A multi-layer film composite hardening process for optical resin lenses

Abstract

The application discloses a kind of optical resin lens multilayer film composite hardening process, by plating zirconium dioxide and coupling agent mixed film layer on resin substrate, then plasma etching into nanoscale microporous, then plating zirconium dioxide and coupling agent mixed film layer, reflection-reducing film layer, blue light prevention film layer and zirconium dioxide and coupling agent mixed film layer in turn, and again plasma etching outermost zirconium dioxide and coupling agent mixed film layer into nanoscale microporous, by zirconium dioxide and coupling agent mixed film layer, the hardness of lens surface is strengthened, etched nanoscale microporous improves film layer adhesion, strengthens composite, so that each film layer is mutually close, further improve surface hardness.

Description

Technical Field

[0001] This invention belongs to the field of lens molding technology, specifically, it relates to a multilayer film composite hardening process for optical resin lenses. Background Technology

[0002] Currently, the market urgently needs resin lenses suitable for sports applications, characterized by high impact resistance, low chromatic aberration, high transmittance, and lightweight. Ordinary optical resin lenses are generally composed of a single ADC (CR-39) monomer or diallyl isophthalate, diallyl terephthalate, and their oligomers (03822475.5 / ). Resin lenses manufactured under CN1522374, without coating (i.e., covering the lens surface with an organic silicone hard film and vapor-deposited anti-reflective coating), only basically meet the minimum requirements of the US FDA (i.e., impact from a 16mm diameter, 16g steel ball dropped freely from 1.27m). The transmittance and durability of uncoated resin lenses are far from meeting the requirements of daily use. In contrast, a batch of PC lenses with excellent impact resistance has appeared on the domestic market. These lenses are mainly produced using injection molding, but there is significant irregular stress inside the lens, leading to problems such as birefringence and optical distortion that seriously affect the lens's optical performance. Furthermore, their dispersion coefficient is only 28-30, lower than the international ophthalmological organization's recommendation of a dispersion value of no less than 32 for ophthalmic lenses. PC lenses also have very poor abrasion resistance and lack good usability.

[0003] Therefore, there is an urgent need for a resin lens manufacturing process that provides high hardness, strong impact resistance, and good transmittance. Summary of the Invention

[0004] In view of this, the technical problem to be solved by the present invention is to provide a multilayer film composite hardening process for optical resin lenses, which avoids the problem of low hardness and weak impact resistance of resin lenses by hardening the composite film layer.

[0005] To address the aforementioned technical problems, this invention discloses a multilayer film composite hardening process for optical resin lenses, comprising:

[0006] S1. Provide a cured resin substrate, which is treated with sodium hydroxide solvent, then ultrasonically cleaned and dried;

[0007] S2. The dried resin substrate is sent into a plasma cleaner, and the particle energy in the plasma is controlled at 0-20eV to clean the surface of the resin substrate and enhance its activity.

[0008] S3. The treated resin substrate is fed into the hardening tank and repeatedly pulled up 4-5 times to form a dense hardened film layer.

[0009] S4. After the hardened resin substrate is cleaned by spraying with deionized water and dried, it is sent into the coating machine;

[0010] S5. A mixed film of zirconium dioxide and coupling agent is deposited on a resin substrate; the mixed film of zirconium dioxide and coupling agent can generate crosslinks, enhancing hardness and heat resistance.

[0011] S6. The coated resin substrate is taken out and sent to a plasma etching machine to etch the mixed film of zirconium dioxide and coupling agent to form nanoscale micropores. Etching not only removes the original contaminants and impurities on the surface, but also produces an etching effect, which roughens the surface of the substrate and forms many fine pits, i.e., nanoscale micropores. This increases the specific surface area of ​​the substrate and enhances the adhesion of subsequent film layers. At the same time, the micropores can also avoid stress concentration and enhance the impact and crack resistance.

[0012] S7. The etched resin substrate is fed into a coating machine to sequentially deposit a zirconium dioxide and coupling agent mixed film, an anti-reflection film, an anti-blue light film, and a zirconium dioxide and coupling agent mixed film.

[0013] S8. Take out the coated resin substrate and send it into a plasma etching machine to etch the outermost zirconium dioxide and coupling agent mixed film layer to form nanoscale micropores;

[0014] S9. Remove the etched resin substrate and place it in a spin coater to spin coat a UV-cured protective layer with a thickness of 3µm;

[0015] S10. After spin coating, place the substrate under a UV lamp for light curing. After light curing, perform ultrasonic cleaning and drying on the resin substrate.

[0016] S11. The dried resin lens is sent to a coating machine to coat a mixed refractive index film layer;

[0017] S12. After the coating is completed, the lens can be inspected.

[0018] According to one embodiment of the present invention, the thickness of the above-mentioned zirconium dioxide and coupling agent mixed film is 100-350 nm.

[0019] According to one embodiment of the present invention, the above-mentioned refractive index mixed film layer includes a first low refractive index film layer, a second high refractive index film layer, a third low refractive index film layer, a fourth high refractive index film layer, a fifth low refractive index film layer, a sixth high refractive index film layer, and a seventh low refractive index film layer.

[0020] According to one embodiment of the present invention, the first low-refractive-index film layer is a silicon dioxide and zirconium dioxide dielectric film; the second high-refractive-index film layer is an aluminum oxide and silicon dioxide dielectric film; the third low-refractive-index film layer is a silicon dioxide and zirconium dioxide dielectric film; the fourth high-refractive-index film layer is an aluminum oxide and silicon dioxide dielectric film; the fifth low-refractive-index film layer is a silicon dioxide and zirconium dioxide dielectric film; the sixth high-refractive-index film layer is an aluminum oxide and silicon dioxide dielectric film; and the seventh low-refractive-index film layer is a silicon dioxide and zirconium dioxide dielectric film.

[0021] According to one embodiment of the present invention, the thickness of the above-mentioned refractive index mixed film layer is 445±45nm.

[0022] According to one embodiment of the present invention, the above-mentioned hardened film layer is an organosilicon protective layer with a thickness of 1.5±0.5um.

[0023] Compared with the prior art, the present invention can achieve the following technical effects:

[0024] By depositing a mixed zirconium dioxide and coupling agent film on a resin substrate, and then plasma etching it into nanoscale micropores, a series of other mixed zirconium dioxide and coupling agent films, an anti-reflective film, a blue light blocking film, and another mixed zirconium dioxide and coupling agent film are sequentially deposited. The outermost mixed zirconium dioxide and coupling agent film is then plasma etched again to form nanoscale micropores. The mixed zirconium dioxide and coupling agent film enhances the surface hardness of the lens, and the etched nanoscale micropores improve the adhesion of the film layers and strengthen the composite, thereby making the various film layers tightly bonded to each other and further improving the surface hardness.

[0025] Of course, any product implementing this invention does not necessarily need to achieve all of the technical effects described above at the same time. Detailed Implementation

[0026] The following will describe the implementation of the present invention in detail with reference to the embodiments, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.

[0027] This invention discloses a multilayer film composite hardening process for optical resin lenses, comprising:

[0028] S1. Provide a cured resin substrate, which is treated with sodium hydroxide solvent, then ultrasonically cleaned and dried;

[0029] S2. The dried resin substrate is sent into a plasma cleaner, and the particle energy in the plasma is controlled at 0-20eV to clean the surface of the resin substrate and enhance its activity.

[0030] S3. The treated resin substrate is fed into the hardening tank and repeatedly pulled up 4-5 times to form a dense hardened film layer.

[0031] S4. After the hardened resin substrate is cleaned by spraying with deionized water and dried, it is sent into the coating machine;

[0032] S5. Deposit a mixed film of zirconium dioxide and coupling agent onto a resin substrate;

[0033] S6. Take out the coated resin substrate and send it into a plasma etching machine to etch the mixed film of zirconium dioxide and coupling agent to form nanoscale micropores;

[0034] S7. The etched resin substrate is fed into a coating machine to sequentially deposit a zirconium dioxide and coupling agent mixed film, an anti-reflection film, an anti-blue light film, and a zirconium dioxide and coupling agent mixed film.

[0035] S8. Take out the coated resin substrate and send it into a plasma etching machine to etch the outermost zirconium dioxide and coupling agent mixed film layer to form nanoscale micropores;

[0036] S9. Remove the etched resin substrate and place it in a spin coater to spin coat a UV-cured protective layer with a thickness of 3µm;

[0037] S10. After spin coating, place it under a UV lamp for photocuring. After photocuring, the resin substrate is ultrasonically cleaned and dried. The photocured protective layer is a combination of various epoxy resins and organic solvents, which breaks the C-C bonds of the unsaturated polyester resin and generates free radicals, thereby curing the resin. After adding a photosensitizer, a UV lamp is used to initiate the cross-linking reaction of the resin, which has good antioxidant properties and can effectively extend the service life of the internal functional film layer.

[0038] S11. The dried resin lens is sent to a coating machine to coat a mixed refractive index film layer;

[0039] S12. After the coating is completed, the lens can be inspected.

[0040] Among them, after abrasion resistance testing, the surface hardness of ordinary resin lenses in S1 is 2-3H. After hardening treatment, the hardness reaches 4-5H. After the various film layers are deposited in this application and without plasma cleaning and etching, the hardness of the resin lens exceeds 6-7H, reaching 8H. Finally, the resin lens obtained by the above process, after abrasion resistance testing, achieves a hardness of 8.5-9H. It can be seen that the etching of nanoscale micropores improves the adhesion of the film layers, strengthens the composite, and thus makes the various film layers tightly bonded to each other, further improving the surface hardness.

[0041] Preferably, the thickness of the zirconium dioxide and coupling agent mixed film is 100-350 nm; wherein the use of metal oxide film layer combined with coupling agent crosslinking can enhance the hardness of film layer, and the coupling agent is selected from silane coupling agent.

[0042] In addition, a refractive index mixing coating is used to improve the refractive index of the lens and enhance anti-reflective properties. This coating includes a first low-refractive-index coating, a second high-refractive-index coating, a third low-refractive-index coating, a fourth high-refractive-index coating, a fifth low-refractive-index coating, a sixth high-refractive-index coating, and a seventh low-refractive-index coating. In this embodiment, the seven refractive index coatings work together, with alternating high and low refractive indices, and are continuously superimposed to improve the refractive index of the resin substrate, enhance transmittance, reduce interference from stray strong light, and improve wearing comfort.

[0043] Preferably, the first low-refractive-index film is a silicon dioxide and zirconium dioxide dielectric film; the second high-refractive-index film is an aluminum oxide and silicon dioxide dielectric film; the third low-refractive-index film is a silicon dioxide and zirconium dioxide dielectric film; the fourth high-refractive-index film is an aluminum oxide and silicon dioxide dielectric film; the fifth low-refractive-index film is a silicon dioxide and zirconium dioxide dielectric film; the sixth high-refractive-index film is an aluminum oxide and silicon dioxide dielectric film; and the seventh low-refractive-index film is a silicon dioxide and zirconium dioxide dielectric film. By using low-refractive-index and high-refractive-index dielectric materials in combination, and by adjusting the thickness and number of layers of these two materials, the interference and reflection of light can be adjusted.

[0044] Furthermore, the thickness of the refractive index mixed film is 445±45 nm.

[0045] The hardening film is an organosilicon protective layer with a thickness of 1.5±0.5 μm. This hardening film effectively improves the surface hardness of the substrate and also strengthens the adhesion to the zirconium dioxide and coupling agent mixed film.

[0046] In summary, this invention involves depositing a mixed zirconium dioxide and coupling agent film on a resin substrate, followed by plasma etching to create nanoscale micropores. Then, a mixed zirconium dioxide and coupling agent film, an anti-reflective film, a blue light blocking film, and another mixed zirconium dioxide and coupling agent film are sequentially deposited. Finally, the outermost mixed zirconium dioxide and coupling agent film is plasma etched again to create nanoscale micropores. The mixed zirconium dioxide and coupling agent film enhances the surface hardness of the lens, while the etched nanoscale micropores improve film adhesion and strengthen the composite structure, resulting in a tighter bond between the various film layers and further improving surface hardness.

[0047] The foregoing description illustrates and describes several preferred embodiments of the present invention. However, as previously stated, it should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept described herein through the foregoing teachings or techniques or knowledge in related fields. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. A multilayer film composite hardening process for optical resin lenses, characterized in that, include: S1. Provide a cured resin substrate, which is treated with sodium hydroxide solvent, then ultrasonically cleaned and dried; S2. The dried resin substrate is sent into a plasma cleaner, and the particle energy in the plasma is controlled at 0-20eV to clean the surface of the resin substrate and enhance its activity. S3. The treated resin substrate is fed into the hardening tank and repeatedly pulled up 4-5 times to form a dense hardened film layer. S4. After the hardened resin substrate is cleaned by spraying with deionized water and dried, it is sent into the coating machine; S5. Deposit a mixed film of zirconium dioxide and coupling agent onto a resin substrate; S6. Take out the coated resin substrate and send it into a plasma etching machine to etch the mixed film of zirconium dioxide and coupling agent to form nanoscale micropores; S7. The etched resin substrate is fed into a coating machine to sequentially deposit a zirconium dioxide and coupling agent mixed film, an anti-reflection film, an anti-blue light film, and a zirconium dioxide and coupling agent mixed film. S8. Take out the coated resin substrate and send it into a plasma etching machine to etch the outermost zirconium dioxide and coupling agent mixed film layer to form nanoscale micropores; S9. Remove the etched resin substrate and place it in a spin coater to spin coat a UV-cured protective layer with a thickness of 3µm; S10. After spin coating, place the substrate under a UV lamp for light curing. After light curing, perform ultrasonic cleaning and drying on the resin substrate. S11. The dried resin lens is sent to a coating machine to coat a mixed refractive index film layer; S12. After the coating is completed, the lens can be inspected.

2. The optical resin lens multilayer film composite hardening process according to claim 1, characterized in that, The thickness of the zirconium dioxide and coupling agent mixed film is 100-350 nm.

3. The optical resin lens multilayer film composite hardening process according to claim 1, characterized in that, The refractive index mixed film layer includes a first low refractive index film layer, a second high refractive index film layer, a third low refractive index film layer, a fourth high refractive index film layer, a fifth low refractive index film layer, a sixth high refractive index film layer, and a seventh low refractive index film layer.

4. The optical resin lens multilayer film composite hardening process according to claim 3, characterized in that, The first low-refractive-index film layer is a silicon dioxide and zirconium dioxide dielectric film; the second high-refractive-index film layer is an aluminum oxide and silicon dioxide dielectric film; the third low-refractive-index film layer is a silicon dioxide and zirconium dioxide dielectric film; the fourth high-refractive-index film layer is an aluminum oxide and silicon dioxide dielectric film; the fifth low-refractive-index film layer is a silicon dioxide and zirconium dioxide dielectric film; the sixth high-refractive-index film layer is an aluminum oxide and silicon dioxide dielectric film; and the seventh low-refractive-index film layer is a silicon dioxide and zirconium dioxide dielectric film.

5. The optical resin lens multilayer film composite hardening process according to claim 3, characterized in that, The thickness of the refractive index mixed film is 445±45nm.

6. The optical resin lens multilayer film composite hardening process according to claim 1, characterized in that, The hardening film layer is an organosilicon protective layer with a thickness of 1.5±0.5um.