JP2020106707A - Optical layer and optical component - Google Patents

Abstract

To provide an optical layer capable of enhancing adhesion between a functional layer and a lens layer and an optical component.SOLUTION: A method for manufacturing an optical layer that manufactures an optical layer which has a curved shape and is used in a spectacle lens includes: an ultraviolet irradiation step of irradiating a function layer which contains a first resin material and optically acts on incident light from one surface side thereof with ultraviolet rays, and reducing a molecular weight of the first resin material on the one surface side of the functional layer; a functional layer arrangement step of arranging the function layer on a curved recessed surface from the other surface of the functional layer; and a joining step of melting a second resin material as a lens layer, and joining the molten second resin material to a surface opposite to the curved recessed surface of the functional layer curved according to the curved recessed surface.SELECTED DRAWING: Figure 4

Description

The present invention relates to an optical layer and an optical component.

Optical components such as eyeglasses and sunglasses are laminated on a lens layer and a lens layer made of a light-transmitting material such as a resin material or a glass material, and optically act on light transmitted through the lens layer. And an optical functional layer containing a filler (see, for example, Patent Document 1).

In the optical component described in Patent Document 1, the optical function layer is composed of a half mirror layer in which a metal film is laminated in multiple layers on a lens layer. For this reason, when the optical component is viewed from the outside, the optical component looks shiny and the design is improved, and the eyes of the user are difficult to see from the outside. In addition, the antiglare effect can be exerted, and the feeling of eye fatigue can be reduced.

However, the lens layer often has a curved surface, and it is difficult to stack the optical function layer with a uniform thickness on the curved surface. Therefore, the optical characteristics of the optical functional layer may be uneven.

Therefore, a configuration in which the optical functional layer is molded and then bonded to the lens layer is conceivable. However, in the configuration in which the optical functional layer is bonded to the curved surface, the optical functional layer may be peeled off.
As described above, it is difficult to improve the adhesion between the optical function layer and the lens layer.

WO2014/115705

An object of the present invention is to provide an optical layer and an optical component that can enhance the adhesion between the functional layer and the lens layer.

Such an object is achieved by the present invention of the following (1) to (7).
(1) A manufacturing method for manufacturing an optical layer having a curved shape and used for an eyeglass lens,
The first resin material on the one surface side of the functional layer is irradiated with ultraviolet rays from one surface side of the functional layer that includes the first resin material and optically acts on incident light. An ultraviolet irradiation step to reduce the viscosity average molecular weight,
A functional layer disposing step of disposing the functional layer on the curved concave surface from the other surface of the functional layer,
A bonding step of melting and bonding the second resin material, which will be the lens layer, on the surface of the functional layer that is curved following the curved concave surface and that is opposite to the curved concave surface. A method for producing an optical layer.

(2) peak irradiance of ultraviolet rays irradiated by the ultraviolet irradiation process, method for producing an optical layer according to 10 mW / cm ² or more 1000 mW / cm ² or less above (1).

(3) The method for producing an optical layer according to the above (1) or (2), wherein the integrated light amount of ultraviolet rays irradiated in the ultraviolet ray irradiation step is 50 mJ/cm ² or more and 1000 mJ/cm ² or less.

(4) The method for producing an optical layer according to any one of (1) to (3), wherein the melting point of the first resin material is 240° C. or higher and 260° C. or lower.

(5) The method for producing an optical layer according to any one of (1) to (4), wherein the temperature of the molten second resin material in the bonding step is 270° C. or higher and 320° C. or lower. ..

(6) An optical layer used for a spectacle lens, the overall shape of which is a curved shape,
A functional layer containing a first resin material and optically acting on incident light;
A lens layer provided on the curved concave surface side of the functional layer and containing a second resin material,
The functional layer has a first layer on the lens layer side and a second layer on the side opposite to the lens layer,
An optical layer, wherein the relationship of Mv1<Mv2 is satisfied, where Mv1 is the viscosity average molecular weight of the first layer and Mv2 is the viscosity average molecular weight of the second layer.

(7) The optical layer according to (6), which satisfies a relationship of Mv3≦Mv1<Mv2, where Mv3 is a viscosity average molecular weight of the second resin material.

ADVANTAGE OF THE INVENTION According to this invention, the optical layer and optical component which can raise the adhesiveness of a functional layer and a lens layer can be provided.

It is a perspective view of sunglasses (optical component) provided with the optical layer (1st Embodiment) of the present invention. It is a perspective view of the sun visor (optical component) provided with the optical layer (1st Embodiment) of the present invention. It is the side view which showed typically the functional layer manufacturing apparatus which manufactures the functional layer shown in FIG. It is sectional drawing which showed typically the optical layer manufacturing apparatus which manufactures the optical layer shown in FIG. It is sectional drawing of the optical layer shown in FIG. FIG. 6 is a cross-sectional view for explaining the method for producing an optical layer of the present invention, showing an ultraviolet irradiation step. FIG. 6 is a cross-sectional view for explaining the method for producing an optical layer of the present invention, which is a diagram showing a functional layer arranging step. FIG. 6 is a cross-sectional view for explaining the method for producing an optical layer of the present invention, which is a diagram showing a joining step. It is sectional drawing of the optical component provided with the optical layer (2nd Embodiment) of this invention.

Hereinafter, the optical layer and the optical component of the present invention will be described in detail based on the preferred embodiments shown in the accompanying drawings.

<First Embodiment>
FIG. 1 is a perspective view of sunglasses (optical component) including the optical layer (first embodiment) of the present invention. FIG. 2 is a perspective view of a sun visor (optical component) including the optical layer (first embodiment) of the present invention. FIG. 5 is a cross-sectional view of the optical layer shown in FIG.

1, 2, and 5 (the same applies to FIG. 6), the upper side is also referred to as "upper" or "upper", and the lower side is also referred to as "lower" or "lower". Further, in the drawings referred to in this specification, the dimension in the thickness direction is exaggeratedly illustrated, which is significantly different from the actual dimension.

As shown in FIGS. 6 to 8, the method for producing an optical layer of the present invention is a method for producing an optical layer having a curved shape and used for a spectacle lens, and including a first resin material. , UV irradiation for irradiating ultraviolet light from one surface side of the functional layer 3 that optically acts on incident light to reduce the viscosity average molecular weight of the first resin material on one surface side of the functional layer 3. A step of arranging the functional layer 3 on the curved concave surface from the other surface of the functional layer 3, and a lens on the surface opposite to the curved concave surface of the functional layer 3 which is curved following the curved concave surface. A joining step of melting and joining the second resin material to be the layer 4.

Thereby, the viscosity average molecular weight of one surface of the functional layer 3 can be reduced, and the adhesiveness can be increased. Moreover, by adhering the portion of the functional layer 3 having increased adhesiveness to the lens layer 4, the adhesion between the functional layer 3 and the lens layer 4 can be enhanced.

The functional layer-equipped lens 1 (optical layer) manufactured by such a manufacturing method is used for the sunglasses (optical component 10) shown in FIG. 1 and the sun visor (optical component 10') shown in FIG.

As shown in FIG. 1, the sunglasses (optical component 10) includes a frame 2 that is worn on the head of a user and a lens 1 (optical layer) with a functional layer that is fixed to the frame 2. In the present specification, the term “lens” includes both those having a light collecting function and those not having a light collecting function.

As shown in FIG. 1, the frame 2 is mounted on the user's head, and includes a rim portion 21, a bridge portion 22, a temple portion 23 that is worn on the user's ear, and a nose pad portion 24. And have. Each rim portion 21 has a ring shape, and is a portion to which the functional layer-equipped lens 1 is mounted inside.

The bridge portion 22 is a portion that connects the rim portions 21. The temple portion 23 has a temple shape and is connected to an edge portion of each rim portion 21. The temple portion 23 is a portion that can be worn on the user's ear. The nose pad portion 24 is a portion that comes into contact with the nose of the user when the sunglasses (optical component 10) is worn on the head of the user. Thereby, the mounted state can be stably maintained.

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

The optical component of the present invention is characterized by including the above-mentioned lens 1 with a functional layer (optical layer) of the present invention. With this, it is possible to exhibit the function of sunglasses while enjoying the advantages of the lens with functional layer 1 (optical layer) described above.

As shown in FIG. 2, the sun visor (optical component 10 ′) has a ring-shaped mounting portion 5 to be mounted on the head of the user and a brim 6 provided in front of the mounting portion 5. There is. The brim 6 has the lens 1 with a functional layer (optical layer). As a result, the function as the sun visor can be exerted while enjoying the advantages of the lens with functional layer 1 (optical layer) described above.

Hereinafter, the lens 1 with a functional layer will be described in detail. In the following, a case of stacking on the lens layer 4 (base material) will be representatively described.

As shown in FIG. 5, the lens 1 with a functional layer has a functional layer 3, a lens layer 4, and a fusion zone 7.

<Lens layer>
The lens layer 4 is configured to include the second resin material. The second resin material is not particularly limited, and examples thereof include polycarbonate, polyamide, polyvinyl chloride, polyethylene, polypropylene and the like, and among these, polycarbonate is preferable.

The polycarbonate is not particularly limited and various kinds can be used, but among them, aromatic polycarbonate is preferable. The aromatic polycarbonate has an aromatic ring in its main chain, which makes it possible to further enhance the strength of the lens 1 with a functional layer.

This aromatic polycarbonate is synthesized, for example, by an interfacial polycondensation reaction between bisphenol and phosgene, an ester exchange reaction between bisphenol and diphenyl carbonate, and the like.

Examples of the bisphenol include bisphenol A and bisphenol (modified bisphenol) which is the origin of the repeating unit of the polycarbonate represented by the following formula (1).

（式（１）中、Ｘは、炭素数１〜１８のアルキル基、芳香族基または環状脂肪族基であり、ＲａおよびＲｂは、それぞれ独立して、炭素数１〜１２のアルキル基であり、ｍおよびｎは、それぞれ０〜４の整数であり、ｐは、繰り返し単位の数である。）

(In the formula (1), X is an alkyl group having 1 to 18 carbon atoms, an aromatic group or a cycloaliphatic group, and Ra and Rb are each independently an alkyl group having 1 to 12 carbon atoms. , M and n are each an integer of 0 to 4, and p is the number of repeating units.)

Specific examples of the bisphenol serving as the origin of the repeating unit of the polycarbonate represented by the formula (1) include, for example, 4,4′-(pentane-2,2-diyl)diphenol and 4,4′-( Pentane-3,3-diyl)diphenol, 4,4'-(butane-2,2-diyl)diphenol, 1,1'-(cyclohexanediyl)diphenol, 2-cyclohexyl-1,4-bis( 4-hydroxyphenyl)benzene, 2,3-biscyclohexyl-1,4-bis(4-hydroxyphenyl)benzene, 1,1'-bis(4-hydroxy-3-methylphenyl)cyclohexane, 2,2'- Examples thereof include bis(4-hydroxy-3-methylphenyl)propane and the like, and one or more of these can be used in combination.

In particular, as the polycarbonate, it is preferable that the main component is a bisphenol type polycarbonate having a skeleton derived from bisphenol. By using such a bisphenol-type polycarbonate, the lens layer 4 (lens 1 with a functional layer) exhibits even more excellent strength.

The viscosity average molecular weight Mv3 of such a polycarbonate is preferably 15,000 or more and 28,000 or less, and more preferably 18,000 or more and 23,000 or less.

As a result, the strength of the functional layer-equipped lens 1 can be sufficiently increased. Moreover, in the molten state of the polycarbonate, the fluidity can be sufficiently enhanced.

Further, the polycarbonate has a melt flow rate (MFR) measured according to JIS K7210 of preferably 5 g/10 min or more and 40 g/10 min or less, and more preferably 20 g/10 min or more and 35 g/10 min or less. .. Thereby, the fluidity of the polycarbonate can be sufficiently enhanced in the molten state.

Further, the content of the polycarbonate in the lens layer 4 is preferably 87 wt% or more and 99.949 wt% or less, and more preferably 90 wt% or more and 99.87 wt% or less. Thereby, the effect of the present invention can be exhibited more reliably.

The thickness (average thickness) of such a lens layer 4 is preferably 1 mm or more and 15 mm or less, and more preferably 1.2 mm or more and 5 mm or less. Thereby, sufficient strength of the lens layer 4 can be secured.

<Functional layer>
The functional layer 3 is provided on the curved convex surface side of the lens layer 4. In addition, the functional layer 3 is configured to include an optical particle that optically acts on incident light and a first resin material.

The first resin material is not particularly limited, and examples thereof include polycarbonate, polyamide, polyvinyl chloride, polyethylene, polypropylene and the like, and among these, polycarbonate is preferable.

The polycarbonate is not particularly limited and various kinds can be used, but among them, aromatic polycarbonate is preferable. The aromatic polycarbonate has an aromatic ring in its main chain, which makes it possible to further enhance the strength of the lens 1 with a functional layer.

This aromatic polycarbonate is synthesized, for example, by an interfacial polycondensation reaction between bisphenol and phosgene, an ester exchange reaction between bisphenol and diphenyl carbonate, and the like.

Examples of the bisphenol include bisphenol A and bisphenol (modified bisphenol) which is the origin of the repeating unit of the polycarbonate represented by the following formula (1).

（式（１）中、Ｘは、炭素数１〜１８のアルキル基、芳香族基または環状脂肪族基であり、ＲａおよびＲｂは、それぞれ独立して、炭素数１〜１２のアルキル基であり、ｍおよびｎは、それぞれ０〜４の整数であり、ｐは、繰り返し単位の数である。）

(In the formula (1), X is an alkyl group having 1 to 18 carbon atoms, an aromatic group or a cycloaliphatic group, and Ra and Rb are each independently an alkyl group having 1 to 12 carbon atoms. , M and n are each an integer of 0 to 4, and p is the number of repeating units.)

Specific examples of the bisphenol serving as the origin of the repeating unit of the polycarbonate represented by the formula (1) include, for example, 4,4′-(pentane-2,2-diyl)diphenol and 4,4′-( Pentane-3,3-diyl)diphenol, 4,4'-(butane-2,2-diyl)diphenol, 1,1'-(cyclohexanediyl)diphenol, 2-cyclohexyl-1,4-bis( 4-hydroxyphenyl)benzene, 2,3-biscyclohexyl-1,4-bis(4-hydroxyphenyl)benzene, 1,1'-bis(4-hydroxy-3-methylphenyl)cyclohexane, 2,2'- Examples thereof include bis(4-hydroxy-3-methylphenyl)propane and the like, and one or more of these can be used in combination.

In particular, as the polycarbonate, it is preferable that the main component is a bisphenol type polycarbonate having a skeleton derived from bisphenol. By using such a bisphenol type polycarbonate, the functional layer 3 (lens 1 with a functional layer) exhibits even more excellent strength.

When the first resin material and the second resin material are polycarbonate, the viscosity average molecular weight of the polycarbonate of the lens layer 4 (second resin material) is the same as that of the polycarbonate of the functional layer 3 (first resin material). It is preferably lower than the viscosity average molecular weight of (1). Thereby, even in the curved state, it is possible to achieve both sufficient strength of the convex surface and adhesion between the functional layer 3 and the lens layer 4. Further, it is possible to prevent the functional layer 3 from being deteriorated by the influence of heat applied during molding. Therefore, it is possible to prevent the function of the functional layer 3 from being impaired.

In this case, the difference in viscosity average molecular weight Mv is preferably 2000 or more and 13000 or less, and more preferably 3000 or more and 8000 or less. As a result, the strength of the functional layer-equipped lens 1 can be sufficiently increased. Moreover, in the molten state of the polycarbonate, the fluidity can be sufficiently enhanced.

Further, the polycarbonate has a melt flow rate (MFR) measured according to JIS K7210 of preferably 3 g/10 min or more and 30 g/10 min or less, and more preferably 15 g/10 min or more and 25 g/10 min or less. .. Thereby, the fluidity of the polycarbonate can be sufficiently enhanced in the molten state.

Further, when the first resin material and the second resin material are each polycarbonate, it is preferable that the polycarbonate of the lens layer 4 has a larger melt flow rate than the first resin material and the second resin material. .. Thereby, it is excellent in moldability as described later.

Further, in this case, the difference in melt flow rate is preferably 2 g/10 min or more and 35 g/10 min or less, and more preferably 5 g/10 min or more and 25 g/10 min or less. As a result, the above effect can be exhibited more reliably.

The optical particle has a function (optical function) of optically acting on incident light. The optical particle is not particularly limited as long as it has an optical function, for example, a visible light reflecting material that reflects visible light, an ultraviolet shielding material that shields ultraviolet rays, an infrared shielding material that shields infrared rays, etc. Are listed.

Examples of the visible light reflector include borosilicates such as calcium borosilicate and aluminum borosilicate, TiO ₂ , SnO ₂ , ZnO, Fe ₂ O ₃ , Fe ₃ O ₄ , SiO ₂ , Al ₂ O ₃ , and ZrO _2. Examples thereof include particles that reflect visible light such as metal oxides and the like, and particles that do not reflect visible light and that have been subjected to a treatment of adhering a metal oxide such as titanium oxide and tin oxide. According to such a visible light reflecting material, when the lens 1 with a functional layer is viewed from the outside, it looks glittering and is excellent in design.
The color of the visible light reflector may be any color such as colorless, red, blue and yellow.

On the other hand, examples of the ultraviolet ray shielding material include materials that reflect ultraviolet rays, such as aluminum alloys, aluminum oxides, Al-Mg-based, Al-Mg-Si-based, and Al-Cu-based aluminum alloys. With such an ultraviolet reflecting material, it is possible to suppress the irradiation of the eyes of the user with ultraviolet rays. Therefore, the eyes of the user can be protected.

On the other hand, examples of the infrared shielding material include materials having infrared absorption properties such as metal borides, titanium oxide, zirconium oxide, tin-doped indium oxide (ITO), antimony-doped tin oxide (ATO), and tungsten oxide compounds. As a result, it is possible to suppress the irradiation of infrared rays to the eyes of the user. Therefore, the eyes of the user can be protected.

In addition to the above, a laser color former, a photochromic dye, etc. may be contained.

The shape of these optical particles is not particularly limited, and may be any shape such as spherical, acicular, or scaly.

Further, the average particle diameter of the optical particles is preferably 2 nm or more and 2000 nm or less, and more preferably 5 nm or more and 1000 nm or less. This makes it possible to sufficiently enhance the above-mentioned optical characteristics and prevent the filling amount from becoming too large.

The content of such optical particles in the functional layer 3 is preferably 0.0001 wt% or more and 1 wt% or less, and more preferably 0.0002 wt% or more and 0.5 wt% or less. As a result, it is possible to prevent the functional layer 3 from becoming too thick, and to improve the adhesion between the functional layer 3 and the lens layer 4. If the content of the optical particles is too small, the above-mentioned effects tend to be insufficient. On the other hand, if the content of the optical particles is too large, haze tends to occur.

The thickness (average thickness) of the functional layer 3 is preferably 0.05 mm or more and 2.0 mm or less, and more preferably 0.15 mm or more and 1.5 mm or less. Thereby, sufficient strength of the functional layer 3 can be secured.

Such a functional layer 3 has a first layer 31 on the lens layer 4 side and a second layer 32 on the side opposite to the lens layer 4. As will be described later, the first layer 31 is a layer formed by being irradiated with ultraviolet rays in the manufacturing process and having a reduced viscosity average molecular weight.

When the viscosity average molecular weight of the first layer 31 is Mv1 and the viscosity average molecular weight of the second layer 32 is Mv2, the relationship of Mv1<Mv2 is satisfied. Thereby, the adhesiveness of the first layer 31, which is a portion in contact with the lens layer 4, can be increased. Therefore, the adhesiveness between the functional layer 3 and the lens layer 4 can be improved.

The viscosity average molecular weight Mv1 of the first layer 31 is preferably 15,000 or more and 28,000 or less, and more preferably 18,000 or more and 23,000 or less. Thereby, the productivity can be improved and the adhesion between the functional layer 3 and the lens layer 4 can be improved.

If the viscosity average molecular weight Mv1 is too small, the irradiation time of ultraviolet rays in the ultraviolet irradiation step described later increases, and the production tends to take time. On the other hand, if the viscosity average molecular weight Mv1 is too large, the adhesiveness may be insufficiently expressed and the adhesion between the functional layer 3 and the lens layer 4 may be insufficient.

The viscosity average molecular weight Mv2 of the second layer 32 is preferably 20,000 or more and 30,000 or less, and more preferably 23,000 or more and 28,000 or less. Thereby, sufficient strength of the functional layer 3 can be ensured and productivity can be improved.

If the viscosity average molecular weight Mv2 is too small, the strength of the functional layer 3 may decrease. If the viscosity average molecular weight Mv2 is too large, the irradiation time of ultraviolet rays in the ultraviolet irradiation step described later increases in order to sufficiently reduce the viscosity average molecular weight of the first layer 31, and the production tends to take time.

The average thickness of the first layer 31 is preferably 1 μm or more and 100 μm or less, and more preferably 2 μm or more and 80 μm or less. Thereby, the productivity can be improved and the adhesion between the functional layer 3 and the lens layer 4 can be improved.

If the first layer 31 is too thick, the irradiation time of ultraviolet rays in the ultraviolet irradiation step described later tends to increase, and it takes time to manufacture, and the strength decreases, the durability decreases, and yellowing occurs. Can occur. On the other hand, if the first layer 31 is too thin, the adhesion between the functional layer 3 and the lens layer 4 tends to be low.

The average thickness of the second layer 32 is preferably 0.05 mm or more and 2.0 mm or less, and more preferably 0.15 mm or more and 1.5 mm or less. Thereby, the productivity can be improved and the adhesion between the functional layer 3 and the lens layer 4 can be improved.

If the second layer 32 is too thick, the thickness of the first layer 31 tends to be relatively thin, and the adhesion between the functional layer 3 and the lens layer 4 tends to be low. On the other hand, if the second layer 32 is too thin, the thickness of the first layer 31 becomes relatively thick, and the impact resistance tends to decrease.

Further, it is preferable that the above-mentioned viscosity average molecular weights Mv1, Mv2 and Mv3 satisfy the relationship of Mv3≦Mv1<Mv2. As a result, the effect of the present invention can be obtained, and the strength of the lens layer 4, and thus the strength of the functional layer-equipped lens 1 can be sufficiently increased.

(Method for manufacturing functional layer)
First, the functional layer manufacturing apparatus used in this manufacturing method will be described.

FIG. 3 is a side view schematically showing a functional layer manufacturing apparatus for manufacturing the functional layer shown in FIG. FIG. 4 is a cross-sectional view schematically showing an optical layer manufacturing apparatus for manufacturing the optical layer shown in FIG. In the following description, the upper side in FIGS. 3 and 4 is referred to as “upper” and the lower side is referred to as “lower”.

The functional layer manufacturing apparatus 100 shown in FIG. 3 has a sheet supply unit 200 and a sheet forming unit 300.

In the present embodiment, the sheet supply unit 200 includes an extruder 210 and a T die 220 connected to a molten resin discharge unit of the extruder 210 via a pipe. The T-die 220 supplies the band-shaped functional layer 3 ′ (functional sheet) in a molten state or a softened state to the sheet forming unit 300.

The T die 220 is an extrusion molding unit that extrudes the functional layer 3 ′ in a molten state or a softened state into a band-shaped sheet by an extrusion method. The T-die 220 is loaded with the above-described constituent materials that form the lens with functional layer 1 in a molten state. By extruding the material in the molten state from the T-die 220, the belt-shaped functional layer 3 ′ is continuously formed. Sent out.

The sheet forming unit 300 includes a touch roll 310, a cooling roll 320, and a post-stage cooling roll 330. Each of these rolls is configured to rotate independently by a motor (driving means) (not shown), and is cooled by the rotation of these rolls to be continuously fed. By continuously feeding the functional layer 3 ′ into the sheet forming unit 300, the surface of the functional layer 3 ′ is flattened, and the functional layer 3 ′ is set to a desired thickness and cooled. Then, the functional layer 3 is obtained by cutting the cooled functional layer 3'to a predetermined length.

The functional layer of the present embodiment is manufactured by the method of manufacturing a functional layer using the functional layer manufacturing apparatus 100 as described above.
The production of the functional layer includes an extrusion process, a molding process, and a cooling process.

First, the band-shaped melted or softened functional layer 3'is extruded (extrusion step). In this extrusion step, the extruder 210 is loaded with the constituent materials (first resin material, optical particles, etc.) of the lens with functional layer 1. Further, the constituent material of the lens with functional layer 1 is in a melted or softened state in the extruder 210. Here, as described above, when the first resin material is a polycarbonate having a viscosity average molecular weight of 20,000 or more and 30,000 or less, the polycarbonate and the optical particles are in a sufficiently mixed state. Then, by extruding these in a sufficiently mixed state, in the functional layer 3 obtained through the molding step and the cooling step described later, the optical particles are uniformly dispersed.

Next, the surface of the functional layer 3'is flattened and the functional layer 3'is set to a predetermined thickness (molding step). This step is performed between the touch roll 310 and the cooling roll 320.

Next, the surface of the functional layer 3'is cooled (cooling step). This step is performed between the cooling roll 320 and the post-stage cooling roll 330.

The lens 1 with a functional layer can be obtained through the above steps. Next, a method for manufacturing the optical layer will be described.

(Method for producing optical layer)
First, the optical layer manufacturing apparatus used in this manufacturing method will be described.

FIG. 4 is a cross-sectional view schematically showing an optical layer manufacturing apparatus for manufacturing the optical layer shown in FIG.

The optical layer manufacturing apparatus 400 shown in FIG. 4 has a resin supply unit 500 and a mold 600. The resin supply unit 500 is filled with the second resin material. The mold 600 has a cavity 610 and a supply port 620 that communicates the inside and the outside of the cavity 610. Further, the mold 600 is composed of an upper member 630 and a lower member 640, and in a state where these members are assembled, the mold 600 that defines the optical layer manufacturing apparatus 400 is configured.

The optical layer of the present embodiment is manufactured by the method of manufacturing an optical layer using the optical layer manufacturing apparatus 400 as described above.

FIG. 6 is a cross-sectional view for explaining the method for producing an optical layer of the present invention, showing an ultraviolet ray irradiation step. FIG. 7 is a cross-sectional view for explaining the method for producing an optical layer of the present invention, which is a diagram showing a functional layer arranging step. FIG. 8 is a cross-sectional view for explaining the method for manufacturing an optical layer of the present invention, showing a bonding step.

The method for producing an optical layer has an ultraviolet irradiation step, a functional layer arranging step, and a joining step.

[Ultraviolet irradiation process]
First, as shown in FIG. 6, the functional layer 3 is placed on a flat surface, and ultraviolet rays L are irradiated from one surface side (the side opposite to the mounting surface). Thereby, the viscosity average molecular weight of the polycarbonate decreases from one surface side of the functional layer 3 to the middle of the thickness direction of the functional layer 3. Therefore, the above-mentioned first layer 31 and second layer 32 are formed. In addition, in this specification, ultraviolet rays mean light with a wavelength of about 200 nm to 400 nm.

Further, in this step, the entire surface of the functional layer 3 is irradiated with ultraviolet rays. As a result, the first layer 31 and the second layer 32 are formed over the entire surface of the functional layer 3.

Ultraviolet rays can be obtained from LED lamps, high-pressure mercury lamps, electrodeless lamps, metal halide lamps, xenon lamps and the like. The peak irradiance of ultraviolet rays irradiated in the present process is preferably at 10 mW / cm ² or more 1000 mW / cm ² or less, more preferably 20 mW / cm ² or more 500 mW / cm ² or less. As a result, the effect of the present invention can be obtained more reliably and the productivity can be improved.

If the peak illuminance is too low, it takes a relatively long time to form the first layer 31 and the second layer 32. On the other hand, if the peak illuminance is too high, it becomes difficult to control the thickness of the first layer 31.

Further, the accumulated light quantity of ultraviolet light emitted in this step is preferably at 50 mJ / cm ² or more 1000 mJ / cm ² or less, more preferably 100 mJ / cm ² or more 700 mJ / cm ² or less. As a result, the effect of the present invention can be obtained more reliably, and sufficient strength of the functional layer 3 can be ensured.

If the integrated light quantity is too small, the thickness of the first layer 31 tends to be thin, and the effect of the present invention may not be sufficiently obtained. On the other hand, if the integrated light amount is too large, the thickness of the second layer 32 tends to be thin, and the strength of the functional layer 3 may be insufficient.

[Functional layer placement process]
Next, as shown in FIGS. 4 and 7, with the upper member 630 and the lower member 640 disassembled, the functional layer 3 is arranged on the bottom surface 641 of the lower member 640 (functional layer arrangement step). The bottom surface 641 is a curved concave surface, and thus a curved surface can be formed. The curvature of the bottom surface 641 is preferably 6.54 cm or more and 200 cm or less.

Further, since the functional layer 3 has flexibility, it is arranged according to the curved shape of the bottom surface 641.

[Joining process]
Next, the upper member 630 and the lower member 640 are put into an assembled state, and the lens material in a molten or softened state is poured through the supply port 620 (see FIGS. 4 and 8). At this time, as described above, when the melting point of the polycarbonate (second resin material) of the lens layer 4 is lower than the melting point of the polycarbonate (first resin material) of the functional layer 3, the functional layer 3 is exposed to heat. It is possible to suppress excessive deformation. Therefore, the thickness of the functional layer 3 can be made as uniform as possible. The melting point of the first resin material is preferably 240°C or higher and 260°C or lower. As a result, the above effect can be exhibited more reliably.

The set temperature of the molten second resin material in this step is preferably 270°C or higher and 320°C or lower, more preferably 280°C or higher and 310°C or lower. This can prevent the functional layer 3 from being excessively deformed by heat. Therefore, the thickness of the functional layer 3 can be made as uniform as possible.

Then, by cooling the molten or softened lens material, a laminated body in which the functional layer 3 and the lens layer 4 are joined can be obtained. The functional layer-equipped lens 1 can be obtained by cutting the obtained laminated body into a desired size.

<Second Embodiment>
FIG. 9 is a cross-sectional view of an optical component including the optical layer (second embodiment) of the present invention.

Hereinafter, the second embodiment of the optical layer and the optical component of the present invention will be described with reference to this drawing, but the description will focus on the differences from the above-described embodiment, and the description of the same matters will be omitted. ..
This embodiment is the same as the first embodiment except that it has a polarizing film.

(Lens with functional layer 1A (polarizing plate))
As shown in FIG. 9, the lens with functional layer 1</b>A further includes an adhesive layer 11, a polarizing film 12, an adhesive layer 13, and a polarizing film protective sheet 14 laminated on the functional layer 3. The polarizing film 12 is laminated on the functional layer 3 via the adhesive layer 11. A polarizing film protective sheet 14 is laminated on the surface of the polarizing film 12 opposite to the adhesive layer 11 with an adhesive layer 13 interposed therebetween.

The polarizing film 12 has a function of extracting linearly polarized light having a polarization plane in a predetermined direction from incident light (natural light that is not polarized). As a result, the incident light that enters the eye through the functional layer-equipped lens 1A becomes polarized.

The degree of polarization of the polarizing film 12 is not particularly limited, but is, for example, preferably 50% or more and 100% or less, and more preferably 80% or more and 100% or less. The visible light transmittance of the polarizing film 12 is not particularly limited, but is preferably 10% or more and 80% or less, and more preferably 20% or more and 50% or less.

The constituent material of such a polarizing film 12 is not particularly limited as long as it has the above-mentioned function, but for example, polyvinyl alcohol (PVA), partially formalized polyvinyl alcohol, polyethylene vinyl alcohol, polyvinyl butyral, polycarbonate, ethylene- Vinyl acetate copolymer A polymer film composed of partially saponified products, etc., adsorbed and dyed dichroic substances such as iodine and dichroic dyes, uniaxially stretched, polyvinyl alcohol dehydrated products and poly Examples thereof include polyene oriented films such as dehydrochlorinated products of vinyl chloride.

Among these, the polarizing film 12 is preferably a uniaxially stretched polymer film containing polyvinyl alcohol (PVA) as a main material, adsorbing and dyeing iodine or a dichroic dye. Polyvinyl alcohol (PVA) is a material excellent in transparency, heat resistance, affinity with iodine or dichroic dye as a dyeing agent, and orientation during stretching. Therefore, the polarizing film 12 containing PVA as a main material has excellent heat resistance and an excellent polarizing function.

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

The thickness of the polarizing film 12 is not particularly limited and is, for example, preferably 5 μm or more and 60 μm or less, and more preferably 10 μm or more and 40 μm or less.

The adhesive (or pressure-sensitive adhesive) forming the adhesive layers 11 and 13 is not particularly limited, and examples thereof include acrylic adhesives, urethane adhesives, epoxy adhesives, and silicone adhesives. Can be mentioned.

Of these, urethane adhesives are preferable. As a result, the transparency, adhesive strength, and durability of the adhesive layer 13 can be made more excellent, and the followability to shape changes can be made particularly excellent.

The polarizing film protective sheet 14 is a layer that protects the polarizing film 12, and is made of, for example, a hard resin such as polycarbonate.

According to this embodiment as well, the same effect as that of the first embodiment can be obtained, and further, a polarization function is provided.

Although the preferred embodiments of the present invention have been described above, the present invention is not limited to the above-described ones, and modifications, improvements, etc. within the scope of achieving the object of the present invention are included in the present invention. Is.

For example, each part constituting the optical layer of the present invention can be replaced with one having any structure capable of exhibiting the same function.

Further, in each of the above-described embodiments, the so-called sheet insert method has been described in which the functional layer is disposed in the mold and then the second resin material to be the lens layer is supplied into the mold and injection molding is performed. The present invention is not limited to this, and for example, the functional layer and the lens layer may be separately molded, and these may be melt-bonded.

Further, the optical layer of the present invention may have any constituent added thereto in addition to the above-mentioned constitution.

More specifically, for example, the optical layer of the present invention may include a protective layer for protecting the surface, an intermediate layer, a power adjusting layer for adjusting the power of the lens, and the like.

Hereinafter, the present invention will be described more specifically based on Examples.
1. Examination of Optical Layer 1-1. Preparation of Optical Layer [Example 1]
[1] First, 100 parts by mass of a bisphenol A type polycarbonate (“Upilon E2000F E5111” manufactured by Mitsubishi Gas Chemical Co., Inc.) and optical particles (“Metashine MC1020RSJA1” manufactured by Nippon Sheet Glass Co., Ltd.) are mixed to form a functional layer. Prepared the ingredients.

[2] Next, the functional layer forming material was stored in the extruder 210 of the functional layer manufacturing apparatus 100 shown in FIG. 3, melted, and extruded from the T die 220 to obtain a functional layer. Then, the functional layer was cooled and molded by the sheet molding unit 300, and cut into a rectangular shape having an average thickness of 0.7 mm and a plan view of 500 mm×500 mm to form a functional layer.

[3] Next, using an electrodeless lamp ("RE-1100-G" manufactured by Fusion UV Systems Japan, Inc.), one side of the functional layer is irradiated with ultraviolet rays to reduce the viscosity average molecular weight. The first layer was formed in the vicinity of the surface of one surface of the functional layer. In the functional layer, the portion other than the first layer is the second layer.

Moreover, the peak illuminance of the ultraviolet rays irradiated in this step was 30.0 mW/cm ² . Moreover, the integrated light amount of the ultraviolet rays irradiated in this step was 150.0 mJ/cm ² . In addition, the time of irradiation with ultraviolet rays in this step was 1.0 second.

The viscosity average molecular weight Mv1 of the first layer was 25000, the viscosity average molecular weight Mv2 of the second layer was 26500, and Mv1<Mv2.

[4] Next, the functional layer was arranged on the bottom surface 641 of the lower member 640 of the optical layer manufacturing apparatus 400 shown in FIG. At this time, the entire one surface of the functional layer was in close contact with the bottom surface 641.

[5] Next, a bisphenol A type polycarbonate (“S3000” manufactured by Mitsubishi Gas Chemical Co., Inc.) is stored and melted as a second resin material in the resin supply unit 500, and the second resin material in a molten state is supplied. It was supplied into the cavity 610 through the port 620, and then the inside of the cavity 610 was cooled to obtain an optical layer.

The viscosity average molecular weight Mv3 of the polycarbonate of the lens layer was 21,000, and the melt flow rate was 5.3 g/10 min.

[Examples 2 to 7]
Optical layers of Examples 2 to 7 were obtained in the same manner as in Example 1 except that the constitution of the optical layer was changed as shown in Table 1.

[Comparative Example 1]
An optical layer of Comparative Example 1 was obtained in the same manner as in Example 1 except that the irradiation of the functional layer with ultraviolet rays was omitted.

In Table 1, A1 indicates "Upilon E2000F E5111" manufactured by Mitsubishi Gas Chemical Company, A2 indicates "S3000" manufactured by Mitsubishi Gas Chemical Company, A3 indicates "H4000" manufactured by Mitsubishi Gas Chemical Company, B1 indicates “Metashine MC1020RSJA1” manufactured by Nippon Sheet Glass Co., Ltd.

1-2. Evaluation The optical layers of Examples and Comparative Examples were evaluated by the following methods.

(Adhesion test)
The edge of the optical layer was held with pliers to break the lens, and it was observed in the cross section whether the functional layer and the lens layer were separated. And it evaluated as follows.

A: No peeling B: Fine peeling C: Partial peeling D: Whole peeling

The evaluation results of the optical layers of Examples and Comparative Examples obtained as described above are shown in Table 1 below.

As shown in Table 1, the optical layer in each example exhibited excellent adhesion as compared with the comparative example, which was a satisfactory result for the comparative example.

10 Optical component 10' Optical component 1 Lens with functional layer 1A Lens with functional layer 2 Frame 21 Rim portion 22 Bridge portion 23 Temple portion 24 Nose pad portion 3 Functional layer 3'Functional layer 31 First layer 32 Second layer 4 Lens layer 5 Mounting part 6 Collar 7 Melting part 11 Adhesive layer 12 Polarizing film 13 Adhesive layer 14 Polarizing film protective sheet 100 Functional layer manufacturing device 200 Sheet supply part 210 Extruder 220 T die 300 Sheet forming part 310 Touch roll 320 Cooling Roll 330 Post-cooling roll 400 Optical layer manufacturing apparatus 500 Resin supply unit 600 Mold 610 Cavity 620 Supply port 630 Upper member 640 Lower member 641 Bottom surface

Claims (7)

A manufacturing method for manufacturing an optical layer used for a spectacle lens, which has a curved shape,
The first resin material on the one surface side of the functional layer is irradiated with ultraviolet rays from one surface side of the functional layer that includes the first resin material and optically acts on incident light. An ultraviolet irradiation step to reduce the viscosity average molecular weight,
A functional layer disposing step of disposing the functional layer on the curved concave surface from the other surface of the functional layer,
A bonding step of melting and bonding the second resin material, which will be the lens layer, on the surface of the functional layer that is curved following the curved concave surface and that is opposite to the curved concave surface. A method for producing an optical layer. The peak irradiance of ultraviolet rays irradiated by the ultraviolet irradiation process, method for producing an optical layer according to claim 1 is 10 mW / cm ² or more 1000 mW / cm ² or less. The method for producing an optical layer according to claim 1 or 2, wherein an integrated light amount of ultraviolet rays irradiated in the ultraviolet ray irradiation step is 50 mJ/cm ² or more and 1000 mJ/cm ² or less. The melting point of the said 1st resin material is 240 degreeC or more and 260 degrees C or less, The manufacturing method of the optical layer of any one of Claim 1 thru|or 3. The method for producing an optical layer according to claim 1, wherein a temperature of the second resin material in a molten state in the joining step is 270° C. or higher and 320° C. or lower. The entire shape is a curved shape, which is an optical layer used for spectacle lenses,
A functional layer containing a first resin material and optically acting on incident light;
A lens layer provided on the curved concave surface side of the functional layer and containing a second resin material,
The functional layer has a first layer on the lens layer side and a second layer on the side opposite to the lens layer,
An optical layer, wherein the relationship of Mv1<Mv2 is satisfied, where Mv1 is the viscosity average molecular weight of the first layer and Mv2 is the viscosity average molecular weight of the second layer. The optical layer according to claim 6, wherein a relationship of Mv3≦Mv1<Mv2 is satisfied, where Mv3 is a viscosity average molecular weight of the second resin material.

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