JPWO2005032791A1 - Manufacturing method of ophthalmic lens article and manufacturing apparatus used therefor - Google Patents

Abstract

An object of the present invention is to provide a method for producing an ophthalmic lens article, which can solve problems caused by an ultraviolet lamp, and which can advantageously ensure stable quality, and an ophthalmic lens article producing apparatus used therefor. Using the molding die 10 in which a molding cavity 30 having a shape that gives a target ophthalmic lens article is formed by matching the upper mold 26 and the lower mold 28 made of a light-transmitting material, While the monomer liquid 50 is filled, the polymerization of the filled monomer liquid 50 is performed with light emitted from the LED light source 12 installed on at least one of the upper and lower mold sides of the mold 10. Mold the lens article.

Description

  The present invention relates to a method for manufacturing an ophthalmic lens article and a manufacturing apparatus used therefor, and in particular, a method capable of advantageously manufacturing an ophthalmic lens article using an LED as a light source during photopolymerization and the method used therefor. The present invention relates to a manufacturing apparatus.

  Conventionally, an ophthalmic lens such as a contact lens or an intraocular lens, or a semi-finished product thereof, for example, one surface is molded into a completed lens surface shape, while the other surface is still a lens surface. The ophthalmic lens material which gives the ophthalmic lens formed into a shape that requires post-processing such as cutting, which has not been completed, and further the target contact lens or intraocular lens by processing such as double-sided cutting As a method of manufacturing a so-called ophthalmic lens article such as a lens blank formed with a first mold and a second mold, such as a combination of a male mold and a female mold, a combination of an upper mold and a lower mold, etc. Molding made of a light-transmitting material such as a resin material, in which mold matching is performed by combining two molds, and a molding cavity having a shape that gives the ophthalmic lens article is formed between the molds. Use a mold to After filling the mold cavity of the mold with the predetermined monomer liquid, the filled monomer liquid is polymerized with the UV light transmitted through the mold by irradiating with UV light, and the target ophthalmic lens A technique for molding an article is known.

  By the way, when manufacturing an ophthalmic lens article in this manner, a batch method is usually employed, and a large number of ophthalmic lens articles are molded with UV light emitted from one light source. At this time, as a light source, an ultraviolet lamp such as a xenon lamp, a mercury lamp, or a deuterium lamp is generally used, and UV light from such an ultraviolet lamp is applied to all of a plurality of molds that simultaneously perform photopolymerization. Various ideas have been made so far to irradiate uniformly and uniformly. For example, a reflection plate such as a mirror is installed on the inner surface of the dome-shaped housing, and UV light emitted from a light source disposed on the top of the dome-shaped housing is reflected by the reflection plate. Adjustment is performed so that the UV light is irradiated with a substantially constant irradiance to the monomer liquid filled in the molding cavity of the mold.

  However, even if light irradiation is performed using a reflector such as a mirror in this way, it is extremely difficult to irradiate light to all the molds in the same manner. Has a problem that UV light is not sufficiently irradiated. And in the ophthalmic lens article in which the molding operation is performed simultaneously under such uneven light irradiation, even if it is an ophthalmic lens article having the same manufacturing lot number, for example, a plurality of ophthalmic lens articles There is often a problem that the degree of polymerization and the degree of cross-linking are different between those arranged at the center of the molds and those arranged at the ends. In addition, the difference in the degree of polymerization and the degree of cross-linking causes adverse effects on the lens physical properties and the lens shape. For example, in some contact lenses, the edge is not clearly formed, resulting in variations in quality. It is.

  In addition, UV lamps that have been widely used as light sources in the past generate light with an unnecessary wavelength that causes harmful effects on the lens material in addition to the light with the wavelength required for photopolymerization of the monomer liquid. In order not to be adversely affected by the light of such a wavelength, it is necessary to cut off the light of the extra wavelength by a shielding means such as an optical filter. Furthermore, since the lamp life of the ultraviolet lamp is short, the replacement frequency is high, and each time the lamp is replaced, the irradiance setting is complicated so that the UV light can be irradiated to the monomer liquid in the mold at a predetermined irradiance. Had to be done. In addition, the ultraviolet lamp needs to be cooled from the place where it generates heat, and it takes time for the irradiance to stabilize after lighting, and the irradiance decreases as the lighting time increases. Is inherent.

  On the other hand, in Japanese translations of PCT publication No. 2003-503234 (Patent Document 1), for the purpose of ensuring a constant quality of an ophthalmic molded product made of a biocompatible polymerizable material, a large number of optical fibers are used as ultraviolet lamps. Connect the optical fibers to one of a number of casting molds, and irradiate the mold with UV light from an ultraviolet lamp to perform molding. The method has been clarified.

  In this way, if a plurality of optical molds are not directly irradiated with light from an ultraviolet lamp but light is irradiated for each mold through a plurality of optical fibers, the location of the molds can be changed. Occurrence of uneven light irradiation due to the difference can be prevented, and UV light can be evenly irradiated to each mold. However, the portion of the ultraviolet lamp itself that can ensure uniform irradiance is narrow, and the number of optical fibers that can be attached to one ultraviolet lamp is limited. Furthermore, in this method, problems such as complicated work of attaching a plurality of optical fibers to the ultraviolet lamp and loss of light through the optical fibers are inherent. In addition, cooling is necessary to release the heat generated by turning on the ultraviolet lamp, and there is a problem of irradiance change with the usage time of the ultraviolet lamp. Problems caused by the ultraviolet lamp, such as the influence on the mold, are still not wiped out.

  Also, in Japanese Patent Application Laid-Open No. 59-215838 (Patent Document 2), an ultraviolet light source and a cavity or cavity core are optically coupled with an optical fiber so that an expensive light source can be used in combination with a plurality of molds. However, the same problem as in Patent Document 1 is inherent therein.

Special table 2003-503234 gazette JP 59-215838 A

  Here, the present invention has been made in the background of such circumstances, and the problem to be solved is to solve the above-mentioned problems caused by the use of ultraviolet lamps and to provide stable quality. It is another object of the present invention to provide a method for manufacturing an ophthalmic lens article that can be secured in the above-described manner, and an apparatus for manufacturing an ophthalmic lens article that is used therefor.

  And this invention was made | formed in order to solve the above subjects, Comprising: The place made into the 1st aspect is to match | combine the upper mold | type and lower mold | die which consist of a light-transmitting material. Thus, using such a mold, a molding cavity having a shape that gives a target ophthalmic lens article such as an ophthalmic lens, a semi-finished product thereof, or a lens blank is formed between the molds. While the monomer liquid is filled in the cavity, light is transmitted from the LEDs installed on at least one of the upper and lower mold sides of the mold, so that the mold cavity is irradiated with light transmitted through the mold. The ophthalmic lens article manufacturing method is characterized in that the monomer solution filled is photopolymerized to mold the objective ophthalmic lens article.

  In the second aspect of the method for manufacturing an ophthalmic lens article according to the present invention, a configuration in which a plurality of the molds are arranged and the LED is installed for each of the molds is advantageous. Will be adopted.

  Furthermore, in the third aspect of the method for manufacturing an ophthalmic lens article according to the present invention, the upper mold is a male mold having a convex molding cavity surface, while the lower mold has a concave molding cavity surface. It is a female type | mold, The said LED is installed in the position spaced apart upward from this male type | mold, and on the optical axis of the ophthalmic lens article shape | molded.

  In addition, in the fourth aspect of the method for producing an ophthalmic lens article according to the present invention, the monomer liquid contains at least one acrylic monomer.

  In the fifth aspect of the method for producing an ophthalmic lens article according to the present invention, the acrylic monomer is a silicon-containing acrylic monomer, and the silicon-containing acrylic monomer is 10 to 70 in the monomer liquid. It will be contained in the ratio of weight%.

  Furthermore, in the sixth aspect of the method for producing an ophthalmic lens article according to the present invention, the acrylic monomer is a dialkyl (meth) acrylamide, and the dialkyl (meth) acrylamide is 30 to 30 in the monomer liquid. It will be contained in a proportion of 70% by weight.

  Furthermore, in the seventh aspect of the method for producing an ophthalmic lens article according to the present invention, the irradiation time of the LED is 60 minutes or less.

  In addition, in an eighth aspect of the method for producing an ophthalmic lens article according to the present invention, light having a peak wavelength in the range of 350 to 500 nm, preferably 360 to 470 nm, particularly preferably 360 to 400 nm, is emitted from the LED. The monomer liquid is photopolymerized in the absence of a UV absorber.

  Moreover, in the ninth aspect of the method for producing an ophthalmic lens article according to the present invention, the monomer liquid contains a UV absorber, and the peak wavelength of light emitted from the LED is 380 to 500 nm, Preferably, it is in the range of 400 to 470 nm.

  Furthermore, in the tenth aspect of the method for producing an ophthalmic lens article according to the present invention, the monomer liquid is configured to further contain a pigment. In particular, yellow or orange pigments are preferably used as this pigment.

  In the eleventh aspect of the method for manufacturing an ophthalmic lens article according to the present invention, two of the LEDs are used and are respectively disposed above and below the mold, and are opposed to the two LEDs. In this way, light is irradiated.

  In the twelfth aspect of the method for producing an ophthalmic lens article according to the present invention, a photopolymerization initiator having a high extinction coefficient at 405 nm is used for the photopolymerization of the monomer liquid.

  By the way, the present invention is also directed to a manufacturing apparatus that is advantageously used in the method for manufacturing an ophthalmic lens article as described above, and includes an upper mold and a lower mold made of a light-transmitting material. A mold cavity having a shape that gives a target ophthalmic lens article, such as an ophthalmic lens, a semifinished product thereof, or a lens, is formed between the molds, And an LED for irradiating the monomer liquid filled in the molding cavity of the molding die with light disposed on at least one of the upper and lower mold sides of the molding die. One embodiment is an apparatus for manufacturing an ophthalmic lens article.

  Moreover, in the second aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, a plurality of the molds are arranged on a predetermined conveying means, and the LEDs are installed for each mold. Is adopted.

  Furthermore, in the third aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, a measuring means for measuring the irradiance of light emitted from the LED is interposed between the mold and the LED. It is installed on the opposite side, and the irradiance is measured by such measuring means.

  In addition, in the fourth aspect of the ophthalmic lens article manufacturing apparatus according to the present invention, a control means for controlling the voltage supplied to the LED is provided, and the control means measures the measurement means with the measurement means. The voltage supplied to the LED is controlled so that the target irradiance value matches the target value, and the irradiance of the light emitted from the LED is kept constant.

  Moreover, in the fifth aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, a diffusing unit for diffusing light emitted from the LED is provided between the mold and the LED, and the diffusing unit. By irradiating light through the LED, the irradiation angle of the light from the LED is widened so that the monomer liquid filled in the molding cavity of the mold is uniformly irradiated with the light. Become.

  Furthermore, in the sixth aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, a moving means is provided for moving the diffusing means in a direction separating from or approaching the mold, and the moving means. By adjusting the position of the diffusing means, the light is uniformly irradiated to the monomer liquid filled in the molding cavity.

  And according to the 1st aspect mentioned above in the manufacturing method of the ophthalmic lens article according to the present invention, with the light emitted from the LED, the monomer liquid filled in the molding cavity of the mold made of the light transmissive material is used. From the point of polymerization, the problems caused by the ultraviolet lamp can be solved. That is, since the LED does not emit light having a wavelength unnecessary for polymerization as compared with the ultraviolet lamp, the monomer liquid can be advantageously irradiated only with light having a wavelength effective for the polymerization. Also, UV lamps have a short lamp life and had to be replaced frequently, whereas LEDs have a long life, and stable irradiance can be obtained immediately after lighting. Is also easy. In addition, the light may be extinguished from the end of the polymerization operation of the monomer liquid filled in the molding cavity of a certain mold until the start of the polymerization operation of the monomer liquid filled in the molding cavity of the next mold. It is possible to obtain an advantage that it is not necessary to irradiate light which is harmful to the eyes unnecessarily. Furthermore, since the LED generates much less heat than the ultraviolet lamp, it is not difficult to control the polymerization by the heat conducted to the monomer liquid. Moreover, the LED has a feature that the irradiance can be easily finely adjusted by changing the amount of voltage to be supplied.

  As described above, when an LED is used as a light source, it is possible to irradiate light of stable irradiance over a long period of time advantageously and safely with respect to the monomer liquid. It can be manufactured advantageously with stable quality. In addition, by using the LED, high irradiance can be efficiently obtained, and the monomer liquid can be rapidly polymerized.

  Moreover, the LED is effectively applied to a mold for molding a small ophthalmic lens article because each LED has a small size and a small directivity angle. It can be easily realized.

  Therefore, according to the second aspect of the method for manufacturing an ophthalmic lens article according to the present invention, since at least one LED is installed for one set of molds, at least one light source is used for one set. The monomer liquid filled in the molding cavity of the mold is polymerized. As a result, instability of quality due to uneven irradiation, which has been caused when light is irradiated to a plurality of molds with a single light source, is advantageously eliminated. In addition, there is an advantage that LED light irradiated to each mold can be managed separately. For this reason, the stable quality of the ophthalmic lens article can be maintained even more advantageously.

  Furthermore, according to the 3rd aspect of the manufacturing method of the ophthalmic lens article according to this invention, the light irradiated from LED will be reliably irradiated to the whole monomer liquid with which it filled in the shaping | molding cavity. That is, since the light emitted from the LED has a certain directivity angle, sufficient light is introduced into the molding cavity by being refracted or reflected on the surface of the mold before reaching the molding cavity. The problem of being lost is advantageously prevented, and the LED light is advantageously irradiated on the entire molding cavity.

  In addition, according to the fourth to sixth aspects of the method for producing an ophthalmic lens article according to the present invention, the monomer liquid contains an acrylic monomer having an acrylic group or a methacryl group. Polymerization is effectively realized. In particular, when a silicon-containing acrylic monomer is used at a predetermined ratio as an acrylic monomer, an ophthalmic lens article excellent in oxygen permeability can be advantageously obtained. ) When acrylamide is used in a predetermined ratio, an ophthalmic lens article excellent in hydrophilicity or water content can be advantageously obtained.

  Moreover, according to the seventh aspect of the method for producing an ophthalmic lens article according to the present invention, the ophthalmic lens article can be produced with good workability.

  Furthermore, according to the eighth to tenth aspects of the method for producing an ophthalmic lens article according to the present invention, the polymerization of the monomer liquid is effectively realized, and the object of the present invention can be achieved more advantageously. .

  And according to the 11th aspect of the manufacturing method of the ophthalmic lens article according to this invention, the photopolymerization operation using LED of the monomer liquid containing a UV absorber can be advanced effectively.

  Furthermore, according to the twelfth aspect of the method for manufacturing an ophthalmic lens article according to the present invention, the LED light emission wavelength on the long wavelength side is effectively absorbed, and the polymerization is rapidly advanced. An ophthalmic lens article can be advantageously obtained.

  Further, in the first aspect of the ophthalmic lens article manufacturing apparatus according to the present invention, since the LED is employed as the light source, as described above, the problems caused by the ultraviolet lamp can be solved ugly, The feature that the quality of the ophthalmic lens article can be stably maintained is exhibited.

  Furthermore, according to the second aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, as in the second aspect of the method for manufacturing an ophthalmic lens article, instability of quality due to uneven irradiation is advantageous. Thus, the stable quality of the ophthalmic lens article can be maintained more advantageously, and the ophthalmic lens article can be continuously mass-produced.

  In addition, according to the third aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, from the measurement of the irradiance of the irradiated light, from the measured value of the irradiance, the irradiation condition of light from the LED, As a result, it can be judged whether the polymerization conditions are accurate or not. When the irradiance is too high or too low, the irradiation time of the LED light is appropriately changed, or the voltage supplied to the LED is appropriately changed, and the polymerization of the monomer liquid is performed. It can be controlled and managed to keep the quality of the ophthalmic lens article constant.

  According to the fourth aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, the value of the irradiance measured by the measuring means matches the preset target value in the control means. As described above, since the voltage supplied to the LED is controlled, the irradiance of the light can be automatically kept constant, and further, the stable quality of the ophthalmic lens article is further advantageous. Can be secured.

  Furthermore, according to the fifth aspect and the sixth aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, the monomer liquid in the molding cavity can be uniformly and uniformly irradiated with light from the LED. It is. For this reason, for example, when manufacturing a contact lens as an ophthalmic lens article, the edge portion of the outer peripheral edge of the contact lens is also reliably polymerized, so that an ophthalmic lens article having a target shape can be accurately formed. It will be.

It is a partial cross section explanatory drawing which shows roughly the principal part of an example of the manufacturing apparatus of the ophthalmic lens article | item according to this invention. FIG. 5 is a partial cross-sectional explanatory view showing another example of a process for producing an ophthalmic lens article using a mold for mold polymerization according to the method of the present invention, from an LED light source installed for each of a plurality of molds; FIG. 2 shows a state in which light is irradiated to each of the molds. It is a partial cross section explanatory drawing which shows roughly the principal part of another example of the manufacturing apparatus of the ophthalmic lens article according to this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Mold 12 LED light source 14 Photo detector 16 Light intensity control device 18 Diffuser lens 20 Crank device 22 Stepping motor 24 Transporter 26 Male 28 Female mold 30 Mold cavity 32 Bottom 34 Rear mold cavity surface 44 Recess 48 Front mold cavity surface 50 monomer solution

  Hereinafter, in order to clarify the present invention more specifically, embodiments of the present invention will be described in detail with reference to the drawings.

  First, FIG. 1 schematically shows a contact lens manufacturing apparatus as an embodiment of an apparatus for manufacturing an ophthalmic lens article having a structure according to the present invention. As apparent from FIG. 1, the contact lens manufacturing apparatus of this embodiment irradiates the mold 10 for molding the contact lens and the light having a predetermined peak wavelength to the mold 10. A light source 12 made of LED, a light detector 14 that measures the irradiance of the light emitted from the LED light source 12, and the irradiance measured by the light detector 14 to the LED light source 12. A light intensity control device 16 as control means for controlling the voltage to be supplied, a diffusion lens 18 as diffusion means provided between the molding die 10 and the LED light source 12, and the diffusion lens 18 from the molding die 10. A crank device 20 and a stepping motor 22 as moving means that move in a separating direction or an approaching direction, and a conveying means that conveys the mold 10 while holding it. And a transfer device 24 of Te, is constructed.

  The mold 10 is shown as a cross-sectional view, and is composed of a male mold 26 as an upper mold and a female mold 28 as a lower mold. Each mold is made of a material that can transmit light, and the male mold 26 and the female mold 28 are matched with each other to provide a target contact lens between the molds. A shaped molding cavity 30 is formed. Here, the light transmissive material constituting the mold 10 is not particularly limited as long as it can transmit the light emitted from the LED light source 12, and specific examples include, for example, Polyolefins such as polyethylene, polypropylene and polymethylpentene; resin materials such as polyamides such as nylon 6, nylon 66, nylon 610, nylon 612, nylon 11 and nylon 12, and combinations thereof; glass, quartz, fused quartz, etc. Inorganic materials can be mentioned. Among these, considering the affinity with the monomer liquid filled in the molding cavity 30 and its polymer, economy, moldability, and the like, in particular, resin materials such as polyolefin and polyamide are preferably employed. Become. Further, the male mold 26 and the female mold 28 constituting the mold 10 may be formed of the same light transmitting material, or may be formed of different light transmitting materials. Absent. Furthermore, when the monomer liquid contains a UV absorber, as described later, when the polymerization is performed using irradiation light having a peak wavelength of 380 to 500 nm, The transmittance of the main wavelength of the LED light is generally 20% or more, more preferably 25% or more. For example, polypropylene or polymethylpentene is advantageously used.

  More specifically, the male mold 26 constituting the molding die 10 as a whole has a bottomed cylindrical shape with an upper opening, and a bottom portion 32 positioned below the male mold 26 serves as a cavity forming portion. The outer surface (convex surface) of the bottom portion 32 has a curved surface shape that protrudes outward, and the rear molding cavity surface 34 has a shape that accurately corresponds to the rear surface (base curve surface) of the target contact lens. It is configured. Although the thickness of the bottom portion 32 is not particularly limited, the light from the LED light source 12 to be described later is introduced into the molding cavity 30 through the bottom portion 32, so that the LED light enters the molding cavity 30. Is preferably approximately constant so that the light can be irradiated uniformly, and is preferably about 0.1 mm to 3 mm in consideration of the influence of polymerization shrinkage, light attenuation, and the like. In particular, according to the light irradiation using the LED light source 12, since the temperature rise of the mold material of the mold 10 is hardly caused, the feature that the thickness of the bottom portion 32 can be reduced is exhibited. The male mold 26 is integrally formed with an outer flange portion 38 projecting radially outward at an outer peripheral portion on the upper opening side of the cylindrical wall portion 36.

  On the other hand, the female mold 28 constituting the mold 10 as a whole has a bottomed cylindrical shape with an opening at the bottom, and an upper bottom portion 40 located at the top thereof is recessed downward in a substantially hemispherical shape. The ball-shaped recess 44 is a cavity forming portion. Then, a step 46 is provided at the intermediate portion in the depth direction of the hemispherical recess 44, and the inner surface (concave surface) of the bottom side portion below the step 46 is the front surface (front surface) of the target contact lens. The front molding cavity surface 48 accurately corresponds to the (curved surface).

  Then, as shown in FIG. 1, the male mold 26 and the female mold 28 are in contact with each other at the bottom side corner of the cylindrical wall portion 36 of the male mold 26 and the corner of the step 46 of the female mold 28. In addition, the rear mold cavity surface 34 of the male mold 26 and the female mold 26 are assembled by being assembled and matched so that the lower surface of the outer flange portion 38 of the male mold 26 and the upper end surface of the female mold 28 are in contact with each other. A molding cavity 30 having a shape that provides a target contact lens is formed in a space between the front molding cavity surface 48 of the mold 28.

  Further, as shown in FIG. 1, the molding cavity 30 is filled with a monomer liquid 50 that gives a polymer constituting a target contact lens. This monomer solution 50 is stored in a predetermined amount in the recess 44 of the female mold 28 prior to the matching of the male mold 26 and the female mold 28, and after the storage, as described above, the male mold When the mold 26 and the female mold 28 are matched, the molding cavity 30 is filled. Further, the surplus monomer liquid 50 overflowing from the molding cavity 30 due to such mold matching is brought into contact with the bottom side corner of the cylindrical wall portion 36 of the male mold 26 and the corner of the step 46 of the female mold 28. A space 52 formed above the portion, that is, an annular shape formed between the upper outer peripheral surface of the cylindrical wall portion 36 of the male mold 26 and the inner peripheral surface of the opening-side portion of the concave portion 44 of the female mold 28. It can be stored in the space 52.

  Here, as the monomer liquid 50 to be polymerized, various conventionally known liquid monomer compositions that give a polymer constituting the target contact lens will be used. 50 preferably contains at least one acrylic monomer (acrylic group or methacrylic group-containing monomer), whereby the photopolymerizability of the monomer liquid 50 is ensured satisfactorily. . Specific examples of the acrylic monomer having an acrylic group or a methacryl group include, for example, silicon-containing (meth) acrylate, alkyl (meth) acrylate, fluorine-containing (meth) acrylate, hydroxyalkyl (meth) acrylate, and aryl. Examples thereof include (meth) acrylate, N-alkyl (meth) acrylamide, and N, N-dialkyl (meth) acrylamide. More preferably, the acrylic monomer is preferably contained in the monomer liquid 50 in a proportion of at least 10% by weight. In addition, in the above description, in the following description, “(meth) acryl” indicates acryl and / or methacryl, while “(meth) acrylate” indicates acrylate and / or methacrylate. Yes.

  In particular, as the acrylic monomer, a silicon-containing acrylic monomer as disclosed in International Publication No. 01/71415 pamphlet or JP-A-6-121826 is selected, and this is used as a main component in the monomer liquid 50. If it is contained in a proportion of 10 to 70% by weight, excellent oxygen permeability is advantageously imparted to the obtained contact lens. Moreover, dialkyl (meth) such as N, N-dimethyl (meth) acrylamide, N, N-diethyl (meth) acrylamide, N, N-dipropyl (meth) acrylamide, and N-isopropyl (meth) acrylamide as an acrylic monomer. If acrylamide is used and contained in the monomer liquid 50 as a main component in a proportion of 30 to 70% by weight, the resulting contact lens is advantageously imparted with excellent hydrophilicity or water content. It will be.

  In addition, the monomer solution 50 may include a target lens type (for example, hard, soft, non-hydrous, hydrous, etc.) and characteristics required for the lens (for example, oxygen permeability) as necessary. , Coloring, ultraviolet absorptivity, etc.), conventionally known various monomer components other than acrylic monomers as described above, and various conventionally commonly used additives such as ultraviolet (UV) As in the prior art, there may be no problem even if an absorbent, a dye, or the like is added in an appropriate amount, and a non-polymerizable solvent may be added in an amount that does not hinder the polymerization.

  Here, examples of the UV absorber and dye include known UV absorbers such as benzophenone, benzotriazole, and salicylic acid derivatives, and known dyes such as azo, anthraquinone, nitro, and phthalocyanine. Among them, these UV absorbers and pigments have polymerizable groups such as acryloyl group, methacryloyl group, vinyl group, allyl group, isopropenyl group, and the like by the photopolymerization operation according to the present invention. It is desirable that the target ophthalmic lens article is formed as a component of the polymer by being copolymerized with monomers constituting the monomer liquid 50. The amount of the UV absorber or pigment added to the monomer liquid 50 is appropriately selected within a conventionally known range. Generally, the UV absorber is 100 parts by weight of the total polymerization components. The dye is used in a ratio of about 0.0001 to 0.1 parts by weight with respect to 100 parts by weight of the total polymerization components.

  Further, the monomer solution 50 has methyl orthobenzoyl benzoate, methyl benzoyl formate, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl so that polymerization by light can be advantageously realized as in the conventional case. Benzoin photopolymerization initiators such as ether and benzoin-n-butyl ether, benzophenone photopolymerization initiators such as N, N-tetraethyl-4,4-diaminobenzophenone and 2,4,6-trimethylbenzophenone, benzyl and the like Carbonyl photopolymerization initiator, 2-hydroxy-2-methyl-1-phenyl-propan-1-one, 1- (4- (2-hydroxyethoxy) phenyl) -2-hydroxy-2-methyl-1-phenyl -Propan-1-one, etc. Conventionally known polymerization initiators such as tophenone photopolymerization initiators, peroxides such as benzoyl peroxide, azo polymerization initiators such as azobisisobutyronitrile, and cationic type polymerization initiators such as metallocenes 1 type (s) or 2 or more types are added suitably. Of these polymerization initiators, radical initiators are preferably used from the viewpoint of polymerizability and polymerization rate. Furthermore, it is also effective to use a known photosensitizer in combination with such a polymerization initiator.

In the present invention, the use of a photopolymerization initiator having a high absorption coefficient at a wavelength near 405 nm facilitates absorption of the emission wavelength on the long wavelength side from the LED light source 12, thereby improving the polymerization rate. This is advantageous for rapid polymerization. As an initiator having a high absorption coefficient at a wavelength of 405 nm, 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butanone-1,1,2-octanedione-1- [ 4- (phenylthio) -2- (O-benzoyloxime)], 2,4,6-trimethylbenzoyl-diphenylphosphine oxide, bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide, bis (η ⁵ -2,4-cyclopentadiene-1-yl) - bis (2,6-difluoro-3-(1H-pyrrol-1-yl) - phenyl) titanium, 4-methylbenzoyl - diphenyl phosphine oxide, 2, 4,6-trimethylbenzoyl-dimethoxy-phosphine oxide, isobutylbenzoyl-diphenyl- Phosphine oxide, isobutylbenzoyl-dimethoxy-phosphine oxide, benzoyl-diphenyl-phosphine oxide, 2-methylbenzoyl-diphenyl-phosphine oxide, benzoyl-diethoxy-phosphine oxide, 2,6-dichlorobenzoyl-dimethoxy-phos Fin oxide, bis (2,6-dichlorobenzoyl)-(4-butylphenyl) phosphine oxide, 2,4-trichloromethyl (4'-methoxystyryl) -6-triazine, 2- (2 '-(5' ′ -Methylfuryl) ethylidene) -4,6-bis (trichloromethyl) -s-triazine and the like, and these initiators generally have an extinction coefficient (405 nm) of 100 ml / g · cm or more. ing. These initiators are particularly effective when an LED having an irradiation light peak wavelength of 400 nm or more is used as the LED light source 12. In addition, in the photopolymerization of the monomer liquid 50 containing the UV absorber, the polymerization initiator desirably has a characteristic of absorbing light at a longer wavelength side while avoiding light absorption by the UV absorber. It is recommended to use a polymerization initiator having a high extinction coefficient at the aforementioned wavelength: 405 nm. Furthermore, it is also effective to use such a polymerization initiator having a high extinction coefficient in combination with other polymerization initiators and photosensitizers having a low extinction coefficient at a wavelength of 405 nm. It is also possible to use a combination of photosensitizers.

  By the way, in the manufacturing apparatus of this embodiment, the LED light source 12 that can irradiate light is on the side of the male mold 26 that is the upper mold of the mold 10 having the structure as described above, specifically, in the mold 10. The contact lens is formed on the optical axis (optical center axis) of the contact lens and at a position spaced apart from the male mold 26 by a predetermined distance.

  Thus, the LED light sources 12 can be installed at least one by one with respect to the set of molds 10 because each LED light source 12 is smaller than a conventional ultraviolet lamp. Conventionally, as described above, a relatively large facility such as a dome-shaped housing has been required to irradiate a plurality of molds with the light of one ultraviolet lamp light source. If the LED light source 12 is installed for each mold 10, such a housing or the like becomes unnecessary, and this has the advantage that the apparatus for manufacturing an ophthalmic lens article can be advantageously reduced in size. In addition, if the LED light source 12 is installed for each mold 10, the quality of the ophthalmic lens article is deteriorated due to uneven light irradiation, which has been caused when light is irradiated to a plurality of molds with one light source. There is no stabilization. Furthermore, even if mass production is performed, the irradiation conditions of LED light can be managed for each mold 10. For this reason, the stable quality of the ophthalmic lens article can be maintained even more advantageously.

  In the present embodiment, the LED is arranged on the optical axis of the contact lens molded in the mold 10, in other words, from the side of the male mold 26 having the convex rear molding cavity surface 34. Since the LED light is irradiated from the concave surface side of the contact lens molded in the LED 10, the LED light passes through the male mold 26 of the mold 10 and enters the molding cavity 30 of the mold 10. The charged monomer liquid 50 is advantageously irradiated. That is, when the LED light is irradiated from the female mold 28 side having the concave front molding cavity surface 48, in other words, from the convex side of the contact lens molded in the molding mold 10, the convex surface of the molding mold 10. Since the light emitted from the LED has a directivity angle, it is sufficiently refracted and reflected on the surface of the mold 10 before reaching the inside of the molding cavity 30. Light may not be introduced into the molding cavity 30, particularly in the region corresponding to the peripheral edge of the contact lens. However, if the concave surface of the mold 10 is irradiated, transmitted light due to light refraction or reflection is transmitted. Is advantageously suppressed, and LED light can be advantageously irradiated to the entire molding cavity 30, thereby ensuring high workability, lens completeness, and safety. It becomes a.

  Furthermore, the LED light source 12 does not emit light having a wavelength unnecessary for the polymerization of the monomer liquid 50 as compared with a conventional xenon lamp, an ultraviolet lamp such as a mercury lamp or a deuterium lamp. 50 is advantageous in that only light having an effective wavelength around the peak wavelength can be advantageously irradiated. In addition, the LED light source 12 has advantages such as low heat generation and power consumption, long life, and stable irradiance even immediately after lighting. It can be done. In other words, as described above, the ultraviolet lamp has a short lamp life and therefore has to be frequently replaced, whereas the LED has a long life and also has a stable irradiance even immediately after lighting. Since it is possible to finely adjust the irradiance by changing the amount of voltage to be obtained, it is possible to easily obtain the desired irradiance while being excellent in economic efficiency. In addition, when an LED is used, it is possible to turn off the light in the interval from the end of the polymerization operation to the start of the next polymerization operation, and it is possible to avoid unnecessary irradiation of light that is harmful to the eyes. Further, since the LED generates very little heat compared to the ultraviolet lamp, the atmosphere temperature before polymerization can be kept constant, and the polymerization of the monomer liquid 50 can be conventionally performed without progressing polymerization due to heat. It is easier to control.

  Here, the LED (light emitting diode) used as the LED light source 12 needs to be capable of emitting light having a wavelength capable of polymerizing the monomer liquid 50. Specifically, the wavelength of light emitted from the LED light source 12 depends on the initiator, but from the viewpoint of the polymerizability of the monomer liquid 50, the monomer liquid 50 does not contain a UV absorber. In general, the peak wavelength is desirably in the range of 350 to 500 nm, more preferably in the range of 360 to 470 nm, and still more preferably in the range of 360 to 400 nm. This is because when such a peak wavelength is in a wavelength range shorter than the above range, the contact lens material (polymer constituting the contact lens) may be deteriorated, and the long wavelength range. This is because the polymerizability is lowered and the generation of heat becomes a problem. In particular, when a UV-absorbing lens (ophthalmic lens article) is produced using the monomer liquid 50 containing a UV absorber, the peak wavelength is generally in the range of 380 to 500 nm, preferably 400 to 470 nm. It is desirable. Thus, although the desirable peak wavelength in the irradiation light of the LED light source 12 changes depending on the presence or absence of the UV absorber in the monomer liquid 50, it has almost no influence depending on the presence or absence of a dye appropriately added as necessary. You will not receive it. In addition, it is desirable that the light emitted from the LED light source 12 has substantially no peak wavelength other than the above wavelength range.

  Further, the directivity angle (2θ1 / 2) of the LED light source 12 is known to be smaller than that of a conventional ultraviolet lamp or the like, and is not particularly limited, but if it is too small, an effective irradiation area is obtained. On the contrary, if it is too large, it is difficult to obtain effective irradiance. For this reason, it is desirable that the directivity angle is 10 to 120 ° from the viewpoint of effective use of light energy of the LED. The directivity angle is appropriately set according to the size of the ophthalmic lens article to be manufactured, that is, the area to be irradiated with light, etc. In particular, in the case of a hydrous contact lens, 20 to 110 ° within the above range. In the non-hydrous contact lens, 30 to 120 ° is preferable in the above range.

  Further, when the directivity angle is small with respect to the size of the target ophthalmic lens article, for example, when the directivity angle is less than 10 °, the diffusion for diffusing the LED light as necessary. The means can be installed on the optical path between the LED light source 12 and the mold 10, while the directivity angle is larger than the size of the target ophthalmic lens article, for example, the directivity angle is 120 °. For example, a light collecting means for condensing the LED light can be installed on the optical path between the LED light source 12 and the mold 10. As described above, if the LED light is irradiated through the diffusing unit or the condensing unit, uniform polymerization is advantageously realized. Here, examples of the diffusing unit include a diffusing plate such as a diffusing filter and a diffusing lens, and examples of the condensing unit include a condensing lens.

  In the present embodiment, since the directivity angle of light emitted from the LED light source 12 is small with respect to the molding cavity 10, as shown in a cross-sectional form in FIG. The diffusion lens 18 is disposed between the two, and the light emitted from the LED light source 12 is transmitted through the diffusion lens 18 so that the irradiation angle is widened and the monomer filled in the mold cavity 30 The liquid 50 can be uniformly and uniformly irradiated. As a result, it is advantageously avoided that the polymerization of the monomer liquid 50 proceeds locally, and the uniform polymerization of the monomer liquid 50 can be realized very advantageously. Further, the distance between the LED light source 12 and the mold 10 can be shortened.

  In addition, the vertical distance (irradiation distance: D) from the LED light source 12 to the outer surface of the cavity forming portion (32, 44) of the mold 10 is not particularly limited, but is excellent. In order to ensure workability and avoid the effects of contamination and polymerization heat of the LED light source 12, the peak wavelength of the irradiation light, the presence or absence of a UV absorber, the directivity angle of the LED light source 12, the area to be irradiated with light, etc. In accordance with the above, it is set appropriately within a range of about 0.5 to 30 mm. Specifically, in the case where the monomer liquid 50 does not contain a UV absorber, an irradiation distance (D) of 3 to 30 mm is advantageously employed in the polymerization in which the peak wavelength of the irradiation light is 350 to 400 nm, and the irradiation light In the polymerization in which the peak wavelength is 400 to 500 nm, an irradiation distance (D) of 1 to 30 mm is advantageously employed. Furthermore, in the case where the monomer liquid 50 contains a UV absorber or a pigment together therewith, an irradiation distance (D) of 0.5 to 25 mm is obtained due to polymerization using irradiation light having a peak wavelength of 380 to 500 nm. It will be advantageously employed. In addition, when the transmittance | permeability in the main wavelength of the irradiation light of the shaping | molding die 10 will be 50% or less, it is desirable to make the LED light source 12 approach, and generally irradiation distance (D) of about 0.5-5 mm ) Will be adopted.

  Furthermore, in the manufacturing apparatus according to the present embodiment, the light detector 14 for measuring the intensity of light emitted from the LED light source 12, specifically, the irradiance, is below the female mold 28 that is the lower mold of the mold 10. Further, it is installed so as to face the LED light source 12 with the mold 10 interposed therebetween. Of the light emitted from the LED light source 12, the light transmitted through the mold 10 is detected by the photodetector 14.

  The photodetector 14 is connected to a light intensity control device 16 that includes an arithmetic processing unit such as a computer and a variable voltage circuit. The irradiance data measured by the photodetector 14 is input to the light intensity control device 16, and the amount of voltage supplied to the LED light source 12 is controlled by the light intensity control device 16. . More specifically, in the light intensity control device 16, a target value of irradiance necessary for the polymerization of the monomer liquid 50 is set in advance, and the arithmetic processing unit of the light intensity control device 16 uses the light detector 14. A calculation process is performed to determine whether or not the input measurement value matches a preset target value. When the measured value does not match the target value, the amount of voltage applied to the LED light source 12 is increased or decreased by the variable voltage circuit so that the measured value matches the target value. . The intensity of light emitted from the LED is finely adjusted and kept constant by the voltage supplied from the light intensity controller 16 to the LED light source 12 connected to the light intensity controller 16. It is like that. The target value can be appropriately set by an operator, for example, by an input operation using a keyboard or the like.

  In addition, the manufacturing apparatus according to the present embodiment is a moving means for moving the diffusing lens 18 in a direction away from the mold 10 (upward) or a direction approaching the mold 10 (downward). A crank device 20 and a stepping motor 22 are installed. Then, the rotational motion of the stepping motor 22 is converted into a reciprocating motion by the known crank device 20, so that the diffusing lens 18 connected to the crank device 20 is driven in the vertical direction by the driving force of the stepping motor 22 (FIG. 1). It is possible to move in the direction (b). In this way, if the stepping motor 22 is used, fine adjustment of the position of the diffusing lens 18 can be easily performed. For this reason, when LED light cannot be irradiated to the whole monomer liquid 50 with which the shaping | molding cavity 30 of the shaping | molding die 10 was filled, for example, light is irradiated only to the center part of the shaping | molding cavity 30, and contact lens periphery In the case where light is not irradiated to the part of the molding cavity 30 corresponding to the part, if the diffusion lens 18 is moved upward by the driving force of the stepping motor 22, the light is irradiated to the entire molding cavity 30 of the mold 10. It can be done. Conversely, when the light irradiated to the mold 10 is too wide, the position of the diffusing lens 18 may be moved downward by the driving force of the stepping motor 22.

  Further, in the present embodiment, the mold 10 as described above is placed on the transporting machine 24 serving as transporting means. In addition, although this conveyance machine 24 can be comprised by conventionally well-known things, such as a belt conveyor and a chain conveyor, for example, it is comprised by the belt conveyor here. As the belt is moved by the operation of the conveyor 24, the mold 10 is conveyed in the moving direction of the belt. The belt of the transporter 24 is formed with a large number of through holes 25 having a size smaller than the outer size of the mold 10 at a predetermined interval. It is placed so as to cover the periphery of the hole 25.

  By the way, when the target contact lens is manufactured using the contact lens manufacturing apparatus of the present embodiment having such a structure, for example, the operation is advanced as follows. . In the following, as a specific example, a method for continuously manufacturing a plurality of contact lenses will be described in detail.

  That is, first, a plurality of molds 10 for molding a target contact lens are prepared, and the female mold 28 of the molds 10 is placed and held at a predetermined position of the conveyor 24. Then, the transfer machine 24 is operated to first transfer the female mold 28 to a monomer liquid supply device (not shown). When the female mold 28 reaches the place where the monomer liquid is supplied, the conveying device 24 is temporarily stopped, and the monomer liquid that gives the polymer constituting the target contact lens in the recess 44 of the female mold 28, respectively. 50 is supplied by a predetermined amount. Then, after this monomer liquid supply process, the transporting device 24 is operated again, and the female mold 28 containing the monomer liquid 50 is transported to a place where the mold matching process is performed. Then, when the female mold 28 reaches the place where the mold matching process is performed, the conveying machine 24 is temporarily stopped, and the male mold 26 is moved from above the female mold 28 to the corner of the step 46 in the female mold 28. Thus, the bottom 32 side corner of the outer peripheral surface of the cylindrical wall portion 36 of the male mold 26 abuts, and the lower surface of the outer flange portion 38 of the male mold 26 and the upper surface of the female mold 28 abut each other. Assemble and do mold matching. As a result, a molding cavity 30 is formed between the male mold 26 and the female mold 28, and the monomer liquid 50 is filled into the molding cavity 30.

  Then, as described above, when the filling of the monomer liquid 50 is completed, the transport machine 24 is operated again, and each of the molding dies 10 filled with the monomer liquid 50 is placed downstream in the transport direction of the transport machine 24. As shown in FIG. 1 and FIG. 2, the light irradiation position is arranged and conveyed between the LED light source 12 and the photodetector 14. When the mold 10 reaches between the LED light source 12 and the light detector 14, the conveyor 24 is stopped, and one LED light source 12 is positioned on each optical axis of the contact lens to be molded. On the other hand, light is emitted from each LED light source 12 installed or arranged above the mold 10 to each mold 10. As a result, the light emitted from the LED light source 12 is advantageously introduced into the molding cavity 30 through the male mold 26 of the mold 10 having optical transparency, so that the monomer liquid filled in the molding cavity 30 is obtained. 50 is photopolymerized.

  On the other hand, each of the photodetectors 14 provided for each molding die 10 determines the intensity of light emitted from the LED light source 12 positioned so as to face each other with the molding die 10 interposed therebetween. 10, and the detected light intensity, specifically the irradiance, is input to the light intensity controller 16 via a known interface. In this way, when the irradiance is input, the light intensity control device 16 determines whether or not the irradiance input from the light detection device 14 matches the preset target value. When the target value is below, the application amount of the voltage supplied to the LED light source 12 is increased. On the other hand, when the target value is exceeded, the voltage amount supplied to the LED light source 12 is reduced, Feedback control is performed so that the irradiance detected by the photodetector 14 matches the target value. The irradiation intensity of the light emitted from the LED light source 12 is preferably controlled for each LED light source 12 as shown in FIG. If it is arranged and the light emitted from the LED light source 12 is individually controlled, the quality of the product can be ensured more highly and stably, and the occurrence rate of defective products is also extremely effective. Will be reduced.

  Furthermore, when the directivity angle of the light emitted from the LED light source 12 is smaller than the diameter of the target contact lens, in other words, when the entire molding cavity 30 providing the contact lens is not irradiated with light. As shown by the solid line in FIG. 1 and the two-dot chain line in FIG. 2, a diffusing lens 18 as a diffusing unit is disposed between the LED light source 12 and the mold 10 and the periphery of the contact lens to be molded LED light is irradiated to the entire molding cavity 30 up to a portion corresponding to the part. At this time, the position of the diffusing lens 18 is finely adjusted by the moving means constituted by the stepping motor 22 and the crank device 20. On the other hand, when the directivity angle of the LED light source 12 to be used is too large compared to the diameter of the target contact lens, although not shown, the LED light source 12 and the mold 10 are not illustrated. It is desirable that a light condensing unit such as a condensing lens is disposed between the light source and the light energy of the LED light emitted from the LED light source 12 by the condensing unit. Useless irradiation of light that is effectively used for polymerization and does not contribute to polymerization is advantageously reduced.

  When the plurality of molding dies 10 filled with the monomer liquid 50 are transported between the LED light source 12 and the light detector 14 in the mold matching process for the irradiation of the LED light to the molding dies 10. At the same time, a plurality of other female molds 28 in which the monomer liquid 50 is accommodated are transported to a place where the mold matching process is performed, and at the same time, a plurality of other female molds 28 in which the monomer liquid 50 is not accommodated. However, it is conveyed to the monomer liquid supply device. That is, light is emitted from the LED light source 12 to the mold 10 in which the monomer liquid 50 is filled in the molding cavity 30 by the mold matching process (execution of the light irradiation process), while the monomer liquid 50 is accommodated. In addition, a mold matching process for assembling the male mold 26 to another female mold 28 is performed, and a filling process of the monomer liquid 50 for supplying the monomer liquid 50 into the recess 44 of another female mold 28 is performed. The three steps, which are to be carried out, are made to proceed simultaneously for different molds 10.

In the light irradiation step, the wavelength of the light emitted from the LED light source 12 to the monomer liquid 50 is not particularly limited, but is described above when the monomer components in the monomer liquid 50 are sufficiently polymerized. Thus, when the UV absorber is not present in the monomer liquid 50, the LED light having a peak wavelength in the range of 350 to 500 nm is peaked, and when the UV absorber is present in the monomer liquid 50, the peak is obtained. LED light having a wavelength in the range of 380 to 500 nm is particularly preferably employed. Further, the irradiation amount per unit area from the LED light source 12, that is, so-called irradiance is not particularly limited, but when it is too small, the polymerization of the monomer liquid 50 does not proceed and is too large. However, since there is a possibility of adverse effects such as deterioration of the contact lens material, it is preferably 0.5 to 30 mW / cm ² , more preferably 1 to 20 mW / cm ² .

  Further, the irradiation time of the LED light to the mold 10 is also appropriately determined according to the size of the target contact lens, the intensity of light emitted from the LED light source, the kind of the monomer liquid 50, and the like. In consideration of workability and completeness of the lens, the upper limit is preferably 120 minutes or less, more preferably 60 minutes or less, while the lower limit is preferably 3 minutes or more, more preferably 5 minutes or more. Is done. This is because if the irradiation time is too long, the light irradiation process, and thus the entire manufacturing process of the target contact lens, is unnecessarily prolonged, leading to deterioration in workability and productivity. Yes, if the irradiation time of LED light is too short, the amount of light irradiation to the monomer liquid 50 is too small, and the photopolymerization of the monomer components in the monomer liquid 50 becomes insufficient, and the residual monomer amount increases. This is because problems such as

  Furthermore, in this process, since the LED light source 12 is used as the light source, heat generation due to light irradiation is relatively small and the progress of polymerization due to heat can be suppressed, but more stable polymerization is realized. Therefore, it is desirable that the light irradiation step is performed during the light irradiation step so that the mold 10 does not exceed the environmental temperature + 5 ° C. or lower, that is, approximately 5 ° C. higher than the environmental temperature. However, as the photopolymerization temperature, any temperature can be adopted as long as it is not higher than the appropriate maximum operating temperature of the LED light source 12, and polymerization can be performed while raising the temperature within such a temperature range. In addition, after a certain time from the start of the photopolymerization, only the mold 10 is moved to the thermal polymerization tank, and heating is performed to accelerate the polymerization unless it adversely affects the achievement of the object of the present invention. You can also

  Thus, the target contact lens is formed by photopolymerizing the monomer liquid 50 filled in the molding cavity 30 of the mold 10 by light irradiation to the mold 10 as described above. The contact lens formed in this way is provided with a base curve surface corresponding to the rear molding cavity surface 34 of the male mold 26 and a front curve surface corresponding to the front molding cavity surface 48 of the female mold 28. It will be.

  And after the light irradiation process to this shaping | molding die 10 is complete | finished, the conveyance machine 24 is act | operated again, A plurality of the shaping | molding die 10 in which photopolymerization was implemented from between the LED light source 12 and the photodetector 14 is carried out. Transport to the downstream side of the transport direction of the transport machine 24. Thereafter, the male mold 26 of the mold 10 is removed from the female mold 28 to open the mold, and the contact lens is removed by a mold release operation similar to the conventional one, thereby obtaining the target contact lens. It is.

  As described above, in the present embodiment, the monomer liquid 50 filled in the molding cavity of the mold made of the light transmissive material is polymerized by the light emitted from the LED light source 12, and thus the conventional method is used. The problem caused when using the ultraviolet lamp is advantageously solved, and LED light having a stable irradiance is applied to the monomer liquid 50 filled in the molding cavity 30 of the mold 10 over a long period of time. Irradiation can be advantageously performed over a wide range. Therefore, a contact lens as an ophthalmic lens article can be advantageously manufactured with stable quality.

  Moreover, since one LED light source 12 is installed for one set of molds 10, the quality of the irradiation unevenness caused when one light source emits light to a plurality of molds is improved. The destabilization is advantageously eliminated. In addition, the light irradiated to each mold 10 can be controlled separately, and the high quality of the contact lens that is an ophthalmic lens article can be more easily ensured. In addition, high irradiance can be efficiently obtained, and the monomer liquid 50 can be rapidly polymerized.

  The exemplary embodiments of the present invention have been described in detail above, but these are merely examples, and the present invention is not limited in any way by specific descriptions according to such embodiments. It should be understood that this is not to be interpreted.

  For example, in the above embodiment, one LED light source 12 is arranged for a set of molds 10, but the number of LED light sources 12 arranged for a set of molds 10 is as described above. The number of LED light sources 12 is not limited to one, and two or more LED light sources 12 may be arranged. However, when two or more LED light sources 12 are arranged for a set of molds 10, the light emitted from the LED light sources 12 is used for the photopolymerization of the monomer liquid 50 filled in the molding cavity 30. To advantageously contribute, at least one LED light source 12 is installed above and below the mold 10, and LED light is irradiated from above and below the mold 10. Is desirable. In particular, light irradiation from above and below the mold 10 is performed when the monomer liquid 50 containing a UV absorber or a pigment together with the UV absorber is polymerized with light having a peak wavelength of 380 to 500 nm. This is advantageously employed from the viewpoint of reducing deformation defects of the ophthalmic lens article that is the resulting polymerization product. However, when manufacturing a contact lens, it is possible to obtain sufficient light energy with only one LED light source 12 without using two or more LED light sources 12.

  In the above example, the LED light source 12 is installed at a position separated from the male mold 26 and on the optical axis of the contact lens to be molded, and the light from the LED light source 12 is transmitted to the rear molding cavity surface 34. The problem is that sufficient LED light cannot be introduced into the molding cavity by being refracted on the surface of the mold before reaching into the molding cavity because it was irradiated from the side. Thus, the LED light is advantageously irradiated on the entire molding cavity. As shown in FIG. 3, the LED light source 12 is installed on the female mold 28 side, and the LED light source 12 is placed. It is also possible to irradiate light emitted from the front molding cavity surface 48 side. In addition, when installing the LED light source 12 in the female type | mold 28 side in this way, it is desirable to arrange | position the photodetector 14 in the male type | mold 26 side. Further, the LED light source 12 is desirably installed on the optical axis of the ophthalmic lens article to be molded.

  Further, in the above-described embodiment, the diffusion lens 18 serving as the diffusion means is provided in order to widen the irradiation angle of the light emitted from the LED light source 12. It is appropriately used according to the distance from the light source 12 to the mold 10 and the directivity angle of the LED light source, and is not essential in the present invention. Further, as described above, instead of the diffusing unit, a condensing unit can be used.

  In addition, in the above example, as the moving means for moving the diffusing lens 18 in the vertical direction, a stepping motor and a known crank device are adopted, and the stepping motor as a driving means is used to move the diffusing lens 18 slightly. Although the movement can be advantageously realized, it is possible to adopt conventionally known driving means other than the stepping motor. Also, such moving means can be used as necessary, as with the diffusing lens 18 described above, and is not necessarily required in the present invention.

  Moreover, in the said embodiment, the irradiance of the light irradiated from the LED light source 12 is automatically maintained constant by the light intensity control apparatus 16 incorporating an arithmetic processing part and a variable voltage circuit. However, the operator can set the voltage supplied to the LED light source 12 as appropriate without using such a light intensity control device 16.

  Furthermore, in the above example, the photodetector 14 detects the intensity of light emitted from the LED light source 12, specifically, the irradiance, but the irradiance is directly Even if it is detected or converted indirectly from a physical quantity representing the intensity of light other than irradiance, it may be detected indirectly. The photodetector 14 is also used as necessary, and is not essential in the present invention.

  Moreover, in the said embodiment, although the specific example of what applied this invention with respect to the manufacturing apparatus and its manufacturing method for manufacturing a contact lens was shown, this invention is intraocular other than such a contact lens. Ophthalmic lenses such as lenses, or semi-finished products of these ophthalmic lenses (for example, one surface is molded into a completed lens surface shape, while the other surface is still completed as a lens surface. The ophthalmic lens material which gives the ophthalmic lens formed into a shape that requires post-processing such as cutting, and further, such ophthalmic lens is subjected to processing such as double-sided cutting. The present invention can also be advantageously applied to a mold for molding a so-called ophthalmic lens article, such as a lens blank that can be provided, and a manufacturing method thereof. In particular, when the ophthalmic lens article is an intraocular lens, the thickness thereof is considerably larger than that of the contact lens, and therefore, at least one each above and below the mold 10. It is desirable to install the LED light source 12 and irradiate the LED light from above and below, and the directivity angle of the LED light source 12 when manufacturing the intraocular lens is preferably 10 to 100 °.

  Furthermore, in this embodiment, using the transport machine 24, the plurality of molds 10 (female molds 28) held by the transport machine 24 are moved to the monomer liquid supply position and the mold alignment position by the operation of the transport machine 24. A contact lens as a target ophthalmic lens article is obtained by sequentially transporting to a light irradiation position and simultaneously performing a monomer liquid supply process, a mold matching process, and a light irradiation process at each transport position. Although the specific example of the manufacturing method made to mass-produce continuously was given, this invention is not limited to such a method at all, Each process as mentioned above without using the conveying machine 24. It is also possible to carry out the process independently for each mold 10. In short, in the present invention, since an LED is used as a light source, one light source can be arranged for each mold 10, and therefore, one light source can emit light to a plurality of molds. Unlike the case of performing irradiation, the target ophthalmic lens article can be manufactured individually and efficiently. Moreover, it is also possible to simultaneously perform different light irradiation for each LED light source depending on cases, such as setting the irradiation amount and irradiation time of LED light for each lens standard.

  Furthermore, the structures of the male mold 26 and the female mold 28 constituting the mold 10 can be appropriately selected from various known ones and are not particularly limited to those shown in the embodiment. Of course.

  In addition, although not enumerated one by one, the present invention can be carried out in a mode with various changes, modifications, improvements, etc. based on the knowledge of those skilled in the art. It goes without saying that any one of them falls within the scope of the present invention without departing from the spirit of the present invention.

  Hereinafter, some experimental examples including typical examples of the present invention will be shown to clarify the present invention more specifically. However, the present invention is not limited by the description of such experimental examples. It goes without saying that it is not subject to any restrictions. In addition to the following examples, the present invention includes various modifications based on the knowledge of those skilled in the art without departing from the spirit of the present invention, in addition to the above specific description. It should be understood that modifications, improvements, etc. can be made.

  First, according to the present invention, as the monomer liquid (50) to be photopolymerized, while preparing the blended liquid 1 and the blended liquid 2 having the compositions shown in the following Tables 1 and 2, the peak wavelength of the irradiation light, in other words, the maximum As shown in Table 3 below, five types of LED light sources (12) having different emission wavelengths were prepared. Furthermore, three commercially available photopolymerization initiators, namely 2-hydroxy-2-methyl-1-phenyl-propan-1-one (initiator A), 2,4,6-trimethylbenzoyl-diphenyl-phosphine oxide ( Initiator B) and bis (2,4,6-polymethylbenzoyl) -phenylphosphine oxide (initiator C) were prepared.

  Next, for various monomer liquids (50) obtained by selecting initiators A to C in the blended liquids 1 and 2, LED light sources (12) having various peak wavelengths in the irradiation structure of LED light shown in FIG. Was used to irradiate LED light having a predetermined peak wavelength at room temperature for 30 minutes, and photopolymerization was performed, respectively. The male mold (26) and the female mold (28) constituting the mold (10) are both made of polypropylene, and the LED light source (12) and the female mold (28) The irradiation distance (D), which is the distance between them, was 5 mm.

  About the contact lens product (ophthalmic lens article) which is a polymerization product obtained in the photopolymerization operation using the LED light source (12) having various peak wavelengths for the various monomer liquids (50), unpolymerized monomers remain. The results are shown in Table 4 below. In the evaluation criteria in Table 4 below, ◯ indicates a case where a slight amount of unpolymerized monomer is detected in a contact lens product obtained by photopolymerization, and Δ indicates a contact lens product. , Indicates that unpolymerized monomer is present, and × indicates that the amount of unpolymerized monomer remaining in the contact lens product is large, the product itself is soft, and is easily deformed. Yes.

  Moreover, with respect to the compounding liquid 1 and the compounding liquid 2 shown in Table 1 and Table 2, UV absorber: 2- [2'-hydroxy-5 '(2 "-methacryloyloxyethoxy) -3'- 1 part by weight of tert-butylphenyl] -5-methyl-2H-benzotriazole was added to each of them, and in the combinations as shown in Table 5 below, using initiators A to C, monomer liquid (50 3) is filled into a mold cavity (30) formed between a male mold (26) and a female mold (28) constituting a mold 10 made of polypropylene as shown in FIG. I was damned.

  The mold (10) filled with such various monomer liquids (50) is opposed to the male mold (26) side and the female mold (28) side from two directions, Using two LED light sources (12) having the same peak wavelength, each is irradiated with light of a predetermined peak wavelength, and photopolymerization is performed to produce a target contact lens product (ophthalmic lens article). did. Such photopolymerization is carried out by performing light irradiation for 30 minutes at room temperature, and the irradiation distance that is the distance from each LED light source (12) to the male mold (26) or female mold (28). Each (D) was 2 mm.

  About the molded product (contact lens product) by photopolymerization with LED light of various peak wavelengths of the monomer liquid (50) to which the UV absorber thus obtained was added, the result was evaluated in the same manner as described above. The results are also shown in Table 5 below.

  As is clear from the results of Table 4, in the photopolymerization operation according to the present invention using the monomer liquid (50) containing no UV absorber, an LED light source (12) having a peak wavelength of 400 nm or less is used. By using any of the polymerization initiators, when the contact lens product as the obtained polymerization product is hydrated, a molded product having sufficient shape retention as a contact lens is obtained. I was able to. Further, when phosphine oxide initiator B or initiator C, which is an initiator having a high extinction coefficient at 405 nm, is added, an LED light source (12) having a peak wavelength in the range of 380 nm to 470 nm is used. The intended contact lens product could be advantageously obtained by use and photopolymerization.

  Further, even in the monomer liquid (50) containing the UV absorber, as shown in Table 5, a phosphine oxide-based initiator B or C that is an initiator having a high extinction coefficient at 405 nm is used, and By performing photopolymerization using an LED light source (12) having a peak wavelength of 380 nm to 470 nm, it was possible to advantageously mold the target contact lens product.

  In addition, 0.002 parts by weight of 1-phenylazo-3-methacryloyloxy-2-naphthol was further added as a dye to the monomer liquid (50) having the composition shown in Tables 4 and 5 above. When the photopolymerization was performed using the LED light sources (12) having various peak wavelengths described above, the same results as above were obtained, and the presence of the dye greatly influenced the photopolymerization of the monomer liquid (50). It was confirmed that it does not bring

Claims (18)

Shape that gives the target ophthalmic lens article such as an ophthalmic lens, a semi-finished product thereof, or a lens blank between the molds by matching the upper mold and the lower mold made of a light-transmitting material. The mold cavity is filled with a monomer solution, and light is emitted from the LEDs installed on at least one of the upper and lower mold sides of the mold. Thus, the monomer liquid filled in the molding cavity is photopolymerized with light transmitted through the mold, and the target ophthalmic lens article is molded. Production method. The method for producing an ophthalmic lens article according to claim 1, wherein a plurality of the molds are arranged, and the LEDs are installed for each of the molds. While the upper mold is a male mold having a convex molding cavity surface, the lower mold is a female mold having a concave molding cavity surface, and the LED is spaced upward from the male mold, The method for producing an ophthalmic lens article according to claim 1, wherein the ophthalmic lens article is installed on an optical axis of the ophthalmic lens article to be molded. The method for producing an ophthalmic lens article according to any one of claims 1 to 3, wherein the monomer liquid contains at least one acrylic monomer. The ophthalmic lens article according to claim 4, wherein the acrylic monomer is a silicon-containing acrylic monomer, and the silicon-containing acrylic monomer is contained in the monomer liquid in a proportion of 10 to 70% by weight. Manufacturing method. The said acrylic monomer is dialkyl (meth) acrylamide, This dialkyl (meth) acrylamide is contained in the said monomer liquid in the ratio of 30 to 70 weight%, The claim 4 or Claim 5 characterized by the above-mentioned. A method for producing an ophthalmic lens article. The method for producing an ophthalmic lens article according to any one of claims 1 to 6, wherein the irradiation time of the LED is 60 minutes or less. 8. The light having a peak wavelength within a range of 350 to 500 nm is irradiated from the LED, and the monomer liquid is photopolymerized in the absence of a UV absorber. A method for producing an ophthalmic lens article according to any one of the above. The ophthalmic lens according to claim 1, wherein the monomer liquid contains a UV absorber, and a peak wavelength of light emitted from the LED is in a range of 380 to 500 nm. Article manufacturing method. The method for producing an ophthalmic lens article according to claim 8 or 9, wherein the monomer liquid contains a pigment. The eye according to any one of claims 1 to 10, wherein two of the LEDs are used and are respectively disposed above and below the mold and irradiated with light so as to face each other. Of manufacturing a lens article for an automobile. The method for producing an ophthalmic lens article according to any one of claims 1 to 11, wherein a photopolymerization initiator having a high extinction coefficient at 405 nm is used for photopolymerization of the monomer liquid. Shape that gives the target ophthalmic lens article such as an ophthalmic lens, a semi-finished product thereof, or a lens blank between the molds by matching the upper mold and the lower mold made of a light-transmitting material. The mold is configured to form a mold cavity, and at least one of the molds above and below the mold, and the monomer liquid filled in the mold cavity of the mold is irradiated with light. And a manufacturing apparatus for an ophthalmic lens article. The apparatus for producing an ophthalmic lens article according to claim 13, wherein a plurality of the molds are arranged on a predetermined conveying unit, and the LEDs are installed for each mold. A measuring means for measuring the irradiance of light emitted from the LED is installed on the side facing the LED across the mold, and is configured to measure the irradiance with the measuring means. The apparatus for manufacturing an ophthalmic lens article according to claim 13 or 14, wherein the apparatus is for manufacturing an ophthalmic lens article. Control means for controlling the voltage supplied to the LED is provided, and the voltage supplied to the LED so that the value of the irradiance measured by the measuring means matches the target value by the control means. The apparatus for manufacturing an ophthalmic lens article according to claim 15, wherein the irradiance of light emitted from the LED is kept constant by controlling A diffusing unit for diffusing light emitted from the LED is provided between the mold and the LED, and irradiates light through the diffusing unit, thereby irradiating light from the LED. The eye according to any one of claims 13 to 16, wherein the light is uniformly irradiated to the monomer liquid filled in the molding cavity of the mold. Lens article manufacturing equipment. Moving means for moving the diffusing means away from or close to the mold is provided, and by adjusting the position of the diffusing means with the moving means, the mold cavity is filled. The apparatus for manufacturing an ophthalmic lens article according to claim 17, wherein the monomer liquid is uniformly irradiated with the light.

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