Method of manufacturing an ophthalmic lens

Abstract

Provided is a method for manufacturing an eyeglass lens having a hydrophobic layer, the method including forming the hydrophobic layer by a thermal evaporation method, the forming by the thermal evaporation method including heating a plurality of evaporation sources with different temperature profiles, at least one of the plurality of evaporation sources containing a hydrophobic component, and at least one of the plurality of evaporation sources containing a metallic component.

Description

Technical Field

[0001] This invention relates to a method for manufacturing spectacle lenses. Background Technology

[0002] Eyeglass lenses typically have a structure in which one or more functional layers are formed on the surface of the lens substrate (see, for example, Patent Document 1).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent document 1: Japanese Patent Application Publication No. 2003-14904. Summary of the Invention

[0006] The problem the invention aims to solve

[0007] In the embodiment of Patent Document 1, an optical component capable of being used as an eyeglass lens is manufactured by providing a hydrophobic layer (a hydrophobic film in Patent Document 1) as a functional layer on a plastic lens. By providing a hydrophobic layer on the eyeglass lens, the eyeglass lens can be endowed with hydrophobicity. From the viewpoint of inhibiting the adhesion of dirt (such as sweat, fingerprints, etc.) to the surface of the eyeglass lens and easily removing the adhered dirt, it is preferable that the eyeglass lens is hydrophobic.

[0008] Imbuing eyeglass lenses with various properties helps to increase their added value. In this regard, the inventors have investigated how to impart properties to eyeglass lenses by incorporating metallic components into the hydrophobic layer.

[0009] In addition, eyeglass lenses are routinely wiped by eyeglass users to remove surface dirt. It is also desirable that even with frequent wiping, eyeglass lenses will experience minimal performance degradation (i.e., excellent durability).

[0010] One aspect of the present invention is to provide an eyeglass lens that exhibits hydrophobicity and the properties of the metallic components contained in the hydrophobic layer, and that these properties are also highly durable.

[0011] Solution for solving the problem

[0012] One aspect of the present invention relates to a method for manufacturing an eyeglass lens (hereinafter, also simply referred to as the "manufacturing method").

[0013] The aforementioned eyeglass lenses have a hydrophobic layer.

[0014] The above manufacturing method includes forming a film of the hydrophobic layer by heating and vapor deposition.

[0015] Film formation using the above-described heating vapor deposition method involves heating multiple vapor deposition sources with different temperature profiles.

[0016] Among the above-mentioned multiple vapor deposition sources, at least one vapor deposition source contains a hydrophobic component, and at least one vapor deposition source contains a metallic component.

[0017] In the above manufacturing method, multiple vapor deposition sources are used, and a film is formed by heating these multiple vapor deposition sources with different temperature profiles.

[0018] Typically, metallic and hydrophobic components vaporize at different temperatures. It is believed that in vapor deposition using a single temperature profile, the hydrophobic component, which vaporizes at a lower temperature, vaporizes first during heating, followed by the metallic component, which vaporizes at a higher temperature. When a hydrophobic layer is formed by vapor deposition of both metallic and hydrophobic components in this manner, a deviation occurs in the distribution of the two components within the hydrophobic layer. It is believed that the presence of hydrophobic components that are unevenly distributed within the hydrophobic layer reduces the hydrophobicity of the eyeglass lens. Furthermore, the performance resulting from the uneven distribution of metallic components in the surface layer is expected to have lower durability.

[0019] In contrast, in the aforementioned manufacturing method, during film formation using a heated vapor deposition method, multiple vapor deposition sources are heated with different temperature profiles. Therefore, it is believed that the deviation in the distribution of metallic and hydrophobic components within the hydrophobic layer can be reduced. Consequently, the inventors hypothesize that it is possible to provide an eyeglass lens that exhibits both hydrophobicity and properties exerted by the metallic component, and that these properties are also highly durable. However, the present invention is not limited to the hypotheses described in this specification.

[0020] Invention Effects

[0021] According to one aspect of the invention, it is possible to manufacture an eyeglass lens that exhibits hydrophobicity and the properties of the metallic components contained in the hydrophobic layer, and these properties are also highly durable. Attached Figure Description

[0022] Figure 1 This is a schematic diagram illustrating an example of a method for forming a hydrophobic layer using a heated vapor deposition method.

[0023] Figure 2 yes Figure 1 Example 1 shows the specific temperature curves of heaters 3A and 3B.

[0024] Figure 3 yes Figure 1 Example 2 shows the specific temperature curves of heaters 3A and 3B.

[0025] Figure 4 yes Figure 1 Example 3 shows the specific temperature curves of heaters 3A and 3B.

[0026] Figure 5 This is a schematic cross-sectional view showing an example of the layered structure of an eyeglass lens. Detailed Implementation

[0027] The manufacturing method described above will be explained in further detail below.

[0028] <Hydrophobic layer>

[0029] The aforementioned spectacle lens has a hydrophobic layer. In this invention and this specification, a "hydrophobic layer" refers to a layer that contributes to the hydrophobicity of the spectacle lens surface, or contributes to better hydrophobicity compared to the absence of such a layer.

[0030] <Metal component>

[0031] The aforementioned hydrophobic layer contains one or more metallic components. Eyeglass lenses manufactured using the above method exhibit the functionality provided by the metallic components contained in the hydrophobic layer, and also demonstrate excellent durability of this functionality.

[0032] In this invention and specification, "metallic component" refers to a component containing one or more metals. Examples of the forms in which the metal exists in a metallic component include the form of a metal monomer or alloy, an inorganic or organic compound, and metal ions. Furthermore, metal coordination compounds can also be cited as an example of a metallic component.

[0033] In recent years, with the increasing demand for antibacterial properties, the ability to inhibit bacterial growth (i.e., antibacterial properties) is a desirable property for eyeglass lenses. From the viewpoint that the hydrophobic layer also functions as an antibacterial layer contributing to the antibacterial properties of eyeglass lenses, silver-containing components are preferred metallic components. In the hydrophobic layer formed by vapor deposition of silver-containing components, silver can exist in various forms. This is also true for other metals. The inventors believe that at least a portion of silver can be ionized through oxidation, thereby exhibiting antibacterial properties, which helps the silver-containing hydrophobic layer function as an antibacterial layer. Furthermore, in one embodiment, the metallic component contained in the aforementioned hydrophobic layer can include one or more components containing metals selected from platinum (Pt), gold (Au), palladium (Pd), mercury (Hg), cadmium (Cd), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), titanium (Ti), zirconium (Zr), molybdenum (Mo), and lead (Pb). Using one or more metal components containing the aforementioned other metals together with the silver-containing component to form a hydrophobic layer can help suppress the decline in the function of silver through the other metals.

[0034] <Hydrophobic components>

[0035] The aforementioned hydrophobic layer contains one or more hydrophobic components. Eyeglass lenses manufactured by the above method exhibit the hydrophobicity provided by the hydrophobic components contained in the hydrophobic layer, and also exhibit excellent durability of the hydrophobicity.

[0036] In this invention and specification, "hydrophobic component" refers to a component that contributes to the hydrophobicity of the surface of a layer containing the component, or contributes to better hydrophobicity compared to a case without the component.

[0037] Fluorine-containing components can be cited as examples of hydrophobic components. Fluorine in these components can exist in inorganic or organic forms, preferably organic forms. Specifically, fluorine-containing organic compounds can be cited as a form of hydrophobic component.

[0038] Examples of fluorinated organic compounds include m-bis(trifluoromethyl)benzene (C6H4(CF3)2).

[0039] In addition, examples of fluorinated organosilanes represented by the following general formula (1) can also be cited as fluorinated organic compounds.

[0040] [Chemical Formula 1]

[0041]

[0042] In the above general formula (1), Rf is a straight-chain or branched perfluoroalkyl group with 1 to 16 carbon atoms, preferably CF3-, C2F5-, or C3F7-. R1 is a hydrolyzable group, preferably, for example, a halogen atom, -OR3, -OCOR3, -OC(R3)=C(R4)2, -ON=C(R3)2, or -ON=CR5. More preferably, a chlorine atom, -OCH3, or -OC2H5. Here, R3 is an aliphatic or aromatic hydrocarbon group, R4 is a hydrogen atom or an aliphatic hydrocarbon group (e.g., a lower aliphatic hydrocarbon group), and R5 is a divalent aliphatic hydrocarbon group with 3 to 6 carbon atoms. R2 is a hydrogen atom or a monovalent organic group. The monovalent organic group is preferably an inactive group. The monovalent organic group is more preferably a monovalent hydrocarbon group with 1 to 4 carbon atoms. X is an iodine atom or a hydrogen atom, and Y is a hydrogen atom or an alkyl group (e.g., a lower alkyl group). Z is a fluorine atom or a trifluoromethyl group. a, b, c, and d are each independently an integer in the range of 0 to 200, preferably an integer in the range of 1 to 50. e is 0 or 1. m and n are each independently an integer in the range of 0 to 2, preferably 0. p is an integer greater than or equal to 1, preferably an integer in the range of 1 to 10.

[0043] Furthermore, the molecular weight (weight-average molecular weight Mw) of the fluorinated organosilanes represented by general formula (1) is not particularly limited, and can be, for example, 5 × 10⁻⁶. 2 ~1×10 5 The range or 5×10 2 ~1×10 4 The range.

[0044] Furthermore, in one manner, the fluorinated organosilane compound represented by the above general formula (1) can be a fluorinated organosilane compound represented by the following general formula (2).

[0045] [Chemical Formula 2]

[0046]

[0047] In the above general formula (2), R1, Y, and m have the same meaning as in the above general formula (1). q is an integer in the range of 1 to 50, and r is an integer in the range of 1 to 10.

[0048] <Evaporation Source>

[0049] In the above manufacturing method, a heated vapor deposition method is used as the film-forming method to form a hydrophobic layer. The heated vapor deposition method involves heating the internal environment of a vapor deposition apparatus using a heating unit (heater, etc.) arranged within the apparatus, thereby heating and vaporizing the vapor deposition material. As described above, it is believed that when a hydrophobic layer is formed by heating and vaporizing metal and hydrophobic components with typically different vaporization temperatures using a single temperature profile, a deviation occurs in the distribution of the metal and hydrophobic components within the hydrophobic layer. In contrast, in the above manufacturing method, multiple vapor deposition sources are heated using separate temperature profiles. Therefore, the inventors hypothesize that the deviation in the distribution of metal and hydrophobic components within the hydrophobic layer formed by the heated vapor deposition method can be reduced. As a result, it is possible to manufacture an eyeglass lens that displays properties exerted by the hydrophobic component (i.e., hydrophobicity) and properties exerted by the metal component (e.g., antibacterial properties), and that these properties are highly durable.

[0050] As a vapor deposition source, a vapor deposition source that carries one or more metallic components and / or one or more hydrophobic components on a carrier can be used. Among the multiple vapor deposition sources used in the above manufacturing method, a vapor deposition source containing only one of the metallic component and the hydrophobic component may be included, a vapor deposition source containing both the metallic component and the hydrophobic component may be included, or a vapor deposition source that includes both the former and the latter may be included.

[0051] As a method for carrying vapor-deposited materials (metallic components and / or hydrophobic components) onto a carrier, the following methods can be cited as examples.

[0052] A solution containing the vapor deposition material is impregnated in a carrier. Methods for impregnating the solution in the carrier include, for example, injecting or spraying the solution into the carrier, or immersing the carrier in the solution. The carrier can be, for example, a porous material, and can be made of, for example, metal, alloy, or ceramic. A specific example of a porous material is a sintered filter. A sintered filter can be a sintered body formed by sintering powder materials such as metal powder, alloy powder, or ceramic powder. After impregnating the carrier with the solution, a drying process is performed using known methods, thereby allowing the vapor deposition material to be held on the carrier.

[0053] Regarding hydrophobic components, for example, it is possible to directly or after dilution impregnate a carrier with a hydrophobic component that is commercially available as a liquid hydrophobic agent.

[0054] Regarding the metal component, a solution containing particles of the metal component can be impregnated in a carrier. This solution can be, for example, an aqueous solution or an aqueous dispersion of the metal component particles. The concentration of the metal component in the solution can be, for example, in the range of 1000 to 10000 ppm. In this invention and specification, ppm is a mass standard. Here, when two or more metal components are supported on a single carrier, the above-mentioned concentration is set as the total concentration of the two or more metal components. For example, a commercially available product, either directly or after dilution, can be impregnated in the carrier as an aqueous dispersion of the metal component. The particle size of the metal component can be, for example, 1 nm or more and 10 nm or less, or 1 nm or more and 5 nm or less.

[0055] The volume of each solution impregnated in the carrier can be set to, for example, a range of 0.10 to 5.00 ml.

[0056] The total number of vapor deposition sources used in the above manufacturing method is two or more, and can be two, three, or four, or, for example, five or less. Among the multiple vapor deposition sources used in the above manufacturing method, there may be two or more vapor deposition sources containing the same type and amount of components, or there may be two or more vapor deposition sources containing at least one different type and amount of components.

[0057] <Heating of the vapor deposition source>

[0058] In the above manufacturing method, multiple vapor deposition sources are heated with different temperature profiles. As described above, this is believed to reduce the deviation between the metallic and hydrophobic components within the hydrophobic layer. Furthermore, when using three or more vapor deposition sources, the temperature profiles used to heat at least two vapor deposition sources can be different, or the same temperature profile can be used to heat two or more of the three or more vapor deposition sources.

[0059] In one approach, heating from multiple vapor deposition sources can be performed within a single chamber. For example, a vacuum vapor deposition apparatus can be used, in which multiple vapor deposition sources are configured within a vacuum chamber, allowing the vapor deposition material to be deposited onto the target surface.

[0060] Figure 1 This is a schematic diagram illustrating an example of a method for forming a hydrophobic layer using a heated vapor deposition method. Figure 1 In the image, 2A and 2B are vapor deposition sources, 3A and 3B are heaters, 11 is the lens substrate, and 14 is the hydrophobic layer for film formation.

[0061] The pressure inside the chamber during film formation can be determined based on the type of vapor deposition material, and can be, for example, 2 × 10⁻⁶. -2 Below Pa.

[0062] Heaters 3A and 3B can be, for example, halogen heaters. The temperature profiles of heater 3A (heating the vapor deposition source 2A) and heater 3B (heating the vapor deposition source 2B) can be set to different temperature profiles. These temperature profiles can be set in the control unit of the vacuum vapor deposition apparatus. In the multiple different temperature profiles, one or more heating parameters selected from the heating rate, heating start time, and heating end time can be different.

[0063] Specific examples of the temperature profiles for heaters 3A and 3B are shown in Figures 2-4 .

[0064] Figure 2 The specific example 1 shown illustrates an example where the heating rates of the two heaters differ. For instance, if the vapor deposition source 2A heated by heater 3A contains a hydrophobic component, and the vapor deposition source 2B heated by heater 3B contains a metallic component, and the hydrophobic component is a component that vaporizes more easily at a lower temperature than the metallic component, by setting a period during which the heating rate of heater 3A is slower than that of heater 3B, it is possible to make the vaporization periods of the metallic component and the hydrophobic component the same, or to reduce the difference between these periods. Furthermore, in one mode, the heating rate of each heater can be the same from the start to the end of heating, while in another mode, it can vary in two or more stages from the start to the end of heating.

[0065] Figure 3The specific example 2 shown is an example where the heating rates and heating end times differ in the temperature profiles of the two heaters. For example, if the vapor deposition source 2A heated by heater 3A contains a hydrophobic component, and the vapor deposition source 2B heated by heater 3B contains a metallic component, and the hydrophobic component is a component that is more easily vaporized at a lower temperature than the metallic component, by setting a period during which the heating rate of heater 3A is slower than that of heater 3B, and by making the heating of heater 3B end before the heating of heater A, it is possible to set the vaporization periods of the metallic component and the vaporization periods of the hydrophobic component to be of the same degree, or to reduce the difference between these periods.

[0066] Figure 4 The specific example 3 shown is an example where the heating start time and heating rate differ in the temperature profiles of the two heaters. For example, when both the vapor deposition source 2A heated by heater 3A and the vapor deposition source 2B heated by heater 3B contain metallic and hydrophobic components, according to specific example 3, the periods during which the hydrophobic component vaporizes from vapor deposition source 2A and from vapor deposition source 2B can be different, and the periods during which the metallic component vaporizes from vapor deposition source 2A and from vapor deposition source 2B can be different. Therefore, the deviation in the distribution of hydrophobic and metallic components within the formed hydrophobic layer can be reduced.

[0067] However, examples 1 to 3 are merely examples, and the present invention is not limited to these examples.

[0068] The maximum temperature reached in the temperature curve can be determined according to the type of vapor deposition material. It can be set to, for example, above 100°C and below 750°C, but is not limited to this range.

[0069] The thickness of the hydrophobic layer thus formed can be, for example, 30 nm or less, 25 nm or less, 20 nm or less, or 15 nm or less. The thickness of the aforementioned hydrophobic layer can be, for example, 5 nm or more or 10 nm or more. Furthermore, the contact angle with water at the surface of the hydrophobic layer can be, for example, 100° or more and 120° or less. The hydrophobic layer can, for example, be disposed as the outermost layer on one or both sides of an eyeglass lens.

[0070] <Example of layered structure in eyeglass lenses>

[0071] In the above manufacturing method, the hydrophobic layer can be directly or indirectly disposed on the surface of the lens substrate, with regard to other layers.

[0072] Figure 5 This is a schematic cross-sectional view showing an example of the layer structure of an eyeglass lens manufactured by the above-described manufacturing method. Figure 5The eyeglass lens 1 shown has a hard coating 12 on one surface 11a (e.g., the object-side surface) of the lens substrate 11, and thereon a multilayer film 13. The multilayer film 13 is an alternating layer of low refractive index layer 13L and high refractive index layer 13H. A hydrophobic layer 14 is provided on the surface of the multilayer film. The hydrophobic layer 14 can be referred to the preceding description.

[0073] (Lens substrate)

[0074] The lens substrate for eyeglass lenses can be either a plastic lens substrate or a glass lens substrate. Glass lens substrates can be, for example, made of inorganic glass. From the viewpoints of being lightweight, not easily broken, and easy to handle, plastic lens substrates are preferred as lens substrates. Examples of plastic lens substrates include styrene resins (represented by (meth)acrylic resin), polycarbonate resins, allyl resins, diethylene glycol dielyl carbonate resin (CR-39), vinyl resins, polyester resins, polyether resins, polyurethane resins obtained by reacting isocyanate compounds with hydroxyl compounds such as diethylene glycol, thiopolyurethane resins obtained by reacting isocyanate compounds with polythiol compounds, and cured products (commonly referred to as transparent resins) obtained by curing a curable composition containing a (thio)epoxide compound having one or more disulfide bonds within its molecule. Undyed lens substrates (colorless lenses) or dyed lens substrates (dyed lenses) can be used as lens substrates. The refractive index of the lens substrate can be, for example, around 1.60 to 1.75. However, the refractive index of the lens substrate is not limited to the above range; it can be within the above range or deviate from it. In this invention and this specification, refractive index refers to the refractive index relative to light with a wavelength of 500 nm. Furthermore, the lens substrate can be a lens with refractive power (so-called a prescription lens) or a lens without refractive power (so-called a non-prescription lens).

[0075] Eyeglass lenses can be various types, including single-focal lenses, multifocal lenses, and progressive lenses. The type of lens is determined by the surface shapes of both sides of the lens substrate. Furthermore, the surface of the lens substrate can be convex, concave, or flat. In typical lens substrates and eyeglass lenses, the object-side surface is convex, and the eye-side surface is concave. However, the present invention is not limited to this.

[0076] (Multilayer film)

[0077] Inorganic layers are one type of multilayer film. In this invention and specification, "inorganic layer" refers to a layer containing inorganic substances, preferably a layer containing inorganic substances as a main component. Here, "main component" refers to the component that constitutes the largest proportion of the layer, typically about 50% to 100% by mass, or further about 90% to 100% by mass, relative to the mass of the layer. The same applies to the main components described later. Inorganic layers can be layers directly laminated onto the surface of the lens substrate, or layers indirectly laminated onto the surface of the lens substrate with one or more other layers in between. Examples of the aforementioned other layers include known layers such as cured layers of curable compositions, commonly referred to as hard coatings, and underlayers provided to improve adhesion. The type and thickness of these layers are not particularly limited and can be determined according to the desired function and optical properties of the spectacle lens.

[0078] When the multilayer film is an inorganic layer, i.e., an inorganic multilayer film, a hydrophobic layer can be provided on the uppermost inorganic layer (i.e., the inorganic layer furthest from the lens substrate). Examples of such inorganic multilayer films include multilayer films comprising one or more high-refractive-index layers and one low-refractive-index layer. This multilayer film can be an antireflective film with the property of preventing the reflection of light of a specific wavelength or wavelength range, or a reflective film with the property of reflecting light of a specific wavelength or wavelength range. In this invention and specification, the terms "high" and "low" related to "high refractive index" and "low refractive index" are relative expressions. That is, a high-refractive-index layer refers to a layer with a higher refractive index than a low-refractive-index layer contained in the same multilayer film. In other words, a low-refractive-index layer refers to a layer with a lower refractive index than a high-refractive-index layer contained in the same multilayer film. The refractive index of the high-refractive-index material constituting the high-refractive-index layer can be, for example, 1.60 or higher (e.g., in the range of 1.60 to 2.40), and the refractive index of the low-refractive-index material constituting the low-refractive-index layer can be, for example, 1.59 or lower (e.g., in the range of 1.37 to 1.59). However, as mentioned above, the terms "high" and "low" related to high and low refractive indices are relative, and therefore the refractive indices of the high-refractive-index material and the low-refractive-index material are not limited to the above ranges.

[0079] Specifically, as a high-refractive-index material for forming a high-refractive-index layer, examples include mixtures of one or more oxides selected from zirconium oxide (e.g., ZrO2), tantalum oxide (e.g., Ta2O5), titanium oxide (e.g., TiO2), aluminum oxide (e.g., Al2O3), yttrium oxide (e.g., Y2O3), hafnium oxide (e.g., HfO2), and niobium oxide (e.g., Nb2O5). On the other hand, as a low-refractive-index material for forming a low-refractive-index layer, examples include mixtures of one or more oxides or fluorides selected from silicon oxide (e.g., SiO2), magnesium fluoride (e.g., MgF2), and barium fluoride (e.g., BaF2). In the examples above, for convenience, oxides and fluorides are represented by stoichiometric composition; however, substances in which oxygen or fluorine is deficient or excessive in their stoichiometric composition can also be used as high-refractive-index or low-refractive-index materials.

[0080] Preferably, the high-refractive-index layer is a film mainly composed of a high-refractive-index material, and the low-refractive-index layer is a film mainly composed of a low-refractive-index material. Such a film (e.g., a vapor-deposited film) can be formed by using a film-forming material (e.g., a vapor-deposited material) mainly composed of the aforementioned high-refractive-index or low-refractive-index material. Sometimes, impurities are unavoidably mixed into the film and the film-forming material. Furthermore, other components may be included, such as other inorganic substances or known additives that assist in film formation, without impairing the function of the main component. Film formation can be carried out by known film-forming methods; from the viewpoint of ease of film formation, vapor deposition is preferred, and vacuum vapor deposition is more preferred. The anti-reflective film can be, for example, a multilayer film with 3 to 10 alternating high-refractive-index and low-refractive-index layers. The thickness of the high-refractive-index layer and the thickness of the low-refractive-index layer can be determined according to the layer structure. In detail, the combination of layers and the thickness of each layer in a multilayer film can be determined by optical design simulation using known methods, based on the refractive index of the film-forming materials used to form the high-refractive-index and low-refractive-index layers, and the desired reflection and transmission characteristics that the multilayer film will bring to the spectacle lens. Furthermore, the multilayer film may include one or more layers primarily composed of conductive oxides (conductive oxide layers) at any location, preferably vapor-deposited films of conductive oxides formed by vapor deposition using a vapor deposition material primarily composed of conductive oxides. The thickness of each of the high-refractive-index and low-refractive-index layers in the multilayer film can be, for example, 3 to 500 nm, and the total thickness of the multilayer film can be, for example, 100 to 900 nm. The film thicknesses used in this invention and specification are physical film thicknesses.

[0081] In one embodiment, the spectacle lens manufactured by the above-described manufacturing method can have a hydrophobic layer on the surface of the inorganic layer. For example, the hydrophobic layer can be a layer directly laminated on the surface of the multilayer film, or it can be a layer indirectly laminated on the surface of the multilayer film with one or more other layers in between. Regarding the other layers, please refer to the preceding description.

[0082] The aforementioned hydrophobic layer can be formed on at least one surface of the lens substrate, or it can be formed on two surfaces. For example, the hydrophobic layer can be located on the object side of the spectacle lens, or it can be located on the eyeball side of the spectacle lens, or it can be located on both the object side and the eyeball side of the spectacle lens. When the hydrophobic layer is located on both sides of the spectacle lens, the hydrophobic layer on the object side and the hydrophobic layer on the eyeball side can be the same hydrophobic layer or different hydrophobic layers. In this invention and this specification, "eyeball side" refers to the surface side located on the eyeball side when the spectacle lens is worn by the wearer. "Object side" refers to the surface side opposite to the eyeball side, that is, the surface side located on the object side when the spectacle lens is worn by the wearer.

[0083] By assembling the spectacle lenses manufactured according to the above-described manufacturing method into a frame, eyeglasses having the aforementioned spectacle lenses can be produced. Known techniques can be applied to the structure of the eyeglasses, frames, etc.

[0084] Example

[0085] The present invention will be further illustrated below with reference to embodiments. However, the present invention is not limited to the embodiments shown in the examples.

[0086] Hereinafter, SiO2 layer refers to a vapor-deposited film formed by using silicon oxide as the vapor deposition material, and ZrO2 layer refers to a vapor-deposited film formed by using zirconium oxide as the vapor deposition material. Each vapor deposition material is a vapor deposition material formed solely from the oxides described, except for unavoidable impurities.

[0087] [Example 1]

[0088] Fabrication of lens substrates with hard coatings

[0089] On the entire surface of the convex side of a plastic lens substrate made from a monomer for eyeglass lenses (MR8 manufactured by Mitsui Chemicals Co., Ltd.), a hard coating liquid containing inorganic oxide particles and silicon compounds is applied by spin coating. The coating is then heated and cured in an oven at 100°C for 60 minutes, thereby forming a single-layer hard coating with a film thickness of 3 μm.

[0090] <Fabrication of Multi-Layer Anti-Reflective Film>

[0091] Next, the lens substrate with the aforementioned hard coating is placed in a vacuum evaporation apparatus, and a multilayer antireflective film with a total thickness of approximately 400–600 nm is formed on the entire surface of the hard coating by vacuum evaporation, consisting of seven layers stacked in the pattern "SiO2 layer / ZrO2 layer / SiO2 layer / ZrO2 layer / SiO2 layer / ZrO2 layer / SiO2 layer". The " / " symbol indicates that the parts written to the left and right of the " / " are directly stacked. This is also true in the following description.

[0092] In this way, eyeglass lenses with a layered structure of "lens substrate / hard coating / multi-layer anti-reflective film (inorganic layer)" are produced.

[0093] <Film Formation of Hydrophobic Layers>

[0094] (Preparation of the vapor deposition source)

[0095] The solution containing the hydrophobic component used a hydrophobic agent manufactured by Shin-Etsu Silicon Co., Ltd. (trade name: KY-130, which contains a fluorinated organosilane compound).

[0096] As a solution containing the metal component, an aqueous dispersion containing silver particles with a particle size of 2 to 5 nm was prepared at a concentration of 5000 ppm.

[0097] Two vapor deposition sources were fabricated using a disc-shaped sintered filter (material: SUS) with a diameter of 18 mm as the carrier.

[0098] The first vapor deposition source was fabricated by drying a carrier containing a solution of hydrophobic components in the amounts shown in Table 1 in a drying oven at an internal temperature of 50°C for 1 hour.

[0099] A second vapor deposition source was created by drying a carrier containing a solution of the metal components shown in Table 1 in a drying oven at an internal temperature of 50°C for 1 hour.

[0100] (The hydrophobic layer is formed by heating and vapor deposition)

[0101] like Figure 1 As shown, a spectacle lens with the aforementioned multilayer antireflective film and the aforementioned evaporation source are arranged in the vacuum chamber of the vacuum evaporation apparatus. As evaporation source 2A, a first evaporation source containing a fluorinated organosilane compound as a hydrophobic component is arranged on a carrier; as evaporation source 2B, a second evaporation source containing silver particles as a metallic component is arranged on a carrier. Each evaporation source is mounted on a molybdenum boat (…). Figure 1 (Not shown) and configured within a vacuum chamber. The pressure within the vacuum chamber is set to 2 × 10⁻⁶. -2 Below Pa, Figure 2The temperature profiles in Example 1 demonstrate heating using heaters 3A and 3B (both halogen heaters). Specifically, in the temperature profile of heater 3A, the temperature rises to 400°C over 6 minutes, followed by a rise to 650°C over 1 minute and 30 seconds. In the temperature profile of heater 3B, the temperature rises to 630°C over 3 minutes and 30 seconds, followed by a rise to 650°C over 4 minutes. This heating method allows for the heating and vaporization of both hydrophobic and metallic components, enabling the formation of a vapor-deposited film containing both hydrophobic and metallic components on the surface of the aforementioned multilayer antireflective film.

[0102] Through the above, a hydrophobic layer with a thickness of 10-20 nm containing hydrophobic and metallic components is formed on the surface of the above multilayer antireflective film.

[0103] Through the above processes, an eyeglass lens of Example 1 with a layer structure of "lens substrate / hard coating / multi-layer anti-reflective film (inorganic layer) / hydrophobic layer" was produced.

[0104] [Example 2]

[0105] Except for changing the amount of solution of metal component (silver particles) injected into the carrier in the fabrication of the second vapor deposition source to the values ​​shown in Table 1, the spectacle lens of Example 2 was fabricated by the method described in Example 1.

[0106] [Comparative Example 1]

[0107] Except that the evaporation source was heated using only one evaporation source and the heating of the evaporation source was carried out by the temperature profile of heater 3A of Example 1, the spectacle lens of Comparative Example 1 was produced by the method described in Example 1.

[0108] The vapor deposition source was prepared by the following method. The same carrier, metal component solution, and hydrophobic component solution as those used in Example 1 were used. After injecting the carrier with the amounts of metal component solution shown in Table 1, it was dried in a drying oven at an internal temperature of 50°C for 1 hour. Then, after injecting the amounts of hydrophobic component solution shown in Table 1, it was dried in a drying oven at an internal temperature of 50°C for 1 hour, thus preparing the vapor deposition source.

[0109] Regarding the spectacle lenses of the embodiments and comparative examples, antibacterial tests and contact angle measurements were performed on spectacle lenses with and without abrasion treatment (initial stage) and with abrasion treatment by the following methods.

[0110] The friction and wear treatment was carried out using the following method. A component with lens cleaning paper (dusper manufactured by Ozu Sangyo Co., Ltd.) wound around a piece of rubber cut to a size of 19mm × 24mm was used as a friction and wear component and mounted on a reciprocating friction and wear testing machine (Yamato Scientific TriboGear30S). The hydrophobic surface of the eyeglass lens was rubbed 1000 or 5000 times with the friction and wear component subjected to a 2kg load.

[0111] [Antibacterial test]

[0112] Antimicrobial tests were conducted in accordance with JIS Z 2801:2012. In the antimicrobial tests of each spectacle lens of the Examples and Comparative Examples, the spectacle lenses were manufactured in the same manner as the spectacle lenses of the Examples or Comparative Examples, except that the aforementioned hydrophobic layer was not formed, and these spectacle lenses were used as reference samples.

[0113] After placing 50mm × 50mm test pieces (test pieces cut from the spectacle lenses of the examples and comparative examples and their reference samples) into a sterilized petri dish, 0.4 mL of a solution containing 1.0 × 10⁻⁶ ppm of the solution was added. 5 ~4.0×10 5 A bacterial suspension of one test bacterium (Escherichia coli) was added dropwise to the center of the test slide, which was then covered with a polyethylene film cut into 40mm × 40mm pieces. The concentration of each 1cm column was measured after the culture dish was incubated at a relative humidity of 90% or higher for 24 hours. 2 Calculate the following antibacterial activity values ​​based on the number of viable bacteria.

[0114] Antibacterial activity value = Ut - At ≥ 2.0

[0115] Ut: The percentage of unprocessed test specimens (reference sample) per 1 cm after 24 hours of incubation. 2 The average of the logarithmic values ​​of the number of viable bacteria.

[0116] At: Antimicrobial processing test tablets (example or comparative sample) per 1 cm after 24 hours of incubation 2 The average of the logarithmic values ​​of the number of viable bacteria.

[0117] SIAA (Society for Antimicrobial Products Technology) stipulates that an antimicrobial activity value of 2 or higher indicates that the product has an antimicrobial effect. Therefore, for each spectacle lens of Example 1, Example 2, and Comparative Example 1, the antimicrobial properties were determined based on the antimicrobial activity values ​​calculated above, using the following criteria.

[0118] OK: Antibacterial activity value is above 2.0

[0119] NG: Antibacterial activity value less than 2.0

[0120] [Determination of contact angle]

[0121] As a contact angle measuring instrument, a CA-D model manufactured by Kyowa Interface Science Co., Ltd. was used. Under a measurement environment of 25°C, a 2mm diameter water droplet was created at the needle tip and brought into contact with the uppermost part of the convex surface of the hydrophobic layer of the spectacle lens. The angle between the resulting droplet and the surface was measured as the stationary contact angle. To minimize measurement errors caused by water evaporation, the contact angle was measured within 10 seconds of the water droplet contacting the spectacle lens. The radius of the water droplet (the radius of the portion of the water droplet in contact with the spectacle lens surface) was set as r, and the height of the water droplet was set as h. The stationary contact angle θ was calculated using the following formula.

[0122] θ=2×tan -1 (h / r)

[0123] [Table 1]

[0124]

[0125] The eyeglass lenses in Examples 1 and 2 are eyeglass lenses in which a hydrophobic layer is formed by heating multiple vapor deposition sources with different temperature profiles and by heating vapor deposition.

[0126] In contrast, the eyeglass lens of Comparative Example 1 is an eyeglass lens in which a hydrophobic layer is formed using a single vapor deposition source.

[0127] Based on the results shown in Table 1, it can be confirmed that the spectacle lenses of Examples 1 and 2 exhibit antibacterial properties due to the metal components in both the initial and post-friction / wear treatments; and that, compared with the spectacle lens of Comparative Example 1, the spectacle lenses of Examples 1 and 2 have larger contact angles and superior hydrophobicity in both the initial and post-friction / wear treatments.

[0128] For each spectacle lens of Examples 1 and 2, Staphylococcus aureus was used as the test bacterium, and an antibacterial test was conducted using the method described above. The results were "OK" in any of the following stages: initial stage, after 1000 cycles of friction and wear treatment, and after 5000 cycles of friction and wear test.

[0129] Finally, let's summarize the methods mentioned above.

[0130] According to one aspect, a method for manufacturing an eyeglass lens is provided, the eyeglass lens having a hydrophobic layer, the method comprising forming a film on the hydrophobic layer by a heated vapor deposition method, the film formation by the heated vapor deposition method comprising heating a plurality of vapor deposition sources with different temperature profiles, wherein at least one vapor deposition source contains a hydrophobic component and at least one vapor deposition source contains a metallic component.

[0131] According to the above manufacturing method, it is possible to manufacture an eyeglass lens that exhibits hydrophobicity and the properties of the metallic components contained in the hydrophobic layer, and these properties are also highly durable.

[0132] In one embodiment, the aforementioned metallic components may include silver-containing components.

[0133] In one embodiment, the aforementioned silver-containing component can be silver particles.

[0134] In one embodiment, the hydrophobic component can be a fluorine-containing component.

[0135] In one embodiment, the fluorinated component can be a fluorinated organosilanes.

[0136] In one approach, in the different temperature curves described above, one or more heating parameters selected from the heating rate, heating start time, and heating end time can be different.

[0137] In one embodiment, the plurality of vapor deposition sources can include vapor deposition sources containing only one of the aforementioned metallic components and the aforementioned hydrophobic components.

[0138] In one embodiment, the plurality of vapor deposition sources may include: a vapor deposition source containing only the metal component and the hydrophobic component; and a vapor deposition source containing only the metal component and the hydrophobic component.

[0139] The various methods and forms described in this specification can be combined in any combination of two or more.

[0140] The embodiments disclosed herein should be considered illustrative in all respects and not restrictive. The scope of the invention is not defined by the foregoing description, but by the scope of the claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of the claims.

[0141] Industrial availability

[0142] One aspect of the present invention is useful in the field of eyeglass lens and eyeglass manufacturing.

Claims

1. A method for manufacturing spectacle lenses, The eyeglass lenses have a hydrophobic layer. The manufacturing method includes forming a film of the hydrophobic layer by heating and vapor deposition. Film formation using the aforementioned heating vapor deposition method includes: The vapor deposition source A is heated by heater A, wherein the vapor deposition source A contains silver and fluorine-containing hydrophobic components; as well as The vapor deposition source B is heated by heater B, and the vapor deposition source B contains silver and fluorine-containing hydrophobic components. The heating start time and heating rate of heater A are different from those of heater B.

2. The method for manufacturing spectacle lenses according to claim 1, wherein, The silver-containing component is silver particles.

3. The method for manufacturing spectacle lenses according to claim 1 or 2, wherein, The fluorine-containing component is a fluorine-containing organosilicon compound.

Images