JPH0519212A - Production system of plastic lens for spectacles - Google Patents

Abstract

PURPOSE:To provide the production system of plastic lenses for glasses by which the period necessary for the process from accepting the order of a customer to completion of the product can be largely decreased, and reduction of the production cost and decrease in stock management can be realized. CONSTITUTION:This system features in the following processes. In a lense forming process 2, a lens is molded from photo- or thermo-setting plastic material according to the prescription data of a customer and the molded lens or its carrier is provided with an indications specific to the lens itself such as the kind, degree, etc. Then a photo- or thermo-setting type hard coating liquid is applied on the surface of the molded lens and cured in a hard coating process 3. The surface of the lens is dyed according to the prescription for dyeing in a dyeing process 4. An antireflection film is formed on the surface of the lens in a vapor deposition process 5 to form an antireflection film. These processes are wholly or selectively performed according to the prescription.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a spectacle plastic lens, and more particularly to a spectacle plastic lens manufacturing system suitable for manufacturing a progressive multifocal lens.

[0002]

2. Description of the Related Art A lens for spectacles is made individually for each of myopia, hyperopia, presbyopia and astigmatism according to a prescription based on an optometry.

On the other hand, recently, molded lenses made of plastic have been widely used in place of conventional glass lenses,
In particular, it is remarkable in a progressive multifocal lens for both perspectives.

Conventionally, a spectacle lens is manufactured as a blank and stocked in advance, and is lapped according to a customer's prescription according to necessary conditions such as a power and an angle of astigmatism to obtain a spectacle lens for the customer. Or predict the frequently prescribed prescription content and manufacture it as a finished product in advance and stock it,
It is by selecting and using the lens that best suits the customer. At this time, the prescription data of the customer is ordered from a spectacles retail store to a manufacturing department of a predetermined lens maker by a facsimile or the like, and then processed into manufacturing data for the manufacturing line again and input to the management computer. There is.

[0005]

However, in order to manufacture a lens by polishing from a blank according to the prescription of each customer, it takes at least 1 to 2 weeks from the time of receiving an order to the hand of the customer. In addition, there is a possibility that a transfer error of the manufacturing data from the prescription data may occur. Further, there is a problem that the cost increases because the polishing process requires highly accurate processing machine equipment.

On the other hand, when preparing a finished product in advance,
Although it has the advantage of reaching the customer's hand in a relatively short time, in the case of bifocal spectacle lenses, it covers all types of power in addition to distance, near, astigmatism, etc., as well as combinations of lens sizes. Has the problem that a huge amount of stock is required.

In view of the above points, the present invention greatly shortens the time required for the process from receiving an order from a customer to shipping the product, enables the quick and accurate specification of the product to be supplied, and reduces the manufacturing cost. It is an object of the present invention to provide a plastic lens manufacturing system for spectacles, which can reduce inventory control and can reliably provide a lens suitable for a customer's prescription.

[0008]

Means and Actions for Solving the Problems With the object of solving the problems of the above-mentioned conventional techniques, the present invention forms a lens based on customer prescription data obtained from each retail store, To process the surface treatment of the molded lens (hard coating, dyeing, vapor deposition of antireflection film, etc.) in accordance with the data based on the customer's requirements, and consistently manufacture lenses that meet the above required specifications from orders. In addition, we will create lenses of high demand when the operating rate of the manufacturing line is low, so that it is possible to significantly reduce the time required from order receipt to product shipment while improving the operating rate of the manufacturing line. There is something I did. That is, based on the customer's prescription data, a lens corresponding to the prescription data is molded by a light or thermosetting plastic material, and the lens or its transporter is provided with an indication of the lens uniqueness such as the type or frequency of the molded lens. There is a lens molding process including a display process, a hard coating process that coats the surface of the molded lens with a light or thermosetting type hard coat liquid and cures it, dyeing the lens surface based on the dyeing prescription The present invention is characterized in that a lens is formed through a process or an antireflection film vapor deposition process of forming an antireflection film on the surface of the lens, either consistently or through selective selection based on a prescription. The prescription data of the lens to be manufactured is predicted based on actual results, and when the operating rate of the manufacturing line decreases Further comprising means for instructing,
And a means for receiving prescription data of a customer transmitted online from a terminal such as a retail store to calculate a processing instruction value, and giving an instruction to start the process based on the calculated data.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the embodiments shown in the drawings.

In the plastic lens manufacturing system for spectacles according to the present invention, as shown in the block diagram of FIG. 1, the prescription data obtained from the customer is directly online from the terminal provided in the spectacle retail store by the manufacturing department of the lens maker. No. 1 is transmitted to the host computer 1, or the relay point receives prescription data from a retail store by a transmission means such as a telephone or a facsimile, and is transmitted online from this relay point. And this host computer 1
The above prescription data is processed into manufacturing data for a manufacturing line, and after a molding step 2 for molding a lens based on the manufacturing data, a hard coating for applying a hard coat to the surface of the lens according to the specifications of the surface treatment of the lens. All or selected of the step 3, the dyeing step 4 of dyeing the surface of the lens, and the anti-reflection film deposition step 5 of forming the anti-reflection film on the surface of the lens, followed by packaging the product lens and preparing for shipment. Through the process, integrated production of plastic lenses according to customer's own prescription, or product stock by manufacturing based on past order record at a predetermined time is performed.

The data in each of the above-mentioned processes is assigned from the host computer 1 to a predetermined process block.
Of the above-mentioned manufacturing data, necessary data is provided to a personal computer (hereinafter, referred to as block PC1 to block PC4) for communicating processes between the units. Further, a total of 18 personal computers for communication control (hereinafter, referred to as PC-1 to PC-18) are connected to the subordinates of the blocks PC-1 to PC-4. Each of these PC-1 to PC-18 has a manufacturing number of a bar code attached to a lens or a pallet flowing through a line in each work process. Referring to the above, the predetermined manufacturing data is received from the upper corresponding block PC, and the pass / fail of the input predetermined inspection data is directly determined, or the inspection pass / fail result input by the worker or the defective item is determined as the upper corresponding block. It fulfills communication control functions such as sending to a PC.

Further, since each PC also carries out a product passage check, it is possible to immediately confirm the current state of a predetermined product. Based on this current data, it becomes possible to quickly respond to inquiries about the progress from retail stores via online.

Next, each step will be described together with the contents of data by the PC. [Lens Molding Step] The lens molding step 2 is shown in FIG. 2 as a block diagram in the case of using a photo-curable plastic raw material, and its contents are based on prescription data from PC-1.
In other words, it is classified according to whether it is an integrated product or a built-in product, and in the case of a built-in product, it is classified into a blank stock, a hard coat stock, or a hard coat + antireflection treated stock, and the necessary data for each (Fig. 3). A work label 7 is printed by the printer 6. As the issued work label 7, as shown in FIG. 3, "consistent product", "manufactured product", "polishing product", "HC"
(Hard coat) Disposable product "and" Deposition by evaporation product ". In the data displayed here, "Production No."
Is attached by substituting the production number by the host computer 1 based on the rearrangement number at the time of ordering, and a 5-digit number sequence is used. Further, “glass type (P type)” refers to the upper mold 9, and “glass type (A, C type)” refers to two types of the lower mold 10. The photocurable plastic material used is urethane acrylic.

In the case of an integrated product, the mold tray 8 displayed on the work label 7 is collated by the PC-2 and the mold is ejected. This tray 8 is in the form of a thin box in which two receiving portions 8a and 8b capable of individually receiving the mold pallets 11 and 12 that individually store a pair of upper and lower molds 9 and 10 (made of glass) are adjacent to each other. The work label 7 is attached to the outer surface of the tray 8 manually or by mechanical means. And these mold pallets 1
The trays 1 and 12 are stored in the receiving portions 8a and 8b of the tray 8.

The trays 8 are stacked and set at several places, and are transferred from the stacked lower side to the cleaning step 13 immediately before entering the assembly step 14 of the molds 9 and 10. At this time, the “processing priority” of the instruction content by the work label 7
If there is an express train, the tray will be given priority for cleaning process 1
Sent to 3.

In the cleaning step 13, the molds 9 and 1
The both surfaces thereof are cleaned so that the light transmittance of 0 is perfect, and the peripheral surface is cleaned so as to improve the tape attachment in the subsequent step. This cleaning is performed by applying the peripheral surface of a sponge roll 15 such as urethane foam containing a cleaning liquid to the peripheral surface of each mold 9 or 10 in the first tank as shown in FIGS. Chuck 16 for holding
The (suction pad) is rotated at 500 to 1000 rpm and the sponge roll 15 is rotated in the same direction for cleaning. At this time, the pressing force of the sponge roll 15 is controlled based on the outer diameter measurement results of the molds 9 and 10. In the second tank, the use surfaces of the molds 9 and 10 are chucked, and the non-use surfaces are cleaned by moving the sponge roll 17 from the mold center to the outside while rotating the sponge roll 17 at 200 to 500 rpm. At this time, the molds 9 and 10 are rotated in the same manner as described above, and the moving distance of the sponge roll 17 is controlled based on the outer diameter data of the molds 9 and 10, so that the sponge roll 17 moves outside the molds 9 and 10. When it reaches the end, it is separated from the molds 9 and 10. The third tank is washed with pure water in the same manner as the second tank. After being washed in this manner, an appropriate amount (2 to 3 cc) of IPA (isopropyl alcohol) is applied to the washed surfaces of the molds 9 and 10 in the fourth tank and dried. At this time, the chuck 1
The rotation speed of 6 is low during IPA application and high during drying (see FIG. 8), and the cycle time is about 20 seconds. However, if the transport time is subtracted, the actual time required is 13 seconds.
Can be finished within seconds.

After cleaning and drying the non-use surface in this way, the molds 9 and 10 are inverted and chucked so that the use surface is on the upper side before entering the fifth tank.

In the fifth, sixth and seventh tanks, the molds 9 and 9 are manufactured by the same process as the second, third and fourth tanks.
Cleaning and drying of the 10 use surfaces is performed. However, the 7th
In the tank, in order to control the adhesion between the use surface and the plastic raw material, for example, a cationic activator 50
Apply ~ 3000 ppm IPA and dry. As a result, the mold releasability can be improved regardless of whether the plastic material is photocurable or thermosetting. After the processing in the seventh tank is completed, the mold assembling step 14
Be transferred to.

An example of the mold assembling process 14 is shown in FIGS. In this embodiment, the upper mold 9
Upper and lower molds 9 and 10 are conveyed by conveying means 18 and 19 (specifically, by belts) for the lower mold 10 and the lower jig 10, and the set jig 2 is conveyed from these conveying means 18 and 19.
The molds 9 and 10 are gripped by 0 and 21 and transferred to the positioning unit 22.

As shown in FIG. 9, the positioning portion 22 supports the lower surface of the diametrical front and rear end portions of the molds 9 and 10 and has a space in which the mold holders 23 and 24 can be inserted between the molds 9 and 10. The mold pedestals 25, 25 and 26, 26, which are placed in a completely horizontal state, along the upper surface of the mold pedestals 25, 25 and 26, facing the diametrical front and rear end faces of the molds 9, 10 placed across the opposite ends of the mold pedestals. It has a pair of centering tools 27, 27 and 28, 28 that move evenly, and the opposing end surfaces of the centering tools are V-shaped with a shallow planar shape so as to contact two points on the peripheral surfaces of the molds 9, 10. Abutment edge 27a,
28a.

Therefore, by placing the upper and lower molds 9 and 10 on the respective mold holders 25, 25, 26 and 26, the parallelism of the molds 9 and 10 is obtained on the upper surface thereof, and the centering tools 27, 27, and When the abutting edges 27a, 27a and 28a, 28a are sandwiched between the abutting edges 28a, 28a of the molds 28, 28, the optical axes of the molds 9, 10 are brought out, and the molds 9, 10 are positioned thereby.

The mold holders 23, 24 are moved back and forth toward the center of the back surfaces of the molds 9, 10 by a servomotor, and their tips serve as suction pads for sucking and holding the molds 9, 10 without losing their parallelism. Thus, the molds 9 and 10 are held by suction.

As shown in FIG. 11, the molds 9 and 10 are provided with markings 2 which serve as an index on the peripheral surface for astigmatic axis alignment.
9a, 30a are provided, and the marking position is detected by an optical sensor, and the astigmatic axes between the upper and lower molds 9, 10 are aligned. This operation is performed by rotating the mold holders 23 and 24. At this time, in order to prevent erroneous detection of marks other than the markings 29a and 30a, markings 29b and 30b are also provided at positions deviated from the reference position by a predetermined angle, and first the markings 29a and 30a are detected and then predetermined. It is desirable that the normal position (reference position) is obtained when the second engraved marks 29b and 30b are rotated by an angle.

After detecting the reference positions of the molds 9 and 10, the lower mold 10 is rotated by an angle corresponding to the astigmatic axis,
After the lower mold 10 rotates, the edge thickness of the lower mold 10 corresponding to the raw material injection position 31 formed in the upper mold 9 is scanned and measured by an optical sensor. As shown in FIG. 12, the raw material injection position 31 is composed of a notch 32 that is recessed in the shape of a semi-cylindrical cross section in the radial direction of the peripheral portion of the upper mold 9, and the inner end of the notch 32 is located around the lens to be molded. It extends to a slightly overlapping position.

After measuring the edge thickness of the lower mold 10 corresponding to the raw material injection position 31 as described above, the mold holder 2
3, 24 are moved on the same axis (FIG. 9 (C)-
(D)) Subsequently, the molds 9 and 10 are moved closer to each other in the axial direction so as to have a predetermined center thickness, the center thickness is determined, and then the adhesive tape 33 is laid over the peripheral surfaces of the molds 9 and 10. Wrap around. As a result, the mold assembly 34 having the lens forming cavity formed therein is obtained.

The astigmatic axis and the central thickness are calculated in advance by the PC-3, and are used for rotating the mold holders 23 and 24.
This is performed by controlling the servo motor for controlling the thickness.

Immediately before the adhesive tape 33 is completely wound, the ink jet prints the same number (for verification) 35 on the outer surface of the adhesive tape 33 as that applied to the tray 8.

In the cleaning process 13 to the assembling process 14, the molds 9 and 10 are separated from the tray 8, but the tray 8 is transferred synchronously by the conveying means (eg, belt conveyor) running in parallel.

In the raw material injection step 36, the mold assembly 34 is held so that the injection position 31 determined in the assembly step 14 does not collapse, and the adhesive tape 3 at the injection position 31 is held.
The injection nozzle of the injection head 37 is pierced in 3 to inject the plastic raw material.

In the adhesive tape 33 on both sides of the insertion position of the injection nozzle 38, two holes 39, 39 for venting air are formed on both sides of the injection position between the winding of the adhesive tape and the injection step. The injection nozzle 38 is inserted between the holes to inject the raw material. Air in the cavity escapes from the holes 39, 39 as the raw material is injected. At this time, since the raw material has a viscosity, the raw material gradually flows into both sides from the center of the cavity, and the injection nozzle 3
8, the air in the space portions a on both sides of the hole 8
The electrostatic capacity sensor 40 detects the time when the air is exhausted and the raw material begins to flow out from the holes 39, 39, thereby detecting the filled state and stopping the injection.

Here, the function of the PC-3 will be briefly described.

A personal computer (cell P) is used for all of the above-mentioned cleaning process, assembling process and injection process.
C) is equipped and is controlled by M / C.
Therefore, it is necessary to input the processing data of the corresponding lens (for example, the lens center thickness setting value, the lens diameter, the astigmatic axis setting value, the mold dimension and the injection information) to each cell PC.
Therefore, the manufacturing number of the bar code attached to the lens or the pallet by the PC-3. And the corresponding block P in the higher order
The processing data can be sent from C to the cell PC. At this time, it is possible to judge the set condition of the mold in the cleaning process. Then, this processing data is carried over to the assembly process and the injection process. Finally, when the injection process is completed, the processing completion information is sent to the PC-3, the passage check is executed, and the result is input to the block PC-1.

After the injection of the raw material is completed, the injection head 37 is retracted to remove the injection nozzle 38, and the puncture hole is pressed by the tape surface using a tape-shaped jig 41 as shown in FIG. Hold by means 42, light source 43 (FIG. 14)
To tentatively polymerize by irradiating light (UV irradiation). The jig 41 winds the tape 41a so that it is always pressed using a new tape surface.

When injecting the raw material, as shown in FIG. 15, especially in the case of a lens having a thin edge thickness, the raw material is the mold 9,1.
In order to avoid erroneous detection of a filled state when it spreads on the inner surface of 0, the injection speed in the initial stage of injection was slowed down, and the speed was increased when the flow path of the raw material was formed to approach the filled state. Set it so that it will be late again. The reason for slowing the injection rate at the end of this injection is to improve the detection accuracy. And the control of this injection speed is P
The volume of the cavity is calculated in advance at C-3, and the servomotor for moving the valve body for adjusting the opening degree of the injection valve is controlled. At the end of the injection, the injection rate is slowed at 60 to 95% of the volume of the cavity.
It is preferable that the time is reached when the raw materials are reached.

After passing through the injection step 36, the mold assembly 3
4 is released, and the next polymerization step 44 is carried out.

The irradiation time of light in the polymerization step 44 is 2.5 to 4 minutes in order to secure the physical properties of the lens.
The time corresponding to the minute is performed in an atmosphere of 120 ° C. ± 10 ° C., and the irradiation direction is from both sides of the mold assembly 34.

The raw material temperature after the polymerization step 44 is 16
Since it is a high temperature of 0 ° C. or higher, and the detape and depolymerization work in the subsequent step becomes impossible, a cooling period of about 10 minutes is set in an atmosphere of 50 ° C. to 80 ° C.

On the other hand, the tray 8 is also conveyed by the conveying means in the order in which the molds 9 and 10 are carried into the cleaning step 13, and the mold assembly 34 is returned to the tray 8 by the robot (removing step 45). . After receiving the mold assembly 34 in the tray 8, a buffer heat-retaining step 46 for about 15 minutes is performed in the atmosphere of about 50 ° C. to 80 ° C. in consideration of the speed of the manual work portion in the subsequent step. At this time, the work label 7 attached to the tray 8
The number shown on and the adhesive tape 3 of the mold assembly 34
The number printed on No. 3 is checked to confirm its identity.

After the above-mentioned collation, a tape removing operation for peeling off the adhesive tape 33 and a work 47 for removing a polymer or the like which tends to accumulate at the boundary between the molds 9 and 10 and the adhesive tape 33 are carried out, and then the lower mold 10 is formed. A wedge is driven between the lens 48 and the lens 48 to separate them, and the upper mold 9 is peeled from the lens 48 to take out the lens 48 (mold release step 49). These tape removing and releasing operations are performed manually, but it is possible to automate them.

After being released in this way, the upper and lower molds 9 and 10 are the mold pallets 1 that have flowed correspondingly.
The lenses 48, which have been respectively returned to Nos. 1 and 12, are put into another lens pallet 50, and at the same time, the work label 7 affixed to the tray 8 is affixed to the outer surface of the lens pallet 50. The emptied tray 8 is returned to the tray yard, and the mold pallets 11 and 12 to which the molds 9 and 10 have been returned are spin-cleaned in the cleaning step 51, and at the same time, the appearance is checked and then the PC-18 is used. The mold verification is performed, and the passed product is stored in a predetermined position of the mold stocker 52.

On the other hand, in the appearance inspection step 53, the molded lens 48 is visually observed to determine whether or not there are defects such as scratches and the presence of contaminants. If it is determined by this visual inspection that the product is defective, the defective item is keyed in on the terminal and a remanufacturing instruction is issued through the PC-4.

The lens 48 that has passed the visual inspection is shown in FIG.
The process is divided into a dimensional inspection process 54 shown in (1) and a system 55 for stocking as a polishing product.

In the dimension inspection step 54, the power, center thickness, prism and astigmatic axis of the lens 48 are checked. These checks are performed by an automatic lens meter and a digital gauge. The data of the lens 48 is read and transferred to the PC-5, and the desired prescription data previously displayed (bar code display) on the work label 7 is blocked by the PC. −
1 is received, and the judgment is made by comparing with the actual measurement data in PC-5. If the product is determined to be defective in this step, a remanufacturing instruction is issued together with the defective item, and the defective item is accumulated as measurement data and provided for technical analysis.

In this way, the lens 4 that has passed both appearance and size
Since 8 is independent of the lens pallet 50, the lens itself is marked so that the lens uniqueness can be identified. This display does not necessarily have to match the number given to the tray 8 (or the lens pallet 50), and may be any one that can be used in the work steps thereafter.

The marking 48a on the lens is formed on the outer periphery of the lens 48 by the notch 32 formed in the upper mold 9 for injecting the raw material into the cavity of the mold assembly 34 (FIG. 18A). , (B), which is formed by utilizing the convex portion 56 formed in a semicylindrical shape (marking step 57). Therefore, this can be carried out by detecting the convex portion 56 by the contact type detecting means and marking the peak point as the center. Alternatively, the convex portion 56 may be detected and marked by image processing. The use of a CO ₂ laser is suitable for this marking. This marking has PC-6 above the bar code of work label 7.
The value of the position to be marked (position in the radial direction) is received from and the marking is performed. This is because the position is not affected when the periphery is cut during the outer periphery shaping step 58.

After the marking is made in this manner, the peripheral portion is cut by dry or wet grinding as shown in FIG. 19 and the outer circumference is shaped to a predetermined outer diameter. After the outer peripheral shaping is completed, pairing 59 of a pair of lenses for the right eye and the left eye is performed, whereby the lens molding step 2 is completed.

Among the molds used in the molding process of the lens, the convex mold is used in which the contour of the convex molding die part is close to the shape of the spectacle frame, and the concave surface for normal molding is used. Means are included for molding lenses of substantially smaller diameter by combining the molds for use. [Hard Coating Step] In this embodiment, a thermosetting type hard coating liquid will be described, but it is not limited to the thermosetting type.

Lens 48 molded in molding step 2
When the coating treatment is applied, as shown in FIG. 20, before the process, the specification of the hard coat DC only,
Since it is divided into a hard coat and a product with anti-reflection treatment DMC, a process selection instruction (nozzle conversion instruction) is given in block P.
Received from C-1, Dip slip 60 is issued in the case of DMC.

Here, as a method for applying the hard coat liquid,
DC type is spin type, DMC type is dipping (Di
The p) method is taken as an example.

In the case of shifting to the hard coat DC step, in the lens wiping step 61, the surface of the lens is manually wiped with acetone or the like so as to eliminate the uneven UV irradiation. Next, in the UV irradiation step 62, the surface of the lens is irradiated with UV, and a treatment for improving the adhesion between the lens base material and the hard coat is performed. This UV irradiation is performed by a high pressure mercury lamp, but in addition to this, treatment with acid, alkali, organic solvent, plasma treatment, microwave irradiation, electron beam E
A processing method such as the processing by B may be used.

After the above processing, the spin hard coat SHC step 63 is entered. In this SHC process 63, as shown in the process diagram in FIG. 21, the surface (concave side) of the lens supported by the suction pad and rotating at 500 to 1000 rpm is impregnated with an alumina-based abrasive in the first tank. While 20
A sponge roll rotating at 0 to 500 rpm is wiped while applying a load of about 400 g and pressing to physically remove the lens surface, completely remove surface dirt and remove the heterogeneous layer on the surface. And homogenize. Incidentally, as this treatment, surface peeling means by spraying abrasive grains,
Alternatively, it is possible to employ dry ice, a surface peeling means by eye screening that sprays fine particles of ice, or the like. By this surface treatment, the quality of the appearance is improved, the adhesion of the coating layer and the dyeing property in the case where there is dyeing in the subsequent step are enhanced. The above processing conditions are selected according to the material of the lens substrate.

In the second tank, the abrasive adhered during the treatment in the first tank is completely removed by scrubbing with pure water and sponge. This removal is also performed under the same conditions as the number of rotations of the lens, the number of rotations of the sponge roll, and the load as in the above polishing.

In the third tank, a lens of 500 to 15 is used.
Rinse is performed by IPA while rotating at about 00 rpm to clean the lens surface immediately before the application of the hard coat liquid. Then, the IPA is evaporated by spinning at 2000 rpm or more for 3 to 5 seconds. Then, a hard coat liquid is applied and spin is applied to form a hard coat layer having a constant film thickness. At the time of applying the hard coat liquid, if the hard coat liquid is applied while rotating the lens at about 500 rpm or more, the hard coat liquid does not wrap around to the back side of the lens and a uniform film thickness layer can be formed. When applying the hard coat liquid, the ejection from the nozzle is started near the outer periphery of the lens, and the hard coat liquid is moved to the center of the lens. By doing so, air bubbles in the hard coat liquid generated at the initial stage of ejection of the hard coat liquid scatter from the outer circumference of the lens due to centrifugal force, and no air bubbles remain on the lens, so that the appearance and yield are good. The hard coat liquid may be applied by a spray method other than the nozzle,
Further, the coating by these may be performed on both sides simultaneously instead of one side of the lens.

Immediately after the hard coat layer is formed on the lens surface as described above, the lens is inverted and the concave surface is directed downward to prevent the appearance of the liquid from dripping. In this way, setting is carried out by leaving at room temperature (40 ° C. or less) for 1 to 5 minutes, and the surface tension of the hard coat liquid itself is used to smooth the surface of the hard coat liquid.

Subsequently, by heating at 130 ° C. for about 20 minutes, pre-baking for reacting and curing the hard coat liquid is performed. The heating means for this calcination is selected depending on the type of the hard coat liquid, and there are hot air, infrared rays and the like. The other hard coating solution is U
There are V-curable hard coat, EB-curable hard coat, microwave-curable hard coat, etc.
It is practical to use a curable hard coat. That is, when this UV-curable hard coat is used, there are no restrictions on the spin conditions during the application of the hard-coat liquid, as compared with the case of using a heat-curable hard coat, any number of rotations may be used, and the setting conditions may be high. (40-60
(° C.) has an advantage that the viscosity is lowered and the surface is easily smoothed. Further, the UV irradiation for curing is 5 to 20.
This is because it has the advantage that it can be completed in seconds and the preliminary firing becomes unnecessary.

After heating, if the lens is kept at 60 ° C. or higher, adhesion of the polishing agent, water loss, etc. will occur in the subsequent steps (convex polishing), and the appearance and durability will be deteriorated. Lower to below ℃.

In the fourth tank, similar to the first tank, the convex surface of the lens is surface-modified, the second tank is cleaned, and the third tank is coated with the hard coat liquid. The setting and pre-baking are performed in the same manner as in the case of the concave surface, the lens is removed, and the appearance baking 64 is performed before the main baking 65. This main firing 65 is performed at 135 ° C. for about 3 hours,
This completes the reaction of the hard coat liquid on both sides of the lens.

On the other hand, in the case of the DMC system in which the antireflection film is formed on the surface of the hard coat, the spin hard coat SHC is used in the surface polishing step 66 as shown in FIG.
Similarly to the above, the surface of the lens is wiped with an alumina-based abrasive contained in a sponge to remove the lens surface. As a result, the adhered dirt that cannot be removed by the dipping cleaning of the prewash and the heterogeneous layer on the surface are removed. Then, in a wiping step 67, the lens is wiped with acetone or the like to remove dust and the like.

Subsequently, in a jig setting step 68, lenses are set at intervals in a jig for accommodating a predetermined number of sheets at a time, and batch processing is prepared. Thus, the jig having the lens set therein is subjected to prewashing 69 to clean the surface of the lens with a surfactant or the like, surface modification with an alkaline solution or the like, pulling warm pure water, and drying in 13 to 16 tanks. After the prewash 69 is completed, in a Dip step 70, the lens is dipped in the hard coat liquid and pulled up to a desired film thickness by controlling the uniform speed or pulling speed.

Then, in the calcination step 71, 70 to 10
The hard coat liquid is semi-cured at a relatively low temperature of 0 ° C. (for example, hot air oven). After firing, the lens is taken out of the jig, the lens is laid flat on a pallet through an appearance inspection step 72, and a main firing step 73 is started. In this main firing step 73,
After heating at 135 ° C. for about 3 hours, the reaction of the hard coat solution is completed. This completes the hard coating step 3. If a defect occurs in the visual inspections 64 and 72, the defective item is a block PC via the PC-7 in any process of the hard coat specification (DC) and the hard coat and antireflection treatment specification (DMC). It is sent to -1, and a reproduction instruction is issued.

Now, moving to FIG. 22, a quality assurance mark is imprinted 74 as required. Then, the manufacturing number, the presence or absence of dyeing, the color, the arrival information of the sample color, the presence or absence of vapor deposition, the processing priority, the distinction between shipping and stock, the lens diameter, the delivery date, etc. are keyed into the PC-8, and based on this, A new work label 75 is issued. Then, the work label 75 is attached to the pallet 76 which flows to the subsequent steps.

Subsequently, in the frequency inspection step 77, it is measured whether or not there is a change in the frequency except for the center thickness after hard coating, and the measured data is compared with the prescription data from PC-9 to determine the frequency. A final check is made. As a result, when it is determined that the product is defective, the defective item and the measurement data are input, and a reproduction instruction is issued.

If the check of this frequency is passed, it is judged whether or not the lens has a specification that requires dyeing, whether vapor deposition of the antireflection film is necessary, and whether or not the lens is in stock.
It is sorted by reading the bar code of 5.

When shifting to the dyeing step 4, dyeing sorting 78 is performed in advance. This dyeing sorting 78 is sorted according to the display of the work label 75 for DC or DMC, and the color for DC (DCC), the color for DMC (DM
CC) is selected. After this selection, color selection, dyeing time, etc. are calculated and displayed from the PC, and dyeing is performed according to the instructions. [Dyeing Step] Dyeing of a lens is performed by dispersing a disperse dye in water, adding an additive such as an auxiliary agent, and immersing the lens in a dyeing bath heated to 70 to 90 ° C. The dyeing density is proportional to the immersion time. In the case of dyeing with a predetermined color tone, toning and dyeing time are determined as standard colors. When there is a sample color, the sample color is analyzed by a spectrophotometer to perform the toning. This toning can be performed by computer-processing the data of the target color obtained by measurement with a spectrophotometer and determining an appropriate dyeing bath and dyeing time.

The dyed lens is visually inspected for color difference in step 79, and in the dyeing inspection step 80, dimensional deviation due to color loss or half dyeing (dyeing only in a half region of the lens), The appearance is checked. When it is determined that the product is defective, the defective item is keyed in to the PC-10 and a remanufacturing instruction is issued.

As for the lens which is transferred to the stock 81 system, the lens which is not dyed or vapor-deposited with the antireflection film is put into the stocking process 83 (PC-17) and stocked. This system determines the frequency with the highest order frequency and the astigmatic axis (90 °, 180 °) based on past order data when the operating rate declines when there are few orders from customers (for example, from the middle of the week to the weekend). It is predicted and the predicted lens is built as a hard-coated lens. Immediately after receiving an order for a lens with the same prescription 8
If the goods are processed by the warehouse 2 or dyeing is required, the goods are sent to the dyeing step 4, and the previous steps up to that point are omitted and used.

Further, in the case where the specification is such that dyeing is not required after the hard coating step 3 is completed and the anti-reflection film is required to be deposited, the lens passes the dyeing step 4 and the next deposition step 5 (see FIG. 23). [Antireflection film vapor deposition step] In this vapor deposition step 5, whether vapor deposition is necessary or not is checked and sorting is performed based on it. Lenses requiring vapor deposition are placed in a basket 120 after being subjected to a prewash step 84 (frontless cleaning). It is stored and goes through a visual inspection 85. If the appearance inspection 85 determines that the product is defective, the defective item is keyed into the PC-11 and a rework instruction is issued.

The lens that has passed the visual inspection is set on the dome 86 and deposited in a vacuum chamber. This vapor deposition is performed in the order of the concave vapor deposition 87, the return set 88, and the convex vapor deposition 89, and this chamber uses either a 5-tank type or a 3-tank type. In the case of the 5-tank type, as shown in FIG. 24, a roughing chamber 90, a concave surface deposition chamber 9
1, a return chamber 92, a convex deposition chamber 93, and a take-out chamber 94. In the case of the three-tank type, as shown in FIG. 25, a roughing chamber 95, a double-sided deposition chamber 96, and a take-out chamber 97. 10 ^{-4 in the} roughing chamber
Torr is about 10 ⁻⁵ Torr in the vapor deposition chamber, and the film thickness is controlled by controlling the amount of reflected light. The 5-tank type has an inversion mechanism that automatically inverts the lens on the dome 86. This inversion mechanism
As shown in part in FIG. 26, for example, two lenses are
The holder 98, which is held as a set, is supported by the central shaft 99 so as to be reversible on the dome 86, and the reversing projection 100 is provided on the holder 98. When the vapor deposition on one surface of the lens is completed, the rotation speed of the dome 86 is changed. It is dropped for about 30 seconds / revolution, the reversing cylinder 100 (FIG. 27) pushes the reversing projection 100 from the outside of the chamber, and when it is rotated 90 ° or more, it is reversed by its own weight. After confirming that the dome 86 has rotated one rotation or more, the cylinder 101 is shortened.

After the completion of vapor deposition, the interference color inspection 102 is performed by the PC-11. If it is determined that the product is defective, the defective item is input and a remanufacturing instruction is issued.

The lens that has passed the interference color inspection 102 is placed in the basket 85 again, and the CF process 103 is performed. The CF process is a batch process in which firing (processing with hot air at about 50 ° C. for 15 to 20 minutes) is performed, cleaning is performed, and the process proceeds to the color difference inspection 104. In the color difference inspection 104, whether or not the coating is removed by the prewashing process is performed by using a spectrophotometer, and PC-
12, the required transmission amount and the transmission amount due to color loss are compared and checked. If it is determined that the product is defective, the measurement data by the spectrophotometer, the requested color data (including the sample color data), and the defective item are keyed in, and a rework (return to the pre-dyeing process) instruction is issued. .

Lenses that have passed this color difference inspection 104 are
The process moves to the final outer diameter inspection 105, where the final appearance inspection is performed. This inspection result is keyed into the PC-13, and in the case of a defective product, a defective item is input. Among the non-defective products that have passed this final inspection, the shipped products are thereafter sent to the packaging bag printing process.

On the other hand, when the process proceeds to the dyeing step 4, if the lens has a specification without dyeing, it is housed in a flat state in a pair in the case 106 and subjected to the final appearance inspection 1 described above.
It is turned to 05.

The lens which has completed the final appearance inspection 105 is
It is sorted into a system for immediate shipment and a system for stock 107. The system leading to this stock 107 is prepared for shipment when the operating rate decreases, as in the case of the end stage of the hard coating process 3 described above.

With the above, all the lens manufacturing steps are completed,
Enter the packaging process. [Packaging Step] In this packaging step 108, the required printing 110 is applied to the printer 11 on the outer bag 109 in which the left and right lenses are put.
1 and the lens is subjected to horizontal horizontal line printing 112 in the diametrical direction, which is a guideline for frame fitting cutting at an eyeglass store.
Then, the lens and the outer bag 109 are collated 113, and the lenses are housed as a pair. Then, sorting and packaging 114
Then, the shipping process 115 (PC-14) is performed and the product is shipped. In the shipping processing 115, the PC-14 checks whether or not a predetermined product is shipped to a predetermined destination.

On the other hand, the stock 107 system is subjected to a warehousing process 118 as a stock product through a wading package 117 (packaging in units of one lens). This wadding package 1
The print data from the PC-16 is received by the printer 17, and the print data is printed on the bag 119 by the wading packaging machine based on the print data. The content of the print is printed as a bar code type such as a manufacturing date, a product name, a frequency (SC axis, addition degree), and the presence or absence of vapor deposition.

In the polishing step 121 (FIG. 28) after the lens molding step 2, the lens molded in the lens molding step 2 is used as a blank to polish it into a spectacle lens, which is managed by the block PC-2. , A work label 122 on which a predetermined specification is printed by reading a barcode is issued from the label printer 123 (work slip issuance 124), and at the same time, a confirmation drawing 125 of SS processing (processing specification into a shape close to an eyeglass frame) is given. To be

According to the contents of the work label 122, payout 12 of blanks 126, 126 conforming to the contents
7 is performed, the surface of the blank is blocked 128 by tape attachment, and the outer diameter is specified for the specified outer diameter 1
29 is performed. Next, the CG cut 130, the smoothing 131, and the polishing 132 are performed, and then the deblocking 13 is performed.
At 3, the block is released, and if necessary, chamfering 134 is performed for cleaning 135 and lens marking 136. Then, the dimension inspection 137, the blurring inspection 138, and the outer diameter inspection 139 are checked through the PC-15 and supplied to the above-mentioned marking step 57 or the subsequent pairing 59.

In this embodiment, four block PCs for process communication are provided in order to reduce the load on the host computer.
, And a plurality of PCs for communication control are placed under it to achieve vertical distribution. However, if the capacity of the host computer is large enough, the host computer is connected to each terminal placed in the work process. Then, it is possible to directly access the data in the host computer. Further, instead of the above-mentioned equipment configuration, an engineering workstation (EWS) is connected by a local area network (LAN), and the EWS accesses a data server for data storage provided in the LAN to obtain predetermined data. You can

In any case, the data provided is the latest update data, and the host computer always manages the accumulation of manufacturing data of newly ordered products, the updating of setting data, and the deletion of manufacturing data after processing is completed. You can do it.

Further, the host computer accumulates defective item data and the like generated in each process, and can collect data for technical analysis for reviewing materials used and work procedures. Also, hard coating process 3,
The dyeing process 4 and the antireflection film deposition process 5 can be arranged in any order, not necessarily in the order of the embodiments, and the same applies to the other processes. By arranging the order of this step according to the reference numerals used in the above embodiment, a combination as shown in FIG. 29 can be realized.

[0081]

As described above, according to the present invention, prescription data or option data obtained from a customer is input to a computer to be converted into processing information, and each manufacturing process is managed based on the processed prescription data. Since it can be manufactured by integrated production, it enables consistent continuous production of spectacle lenses, which are high-mix low-volume production products, and there is no need to stock products from order receipt to product shipment. The number of stocks and the stock space related to the product have been reduced, and their management has become easier. Moreover, the time required from order receipt to product shipment required a minimum of 30 hours with conventional grinding. In this case, it can be shortened to about 5 hours, and it can be delivered to the customer as quickly as possible. Further, since the work in each step is automatically or manually performed in accordance with the instruction from the computer, there is little room for individual differences and it is possible to provide a high-quality lens suitable for the prescription of the customer.

[Brief description of drawings]

FIG. 1 is a block diagram showing a manufacturing process of a plastic lens for eyeglasses according to the present invention.

FIG. 2 is a process drawing showing details of a lens molding process in FIG.

3 is an explanatory diagram showing an example of contents of display data of a work label used in FIG. 2. FIG.

FIG. 4 is an explanatory view showing one means for cleaning the peripheral surface of the mold in the cleaning step of FIG.

FIG. 5 is an explanatory view showing one means of surface cleaning.

FIG. 6 is an explanatory diagram showing an IPA applied state.

FIG. 7 is an explanatory view showing a state where the mold is inverted and supported.

FIG. 8 is a graph showing the number of rotations and the time during IPA application and spin drying.

9A to 9F are explanatory views showing an example of the mold assembling process of FIG.

10 is a plan view showing the positional relationship between the upper and lower molds in each step of FIG.

11A and 11B are explanatory views showing the astigmatic axis detection indexes of the upper and lower molds.

FIG. 12 is a perspective view showing a notch formed in the upper mold.

FIG. 13 is a front view showing an example of a plastic raw material injection head.

FIG. 14 is a cross-sectional view showing a state where a plastic material is injected into a mold assembly by an injection head.

FIG. 15 is an explanatory diagram showing an internal condition when viewed from the front.

FIG. 16 is an explanatory view showing one means for sealing the injection port portion after injecting the plastic raw material.

FIG. 17 is a process drawing showing a process after the lens molding process.

18 (A) and 18 (B) are front views showing the positional relationship of markings on a molded lens.

FIG. 19 is a front view showing the lens after peripheral shaping.

FIG. 20 is a process chart showing details of the hard coating process.

FIG. 21 is a block diagram showing details of the spin hard coating process in FIG. 20.

FIG. 22 is a process drawing showing details of the dyeing process that is transferred from the hard coating process.

FIG. 23 is a process drawing showing details of an antireflection film deposition process and a packaging process.

FIG. 24 is a block diagram showing the contents in the case where the number of vapor deposition chambers in FIG. 23 is five.

FIG. 25 is a block diagram showing the contents in the case of three tanks.

FIG. 26 is a partial plan view showing an example of a reversing mechanism of a lens holder on a dome.

FIG. 27 is a side view of the same.

FIG. 28 is a process drawing showing a polishing process when a polishing blank is molded in the lens molding process.

29 is an explanatory diagram showing an example of a layout change of each process of FIG. 1. FIG.

[Explanation of symbols]

1 Host computer 2 Lens molding process 3 hard coating process 4 dyeing process 5 Anti-reflection film deposition process 7,75 work label 8 trays 9 Upper mold 10 Lower mold 11,12 type pallet 15,17 Sponge roll 16 chuck 22 Positioning unit 23,24 Mold holder 25,26 mold pedestal 27,28 Centering tool 31 Raw material injection position 32 notches 33 Adhesive tape 34 Mold Assembly 37 injection head 39 injection nozzle 40 detection sensor 41 Fixing jig 48 molded lens 50 lens palette 52 Mold Stocker 56 convex 60 Dip slip 76 pallets 85 baskets 86 Dome 109 outer bag 117 wading packaging bag

Continuation of front page (51) Int.Cl. ⁵ Identification number Office reference number FI technical display location // B29L 11:00 4F

Claims (5)

[Claims] 1. A lens corresponding to the prescription data is molded with a light or thermosetting plastic material based on the customer's prescription data, and the type of the molded lens, a frequency, a manufacturing identification number, or the like is displayed. It has a lens molding process including a display process to be applied to the lens or its transfer body, and a polishing process, a hard coating process for curing a light or thermosetting type hard coat liquid on the surface of the molded lens, a lens surface based on a dyeing prescription A manufacturing system for a plastic lens for spectacles, which comprises forming a lens through a dyeing process for dyeing an anti-reflection film and an anti-reflection film deposition process for forming an anti-reflection film on the surface of the lens consistently or according to a prescription. 2. A lens or its transporter is provided by molding a lens corresponding to predicted prescription data with a light or thermosetting plastic material, and indicating the type of the molded lens, the frequency, or the manufacturing identification number of the lens. There is a lens molding process including a display process to be applied to, a polishing process, a hard coating process for curing a light or heat curing type hard coating liquid on the surface of the molded lens, and a dyeing for dyeing the lens surface based on a dyeing prescription. A manufacturing system for a plastic lens for spectacles, characterized in that an antireflection film vapor deposition process of forming an antireflection film on a surface of a lens is selectively or consistently or selectively made according to a prescription to build and form a lens of a regular item. 3. The manufacturing system for a plastic lens for spectacles according to claim 2, wherein the manufacturing is performed when the operating rate of the manufacturing line is lowered. 4. A pre-ordered product from a hard coat process to a vapor deposition process is molded when the operating rate of the manufacturing line is lowered by predicting or not predicting the prescription data of the lens to be manufactured based on the past order record, and receiving the order. 3. The manufacturing system for a plastic lens for spectacles according to claim 1, wherein the manufactured product is selected and the subsequent steps are performed. 5. A prescription data of a customer transmitted online from a terminal such as a retail store is received to calculate a processing instruction value,
The manufacturing system for a plastic lens for spectacles according to claim 1, further comprising means for giving an instruction to start the process based on the calculated data.