WO2005032791A1 - Process for producing eyelens article and production apparatus therefor - Google Patents

Abstract

A process for producing an eyelens article that realizes resolution of all the problems attributed to ultraviolet lamps and advantageously ensuring of stable quality; and an eyelens article production apparatus therefor. Use is made of shaping mold (10) wherein shaping cavity (30) of configuration capable of producing desired eyelens articles is provided by registering of upper die (26) and lower die (28) both constituted of a light transmissive material. Monomer liquid (50) is charged in the shaping cavity (30), and polymerization of the charged monomer liquid (50) is carried out by exposing the same to light emitted from LED light source (12) disposed on the side of at least one of the upper and lower dies of the shaping mold (10). Thus, mold shaping of eyelens articles can be accomplished.

Description

 Specification

 Ophthalmic lens article manufacturing method and manufacturing apparatus used therefor

 Technical field

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

 Background art

 [0002] Conventionally, ophthalmic lenses such as contact lenses and intraocular lenses, or semi-finished products thereof, for example, one surface is formed into a completed lens surface shape, while the other surface is a lens surface. It is still completed, but it is formed into a shape that requires post-processing such as cutting, the ophthalmic lens material that gives the ophthalmic lens, and further processed by double-sided cutting, etc. One of the methods for manufacturing so-called ophthalmic lens articles such as a lens blank on which a contact lens or an intraocular lens is formed, such as a combination of a male mold and a female mold or a combination of an upper mold and a lower mold. A resin material configured to perform mold matching by combining the first mold and the second mold, and to form a molding cavity in a shape that gives the ophthalmic lens article between the molds. Molds made of light transmissive materials such as After filling the molding cavity of the mold with a predetermined monomer liquid, the monomer liquid is irradiated with UV light, and the filled monomer liquid is polymerized by the UV light transmitted through the molding die. The technical ability to mold ophthalmic lens products is known.

 [0003] By the way, in manufacturing an ophthalmic lens article in this way, a batch method is usually employed, and a large number of ophthalmic lens articles are subjected to irradiation with UV light irradiated from one light source. It is molded. In this case, the light source is generally a xenon lamp or a mercury lamp

UV lamps such as deuterium lamps are used, and UV light from such UV lamps

Conventionally, various devices have been devised so that all of a plurality of molds simultaneously performing photopolymerization are uniformly irradiated. For example, a reflector such as a mirror is installed on the inner surface of a dome-shaped housing, and UV light radiated from a light source provided on the top of the dome-shaped housing that is powerful is reflected by the reflector to achieve all of the above. Molding mold cavity Adjustments are made so that the UV light is irradiated at a substantially constant irradiance to the monomer liquid filled therein.

 [0004] Even if light is irradiated 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. However, there is a problem that the UV light is not sufficiently irradiated depending on the portion where the LED is arranged. Then, in the case of the ophthalmic lens article on which the molding operation has been performed simultaneously under such uneven light irradiation, even if the so-called ophthalmic lens article having the same production lot number, for example, The problem was that the degree of polymerization and the degree of cross-linking differed between the one placed at the center and the one placed at the end of the arrangement of multiple molds. . In addition, the difference in the degree of polymerization and the degree of cross-linking adversely affects the physical properties and lens shape of the lens.For example, in a certain contact lens, the edge is not clearly formed, and the quality varies. That's it.

 [0005] Further, an ultraviolet lamp generally used as a light source conventionally emits not only light having a wavelength necessary for photopolymerizing a monomer liquid but also light having an unnecessary wavelength that adversely affects a lens material. Therefore, it is necessary to cut off light of an extra wavelength by a shielding means such as an optical filter so that light of such a wavelength is not adversely affected. Further, since the ultraviolet lamp has a short lamp life, complicated irradiance is required so that the UV light can be irradiated to the monomer liquid in the mold at a predetermined irradiance every time the frequency of replacement is high. We had to make settings. In addition to the fact that UV lamps generate heat and need to cool down the power, it takes time for the irradiance to stabilize after lighting, and the longer the lighting time, the lower the irradiance will be. Are also inherent.

[0006] On the other hand, Japanese Unexamined Patent Application Publication No. 2003-503234 (Patent Document 1) describes the purpose of Japanese Patent Application Laid-Open Publication No. 2003-503234 (JP-A-2003-503234) to secure a constant quality of an ophthalmic molded product that is biocompatible and has a polymer material strength. As an example, a number of optical fibers are connected to an ultraviolet light, each of the powerful optical fibers is attached to one of a number of casting molds, and UV light from the ultraviolet light is applied to the mold. A method of irradiating a mold through an optical fiber and performing molding has been clarified. [0007] As described above, if a large number of molds are irradiated with light from each of the molds through a plurality of optical fibers instead of directly irradiating the light of the ultraviolet lamp, the molds can be molded. Irradiation unevenness of light due to the difference in the arrangement location of the dies can be prevented, and each mold can be evenly irradiated with UV light. However, there is a limit in the number of optical fibers that can be attached to a single ultraviolet light because the part of the ultraviolet light itself that can ensure uniform irradiance is narrow. Further, in such a method, there are problems such as a complicated operation of attaching a plurality of optical fibers to an ultraviolet light and a loss of light in the optical fibers. As for the power, cooling to release the heat generated by turning on the ultraviolet light is required, the irradiance change due to the usage time of the ultraviolet light, and when the ultraviolet light is broken Problems caused by UV lamps, such as affecting many molds, have not yet been eliminated.

 [0008] Also, in Japanese Unexamined Patent Application Publication No. 59-215838 (Patent Document 2), an ultraviolet light source and a cavity or a cavity core are optically connected by an optical fiber, and an expensive light source is formed into a plurality of molding dies. There has been proposed a molding apparatus that is also used in the above-mentioned, but also in this case, there is an inherent problem similar to that of Patent Document 1.

 Patent Document 1: Japanese Patent Application Publication No. 2003-503234

 Patent Document 2: JP-A-59-215838

 Disclosure of the invention

 Problems to be solved by the invention

[0010] Here, the present invention has been made in the background of vigorous circumstances, and a problem to be solved is to solve all the above-mentioned problems caused by the use of an ultraviolet lamp, It is an object of the present invention to provide a method for manufacturing an ophthalmic lens article that can advantageously ensure the above-mentioned quality, and an apparatus for manufacturing an ophthalmic lens article used in the method.

 Means for solving the problem

[0011] The present invention has been made to solve the above-described problems, and a first aspect of the present invention is to form an upper mold and a lower mold that also have a light transmitting material strength. By forming the molds, a mold having a shape that gives a desired ophthalmic lens article, such as an ophthalmic lens, a semi-finished product thereof, and a lens blank, is formed between the molds. The molding cavity is filled with the monomer liquid while the molding cavity is filled with the monomer liquid, and at least one of the upper and lower sides of the molding cavity is illuminated with the LED light, and the molding cavity is transmitted through the molding cavity. A method for producing an ophthalmic lens article, characterized in that the monomer liquid filled in the molding cavity is photopolymerized with light to mold the objective ophthalmic lens article.

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

 [0013] Further, in a 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 is a concave molding. A female mold having a cavity surface, wherein the LED is installed at a position separated upward from the male mold and on the optical axis of the ophthalmic lens article to be molded.

 [0014] Power! In a 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.

 [0015] In a fifth aspect of the method for manufacturing an ophthalmic lens article according to the present invention, the acrylic monomer is a silicon-containing acrylic monomer, and a vigorous silicon-containing acrylic monomer is contained in the monomer liquid. To 10 to 70% by weight.

 [0016] Further, in a sixth aspect of the method for manufacturing an ophthalmic lens article according to the present invention, the acrylic monomer is dialkyl (meth) acrylamide, and strong dialkyl (meth) acrylamide is contained in the monomer liquid. In addition, 30-70% by weight will be contained.

 [0017] Furthermore, in the seventh aspect of the method for manufacturing an ophthalmic lens article according to the present invention, the irradiation time of the LED is set to 60 minutes or less.

[0018] Power! In an eighth embodiment of the method for producing an ophthalmic lens article according to the present invention, light having a peak wavelength power of 350 to 500 nm, preferably 360 to 470 nm, particularly preferably 360 to 400 nm is used. Irradiating from the LED, the monomer solution is photopolymerized in the absence of a UV absorber.

In a ninth aspect of the method for manufacturing an ophthalmic lens article according to the present invention, the module The Nomer liquid contains a UV absorber, and the LED power is adjusted so that the peak wavelength power of the irradiated light is in the range of 380 to 500 nm, preferably 400 to 470 nm.

[0020] Further, in a tenth aspect of the method for manufacturing an ophthalmic lens article according to the present invention, the monomer liquid further includes a dye. In particular, as this dye, a yellow or orange dye is preferably used.

[0021] 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 disposed above and below the mold, respectively. The light is applied so that the forces also face each other.

[0022] In a 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 in the photopolymerization of the monomer solution.

 Meanwhile, the present invention is also directed to a manufacturing apparatus which is advantageously used in the method for manufacturing an ophthalmic lens article as described above, and is also an object thereof, and includes an upper mold and a lower mold having a light-transmitting material strength. A molding die in which a molding cavity, such as an ophthalmic lens, a semi-finished product, and a lens, having a shape that gives a desired ophthalmic lens article is formed between the dies by matching the and the dies. And an LED installed on at least one of the upper and lower mold sides of the molding die to irradiate the monomer liquid filled in the molding cavity of the molding die with light. An apparatus for manufacturing an ophthalmic lens article, which is a feature of the present invention, is one embodiment thereof.

 [0024] In the second aspect of the ophthalmic lens article manufacturing apparatus according to the present invention, a plurality of the molding dies are arranged in a predetermined conveying means, and the LED is provided for each of the molding dies. Is adopted.

 [0025] Further, in the third aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, the measuring means for measuring the irradiance of the light irradiated with the LED force may be provided so as to sandwich the mold. The irradiance is installed on the side facing the LED, and the irradiance is measured by a powerful measuring means.

[0026] Power! In a fourth aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, control means for controlling a voltage to be supplied to the LED is provided. The voltage supplied to the LED is controlled so that the value of the irradiance measured by the measuring means matches the target value, and the irradiance of light emitted from the LED is kept constant. That is.

 [0027] In the fifth aspect of the ophthalmic lens article manufacturing apparatus according to the present invention, a diffusing unit for diffusing light emitted from the LED is provided between the mold and the LED. By irradiating the light through the powerful diffusion means, the irradiation angle of the light from the LED is widened, and the light is uniform with respect to the monomer liquid filled in the molding cavity of the molding die. Will be irradiated.

 [0028] Further, in a sixth aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, a moving means for moving the diffusing means in a direction away from or approaching the mold is provided. By adjusting the position of the diffusing means with a powerful moving means, the light can be uniformly applied to the monomer liquid filled in the molding cavity.

 The invention's effect

According to the above-described first aspect of the method for manufacturing an ophthalmic lens article according to the present invention, the monomer liquid filled in the molding cavity of the molding die made of a light transmissive material can be generated by the LED power. By polymerizing with light, the problems caused by the ultraviolet lamp can be completely eliminated. That is, since an LED does not emit light having a wavelength unnecessary for polymerization as compared with an ultraviolet lamp, it is possible to irradiate the monomer liquid only with light having a wavelength effective for the polymerization. In addition, UV lamps have a short lamp life and must be replaced frequently, whereas LEDs have a long life and provide stable irradiance immediately after lighting. Setting is easy. In addition, the light is turned off from the end of the polymerization operation of the monomer liquid filled in the molding cavity of a certain molding die until the start of the polymerization operation of the monomer liquid filled in the molding cavity of the next molding die. This also has the advantage of eliminating the need to unnecessarily irradiate light harmful to the eyes. In addition, LEDs generate much less heat than UV lamps, so the heat conducted through the monomer solution does not make it difficult to control the polymerization. LED also varies the amount of voltage supplied Therefore, it also has the feature that fine adjustment of irradiance can be easily performed.

 [0030] As described above, when an LED is used as a light source, the monomer liquid can be irradiated with stable irradiance light for a long time, advantageously and safely. Articles can be advantageously produced with stable quality. Also, by using LEDs, high irradiance can be efficiently obtained by using LEDs, and rapid polymerization of a monomer liquid can be performed.

 Since LEDs are small in size and small in angle of directivity, they are effectively applied to molding dies for molding small ophthalmic lens articles. Separate installation for each mold can be easily realized.

 [0032] Therefore, according to the second embodiment of the method for manufacturing an ophthalmic lens article according to the present invention, at least one light source is provided because at least one LED is provided for one set of molds. Thus, the monomer liquid filled in the molding cavities of a pair of molding dies is polymerized. As a result, the instability of quality due to irradiation unevenness, which is caused when one light source irradiates a plurality of molds with light, can be advantageously solved. Another advantage is that the LED light applied to each mold can be managed separately. Therefore, the stable quality of the ophthalmic lens article can be maintained more advantageously.

 Further, according to the third aspect of the method for manufacturing an ophthalmic lens article according to the present invention, it is ensured that the entirety of the monomer liquid filled in the optical power molding cavity irradiated from the LED power is irradiated. Become. In other words, since the light emitted from the LED has a certain directional angle, sufficient light is introduced into the molding cavity by refraction or reflection on the surface of the molding die before reaching the molding cavity. The problem of unavailability is advantageously prevented, and the LED light is advantageously directed to the entire molding cavity.

In addition, according to the fourth to sixth aspects of the method for manufacturing an ophthalmic lens article according to the present invention, the monomer liquid contains an acrylic monomer having an acryl group or a methacryl group. Thus, photopolymerization is effectively realized. In particular, when a silicon-containing acrylic monomer is used at a predetermined ratio as an acryl monomer, Is advantageous in that an ophthalmic lens article excellent in oxygen permeability can be obtained.When dialkyl (meth) acrylamide is used in a predetermined ratio as an acrylic monomer, it is excellent in hydrophilicity or water content. An ophthalmic lens article will advantageously be obtained.

 Further, according to the seventh aspect of the method for manufacturing an ophthalmic lens article according to the present invention, an ophthalmic lens article can be manufactured with good workability.

Further, according to the eighth to tenth aspects of the method for manufacturing an ophthalmic lens article according to the present invention,

In addition, the polymerization of the monomer liquid is effectively realized, and the object of the present invention can be more advantageously achieved.

 [0037] According to the eleventh aspect of the method for manufacturing an ophthalmic lens article according to the present invention, the photopolymerization operation of a monomer liquid containing a UV absorber using an LED can proceed effectively. It can be done.

 [0038] 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 proceeds rapidly. The intended ophthalmic lens article can be advantageously obtained.

 Further, in the first embodiment of the apparatus for manufacturing an ophthalmic lens article according to the present invention, since an LED is used as a light source, there is a problem caused by an ultraviolet lamp as described above. In addition to being able to be eliminated altogether, it is possible to stably maintain the quality of the ophthalmic lens article.

 Further, according to the second aspect of the apparatus for manufacturing an ophthalmic lens article according to the present invention, similarly to the second aspect of the method for manufacturing an ophthalmic lens article, the quality is unstable due to irradiation unevenness. The dangling power is advantageously eliminated, and the stable quality of the ophthalmic lens article can be maintained more advantageously, and the ophthalmic lens article can be continuously mass-produced.

[0041] Power! According to the third aspect of the ophthalmic lens article manufacturing apparatus according to the present invention, the irradiance of the irradiation light is measured, and the irradiation condition of the light from the LED is obtained from the measured value of the irradiance that is strong. Thus, it can be determined 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, for example, to change the monomer liquid. The polymerization can be controlled and controlled to keep the quality of the ophthalmic lens article constant.

 [0042] Further, according to the fourth aspect of the ophthalmic lens article manufacturing apparatus according to the present invention, the control means controls the irradiance value measured by the measurement means and the preset target value. The voltage supplied to the LED is controlled so that the light intensity of the LED lens is controlled so that the irradiance of light can be automatically kept constant. Quality can be further advantageously ensured.

 Further, according to the fifth and sixth aspects of the apparatus for manufacturing an ophthalmic lens article according to the present invention, the light from the LEDs is evenly and uniformly applied to the monomer liquid in the molding cavity. It can be irradiated. Therefore, for example, in the case of manufacturing a contact lens as an ophthalmic lens article, the edge portion of the outer peripheral edge of the contact lens is also surely polymerized, so that an ophthalmic lens article having a desired shape can be accurately formed. It will be.

 Brief Description of Drawings

 FIG. 1 is an explanatory partial cross-sectional view schematically showing a main part of an example of an apparatus for manufacturing an ophthalmic lens article according to the present invention.

 FIG. 2 is a partial cross-sectional explanatory view showing another example of the process of manufacturing an ophthalmic lens article using a mold for mold polymerization according to the method of the present invention, and is provided for each of a plurality of molds. This shows a state in which each of the molds is irradiated with light from the LED light source.

 FIG. 3 is a partial cross-sectional explanatory view schematically showing a main part of another example of the apparatus for manufacturing an ophthalmic lens article according to the present invention.

 Explanation of symbols

[0045] 10 Mold 12 LED light source

 14 Photodetector 16 Light intensity controller

 18 Diffusing lens 20 Crank device

 22 Stepping motor 24 Conveyor

 26 Male 28 Female

 30 Molded cavity 32 Bottom

 34 Rear molding cavity surface 44 Recess

48 Front molding cavity surface 50 Monomer liquid BEST MODE FOR CARRYING OUT THE INVENTION

 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 an apparatus for manufacturing a contact lens as one embodiment of an apparatus for manufacturing an ophthalmic lens article having a structure according to the present invention. As is apparent from FIG. 1, the contact lens manufacturing apparatus of the present embodiment emits light having a predetermined peak wavelength to a molding die 10 for molding a contact lens and a powerful molding die 10. A light source 12 that also emits LED power, a light detector 14 that measures irradiance of light emitted from the LED light source 12, and a irradiance power measured by the light detector 14 is also an LED light source 12. A light intensity control device 16 as control means for controlling a voltage supplied to the light source; a diffusion lens 18 as diffusion means provided between the molding die 10 and the LED light source 12; It has a crank device 20 and a stepping motor 22 as moving means for moving in a direction away from or approaching from the machine 10, and a transfer machine 24 as a transfer means for holding and transferring the molding die 10. , Composed! .

[0048] Here, the molding die 10 is shown as a cross-sectional view, and includes a male die 26 as an upper die and a female die 28 as a lower die. In addition, each of the molds is formed of a material through which light can be transmitted, and by mating the male mold 26 and the female mold 28, a desired contact lens is formed between the molds. A molding cavity 30 having a given shape is formed. Here, the light-transmitting material constituting the bulky molding die 10 is not particularly limited as long as it can transmit light emitted from the LED light source 12, and is not limited to a specific example. Are, 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, nylon 12, and combinations thereof; glass, quartz, An inorganic material such as fused quartz can be used. Among these, resin materials such as polyolefins and polyamides are preferably used in consideration of the affinity, economics, moldability, etc., of the monomer liquid filled in the molding cavity 30 and its polymer. It becomes. Further, the male mold 26 and the female mold 28 constituting the molding die 10 may be formed of the same light transmissive material, or may be formed of different light transmissive materials separately from each other. The difference I don't support it. Further, in the case where the monomer liquid contains a uv absorber, as described later, when polymerizing using irradiation light having a peak wavelength of 380 to 500 nm, the light transmitting material constituting the mold 10 may be In general, it is desirable that the transmittance of the LED light at the main wavelength be 20% or more, more preferably 25% or more. For example, polypropylene or polymethylpentene is advantageously used.

 [0049] More specifically, the male mold 26 constituting the above-described molding die 10 has a cylindrical shape with an opening at the top as a whole, and a bottom portion 32 located at the lower portion thereof has a cavity forming portion. The outer surface (convex surface) of the strong bottom 32 has a rear surface shape that accurately corresponds to the rear surface (base curve surface) of the target contact lens. The cavity surface 34 is configured to give. Although the thickness of the bottom portion 32 is not particularly limited, it is introduced into the molding cavity 30 through the light power from the LED light source 12 to be described later, and the inside of the molding cavity 30 is formed. It is desirable that the LED light be substantially constant so that the LED light can be evenly radiated. Further, in consideration of the effects of polymerization shrinkage and the like and the attenuation of light, it is desirable that the force be approximately 0.1 mm to 3 mm. In particular, according to the light irradiation using the LED light source 12, since the temperature rise of the mold material of the molding die 10 is hardly caused, the thickness of the bottom portion 32 can be reduced. The male mold 26 is formed integrally with an outer flange portion 38 protruding radially outward on the outer peripheral portion on the upper opening side of the cylindrical wall portion 36.

 On the other hand, the female mold 28 constituting the molding die 10 has a cylindrical shape with a bottom and an opening at the bottom as a whole. A ball-shaped concave portion 44 which is depressed in response to the force acts as a cavity forming portion. In addition, a step 46 is provided at a middle portion in the depth direction of the hemispherical concave portion 44, and an inner surface (concave surface) of a bottom side portion below the step 46 is provided. Surface), which corresponds to the front molding cavity surface 48 that exactly corresponds to the surface.

As shown in FIG. 1, the male mold 26 and the female mold 28 are separated from each other at the bottom corner of the cylindrical wall 36 of the male mold 26 and the corner of the step 46 of the female mold 28. The rear surface of the male mold 26 is formed by assembling and matching 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 abut each other. Front side of cavity face 34 and female mold 28 In the space between the molded cavity surface 48 and the molded cavity 30 having a shape that gives a desired contact lens, the molded cavity 30 is formed.

Further, as shown in FIG. 1, the molding liquid 30 that is strong is filled with a monomer liquid 50 that gives a polymer constituting a target contact lens. This monomer liquid 50 is contained in a predetermined amount in the concave portion 44 of the female mold 28 prior to the matching of the male mold 26 and the female mold 28, and after the accommodation, the male liquid is formed as described above. When the mold 26 and the female mold 28 are matched, the mold cavity 30 is filled. In addition, the excess monomer liquid 50 that overflows from the molding cavity 30 due to such a mold matching is applied to the corner of the bottom side of the cylindrical wall 36 of the male mold 26 and the corner of the step 46 of the female mold 28. The space 52 formed above the contact portion, that is, 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. , And can be stored in the annular space 52.

 [0053] Here, as the monomer liquid 50 to be polymerized, various known liquid monomer compositions which give a polymer constituting the target contact lens can be used. It is desirable that the monomer liquid 50 contains at least one acrylic monomer (acrylic or methacrylic group-containing monomer), so that the photopolymerizability of the monomer liquid 50 is good. Will be secured. Specific examples of the acrylic monomer having a powerful acrylic group or methacryl group include, for example, silicon-containing (meth) acrylate, alkyl (meth) acrylate, fluorine-containing (meth) acrylate, and hydroxyalkyl ( Examples thereof include (meth) acrylate, aryl-containing (meth) acrylate, N alkyl (meth) acrylamide, and N, N-dialkyl (meth) acrylamide. More preferably, the strong acrylic monomer is contained in the monomer liquid 50 at a ratio of at least 10% by weight. In the description above and further in the following description, “(meth) acryl” means acryl and Z or methacryl, while “(meth) atalylate” means atalylate and Z or metharylate. Used.

In particular, as an acrylic monomer, a silicon-containing acrylic monomer as disclosed in International Publication No. 01Z71415 pamphlet, JP-A-6-121826, etc. was selected, If the monomer component 50 contains 10 to 70% by weight as a main component, excellent oxygen permeability can be advantageously imparted to the obtained contact lens. In addition, as acrylic monomers, dialkyl (meth) acrylic compounds such as N, N-dimethyl (meth) acrylamide, N, N-diethyl (meth) acrylamide, N, N-dipropyl (meth) acrylamide, and N-isopropyl (meth) acrylamide ) When acrylamide is used as a main component in the monomer liquid 50 at a ratio of 30 to 70% by weight, excellent hydrophilicity or water content is advantageously imparted to the obtained contact lens. Will be done.

 [0055] Further, the powerful monomer liquid 50 may include, if necessary, a desired lens type (for example, hard, soft, non-water-containing, water-containing, and the like) and properties required for the lens (for example, Depending on the oxygen permeability, coloring, ultraviolet absorption, etc.), various conventional monomer components other than the acrylic monomers as described above, and various conventional additives commonly used. For example, as in the prior art, an appropriate amount of an ultraviolet (UV) absorber, a coloring agent, etc., does not interfere with the addition of added calories, and the amount of the non-polymerizable solvent does not hinder the polymerization.ぉ て て て て て も て も て も て も.

 Here, examples of the above-mentioned UV absorbers and dyes include known UV absorbers such as benzophenone type, benzotriazole type and salicylic acid derivative type, and azo type, anthraquinone type, nitro type and phthalocyanine type. Known UV-absorbing agents and pigments, among which those having a polymerizable group such as an atalyloyl group, a methacryloyl group, a butyl group, an aryl group, and an isobutyl group. It is desirable that the polymer is copolymerized with the monomers constituting the monomer liquid 50 by the photopolymerization operation according to the present invention so as to form a desired ophthalmic lens article as a component of the polymer. In addition, the amount of the additive added to the monomer liquid 50 of the UV absorber and the dye is appropriately selected within a conventionally known range, but generally, the UV absorber is 100% of all the polymerization components. The dye is used in a ratio of about 0.02 to 12 parts by weight based on parts by weight, and the dye is used in a ratio of about 0.0001 to 0.1 part by weight based on 100 parts by weight of all the polymerization components. Become.

[0057] Further, as in the conventional case, the monomer liquid 50 contains methylorthobenzoylbenzoate, methylbenzoylformate, benzoinmethylether, and benzoin so that polymerization by light can be advantageously achieved. Ethyl ether, benzoin isopropyl ether, Benzoin-based photopolymerization initiators such as benzoin isobutyl ether and benzoin n-butyl ether; benzophenone-based photopolymerization initiators such as N, N-tetraethyl-4,4 diaminobenzozophenone and 2,4,6-trimethylbenzophenone; and carbohydrates such as benzyl -Hydroxy photoinitiator, 2-hydroxy-2-methyl-1-phenyl-1-propane, 1-on, 1- (4- (2-hydroxyethoxy) phenyl) -2-hydroxy-2-methyl-1-phenyl- Acetophenone-based photopolymerization initiators such as loop ropane-1-one; peroxides such as benzoyl peroxide; azo-based polymerization initiators such as azobisisobutymouth-tolyl; One or two or more of conventionally known polymerization initiators, such as the above polymerization initiator, are appropriately added. Then, among these polymerization initiators, radical initiators are also suitably used in terms of polymerizability and point strength of polymerization rate. It is also effective to use a known photosensitizer in addition to such a polymerization initiator.

Further, in the present invention, the use of a photopolymerization initiator having a high extinction coefficient at a wavelength around 405 nm makes it easier to absorb the emission wavelength on the long wavelength side from the LED light source 12, thereby improving the polymerization rate. However, it is advantageous in promptly proceeding polymerization. The initiator having a high extinction coefficient at such a wavelength: 405 nm is 2-benzyl-2-dimethylamino-1 (4 morpholinophenyl) butanone-1,1,1,2 octanedione 1— [4— (Ferthiol) -1- 2-(O-benzoyloxime)], 2,4,6-trimethylbenzoyldiphenylphosphine oxide, bis (2,4,6-trimethylbenzoyl) -phenylphosphine scan fins oxide, bi scan (7 ⁵ -? 2, 4-cyclopentadiene-1 I-le) bis (2, 6-Jifuruoro - 3- (IH pyro one rule 1 I Le) - Hue - Le) titanium, 4-methyl Benzoyl-diphenylphosphine oxide, 2,4,6-trimethylbenzoyldimethoxy-phosphine oxide, isobutylbenzoyldiphenyl-phosphine oxide, isobutylbenzoyldimethoxyphosphine Oxide, benzoyl sulfide-ruphosphine oxide, 2-methyl benzoyl sulfide-ruo phosphine oxide, benzoyl lute oxy phosphine oxide, 2,6-dichloro mouth benzoyl methoxy phosphine 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 The agent generally has an extinction coefficient (405 nm) of lOOmlZg'cm or more. These initiators are particularly effective when an LED whose irradiation light has a peak wavelength of 400 nm or more is used as the LED light source 12. In addition, in the photopolymerization of monomer liquid 50 containing a UV absorber, it is desirable that the polymerization initiator has the property of avoiding light absorption by the UV absorber and exhibiting light absorption at a longer wavelength side. It is recommended to use a polymerization initiator having a high extinction coefficient at the above-mentioned wavelength: 405 nm. Further, it is effective to use such a polymerization initiator having a high extinction coefficient in combination with another polymerization initiator having a low extinction coefficient at a wavelength of 405 nm ゃ a photosensitizer. It is also possible to use a photosensitizer in combination.

 Meanwhile, in the manufacturing apparatus of the present embodiment, the LED light source 12 capable of irradiating light is provided on the side of the male die 26 which is the upper die of the molding die 10 having the structure as described above, specifically, The contact lens is arranged on the optical axis (optical center axis) of the contact lens molded in the mold 10 and at a predetermined distance above the male mold 26.

 [0060] As described above, since the size of each LED light source 12 is smaller than that of the conventional ultraviolet lamp, at least one LED light source 12 can be installed in one set of molds 10. You can. Conventionally, as described above, relatively large equipment, such as a dome-shaped housing, was required to irradiate the light of one ultraviolet lamp light source to a plurality of molds. If the LED light source 12 is provided for each force forming die 10, such a housing or the like becomes unnecessary, and thus, there is an advantage that the manufacturing apparatus of the 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 due to uneven light irradiation, which is caused when one light source irradiates light to a plurality of molds, is improved. Instability disappears. Furthermore, even when mass production is performed, the LED light irradiation conditions can be controlled for each mold 10. For this reason, the stable quality of the ophthalmic lens article can be maintained more advantageously.

In the present embodiment, an LED is arranged on the optical axis of the contact lens molded in the molding die 10, and in other words, from the male mold 26 side having a convex rear molding cavity surface 34. For example, since the LED light is emitted from the concave side of the contact lens molded in the mold 10, the LED light passes through the male mold 26 of the mold 10 and The monomer liquid 50 filled in the molding cavity 30 is advantageously irradiated. In other words, when the LED light is irradiated from the female mold 28 side having the concave front mold cavity surface 48, in other words, from the convex side of the contact lens molded in the mold 10, the convex surface of the mold 10 Since the surface of the mold is irradiated with light, and the light that also emits LED power has a directional angle, it can be sufficiently refracted or reflected on the surface of the mold 10 before reaching the inside of the mold cavity 30. There is a risk that the light may not be able to be introduced into the molding cavity 30, in particular, the portion corresponding to the peripheral edge of the contact lens.However, if the concave surface of the molding die 10 is irradiated, The reduction in light is advantageously suppressed, and the entire molding cavity 30 can be advantageously irradiated with LED light, thereby ensuring high workability, lens perfection, and safety. Become.

 [0062] Further, the LED light source 12 does not emit light of a wavelength unnecessary for polymerization of the monomer liquid 50 as compared with a conventional xenon lamp, a mercury lamp, a deuterium lamp, or other ultraviolet lamp. This has the advantage that the monomer liquid 50 can be advantageously irradiated with only light having an effective wavelength centered on the peak wavelength. The LED light source 12 has advantages such as low heat generation and power consumption, long service life, and stable irradiance even immediately after lighting.It eliminates all problems with conventional UV lamps. You can do it. In other words, as mentioned above, UV lamps have a short life span and must be replaced frequently, whereas LEDs have a long life span and have a stable irradiance even immediately after lighting. The irradiance can be easily adjusted by changing the amount of voltage to be supplied, so that it is easy to finely adjust the irradiance. I can do it. By using LEDs, it is possible to turn off the light during the interval from the end of the polymerization operation to the start of the next polymerization operation, thus avoiding unnecessary irradiation of harmful light to the eyes. It becomes possible. Further, since the LED generates much less heat than an ultraviolet lamp, the temperature of the atmosphere before polymerization can be kept constant, and the polymerization of the monomer liquid 50 without the progress of polymerization due to heat can be reduced. It is easier to control than in the past.

[0063] 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 the light emitted from the LED light source 12 depends on the initiator. In view of the polymerizability of the monomer solution 50, when the strong monomer solution 50 does not contain a UV absorber, In the above, it is desirable that the peak wavelength is generally in the range of 350-500 nm, more preferably in the range of 360-470 nm, and even more preferably in the range of 360-400 nm. If the peak wavelength is shorter than the above range, the contact lens material (polymer forming the contact lens) may be deteriorated. This is because, when the wavelength is within the wavelength range, the polymerizability is reduced and heat generation becomes a problem. In particular, when a UV-absorbing lens (ophthalmic lens article) is manufactured using a 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. Desirably. As described above, the desired 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 solution 50, but depends on the presence or absence of the dye appropriately added as necessary. It is hardly affected. It is desirable that the light emitted from the LED light source 12 has substantially no peak wavelength other than the above-mentioned wavelength range.

 Further, it is known that the directivity angle (2Θ1 / 2) of the LED light source 12 is smaller than that of a conventional ultraviolet lamp or the like, and is not particularly limited. On the other hand, if it is too large, it is difficult to obtain effective irradiance. Therefore, from the viewpoint of effective use of light energy of the LED, it is desirable that the above-mentioned directional angle is 10 to 120 °. The directional 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. In particular, in the case of a hydrated contact lens, the directional angle is within the range of 20 to 110 °. For non-hydrated contact lenses, 30-120 ° force is preferred within the above range! / ヽ.

Further, when the above-mentioned directivity angle is smaller than the size of the target ophthalmic lens article, for example, when the directivity angle is less than 10 °, the LED light is diffused as necessary. For example, when the directional angle is large with respect to the size of the target ophthalmic lens article, for example, the directional light can be provided on the optical path between the LED light source 12 and the mold 10. If the angle exceeds 120 °, etc., use a light condensing means for condensing LED light. It can be installed on the optical path between 2 and the mold 10. As described above, by irradiating the LED light via the diffusing means or the condensing means, uniform polymerization can be advantageously achieved. Here, the diffusing means may include a diffusing plate such as a diffusing filter, a diffusing lens, or the like, while the condensing means may include a condensing lens.

 In the present embodiment, since the directivity angle of the light emitted from the LED light source 12 is smaller than the molding cavity 10, as shown in the cross-sectional form in FIG. A diffusion lens 18 is arranged between the molding die 10 and the light power emitted from the LED light source 12 is transmitted through the diffusion lens 18, so that the irradiation angle is widened, and the light is transmitted into the molding cavity 30. The charged monomer liquid 50 can be evenly and uniformly irradiated. As a result, local progress of polymerization of the monomer liquid 50 is advantageously prevented, and uniform polymerization of the monomer liquid 50 can be realized extremely advantageously. Also, the distance between the LED light source 12 and the mold 10 can be reduced.

[0067] 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 molding die 10 is not particularly limited. In order to ensure good workability and avoid contamination of the LED light source 12 and the effects of polymerization heat, etc., the peak wavelength of the irradiation light, the presence or absence of a UV absorber, the directional angle of the LED light source 12 and light irradiation Depending on the power area, etc., it will be set appropriately within the range of about 0.5 to 30 mm. Specifically, when the monomer liquid 50 does not contain a UV absorber, the irradiation distance (D) of 3 to 30 mm is advantageously used for polymerization in which the peak wavelength of irradiation light is 350 to 400 nm. In polymerizations where the peak wavelength of light is 400-500 nm, an irradiation distance (D) of 1-130 mm is advantageously employed. Further, when the monomer liquid 50 contains a UV absorber or a pigment together therewith, the irradiation distance (D) of 0.5 to 25 mm is increased due to polymerization using irradiation light having a peak wavelength of 380 to 500 nm. It will be adopted advantageously. When the transmittance of the irradiation light of the mold 10 at the main wavelength is 50% or less, it is generally desirable to bring the LED light source 12 close to the irradiation distance of about 0.5 to 5 mm. (D) will be adopted. Further, in the manufacturing apparatus of the present embodiment, the photodetector 14 for measuring the intensity of light emitted from the LED light source 12, specifically, the irradiance is provided by the female mold as the lower mold of the mold 10. Below the mold 28, it is installed so as to face the LED light source 12 with the mold 10 interposed therebetween. Then, of the light emitted from the LED light source 12, the light transmitted through the mold 10 is detected by the photodetector 14.

 [0069] Further, the photodetector 14 is connected to a light intensity control device 16 including an arithmetic processing unit such as a computer and a variable voltage circuit. Then, the data of the irradiance measured by the photodetector 14 is input to the light intensity control device 16, and the light intensity control device 16 controls the voltage supplied to the LED light source 12. . More specifically, in the light intensity control device 16, a target value of the irradiance required for the polymerization of the monomer liquid 50 is set in advance, and the arithmetic processing unit of the light intensity control device 16 transmits the irradiance target value from the photodetector 14. A calculation process is performed to determine whether the input measured value matches a preset target value. If the measured value does not match the target value, the variable voltage circuit increases or decreases the amount of voltage applied to the LED light source 12 so that the measured value matches the target value. is there. Then, the intensity of the light emitted from the LED is finely adjusted by the voltage supplied from the light intensity control device 16 to the LED light source 12 connected to the light intensity control device 16, and is kept constant. It is like that. Note that the target value can be appropriately set by an operator through an input operation using a keyboard or the like!

[0070] Power! In addition, the manufacturing apparatus according to the present embodiment includes a movement for moving the diffusion lens 18 in a direction away from the mold 10 (upward) or in a direction approaching the mold 10 (downward). Means, a crank device 20 and a stepping motor 22, are provided. The rotational motion of the stepping motor 22 is converted into a reciprocating motion by the known crank device 20, and the driving force of the stepping motor 22 causes the diffusion lens 18 connected to the crank device 20 to move vertically (see FIG. 1 in the direction of ィ). As described above, if the stepping motor 22 is used, fine adjustment of the position of the diffusion lens 18 can be easily performed. For this reason, in the case where the entire monomer liquid 50 filled in the molding cavity 30 of the molding die 10 cannot be irradiated with LED light, for example, the molding cavity In the case where light is irradiated only to the center of the cavity 30 and light is not irradiated to the portion of the molding cavity 30 corresponding to the periphery of the contact lens, the diffusion lens 18 is driven by the driving force of the stepping motor 22. If it is moved upward, the entire molding cavity 30 of the molding die 10 can be irradiated with light. Conversely, when the light irradiated on the mold 10 is too wide, the position of the diffusion lens 18 may be moved downward by the driving force of the stepping motor 22.

[0071] Further, in the present embodiment, the molding die 10 as described above is placed on a transfer device 24 as a transfer means. In addition, the powerful transfer device 24 is a force that can be configured by a conventionally known device such as a belt conveyor or a chain conveyor, and is configured by a belt conveyor here. With the movement of the belt by the operation of the conveyor 24, the molding die 10 is conveyed in the moving direction of the belt. The belt of the conveyor 24 has a large number of through-holes 25 having a size smaller than the outer dimension of the molding die 10 at a predetermined interval from each other. 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 a structure like a brute force, for example, the operation is performed as follows. It will be advanced. In the following, as a specific example, a method for continuously manufacturing a plurality of contact lenses will be described in detail.

[0073] That is, first, a plurality of molds 10 for molding a target contact lens are prepared, and the female mold 28 of the powerful molds 10 is placed at a predetermined position of the transfer device 24, Will be retained. Then, the transfer device 24 is operated to first transfer the female mold 28 to a monomer liquid supply device (not shown). Then, when the female mold 28 reaches the place where the monomer liquid is supplied, the transfer device 24 is stopped and the polymer constituting the target contact lens is provided in the concave portion 44 of the female mold 28, respectively. A predetermined amount of the monomer liquid 50 is supplied. Then, after the monomer liquid supply step, the transporter 24 is operated again, and the female mold 28 containing the monomer liquid 50 is transported to a place where the mold matching step is performed. Then, when the female mold 28 reaches a place where the mold matching process is performed, the transfer device 24 is temporarily stopped, and the upward force of the female mold 28 is also applied to the male mold 26 at the corner of the step 46 in the female mold 28. On the other hand, the cylinder in the male mold 26 Assemble the mold so that the corners on the bottom 32 side of the outer peripheral surface of the wall 36 abut, and the lower surface of the outer flange 38 of the male mold 26 and the upper surface of the female mold 28 abut each other. Perform. 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 in the molding cavity 30.

 Then, as described above, when the charging of the monomer liquid 50 is completed, the transporter 24 is operated again, and each of the molds 10 filled with the monomer liquid 50 is moved in the transport direction of the transporter 24. The light is conveyed to the light irradiation position arranged on the downstream side, that is, between the LED light source 12 and the photodetector 14, as shown in FIGS. When the mold 10 reaches between the LED light source 12 and the photodetector 14, the transporter 24 is stopped, and the LED light sources 12 are positioned one by one on the optical axis of the contact lens to be molded. On the other hand, for each of the molds 10, light is emitted from each of the LED light sources 12 installed or arranged above the molds 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 molding die 10 having light transmittance, thereby filling the molding cavity 30. The monomer liquid 50 is photopolymerized.

[0075] On the other hand, the photodetectors 14 arranged one by one for each of the molding dies 10 serve to detect the intensity of light emitted from the LED light sources 12 which are positioned to face each other with the molding dies 10 therebetween. , Detected via the mold 10 and the detected light intensity, specifically 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 the irradiance input from the light detection device 14 matches the preset target value, and If it is lower than the target value, the amount of voltage supplied to the LED light source 12 is increased, while if it exceeds the target value, the amount of voltage supplied to the LED light source 12 is reduced. Then, feedback control is performed so that the irradiance detected by the photodetector 14 matches the target value. As shown in FIG. 2, it is desirable that the irradiation intensity of light emitted from the LED light source 12 be controlled for each LED light source 12 as described above. By arranging the 12 and individually controlling the light emitted from the LED light source 12, the quality of the product can be further enhanced and stabilized more stably, and the occurrence rate of defective products can be reduced. It will be reduced very effectively. Further, when the directivity angular power of the light emitted from the LED light source 12 is smaller than the target contact lens diameter, in other words, when the entire molded cavity 30 for providing the contact lens is not irradiated with light. As shown by a solid line in FIG. 1 and a two-dot chain line in FIG. 2, a diffusion lens 18 as a diffusion means is disposed between the LED light source 12 and the molding die 10 to form a contact lens. The entire molding cavity 30 is irradiated with the LED light up to the portion corresponding to the peripheral portion of the LED. At this time, the position of the diffusion lens 18 is finely adjusted by the moving means including the stepping motor 22 and the crank device 20. On the other hand, if the directional angular force of the LED light source 12 to be used is too large as compared with the diameter of the target contact lens, the LED light source 12 and the molding die 10 are not illustrated, but are similar to the diffusion means. It is desirable that a light-collecting means such as a light-collecting lens be disposed between the light sources. By arranging such light-collecting means, the light energy of the LED light emitted from the LED light source 12 is polymerized in the monomer liquid 50. It is effectively used for the above, and wasteful irradiation of light which does not contribute to polymerization is advantageously reduced.

 In order to irradiate the molding die 10 with LED light, a plurality of molding dies 10 filled with the monomer liquid 50 in the molding matching process are transported between the LED light source 12 and the photodetector 14. At the same time, a plurality of other female molds 28 containing the monomer liquid 50 are transported to the place where the matching process is performed, and at the same time, another female mold 28 containing no monomer liquid 50 is stored. The female mold 28 is transported to the monomer liquid supply device. That is, light is emitted from the LED light source 12 to the molding die 10 filled in the molding cavity 30 with the monomer liquid 50 by the mold matching process (the light irradiation step is performed), while the monomer liquid 50 is contained. A mold matching process of assembling the male mold 26 with another female mold 28 is performed, and a filling process of the monomer liquid 50 for supplying the monomer liquid 50 into the concave portion 44 of another female mold 28 is further performed. Thus, the three steps, which are performed, are performed simultaneously on different molds 10.

[0078] In the light irradiation step, the wavelength of light emitted from the LED light source 12 to the monomer liquid 50 is not particularly limited, but may be sufficient to sufficiently polymerize the monomer component in the monomer liquid 50. However, as described above, when no UV absorber is present in the monomer solution 50, the LED light power whose peak wavelength is in the range of 350 to 500 nm. When V absorbers are present, LED light power with a peak wavelength in the range of 380-500 nm is particularly preferably employed. Further, the irradiation amount per unit area from the LED light source 12, the so-called irradiance is not particularly limited, but if it is too small, the polymerization of the monomer liquid 50 does not proceed and it is too large. Also, since there is a possibility that adverse effects such as deterioration of the contact lens material may be exerted, it is preferably 0.5 to 30 mWZcm ² , and more preferably 111 to ²⁰ mWZcm ² .

 [0079] 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 the light emitted from the LED light source, the type of the monomer liquid 50, and the like. However, in consideration of workability and the degree of perfection 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, and more preferably. Is 5 minutes or longer. This is because, if the irradiation time is too long, the light irradiation step and, consequently, the entire production process of the target contact lens are unnecessarily lengthened, leading to poor workability and reduced productivity. In addition, if the irradiation time of the LED light is too short, if the irradiation amount of the light to the monomer liquid 50 is too small, the photopolymerization of the monomer component in the monomer liquid 50 becomes insufficient due to the excessive force. This is because a problem is caused when the amount of residual monomer increases.

 Further, in this step, since the LED light source 12 is employed as the light source, the heat generated by light irradiation is relatively small, and the progress of polymerization due to heat can be suppressed, so that the polymerization is more stable. During the light irradiation step, the light irradiation step is performed so that the mold 10 does not exceed the ambient temperature + 5 ° C, that is, does not exceed the ambient temperature approximately 5 ° C. It is desirable to be done. However, as the vigorous photopolymerization temperature, any temperature can be adopted as long as it is lower than the proper operation maximum temperature of the LED light source 12, and the polymerization can be performed while increasing the temperature in such a temperature range. is there. Also, after a certain period of time from the start of the photopolymerization, only the mold 10 is moved to the thermal polymerization tank, and heating is carried out to promote the polymerization as long as it does not adversely affect the achievement of the object of the present invention. Can also be

The monomer liquid 50 filled in the molding cavity 30 of the molding die 10 is photopolymerized by vigorously irradiating the molding die 10 with light. Is formed. The contact lens thus formed is provided with a base curve surface corresponding to the rear mold cavity surface 34 of the male mold 26 and a front curve surface corresponding to the front mold cavity surface 48 of the female mold 28. It will be.

 [0082] Then, after the step of irradiating the mold 10 with light to be vigorous, the conveyor 24 is operated again, and the plurality of molds 10 on which the photopolymerization has been performed are connected to the LED light source 12 and the photodetector 14. Between the transfer devices 24 in the transfer direction of the transfer device 24. Thereafter, the mold is opened by removing the male mold 26 of the mold 10 from the female mold 28, and the contact lens is removed by the same release operation as in the past, thereby obtaining the desired contact lens. It is done.

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

 [0084] The force is also caused when one LED light source 12 is provided for one set of molds 10 and one light source irradiates a plurality of molds with light. Instability of quality due to irradiation unevenness is advantageously eliminated. In addition, since the light applied to each mold 10 can be controlled separately, high quality of a contact lens as an ophthalmic lens article can be more easily ensured. In addition, high irradiance can be efficiently obtained, and rapid polymerization of the monomer liquid 50 can be achieved.

 [0085] Although the representative embodiment of the present invention has been described in detail above, it is merely an example, and the present invention is not limited to the specific description according to such an embodiment. It should be understood that they are not to be construed as limiting in any way.

[0086] For example, in the above embodiment, the force in which one LED light source 12 is arranged for one set of molds 10 The number of LED light sources 12 arranged for one set of molds 10 is as follows. It is also possible to dispose two or more LED light sources 12 which are not limited to the one described above. However, when two or more LED light sources 12 are arranged for one set of molds 10, In this case, at least one of the light sources emitted from the LED light source 12 is provided above and below the mold 10 so as to advantageously contribute to the photopolymerization of the monomer liquid 50 filled in the mold cavity 30. It is preferable that the LED light sources 12 be installed one by one, and that the LED light be emitted from the upper and lower sides of the mold 10. In particular, such light irradiation with a two-directional force above and below the mold 10 may cause a monomer solution 50 containing a UV absorber or a pigment to be polymerized with light having a peak wavelength of 380 to 500 nm. It is advantageously employed from the viewpoint of, for example, reducing the deformation defect of the obtained ophthalmic lens product as a polymer product. However, in 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. Since the irradiation was started from the molding cavity surface 34 side, sufficient LED light could not be introduced into the molding cavity because it was refracted on the surface of the molding die before reaching the molding cavity. However, as shown in FIG. 3, the LED light source 12 was moved to the female mold 28 side, as shown in FIG. When installed, the light emitted from the LED light source 12 can be irradiated from the front molding cavity surface 48 side. When the LED light source 12 is installed on the female mold 28 side as described above, it is preferable that the photodetector 14 is arranged on the male mold 26 side. Further, it is desirable that the LED light source 12 is installed on the optical axis of the ophthalmic lens article to be molded.

 Further, in the above embodiment, in order to widen the irradiation angle of the light emitted from the LED light source 12, the diffusion lens 18 as the diffusion means was provided. It is appropriately used according to the size of the LED light source, the distance from the LED light source 12 to the molding die 10, the directional angle of the LED light source, and the like, and is not essential in the present invention. Further, as described above, it is also possible to use a light collecting means instead of the diffusing means.

In the above example, as the moving means for moving the diffusing lens 18 in the up and down direction, a means that also has a steering motor and a known crank device force is adopted, and the diffusing lens 18 is driven by the stepping motor as the driving means. Small movements of the lens 18 can be advantageously achieved. However, a conventionally known driving means other than a stepping motor can be used as the driving means. Further, such a moving means can be used as needed, similarly to the diffusion lens 18 described above, and is not necessarily required in the present invention.

 In the above embodiment, the irradiance of the light emitted from the LED light source 12 is automatically kept constant by the light intensity control device 16 including the arithmetic processing unit and the variable voltage circuit. However, it is possible for an operator who does not use such light intensity control device 16 to appropriately set the voltage to be supplied to the LED light source 12.

 [0091] Further, in the above example, the intensity of the light emitted from the LED light source 12, specifically, the irradiance is detected by the photodetector 14, but such irradiance is Even if it is detected directly, or indirectly detected by being converted into a physical force representing the intensity of light other than irradiance, there is no problem at all. The photodetector 14 is also used as needed, and is not essential in the present invention.

 [0092] Further, in the above-described embodiment, a specific example in which the present invention is applied to a manufacturing apparatus and a manufacturing method thereof for manufacturing a contact lens has been described. However, the present invention relates to such a contact lens. In addition, an ophthalmic lens such as an intraocular lens, or a semi-finished product of such an ophthalmic lens (for example, one surface is formed into a completed lens surface shape, while the other surface is used as a lens surface) Is an ophthalmic lens material that has not yet been completed and is formed into a shape that requires post-processing such as cutting, and that provides the ophthalmic lens). The present invention can also be advantageously applied to a molding die for molding a so-called ophthalmic lens article such as a lens blank which can be provided by performing the above-described processing, and a method for producing the same. In particular, when the ophthalmic lens article is an intraocular lens, since its thickness is considerably larger than that of a contact lens, at least one of each is provided 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. In addition, when manufacturing the intraocular lens, the direction angle of the LED light source 12 is 10-100 °. preferable.

[0093] Further, in the present embodiment, the plurality of molding dies 10 (female dies 28) held by the transfer machine 24 are moved to the monomer liquid supply position and the mold by the transfer machine 24 using the transfer machine 24. Alignment position And the light irradiation position, and the monomer solution supply step, the mold matching step, and the light irradiation step are simultaneously performed at each of the transfer positions, so that the contact lens as the objective ophthalmic lens article is obtained. Although specific examples of the manufacturing method for continuously mass-producing the above have been given, the present invention is not limited to such a method, and each step as described above without using the transporter 24 is not limited. Can be performed independently for each molding die 10. In short, in the present invention, since the LED is used as the light source, one light source can be arranged for each one of the molds 10, and therefore, one light source can be used for a plurality of molds. In contrast to the case where light irradiation is performed, the intended ophthalmic lens article can be manufactured individually and efficiently. In addition, it is also possible to simultaneously perform different light irradiation for each LED light source depending on the case, such as setting the irradiation amount and irradiation time of the LED light for each lens standard.

 [0094] Furthermore, the structure of the male mold 26 and the female mold 28 constituting the molding die 10 may be appropriately selected from various known structures, and is not particularly limited to the structure shown in the embodiment. Of course, this is not the case.

 [0095] Although not enumerated one by one, the present invention can be embodied in embodiments in which various changes, modifications, improvements, and the like are added based on the knowledge of those skilled in the art. It goes without saying that all embodiments fall within the scope of the present invention unless they depart from the gist of the present invention.

 Example

 [0096] Hereinafter, several experimental examples including representative examples of the present invention will be shown, and the present invention will be described in more detail with reference to such experimental examples. It goes without saying that it is not subject to any restrictions. In addition, in addition to the specific examples described above, various modifications of the present invention may be made based on the knowledge of those skilled in the art in addition to the specific examples described above without departing from the spirit of the present invention. It should be understood that modifications, improvements, etc. can be made.

First, according to the present invention, as a monomer solution (50) to be photopolymerized, Formulation Solution 1 and Formulation Solution 2 having the compositions shown in Tables 1 and 2 below are prepared, while the peak wavelength of irradiation light, Table 3 below shows five types of LED light sources (12) with different maximum emission wavelengths. Prepared as indicated. In addition, three commercially available photopolymerization initiators, namely, 2-hydroxy-2-methyl-1-phenylene-propane-1one (initiator A), 2,4,6-trimethylbenzoyl-diphenylphosphine oxide ( Initiator B) and bis (2,4,6 polymethylbenzoyl) phenylphosphine oxide (Initiator C) were prepared.

[0098] [Table 1]

 [0099] [Table 2]

[0100] [Table 3]

Next, with respect to various monomer liquids (50) obtained by selecting initiators A to C in vigorous compounding liquids 1 and 2, in the LED light irradiation structure shown in FIG. Using 12), LED light having a predetermined peak wavelength was irradiated at room temperature for 30 minutes, and photopolymerization was performed, respectively. Note that the male mold (26) and female Each of the molds (28) was made of polypropylene, and the irradiation distance (D), which was the distance between the LED light source (12) and the female mold (28), was 5 mm.

 [0102] For contact lens products (ophthalmic lens articles), which are polymerization products obtained by photopolymerization using various LED light sources (12) with various peak wavelengths against various powerful monomer liquids (50), It was examined whether the unpolymerized monomer remained or not, and the results are shown in Table 4 below. In the evaluation criteria in Table 4 below, 〇 indicates the case where it was detected that a small amount of unpolymerized monomer remained in the contact lens product obtained by photopolymerization. X indicates that unpolymerized monomer is present in the product, and X indicates that the product itself, which has a large amount of unpolymerized monomer in the contact lens product, is soft and easily deformed. ing.

 [0103] [Table 4]

 [0104] Further, with respect to the mixed liquid 1 and the mixed liquid 2 shown in Tables 1 and 2, a UV absorber: 2- [2'-hydroxy-5 '(2--methacryloyloxyethoxy) -3 '-Tert-butylphenyl] -5-methyl-2H-benzotriazole (1 part by weight) was added to each mixture, and the initiators A to C were added thereto in a combination as shown in Table 5 below. After preparing a monomer liquid (50) by using the same, a molding liquid formed between a male mold (26) and a female mold (28) constituting a polypropylene mold 10 as shown in FIG. 3 is formed. The cavity (30) was filled.

[0105] The mold (10) filled with such various monomer liquids (50) is opposed to the mold (26) and the female mold (28) from two directions. Then, by using two LED light sources (12) having the same peak wavelength and irradiating light with a predetermined peak wavelength, respectively, photopolymerization is performed, and the objective lens product outside the contour (eye) Lens products). The photopolymerization is carried out by irradiating light for 30 minutes at room temperature. The irradiation distance (D), which is the distance of each LED light source (12) from the male type (26) or the female type (28), was 2 mm, respectively.

[0106] The monomer liquid (50) to which the UV absorber obtained by the addition of the force was added had various peak wavelengths.

Molded products (contact lens products) by photopolymerization using LED light were evaluated in the same manner as above, and the results are shown in Table 5 below.

[0107] [Table 5]

 As apparent from the results in Table 4, in the photopolymerization operation according to the present invention using the monomer liquid (50) containing no UV absorber, the LED light source (12) having a peak wavelength of 400 nm or less was used. No matter which polymerization initiator is used, a molded product having sufficient shape retention as a contact lens when the contact lens product obtained as a polymerization product is hydrated, As a result. In addition, when phosphine oxide-based initiator B or initiator C, which is an initiator having a high extinction coefficient at 405 nm, is added, an LED light source having a peak wavelength in the range of 380 nm to 470 nm ( The desired contact lens product could be advantageously obtained by photopolymerization using (12).

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

[0110] The monomer liquid (50) having the composition shown in Tables 4 and 5 above was further added with 0.002% by weight of 1-phenylazo-3-methacryloyloxy-2-naphthol as a pigment. Caro part Instead, when photopolymerization was performed using the LED light sources (12) having the various peak wavelengths described above, the same results were obtained in each case, and the photopolymerization of the monomer liquid (50) showed the presence of a dye. It was confirmed that it did not have a significant effect.

Claims

The scope of the claims

 [1] By molding an upper mold and a lower mold that also have a light-transmitting material strength, a desired ophthalmic lens article such as an ophthalmic lens, a semi-finished product thereof, or a lens blank is formed between the molds. The molding liquid is filled with the monomer liquid using a molding die in which a molding cavity having a shape giving the shape is formed, and the molding liquid is placed on at least one of the upper and lower sides of the molding die. By irradiating the LED light, the monomer liquid filled in the molding cavity is photopolymerized by light transmitted through the molding die, and the target ophthalmic lens article is molded. A method for producing an ophthalmic lens article, comprising:

[2] A plurality of the molds are arranged, and the LED is installed for each of the molds.

V. The method for producing an ophthalmic lens article according to claim 1.

 [3] The upper mold is a male mold having a convex molding cavity surface, while the lower mold is a female mold having a concave molding cavity surface, and the LED is separated upward from the male mold. The method for producing an ophthalmic lens article according to claim 1, wherein the ophthalmic lens article is installed at an inclined position and on an optical axis of an ophthalmic lens article to be molded.

[4] 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.

[5] The eye according to claim 4, wherein the acrylic monomer power is a silicon-containing acrylic monomer, and the silicon-containing acrylic monomer power is contained in the monomer liquid at a ratio of 10 to 70% by weight. Of manufacturing lens articles for automobiles.

[6] The acrylic monomer power is a dialkyl (meth) acrylamide, which is contained in the monomer liquid in a ratio of 30 to 70% by weight.

6. The method for manufacturing an ophthalmic lens article according to claim 4 or claim 5.

 7. The method for manufacturing an ophthalmic lens article according to claim 1, wherein the irradiation time of the LED is 60 minutes or less.

 [8] The method according to claim 1, wherein light having a peak wavelength in 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 claims 1 to 7.

[9] The monomer liquid contains a UV absorber, and the light emitted from the LED 8. The method for producing an ophthalmic lens article according to claim 1, wherein the peak wavelength is in a range of 380 to 500 nm.

10. The method for manufacturing an ophthalmic lens article according to claim 8, wherein the monomer liquid contains a dye.

 11. The method according to claim 1, wherein two of the LEDs are used, arranged above and below the molding die, respectively, and the two LEDs are irradiated with light so that the two LEDs also face each other. A method for producing an ophthalmic lens article according to any one of the above.

 12. The method for producing an ophthalmic lens article according to claim 1, wherein a photopolymerization initiator having a high extinction coefficient at 405 nm is used in the photopolymerization of the monomer liquid.

 [13] By molding an upper mold and a lower mold that also have a light-transmitting material strength, a desired ophthalmic lens article such as an ophthalmic lens, a semi-finished product thereof, or a lens blank is formed between the molds. A molding die having a shape capable of forming a mold cavity, and a one-component monomer which is disposed on at least one of the upper and lower sides of the molding die and is filled in the molding cavity of the molding die. An ophthalmic lens article manufacturing apparatus, comprising: an LED for irradiating light to the lens.

 14. The apparatus for manufacturing an ophthalmic lens article according to claim 13, wherein a plurality of the molding dies are arranged in a predetermined conveying means, and the LED is provided for each of the molding dies.

 [15] Measuring means for measuring the irradiance of the light emitted from the LED is provided on the side opposite to the LED with the molding die interposed therebetween, and the irradiance is measured by a powerful measuring means. 15. The apparatus for manufacturing an ophthalmic lens article according to claim 13, wherein the apparatus is configured to perform the following.

 [16] Control means for controlling the voltage supplied to the LED is provided, and the control means controls the LED so that the irradiance value measured by the measurement means and a target value match. 16. The apparatus for manufacturing an ophthalmic lens article according to claim 15, wherein a voltage supplied to the lens is controlled so as to keep the irradiance of the light irradiated with the LED force constant.

[17] A diffusing means for diffusing the light emitted from the LED is provided between the mold and the LED, and by irradiating the light through the diffusing means, the light of the LED power is reduced. The irradiation angle of the monomer liquid filled in the molding cavity of the molding die The apparatus for manufacturing an ophthalmic lens article according to any one of claims 13 to 16, wherein a strong light is uniformly applied to the lens.

 A moving means for moving the diffusing means in a direction away from or approaching the mold is provided, and the position of the diffusing means is adjusted by a powerful moving means, so that the molding cavity can be moved. 18. The manufacturing apparatus for an ophthalmic lens article according to claim 17, wherein the light is uniformly applied to the filled monomer liquid.