A method for manufacturing a polarizing lens

Abstract

This invention provides a method for manufacturing a polarizing lens. The method includes: preparing a substrate by forming a plurality of parallel grooves on the working surface of the substrate; and preparing a photochromic polarizing layer by applying a photochromic polarizing coating to the working surface to fill the grooves, and then curing the photochromic polarizing coating to form the photochromic polarizing layer. This manufacturing method enables the lens to simultaneously possess photochromic and polarizing functions. By constraining the alignment direction of dichroic dye molecules through the grooves, it achieves uniaxial orientation, avoiding the stretching operation of the photochromic polarizing layer during the manufacturing process to adjust the extension direction of the dichroic dye molecules. It also eliminates the need to prepare the dichroic dye as a thin film and then bond it to the substrate through lamination, embedding, or other methods, simplifying the manufacturing process, improving production efficiency and yield, and making it suitable for various types of lenses, thus expanding the application scenarios of the lenses.

Description

Technical Field

[0001] This invention relates to the field of lens technology, and more specifically to a method for manufacturing polarized lenses. Background Technology

[0002] In recent years, polarized lenses have become increasingly popular.

[0003] Polarized lenses can filter out horizontally vibrating light while absorbing very little light vibrating in other directions. They can effectively filter the light reflected from the sun on water, land, or snow, and can more effectively protect the eyes when used in activities such as water sports, skiing, driving, or fishing. Summary of the Invention

[0004] In view of this, embodiments of this application aim to provide a method for manufacturing a polarizing lens with photochromic function.

[0005] To achieve the above objectives, the technical solution of this application embodiment is implemented as follows:

[0006] This invention provides a method for manufacturing a polarizing lens, the method comprising:

[0007] Substrate preparation: Several parallel grooves are formed on the working surface of the substrate;

[0008] Preparation of the color-changing polarizing layer: Apply the color-changing polarizing coating liquid to the working surface to fill the groove, and cure the color-changing polarizing coating liquid to form the color-changing polarizing layer.

[0009] In some embodiments, the spacing between adjacent grooves is equal; and / or, the spacing between adjacent grooves ranges from 0.5 μm to 20 μm.

[0010] In some embodiments, the step of preparing the substrate specifically includes:

[0011] Determine the preset position on the working surface where the groove needs to be set;

[0012] Once the brush reaches the preset position, control the brush to contact the working surface, and control the brush to move according to the preset path to form several parallel grooves.

[0013] In some embodiments, controlling the movement of the brush according to a preset path specifically includes:

[0014] The brush is controlled to move unidirectionally along the preset path, and the area where the brush contacts the working surface is separated from the area where the brush has finished brushing.

[0015] In some embodiments, applying the color-changing polarizing coating to the working surface specifically includes:

[0016] Rotate the substrate to apply the color-changing polarizing coating to the center of rotation of the working surface.

[0017] In some embodiments, the thickness of the color-changing polarizing layer ranges from 10 μm to 100 μm.

[0018] In some embodiments, the color-changing polarizing coating liquid comprises: 30wt% to 45wt% polyvinyl alcohol, 25wt% to 35wt% acrylate compound, 0.1wt% to 0.2wt% polarizing dye, 2wt% to 5wt% photochromic agent, 23wt% to 35wt% polymeric polyol, 4wt% to 10wt% photoinitiator, and 6wt% to 15wt% thermosetting agent.

[0019] In some embodiments, after the step of preparing the color-changing polarizing layer, the method further includes:

[0020] Preparation of antireflective and anti-reflective layer: The antireflective and anti-reflective material is deposited on the surface of the lens away from the substrate by vacuum ion sputtering.

[0021] In some embodiments, the antireflective and anti-reflective material includes indium tin oxide, silicon dioxide, aluminum oxide, and zirconium dioxide.

[0022] In some embodiments, after the step of preparing the color-changing polarizing layer, the method further includes:

[0023] Preparation of the hardening layer: The lens is immersed in the hardening agent solution. After a preset time, the lens is removed and the hardening agent solution remaining on the lens surface is cured to form a hardening layer.

[0024] The manufacturing method in this invention enables the lens to simultaneously possess photochromic and polarizing functions. Through the interaction between the photochromic agent and the dichroic dye, under light irradiation, as the lens's photochromic degree deepens and its polarizing effect becomes more pronounced, the light transmittance under strong light is effectively reduced, making the lens more widely applicable. The groove constrains the alignment direction of the dichroic dye molecules, thereby achieving their uniaxial orientation and forming a grating. This avoids the stretching operation of the photochromic polarizing layer during the preparation process to adjust the extension direction of the dichroic dye molecules, enhancing its polarizing effect. It eliminates the need to prepare the dichroic dye as a thin film and then combine it with the substrate through bonding, embedding, or other methods, simplifying the manufacturing process, improving production efficiency and yield, and making it suitable for various types of lenses, thus expanding the application scenarios of the lenses. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the manufacturing steps of a polarizing lens in one embodiment of the present invention;

[0026] Figure 2 This is a schematic diagram of a substrate in one embodiment of the present invention;

[0027] Figure 3 This is a cross-sectional view of a lens in one embodiment of the present invention;

[0028] Figure 4 This is a cross-sectional view of the lens in another embodiment of the present invention;

[0029] Figure 5 This is a cross-sectional schematic diagram of the lens in another embodiment of the present invention.

[0030] Explanation of reference numerals in the attached figures

[0031] Substrate 10; Groove 10a; Working surface 10b; Photochromic polarizing layer 20; Anti-reflective and anti-reflective layer 30; Hardening layer 40 Detailed Implementation

[0032] It should be noted that, unless otherwise specified, the embodiments and technical features in the embodiments of this application can be combined with each other, and the detailed descriptions in the specific implementation should be understood as explanations of the purpose of this application and should not be regarded as undue limitations on this application.

[0033] In the description of this application, the terms "outer" and "inner" or their orientation or positional relationship are based on the appendix. Figure 3 The orientations or positional relationships shown are intended only for the convenience of describing this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0034] This invention provides a method for manufacturing a polarizing lens, see reference. Figure 1 The manufacturing method includes:

[0035] S1: Preparing the substrate 10: Forming several parallel grooves 10a on the working surface 10b of the substrate 10.

[0036] The substrate 10 is a lens, and its specific material is not limited, such as plastic lenses, glass lenses, etc. The material used for the substrate 10 must have light transmittance that meets the preset usage scenario.

[0037] In some embodiments, the substrate 10 is a resin lens, which has a low density and is not easily broken due to drops, collisions, etc. The resin lens is obtained by injecting the resin into a molding mold, allowing it to cure, and then demolding it.

[0038] Understandably, the substrate 10 can be either a colorless lens or a colored lens, and the choice can be made flexibly according to the intended use scenario of the lens.

[0039] Understandably, the specific type of surface of the substrate 10 is not limited, such as planar, convex, and concave surfaces.

[0040] S2: Preparation of color-changing polarizing layer 20: Apply color-changing polarizing coating liquid to the working surface 10b and fill the groove 10a, and cure the color-changing polarizing coating liquid to form color-changing polarizing layer 20.

[0041] It is understandable that color-changing polarizing coatings include dichroic dyes.

[0042] See Figure 2 and Figure 3 After the photochromic polarizing coating enters the groove 10a, it flows along the extension direction of the groove 10a, causing the dichroic dye molecules in the coating to extend along the extension direction of the groove 10a. After curing, the dichroic dye molecules in each groove 10a are oriented along the extension direction of the groove 10a, collectively forming a grating extending along the extension direction of the groove 10a. This filters light beams in a specific optical axis direction from the light passing through the lens, achieving the effect of polarization and reducing the light transmittance of the lens.

[0043] It is understandable that photochromic polarizing coatings include photochromic agents, which can cause a reversible change in color under light, thereby further reducing the light transmittance of the lens.

[0044] The manufacturing method in this embodiment enables the lens to simultaneously possess photochromic and polarizing functions. Through the interaction between the photochromic agent and the dichroic dye, under light irradiation, as the degree of photochromic change of the lens deepens and its polarization effect becomes more significant, the light transmittance under strong light is effectively reduced, making the lens more widely applicable. The groove 10a constrains the alignment direction of the dichroic dye molecules, thereby achieving their uniaxial orientation and forming a grating. This avoids the stretching operation of the photochromic polarizing layer 20 during the preparation process to adjust the extension direction of the dichroic dye molecules, enhancing its polarization effect. It eliminates the need to prepare the dichroic dye as a thin film and then combine it with the substrate 10 through bonding, embedding, or other methods, simplifying the preparation process, improving production efficiency and yield, and making it suitable for various types of lenses, thus expanding the application scenarios of the lenses.

[0045] The lens obtained by the manufacturing method in this embodiment of the invention has a light transmittance of over 95%, which meets the standards for everyday glasses. After the color change reaches its deepest level, the light transmittance can reach 15%, the polarization rate is ≥95%, and the color change response value is ≥1.25.

[0046] It is understandable that the extension direction of the groove 10a is determined according to the optical axis direction of the beam that needs to be filtered in the preset usage scenario.

[0047] In some embodiments, adjacent grooves 10a are spaced apart to reduce the impact on adjacent already prepared grooves 10a during the formation of grooves 10a, improve the manufacturing accuracy of grooves 10a, and reduce the mutual interference between dichroic dyes in adjacent grooves.

[0048] In some embodiments, the spacing between adjacent grooves 10a is equal, so that the slits of the grating formed by the color-changing polarizing layer 20 can filter light beams of the same wavelength, thereby achieving a better filtering effect on light beams of a specific wavelength.

[0049] In some embodiments, see Figure 2 The spacing between adjacent grooves 10a ranges from 0.5 μm (micrometer) to 20 μm, i.e., 0.5 μm ≤ L ≤ 20 μm. The specific value of L is not limited, for example, 0.5 μm, 1 μm, 5 μm, 10 μm, 20 μm, thereby achieving a filtering effect on a specific wavelength of light.

[0050] It is understandable that the width and depth of groove 10a must meet the requirements of uniaxial orientation of dichroic dye molecules.

[0051] Understandably, due to the small size of the groove 10a, it is necessary to be able to make fine adjustments to the amount of material removed from the substrate 10 during the formation of the groove 10a.

[0052] In some embodiments, the step of preparing the substrate 10 specifically includes:

[0053] Determine the preset position where the groove 10a needs to be set on the working surface 10b;

[0054] Once the brush reaches the preset position, control the brush to contact the working surface 10b, and control the brush to move according to the preset path to form several parallel grooves 10a.

[0055] The preset position is set according to the wavelength of the beam that needs to be filtered for the preset usage environment.

[0056] As the brush moves along the preset path, it generates friction with the working surface 10b, thereby removing material from the working surface 10b of the substrate 10 at the preset path position, thus forming a groove 10a in the area where the brush has finished brushing. Removing material from the substrate 10 by brushing reduces the force on the substrate 10, lowering the chance of breakage during the brushing process. Simultaneously, by adjusting the contact force between the brush and the substrate 10, the material removal rate can be slightly adjusted, facilitating the achievement of a preset groove 10a size. Furthermore, the brushing process also provides a polishing effect, reducing the likelihood of scratches on the working surface 10b.

[0057] The specific form of the brush is not limited, such as a soft-bristled brush or a cloth.

[0058] In some embodiments, the brush rotates while in contact with the working surface 10b to make the material removal on the preset path more uniform and reduce the probability of uneven material removal due to wear of the brush itself.

[0059] In some embodiments, controlling the movement of the brush according to a preset path specifically includes:

[0060] The brush is controlled to move unidirectionally along a preset path, and the area in contact with the working surface 10b is separated from the area that has been brushed by the brush, thereby avoiding the brush from brushing the same area multiple times and causing the groove 10a in that area to not meet the design requirements.

[0061] In some embodiments, after the brush completes its movement along a preset path, the size of the groove 10a is checked. If the size of the groove 10a is qualified, the step of preparing the color-changing polarizing layer 20 is performed. If the size of the groove 10a is not qualified, the area with unqualified size is brushed again until the size of the groove 10a is qualified.

[0062] Understandably, after completing the step of preparing the substrate 10, the substrate 10 is cleaned and dried in order to reduce the impact of impurities remaining on the working surface 10b on the bonding between the photochromic polarizing layer 20 and the working surface 10b in subsequent steps, as well as the light transmission effect of the lens.

[0063] In some embodiments, applying the color-changing polarizing coating to the work surface 10b specifically includes:

[0064] Rotate the substrate 10 and apply the color-changing polarizing coating to the center of rotation of the working surface 10b.

[0065] The photochromic polarizing coating is applied to the rotation center of the substrate 10 using a glue gun. Under the action of centrifugal force, the photochromic polarizing coating spreads outward in all radial directions to form a liquid film of photochromic polarizing coating on the working surface 10b. Excess photochromic polarizing coating is thrown off from the edge of the lens under the action of centrifugal force, thereby making the film thickness of photochromic polarizing coating uniform.

[0066] Understandably, by controlling the rotation speed of the substrate 10, the film thickness of the color-changing polarizing coating can be adjusted to meet the design requirements.

[0067] The specific method of curing the color-changing polarizing coating to form the color-changing polarizing layer 20 is not limited, such as drying it in a heating oven.

[0068] In some embodiments, the thickness of the color-changing polarizing layer 20 ranges from 10 μm to 100 μm to achieve better color-changing and polarizing effects.

[0069] The specific thickness of the color-changing polarizing layer 20 is not limited, for example, 10μm, 20μm, 50μm, 80μm, 100μm, etc.

[0070] In some embodiments, the color-changing polarizing coating liquid includes polyvinyl alcohol, acrylate compounds, polarizing dyes, photochromic agents, polymeric polyols, photoinitiators, and thermosetting agents, which are mixed and stirred to form the color-changing polarizing coating liquid. The polarizing dye is a dichroic dye, which has the property of enhancing the absorption of a specific light beam in a specific direction and reducing the absorption of the same light beam in a direction orthogonal to it. The polarizing dye molecules are contained in a film formed of polyvinyl alcohol, and the film extends along a specific direction due to the constraint of the grooves 10a, thereby achieving uniaxial orientation.

[0071] It should be noted that the specific components and corresponding ratios of polarizing dyes, photochromic agents, photoinitiators, and thermosetting agents have been widely used in related technologies and will not be elaborated here.

[0072] In some embodiments, the color-changing polarizing coating liquid includes: 30wt% to 45wt% polyvinyl alcohol, 25wt% to 35wt% acrylate compound, 0.1wt% to 0.2wt% polarizing dye, 2wt% to 5wt% photochromic agent, 23wt% to 35wt% polymer polyol, 4wt% to 10wt% photoinitiator, and 6wt% to 15wt% thermosetting agent, to achieve better color-changing and polarizing effects.

[0073] It is understood that the sum of the above components is 100 wt%.

[0074] The specific value of polyvinyl alcohol is not limited, for example, 30wt%, 35wt%, 40wt%, 45wt%, etc.

[0075] The specific values ​​of the acrylate compounds are not limited, for example, 25wt%, 30wt%, 35wt%, etc.

[0076] The specific value of the polarizing dye is not limited, for example, 0.1wt%, 0.15wt%, 0.2wt%, etc.

[0077] The specific value of the photochromic agent is not limited, for example, 2wt%, 3wt%, 4wt%, 5wt%, etc.

[0078] The specific value of the polymer polyol is not limited, for example, 23wt%, 27wt%, 31wt%, 35wt%, etc.

[0079] The specific value of the photoinitiator is not limited, for example, 4wt%, 6wt%, 8wt%, 10wt%, etc.

[0080] The specific value of the thermosetting agent is not limited, for example, 6wt%, 9wt%, 12wt%, 15wt%, etc.

[0081] Understandably, other light beams that are harmful to the glasses are placed on the outside of the photochromic polarizing layer 20.

[0082] In some embodiments, after the step of preparing the color-changing polarizing layer 20, the method further includes:

[0083] Preparation of antireflective and anti-reflective layer 30: Antireflective and anti-reflective material is deposited on the surface of the lens away from the substrate 10. That is, see [reference needed]. Figure 4 An antireflective and anti-reflective material is deposited on the surface of the photochromic polarizing layer 20 facing away from the substrate 10 to form the antireflective and anti-reflective layer 30. This reduces reflected and stray light passing through the lens, increases light transmittance, effectively filters out harmful blue and green light, reduces radiation, improves eye protection, and extends the lifespan of the photochromic polarizing layer 20.

[0084] The specific method of coating with anti-reflective and anti-reflective materials is not limited.

[0085] For example, antireflective and anti-reflective materials can be deposited on the surface of the lens away from the substrate 10 by vacuum ion sputtering to increase the coating speed, make the film layer denser, and improve the adhesion performance of the antireflective and anti-reflective materials.

[0086] In some embodiments, the antireflective and anti-reflective materials include indium tin oxide, silicon dioxide, aluminum oxide, and zirconium dioxide.

[0087] The anti-reflective and anti-reflective coating 30 comprises multiple sublayers, each made of only one material.

[0088] For example, the anti-reflection and anti-reflection layer 30 includes a stacked indium tin oxide sublayer, a silicon dioxide sublayer, an aluminum oxide sublayer, and a zirconium dioxide sublayer to achieve a better anti-reflection and anti-reflection effect.

[0089] It is understandable that the thickness of each of the above sub-layers is not limited; and the thickness of each sub-layer can be the same or different depending on the design requirements.

[0090] It is understandable that the stacking order of the above sub-layers from the inside out is not limited and can be selected according to design requirements.

[0091] Understandably, the color-changing polarizing layer 20 needs to be protected.

[0092] In some embodiments, after the step of preparing the color-changing polarizing layer 20, the method further includes:

[0093] Preparation of hardening layer 40: The lens is immersed in the hardening agent solution for a preset time. After this time, the lens is removed and the hardening agent solution remaining on the lens surface is cured to form hardening layer 40. (See also...) Figure 5 By forming a hardened layer 40, the color-changing polarizing layer 20 is protected.

[0094] The specific type of hardener solution is not limited, such as silicone resin solution, etc.

[0095] There are no restrictions on the method of curing the hardener solution, such as baking and curing in an oven.

[0096] Understandably, the lens is ultrasonically cleaned before the hardened layer 40 is prepared to remove any residual photochromic polarizing coating on the lens surface.

[0097] Understandably, the lens can be prepared with the hardening layer 40 multiple times to continuously increase the hardness to meet the requirements.

[0098] In some embodiments, after preparing the color-changing polarizing layer 20, a hardening layer 40 is prepared, followed by the preparation of the anti-reflection and anti-reflection layer 30. See also... Figure 5 The lens has a photochromic polarizing layer 20, a hardening layer 40 and an anti-reflective and anti-reflective layer 30, with the hardening layer 40 located between the photochromic polarizing layer 20 and the anti-reflective and anti-reflective layer 30.

[0099] In some embodiments, see Figure 3 One side of the substrate 10 is convex and the other side is concave, wherein the convex side is the working surface 10b.

[0100] The lens can be used to make eyeglass lenses, with a convex outer surface and a concave inner surface, so that the photochromic polarizing layer 20 is located on the side away from the human eye.

[0101] In some embodiments, see Figure 3 The convex and concave surfaces of the substrate 10 have different curvatures to achieve high refractive power molding and to manufacture myopic or hyperopic lenses, and to reduce the wall thickness around the resin substrate 10 and reduce the wearing weight.

[0102] In some embodiments, the curvature of the convex surface is greater than that of the concave surface, thereby achieving high refractive power shaping.

[0103] Understandably, after all the preparation steps are completed, the lenses are cleaned, dried, and then packaged and stored.

[0104] The various embodiments / implementations provided in this application can be combined with each other without creating contradictions.

[0105] The above description is merely a preferred embodiment of this application and is not intended to limit the application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method for manufacturing a polarizing lens, characterized in that, The manufacturing method includes: Substrate preparation: Several parallel grooves are formed on the working surface of the substrate, with adjacent grooves spaced apart, and the distance between adjacent grooves ranging from 0.5 μm to 20 μm; Preparation of the color-changing polarizing layer: Apply the color-changing polarizing coating liquid to the working surface to fill the groove, and cure the color-changing polarizing coating liquid to form the color-changing polarizing layer.

2. The manufacturing method according to claim 1, characterized in that, The spacing between adjacent grooves is equal.

3. The manufacturing method according to claim 1, characterized in that, The specific steps for preparing the substrate include: Determine the preset position on the working surface where the groove needs to be set; Once the brush reaches the preset position, control the brush to contact the working surface, and control the brush to move according to the preset path to form several parallel grooves.

4. The manufacturing method according to claim 3, characterized in that, The aforementioned control of the brush movement according to a preset path specifically includes: The brush is controlled to move unidirectionally along the preset path, and the area where the brush contacts the working surface is separated from the area where the brush has finished brushing.

5. The manufacturing method according to claim 1, characterized in that, The application of the color-changing polarizing coating to the work surface specifically includes: Rotate the substrate to apply the color-changing polarizing coating to the center of rotation of the working surface.

6. The manufacturing method according to claim 1, characterized in that, The thickness of the color-changing polarizing layer ranges from 10 μm to 100 μm.

7. The manufacturing method according to claim 1, characterized in that, The color-changing polarizing coating comprises: 30wt% to 45wt% polyvinyl alcohol, 25wt% to 35wt% acrylate compound, 0.1wt% to 0.2wt% polarizing dye, 2wt% to 5wt% photochromic agent, 23wt% to 35wt% polymer polyol, 4wt% to 10wt% photoinitiator, and 6wt% to 15wt% thermosetting agent.

8. The manufacturing method according to claim 1, characterized in that, Following the step of preparing the color-changing polarizing layer, the method further includes: Preparation of antireflective and anti-reflective layer: The antireflective and anti-reflective material is deposited on the surface of the lens away from the substrate by vacuum ion sputtering.

9. The manufacturing method according to claim 8, characterized in that, The anti-reflective and anti-reflective materials include indium tin oxide, silicon dioxide, aluminum oxide, and zirconium dioxide.

10. The manufacturing method according to claim 1, characterized in that, Following the step of preparing the color-changing polarizing layer, the method further includes: Preparation of the hardening layer: The lens is immersed in the hardening agent solution. After a preset time, the lens is removed and the hardening agent solution remaining on the lens surface is cured to form a hardening layer.

Images