used as the first adhesive layer, a polarizing layer and a second adhesive layer may be provided between the first adhesive layer and the second base material 20. In this case, the optical laminate 100 is laminated in the order of the second base material 20, the second adhesive layer, the polarizing layer, the adhesive layer 40, the half mirror layer 30, and the first base material 10. By providing the deflection film, it is possible to impart a polarization function to the optical laminate 100.

The polarizing layer has a function of extracting linearly polarized light having a plane of polarization in a predetermined direction from incident light (natural light that is not polarized). As a result, the incident light incident on the eyes through the optical laminate 100 becomes polarized.

The degree of polarization of the polarizing layer is not particularly limited, but is preferably 50% or more and 100% or less, and more preferably 80% or more and 100% or less. The visible light transmittance of the polarizing layer is not particularly limited, but is preferably 5% or more and 60% or less, and more preferably 10% or more and 50% or less.

The constituent material of such a polarizing layer is not particularly limited as long as it has the above-mentioned functions, and for example, polyvinyl alcohol (PVA), partially formalized polyvinyl alcohol, polyethylene vinyl alcohol, polyvinyl butyral, polycarbonate, and ethylene-acetic acid. A polymer film composed of a vinyl copolymer partially ken-valent material, etc., which is uniaxially stretched by adsorbing and dyeing a bicolor substance such as iodine or a bicolor dye, a dehydrated product of polyvinyl alcohol, or polychloride. Examples thereof include a polyene-based oriented film such as a vinyl dehydrochloride-treated product.

Among these, the polarizing layer is preferably a polymer film mainly made of polyvinyl alcohol (PVA), which is adsorbed and dyed with iodine or a dichroic dye and uniaxially stretched. Polyvinyl alcohol (PVA) is a material having excellent transparency, heat resistance, affinity with iodine or a dichroic dye as a dye, and orientation during stretching. Therefore, the polarizing layer using PVA as the main material has excellent heat resistance and polarization ability.

Examples of the dichroic dyes include chloratin fast red, congo red, brilliant blue 6B, benzopurine, chlorazole black BH, direct blue 2B, diamine green, chrysophenone, sirius yellow, direct first red, and acid black. And so on.

The thickness of the polarizing layer is not particularly limited, and is preferably 5 μm or more and 60 μm or less, and more preferably 10 μm or more and 40 μm or less.

Next, a method of manufacturing an optical component including the optical laminate 100 (a method of manufacturing an optical component of the present invention) will be described.

FIG. 4 is a cross-sectional view for explaining the manufacturing method (first embodiment) of the optical component of the present invention, and is a diagram showing a preparation process. FIG. 5 is a cross-sectional view for explaining the manufacturing method (first embodiment) of the optical component of the present invention, and is a diagram showing a half mirror layer forming step. FIG. 6 is a cross-sectional view for explaining a method for manufacturing an optical component (first embodiment) of the present invention, and is a diagram showing a first joining step. FIG. 7 is a cross-sectional view for explaining a method for manufacturing an optical component (first embodiment) of the present invention, and is a diagram showing a first joining step. FIG. 8 is a cross-sectional view showing an optical component manufacturing apparatus (first embodiment) used in the second joining step of the optical component manufacturing method of the present invention. FIG. 9 is an enlarged schematic cross-sectional view showing a state in which the second joining step of the method for manufacturing an optical component of the present invention is being performed. FIG. 10 is an enlarged schematic cross-sectional view showing a state in which the lens and the optical laminate are joined by a conventional manufacturing method.

First, an optical component manufacturing apparatus used in a method for manufacturing an optical component will be described.
The optical component manufacturing apparatus 400 shown in FIG. 8 has a resin supply unit 500 and a mold 600. The resin supply unit 500 is filled with the above-mentioned polycarbonate. The mold 600 has a cavity 610 having a bottom surface 611 and a supply port 620 communicating the inside and outside of the cavity 610. Further, the mold 600 is composed of an upper member 630 and a lower member 640, and in an assembled state in which these are assembled, the mold 600 that defines the optical component manufacturing apparatus 400 is configured.

The method for manufacturing an optical component of the present invention includes a preparation step, a half mirror layer forming step, a first joining step, and a second joining step.

(1) Preparation Step First, as shown in FIG. 4, the first base material 10 is prepared. The first base material 10 can be produced, for example, by extrusion molding. Further, although not shown, in this step, a second base material 20, a liquid adhesive 40A which becomes an adhesive layer 40 after curing, and the like may be prepared, and are appropriately prepared when performing a later step. You may.

Further, examples of the liquid adhesive 40A include those described above. The viscosity of the liquid adhesive 40A is preferably 0.01 Pa · s or more and 1000 Pa · s or less, and more preferably 0.1 Pa · s or more and 500 Pa · s or less. This facilitates thickness control.

(2) Half Mirror Layer Forming Step First, as shown in FIG. 5, the high refractive index layer 31 and the low refractive index layer 32 are sequentially laminated on one surface of the first base material 10. As a result, the first laminated body 100A in which the first base material 10 and the half mirror layer 30 are laminated can be obtained.

As this laminating method, any method such as a vapor deposition method or a sputtering method can be used.

Further, in the illustrated configuration, the half mirror layer 30 has a two-layer structure in which the high refractive index layer 31 and the low refractive index layer 32 are laminated one by one, but three or more layers may be laminated.

Further, the base layer as described above may be formed on one surface of the first base material 10 (the surface on which the half mirror layer 30 is formed).

(3) First Joining Step Next, as shown in FIG. 6, the adhesive 40A is applied onto one surface of the half mirror layer 30. As a result, the second laminated body 100B in which the half mirror layer 30 and the adhesive 40A are laminated can be obtained. Further, the coated thickness of the adhesive 40A, that is, the thickness (average thickness) before drying is preferably 1 μm or more and 300 μm or less, and more preferably 5 μm or more and 100 μm or less. As a result, after the adhesive 40A is dried, the adhesive layer 40 having the thickness as described above can be obtained.

Next, the first laminated body 100A and the second laminated body 100B are laminated so that the adhesive 40A and the second base material 20 come into contact with each other before drying. Then, by drying the adhesive 40A in the laminated state, the optical laminated body 100 can be obtained as shown in FIG. 7.

As described above, in the first joining step, the half mirror layer 30 and the second base material 20 are joined via the adhesive layer 40. As a result, both sides of the half mirror layer 30 can be protected by the first base material 10 and the second base material 20. Further, since the second base material 20 is bonded using the adhesive 40A, the bonding can be performed without applying excessive heat to the half mirror layer 30. Therefore, it is possible to prevent or suppress the half mirror layer 30 from being damaged in the first joining step.

(4) Second Joining Step Then, as shown in FIG. 8, the optical laminate 100 is arranged on the bottom surface 611 in the cavity 610 of the mold 600. At this time, the optical laminate 100 is arranged so that the first base material 10 comes into contact with the bottom surface 611. Then, as shown in FIG. 8, the molten lens forming material 4A is poured from the supply port 620 (see FIG. 8). Then, by curing the lens forming material 4A, the lens 4 and the optical laminate 100 are welded together, and an optical component can be manufactured.

Here, the lens forming material 4A in a molten state generally has a temperature of about 180 ° C. or higher and 350 ° C. or lower, a viscosity of about 100 Pa · s or more and 10000 Pa · s or less, and a pressure of 1 MPa or more and 200 MPa or less. It flows in at the following degree. When such a lens forming material 4A is poured, as shown in FIG. 10, in the optical laminate 100'in which the second base material 20 is omitted, the half mirror layer 30 faces the inside of the cavity 610. Therefore, the half mirror layer 30 is peeled off or the half mirror layer 30 is deformed by the inflowing high temperature lens forming material 4A. In this case, in the obtained optical component, the optical multilayer film may be peeled off or the optical multilayer film may be deformed. In such a portion where the half mirror is damaged, the desired optical characteristics cannot be obtained, and the optical characteristics deteriorate. Further, in order to prevent damage to the half mirror layer 30 due to the inflow of the lens forming material 4A, the optical laminate 100'is arranged in the cavity 610 so that the half mirror layer 30 is located on the bottom surface 611 side. However, in this case, the half mirror layer 30 is exposed to the front side after manufacturing, and the half mirror layer 30 cannot be protected.

In view of this, in the present invention, as described above, when the optical laminate 100 is arranged on the bottom surface 611 in the cavity 610, the first base material 10 is optically in the direction of contact with the bottom surface 611. The laminated body 100 is arranged. As a result, as shown in FIG. 9, the second base material 20 can protect the half mirror layer 30 from the inflowing lens forming material 4A. That is, since the second base material 20 covers the half mirror layer 30, it is possible to prevent the half mirror layer 30 from coming into contact with the lens forming material 4A. Therefore, the half mirror layer 30 can be protected at the time of manufacturing. Further, even after manufacturing, as shown in FIG. 3, since the half mirror layer 30 is not exposed on the surface (upper surface or lower surface of the optical laminate 100), the half mirror layer 30 is protected and worn or scratched. It can be prevented from sticking. Therefore, excellent optical characteristics can be exhibited for a long period of time. From the above, according to the present invention, the half mirror layer 30 can be protected during and after production, and can have excellent optical characteristics.

The melting point of the lens forming material 4A is preferably 200 ° C. or higher and 280 ° C. or lower, and more preferably 230 ° C. or higher and 270 ° C. or lower. This makes it possible to prevent the optical laminate 100 from being deformed by the heat of the lens forming material 4A during manufacturing. Therefore, the half mirror layer 30 can be protected more reliably.

Further, the melting point of the second base material 20 may be the same as or different from the melting point of the lens forming material 4A, but it is preferably higher than the melting point of the lens forming material 4A. This makes it possible to prevent the optical laminate 100 from being deformed by the heat of the lens forming material 4A during manufacturing. Therefore, the half mirror layer 30 can be protected more reliably.

As described above, the method for manufacturing an optical component of the present invention is located between a lens 4 having light transmission, a first base material 10 and a second base material 20 having light transmission, and between them. A method for manufacturing an optical component, comprising: an optical laminate 100 having a half mirror layer 30 that transmits a part of incident light and reflects the rest, and a first base material 10. A half mirror layer forming step of laminating the half mirror layer 30 on the surface, a first joining step of joining the second base material 20 to the surface side of the half mirror layer 30 opposite to the first base material 10, and a second base material. A second joining step of melting and joining the resin material to be the lens 4 is provided on the surface side of the 20 half mirror layer 30 opposite to the half mirror layer 30.

As a result, as shown in FIG. 9, the second base material 20 can protect the half mirror layer 30 from the inflowing lens forming material 4A. That is, since the second base material 20 covers the half mirror layer 30, it is possible to prevent the half mirror layer 30 from coming into contact with the lens forming material 4A. Therefore, the half mirror layer 30 can be protected at the time of manufacturing. Further, even after manufacturing, as shown in FIG. 3, since the half mirror layer 30 is not exposed on the surface (upper surface or lower surface of the optical laminate 100), the half mirror layer 30 is protected and worn or scratched. It can be prevented from sticking. Therefore, excellent optical characteristics can be exhibited for a long period of time. From the above, according to the present invention, the half mirror layer 30 can be protected during and after production, and can have excellent optical characteristics.

Although the method of manufacturing the optical component of the present invention has been described above with respect to the illustrated embodiment, the present invention is not limited to this, and each part constituting the device for manufacturing the optical laminate has the same function. It can be replaced with any configuration that can be exerted. Moreover, an arbitrary composition may be added.

Further, each step of the method for manufacturing an optical component of the present invention can be replaced with an arbitrary step capable of exhibiting the same function. Moreover, an arbitrary step may be added.

Further, the optical laminate can also be used by being laminated on a vehicle such as an automobile, a motorcycle or a railroad, or a window member such as an aircraft, a ship or a house.

Further, in the above embodiment, the case where the half mirror layer is two layers has been described, but the present invention is not limited to this, and one layer or three or more layers may be used.

100 Optical laminate 100'Optical laminate 100A 1st laminate 100B 2nd laminate 1 Sunglasses 1'Sunvisor 2 Frame 3 Lens with optical laminate 4 Lens 4A Lens forming material 5 Mounting part 6 Brim 7 Light transmission Sex member 10 1st base material 20 2nd base material 21 Rim part 22 Bridge part 23 Temple part 24 Nose pad part 30 Half mirror layer 31 High refractive index layer 32 Low refractive index layer 40 Adhesive layer 40A Adhesive 400 Optical component manufacturing Device 500 Resin supply unit 600 Mold 610 Cavity 611 Bottom surface 620 Supply port 630 Upper member 640 Lower member

Claims (7)

A lens layer with light transmission and
An optical laminate having a first base material and a second base material having light transmittance, and a half mirror layer located between them, which transmits a part of incident light and reflects the rest. It is a manufacturing method of an optical component for manufacturing an optical component provided with
A half mirror layer forming step of laminating the half mirror layer on the first base material,
A first joining step of joining the second base material to the surface side of the half mirror layer opposite to the first base material,
A method for manufacturing an optical component, which comprises a second joining step of melting and joining a resin material to be a lens layer on a surface side of the second base material opposite to the half mirror layer. The method for manufacturing an optical component according to claim 1, wherein in the first bonding step, the half mirror layer and the second base material are bonded via an adhesive layer. The method for manufacturing an optical component according to claim 2, wherein the adhesive layer contains a silylated urethane adhesive. In the second joining step, a jig having a concave portion having a curved concave surface at the bottom is used to arrange the optical laminate on the curved concave surface, and in the arranged state, the resin material in a molten state is placed in the concave portion. The method for manufacturing an optical component according to any one of claims 1 to 3. The method for manufacturing an optical component according to any one of claims 1 to 4, wherein the melting point of the resin material is 200 ° C. or higher and 280 ° C. or lower. The method for manufacturing an optical component according to any one of claims 1 to 5, wherein the melting point of the second base material is higher than the melting point of the resin material. The method for manufacturing an optical component according to any one of claims 1 to 6, wherein the thickness of the second base material is 100 μm or more and 1000 μm or less.

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