Method for manufacturing visual lens, combined die and myopic lens

Abstract

The embodiment of the invention discloses a method for manufacturing a visual lens, a combined mold and a myopia lens, a plastic mold is manufactured through a metal mold in a vacuum molding mode, and the plastic mold is used as the combined mold for manufacturing the visual lens. And meanwhile, the plastic mold is used for transferring the microstructure obtained by bearing the plastic mold from the metal mold to the eye vision lens by a casting molding method, wherein the eye vision lens is a polyurethane lens, an acrylic acid lens and a light-cured resin lens. According to the process, the plastic mold can be obtained at low cost, and good dimensional stability can be kept at a set temperature, so that the accuracy of the stability of the microstructure is ensured, and in addition, the requirements of smoothness and roughness for manufacturing the lens can be met.

Description

Technical Field

[0001] The present invention relates to the field of ophthalmic lens manufacturing and spectacle lenses, and particularly to a method for manufacturing ophthalmic lenses, a combined mold, and myopia lenses. Background Art

[0002] In the traditional field of ophthalmic lens production, the main type of mold widely used is the tempered glass mold. This type of mold is highly favored due to its excellent performance, including excellent impact resistance, good thermal stability, and extremely low mold rejection rate. These characteristics enable the tempered glass mold to withstand various mechanical stresses and high-temperature operations during the spectacle manufacturing process, ensuring the long life and stability of the mold. Among them, high impact resistance is a key characteristic of the tempered glass mold during the manufacturing process. This strength not only helps to maintain the integrity of the mold, preventing breakage during operation, but also ensures that the mold can maintain its shape and size for a long time, thus maintaining the consistency and precision of the spectacle lenses. Good thermal stability is another factor that makes the tempered glass mold popular. During the hot processing of ophthalmic lenses, the mold needs to withstand high-temperature environments, and the excellent thermal stability of the tempered glass mold ensures its stability and durability under these conditions. This is crucial for processes such as high-temperature grinding in spectacle manufacturing.

[0003] With the emergence of new vision control lenses in the field of optometry, the spectacle manufacturing industry is facing higher requirements for personalized and innovative production. These new lenses not only require the function of traditional ophthalmic vision correction, but also need to introduce precise and complex microstructures on the lens surface to achieve more accurate vision control. The design of these microstructures can include various shapes and arrangements, aiming to provide more customized vision solutions, such as reducing glare, improving contrast, or preventing the transmission of light of specific wavelengths.

[0004] However, the existing tempered glass molds are unable to cope with this trend. Firstly, their high cost becomes a restricting factor, especially when large-scale production is required to meet market demand. Secondly, it is difficult to ensure the consistency of the microstructures, which may lead to unstable lens quality and affect the user experience. Most importantly, the non-reworkable nature makes the tempered glass mold unable to adapt to these new requirements. Once the mold is manufactured, it cannot be modified according to different design requirements, which becomes inflexible in the face of rapidly evolving market demands. Summary of the Invention

[0005] To solve the above technical problems, an embodiment of the present invention is expected to provide a method for manufacturing an eye vision lens, a combined mold, and a myopia lens. By the above method, a mold can be accurately manufactured at low cost. In addition, a vision prevention and control type microstructure can be accurately realized on the surface of a polyurethane-based, acrylic-based, or photocurable resin-based lens.

[0006] The technical solution of the present invention is realized as follows:

[0007] In a first aspect, the present invention provides a method for manufacturing an eye vision lens, the method comprising:

[0008] Manufacturing a first mold by vacuum molding using a metal mold, the first mold having a shaping end face that receives an uneven microstructure from the metal mold; defining a casting cavity for casting the eye vision lens by the first mold and a second mold through a seal, wherein the shaping end face is located within the casting cavity; casting a thermosetting resin or a photocurable resin into the casting cavity to form the eye vision lens, wherein the microstructure is integrally formed on the eye vision lens.

[0009] Specifically, the step of "manufacturing a first mold by vacuum molding using a metal mold" specifically includes the following steps: placing a metal lower mold with an arc-shaped groove into the bottom opening of a cylindrical mold, placing a plastic preform for manufacturing the first mold on the arc-shaped groove, wherein the shape of the plastic preform is close to the shape of the final product; placing a metal upper mold into the top opening of the cylindrical mold, wherein one end of the metal upper mold facing the metal lower mold has an arc-shaped boss, the arc-shaped boss is processed with a microstructure by ultra-precision machining, and the arc-shaped boss and the arc-shaped groove correspondingly hold the plastic preform; placing the metal mold composed of the metal upper mold, the metal lower mold, and the cylindrical mold into a vacuum environment; driving the metal upper mold and the metal lower mold to approach by a driving device, and the plastic preform is extruded to extend in the space between the arc-shaped boss and the arc-shaped groove to form the first mold, wherein one side of the plastic preform facing the arc-shaped boss is the shaping end face, and the microstructure is integrally formed on the shaping end face.

[0010] Preferably, the step of "manufacturing a first mold by vacuum molding using a metal mold" further includes: coating the shaping end face.

[0011] Specifically, the step of "defining a pouring cavity for pouring the ophthalmic vision lens by the first mold and the second mold through a seal" specifically includes the following steps: A gap is maintained between the first mold and the second mold, wherein the shaping end face is arranged to face the second end face of the second mold; The seal is fixedly connected to the outer diameter surfaces of both the first mold and the second mold simultaneously, so as to form the pouring cavity between the first mold and the second mold.

[0012] Specifically, the step of "pouring a thermosetting resin or a photocurable resin into the pouring cavity to form the ophthalmic vision lens" specifically includes the following steps: Pouring a thermosetting resin or a photocurable resin into the interior of the pouring cavity; Placing the mold for manufacturing the ophthalmic vision lens at the curing temperature required for the ophthalmic vision lens for curing; After the resin cools and solidifies into a shape, taking out the ophthalmic vision lens from the pouring cavity.

[0013] In a second aspect, the present invention further provides a combined mold for manufacturing an ophthalmic vision lens, which is configured to replicate an uneven microstructure onto the surface of a resin lens by a pouring method. The combined mold includes: A first mold, which is made by a vacuum molding method through a metal mold. The first mold has a shaping end face, and the shaping end face has an uneven microstructure, wherein the surface roughness of the shaping end face is less than 10 nm; A second mold, which has a second end face; And a seal, which is detachably fixed to the outer diameter surfaces of the first mold and the second mold, wherein the shaping end face, the second end face and the inner surface of the seal form a sealable pouring cavity.

[0014] Preferably, the combined mold is configured to grow one or more dense films on all or part of the surface of the pouring cavity.

[0015] Preferably, the combined mold is made of a material with a glass transition temperature > 180 °C.

[0016] In a third aspect, the present invention further provides a myopia lens, which is made by the method described in the first aspect above.

[0017] Preferably, the myopia lens is made of a polyurethane series, an acrylic type or a photocurable resin material.

[0018] The present invention manufactures a plastic mold by means of vacuum molding with a metal mold. Among them, the metal mold has a precise microstructure, and then the plastic mold is used as a combined mold for manufacturing ophthalmic lenses. In the combined mold, the microstructure is transferred to the ophthalmic lenses by means of casting molding, where the ophthalmic lenses are polyurethane, acrylic, and photocurable resin lenses. Through the above process, plastic molds can be mass-produced at low cost, achieving good dimensional stability at a given temperature, thereby ensuring the stable accuracy of the microstructure. In addition, it can also meet the requirements of surface finish and roughness for manufacturing the above lenses. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic flow chart of a method for manufacturing ophthalmic lenses in an embodiment of the present invention;

[0020] Figure 2 It is a schematic flow chart of manufacturing a first mold by means of vacuum molding with a metal mold in a method for manufacturing ophthalmic lenses in an embodiment of the present invention;

[0021] Figure 3 It is a schematic flow chart of defining a casting cavity for casting the ophthalmic lenses by the first mold and the second mold with a seal in a method for manufacturing ophthalmic lenses in an embodiment of the present invention;

[0022] Figure 4 It is a schematic flow chart of pouring a thermosetting resin or a photocurable resin into the casting cavity to form the ophthalmic lenses in a method for manufacturing ophthalmic lenses in an embodiment of the present invention;

[0023] Figure 5 It is a schematic structural diagram of a metal mold used in a method for manufacturing ophthalmic lenses in an embodiment of the present invention;

[0024] Figure 6 It is a schematic structural diagram of a combined mold for manufacturing ophthalmic lenses in an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0025] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention.

[0026] To make the objectives, technical solutions, and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are some, but not all, of the embodiments of the present application. Usually, the components of the embodiments of the present application described and illustrated in the accompanying drawings here can be arranged and designed in various different configurations.

[0027] Accordingly, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the claimed present application, but merely represents selected embodiments of the present application. It should be noted that, without conflict, the various features in the embodiments of the present application can be combined with each other, and the combined embodiments are still within the protection scope of the present application.

[0028] It should be noted that like reference numerals and letters indicate like items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0029] In the description of the present application, it should be noted that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "left", "right", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the product of this application is customarily placed when in use. It is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present application. In addition, the terms "first", "second", "third", etc. are only used for descriptive distinction and cannot be understood as indicating or implying relative importance.

[0030] In the description of the present application, it should also be noted that unless otherwise clearly specified and defined, the terms "set", "installed", "connected", "connected to" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.

[0031] In the prior art, in view of the deficiencies of glass molds, in order to produce vision prevention and control lenses, major lens manufacturers have to turn to injection metal molds to produce injection-molded or light-cured vision prevention and control lenses. However, in the field of optical resin lenses, the materials that can be used to make lenses through the injection process are quite limited, mainly concentrated in acrylic and PC. At the same time, due to the problem of material shrinkage stability, the degrees of the lenses made by light-cured lenses vary greatly. The current vision prevention and control lenses are mainly dominated by PC injection-molded lenses and light-cured resins, which makes it difficult to fully utilize the existing huge casting production capacity of the industry, and at the same time seriously limits the diversity of lens refractive indices. This situation not only affects the diversity of lens products, but also cannot meet the urgent needs of consumers for the diversity of vision prevention and control lens products.

[0032] Therefore, in the current technology, a common method is to use metal molds to manufacture molds by injection molding and use these molds to manufacture vision control lenses. The process steps of manufacturing molds using injection molding equipment include: raw material preparation, heating and melting, injection, cooling, and mold opening and post-treatment. First, raw materials need to be prepared. The plastic pellet raw materials are placed in the melting chamber, and the plastic raw materials are heated to a molten state to form a melt through a heating system; the melt is injected into the cavity of the metal mold through an injection module. Once the melt filling is completed, the mold starts to cool, causing the plastic to cool and solidify. Given the thickness and size of the target product, the cooling time will vary; when the plastic is completely cooled, the metal mold is opened to obtain the formed mold.

[0033] Through the above process flow, molds with microstructures can be prepared. However, when using the currently available injection molding equipment to manufacture molds for producing vision control lenses, especially those made of polyurethane, acrylic, or photocurable resin materials, it is often difficult to reach the set manufacturing temperature. In other words, the equipment for melting raw materials cannot heat the raw materials to the molten state required to meet the injection fluidity. Additionally, the plastic in the molten state has a high viscosity, and the air flow resistance inside the entire injection system is relatively large, resulting in poor fluidity of the molten plastic entering the cavity of the metal mold by injection. Eventually, the formed mold will have defects such as air streaks, bubbles, and deformation. Subsequently, when manufacturing vision control lenses in a high-temperature production environment, these defects may lead to poor lens quality and a reduction in the output of finished products.

[0034] Furthermore, when obtaining the microstructures on the metal mold, the plastic in the molten state needs to flow fully inside the cavity to fill the entire cavity, and the liquid inside the cavity is squeezed against each other to ensure that the gaps of the microstructures are filled. However, in this process, it is often impossible to obtain the accurate outer shape of the microstructures, resulting in problems such as air pockets and poor appearance at the connecting parts of the microstructures. The resulting air entrapment phenomenon makes the surface finish and roughness of the microstructures on the mold unable to meet the strict requirements of the US military standard MIL13830 20 / 10. Given that the roughness and microstructure accuracy of the plastic mold obtained in the steps of manufacturing a plastic mold using a metal mold do not meet the standards and cannot meet the process standards for subsequent manufacturing of myopia lenses, it is very difficult to achieve the full-scale production of the myopia lens process through the above process.

[0035] To solve the above technical problems, refer to the appendix Figure 1 , which shows a schematic flow diagram of a method for manufacturing eye vision lenses provided by an embodiment of the present invention. The method includes:

[0036] S101. Use a metal mold to manufacture a first mold in a vacuum molding manner. The first mold has a shaping end face, and the shaping end face receives the uneven microstructures from the metal mold.

[0037] Based on the above disclosure of the present invention, the first mold is used as the main mold for manufacturing ophthalmic vision lenses. The first mold has a shaping end face, and uneven microstructures are prepared on the shaping end face. With the rise of new vision prevention and control lenses in the field of optometry, it is necessary to implant microstructures of different shapes on the lens surface to achieve the purpose of vision prevention and control. Through the shaping end face, it can be ensured that the first mold meets the production requirements of ophthalmic vision lenses. It should be noted that the microstructures can cover the entire area of the shaping end face or can exist on a part of the shaping end face according to requirements.

[0038] Based on the above disclosure, the present invention also discloses a process for preparing the first mold using vacuum molding. Specifically, see the appendix Figure 2 , and the process specifically includes the following steps:

[0039] S201: Place a metal lower mold with an arc-shaped groove into the bottom opening of a cylindrical mold. A plastic preform for manufacturing the first mold is placed on the arc-shaped groove. Among them, the shape of the plastic preform is close to the shape of the final product; S202: Place a metal upper mold into the top opening of the cylindrical mold. One end of the metal upper mold facing the metal lower mold has an arc-shaped boss, and the arc-shaped boss is processed with microstructures by ultra-precision machining. The arc-shaped boss holds the plastic preform corresponding to the arc-shaped groove.

[0040] In the present invention, a metal mold is used to prepare the first mold. See the appendix Figure 5 , which shows a schematic structural diagram of the metal mold 50. The metal mold 50 includes a metal lower mold 52, a metal upper mold 51, and a sleeve 53. Among them, the metal upper mold 51 and the metal lower mold 52 are respectively assembled in the upper opening and the lower opening of the sleeve 53. A gap space is left between the metal upper mold 51 and the metal lower mold 52, and this gap space is used as the forming cavity for forming the first metal mold 50.

[0041] Specifically, the metal upper mold 51 has an arc-shaped convex platform. Correspondingly, the metal lower mold 52 has an arc-shaped groove. When the metal upper mold 51 and the metal lower mold 52 are assembled in the sleeve 53, the arc-shaped convex platform is aligned with the arc-shaped groove and the above-mentioned forming cavity is formed therebetween. The surface of the arc-shaped convex platform is manufactured with microstructures that meet the process requirements in the form of ultra-precision machining. The microstructures can be special structures such as dot-shaped, ring-shaped, dot / ring alternating, hexagonal shape, etc. In the specific preparation process, the plastic preform M for preparing the first metal mold 50 is heated to a processable state, such as a viscous flow state or a highly elastic state, and placed in the arc-shaped groove. The metal upper mold 51 moves downward along the inner wall of the sleeve 53 to approach the metal lower mold 52, so that the arc-shaped convex platform enters the arc-shaped groove. In this case, the arc-shaped convex platform and the arc-shaped groove hold the plastic preform M in a squeezing manner. In another embodiment of the present invention, the metal upper mold 51 has a groove with an arc-shaped depression, and the metal lower mold 52 has a platform with an arc-shaped protrusion. A space for accommodating the plastic preform M can also be formed therebetween. Similarly, when the metal upper mold 51 and the metal lower mold 52 approach, the plastic preform M is squeezed to form the first mold. In this case, the microstructures are adaptively arranged on the arc-shaped protrusion platform of the metal lower mold 52.

[0042] S203. Place the metal mold composed of the metal upper mold, the metal lower mold, and the cylindrical mold into a vacuum environment; S204. The driving device drives the metal upper mold and the metal lower mold to approach, and the plastic preform is extruded to extend in the space between the arc-shaped convex platform and the arc-shaped groove to form the first mold. Among them, the surface of the plastic preform facing the arc-shaped convex platform is the shaping end face, and the shaping end face is integrally formed with microstructures.

[0043] In the process disclosed by the present invention, it is necessary to place the assembled metal mold in a vacuum environment. By creating a vacuum environment, air bubbles in the plastic preform can be effectively discharged. Additionally, since it is necessary to form microstructures on the surface of the plastic preform, in a vacuum environment, a plastic preform in a processable state, such as a viscous flow state or a highly elastic state, is more likely to fill the gaps between the microstructures. By eliminating air resistance, the plastic preform in the viscous flow state can reach each gap and detail part of the microstructures more evenly, ensuring that the first mold accurately obtains the microstructures from the metal mold. Furthermore, the curing process of the material can be better controlled through a vacuum environment. In a vacuum environment, the material may have a longer curing time, which makes the manufacturing process more controllable. The upper metal mold is driven by a motor or other existing technical means to approach the lower metal mold, and at the same time, the plastic preform is extruded, so that the plastic preform extends in the molding cavity. During the extension process, the plastic preform fills all the gaps and details of the microstructures, and the outer shape of the microstructures is transferred to the first mold. Among them, the surface of the first mold with microstructures is the shaping end face of the first mold. In another embodiment of the present invention, in order to further ensure the accuracy of the microstructures, when processing the microstructures on the arc-shaped boss surface of the upper metal mold, a high-precision detection device is used to measure the microstructures on the arc-shaped boss surface, and the results are compared with the original design drawing to ensure the processing accuracy of the microstructures on the arc-shaped boss surface. In addition, after the first mold is manufactured through the metal mold, the same high-precision detection device is used again to measure the microstructures on the shaping end face, and the results are compared with the original design drawing to ensure the processing accuracy of the microstructures on the shaping end face.

[0044] In another embodiment of the present invention, after the first mold is manufactured through the metal mold, the shaping end face is coated with a film. The shaping end face is formed with microstructures, and these microstructures are used to form microstructures on the surface of the lens during the lens preparation process. That is to say, the shaping end face is the working surface for preparing the lens. Coating the above-mentioned shaping end face with at least one preset film layer by chemical or physical growth methods can improve the performance of the lens product or improve the process flow. For example, a waterproof layer, an anti-fouling layer, or an anti-sticking layer, etc., is coated on the shaping end face. Exemplarily, silicon oxide, titanium oxide, magnesium fluoride, and a waterproof layer, etc., are coated on the shaping end face by chemical or physical methods; or Au, Ag, Sn, etc., are coated on the shaping end face to improve the sticking of the resin lens to the mold. Among them, when the pre-film layer is multiple layers, the multiple film layers can include different types of film layers, and the multiple film layers can be sequentially coated in a stacked manner. It should be noted that the above-mentioned preset film layer can remain on the first mold during the lens demolding process to improve the demolding process, or can directly adhere to the lens product along with the lens demolding to improve the lens quality.

[0045] After obtaining the first mold through a metal mold, an embodiment of the present invention provides a method for manufacturing an ophthalmic vision lens, which further includes: S102. The first mold and the second mold define a casting cavity for casting the ophthalmic vision lens through a seal. Wherein, the shaping end face is located in the casting cavity. After obtaining the first mold through the above process, the second mold is used in cooperation with the first mold to form a plastic mold for preparing the ophthalmic vision lens. Specifically, a cavity for casting is formed by the first mold and the second mold. In view that the micro-structure is formed on the shaping end face of the first mold, the shaping end face of the first mold constitutes the inner surface. In this way, during the process of preparing the ophthalmic vision lens by the casting process, the micro-structure is transferred to the surface of the ophthalmic vision lens.

[0046] Specifically, during the process that the first mold and the second mold define a casting cavity for casting the ophthalmic vision lens through a seal, refer to the appendix Figure 3 , which shows a schematic flow diagram of the first mold and the second mold defining a casting chamber, and specifically includes the following steps:

[0047] S401. A gap is maintained between the first mold and the second mold. Wherein, the shaping end face is arranged to face the second end face of the second mold; S402. The seal is simultaneously fixed to the outer diameter surfaces of the first mold and the second mold, so that the casting cavity is formed between the first mold and the second mold.

[0048] After obtaining the first mold through a metal mold, the first mold is used as the main mold for preparing the ophthalmic vision lens. The shaping end face of the first mold has a micro-structure. The second mold and the first mold are used in cooperation to form a casting cavity for preparing the ophthalmic vision lens. The second mold has a second end face, and the second end face is preferably a smooth plane. The shaping end face and the second end face are arranged opposite to each other, and there is a gap for forming the casting cavity in the middle. The seal fixes the first mold and the second mold through a circumferentially formed structure. The inner surface of the seal surrounds the above gap to form a casting cavity. Specifically, the inner surface of the seal, the shaping end face and the second end face surround a sealable chamber. It should be noted that there must be an opening for pouring the raw materials for preparing the ophthalmic vision lens in the above chamber, and the opening is closable. The opening is preferably arranged above or on the side of the chamber.

[0049] It should be noted that the preparation process of the second mold and the preparation process of the first mold may be the same or different. Preferably, the preparation process of the second mold is the same as the preparation process of the first mold.

[0050] An embodiment of the present invention further includes step S103 of pouring a thermosetting resin or a photocuring resin into the pouring cavity to form the ophthalmic vision lens, wherein the microstructure is integrally formed on the ophthalmic vision lens.

[0051] After the first mold and the second mold are combined to form a combined mold for manufacturing an ophthalmic vision lens, that is, after the first mold, the second mold and the seal form a pouring cavity, the raw material for preparing the ophthalmic vision lens is poured into the pouring cavity. Among them, a thermosetting resin or a photocuring resin is used as the raw material for preparing the ophthalmic vision. Preferably, the ophthalmic vision lens can be cast and produced using polyurethane series (MR7, MR8, MR10, MR174) or acrylic or photocuring resin lenses. In the process of preparing the ophthalmic vision lens, the following steps are specifically included. See the appendix Figure 4 , which shows a schematic flow chart of preparing an ophthalmic vision lens using a combined mold:

[0052] S501. Pour a thermosetting resin or a photocuring resin into the interior of the pouring cavity; S502. Place the mold for manufacturing the ophthalmic vision lens at the curing temperature required for the ophthalmic vision lens for curing; S503. Wait until the resin cools and solidifies into a shape, and take out the ophthalmic vision lens from the pouring cavity.

[0053] Based on the above disclosure, the plastic mold obtained by the above process can maintain good strength and dimensional stability at high temperatures. Preferably, the raw material of the plastic mold is selected from materials with Tg (glass transition temperature) > 180°C. By the above selection of raw materials, good dimensional stability of the plastic mold can be maintained during the curing process of the ophthalmic vision lens. Exemplarily, when preparing ophthalmic vision lenses made of polyurethane (MR series), acrylic and photocuring resins, the above material selection can make the plastic raw material maintain good dimensional stability at about 150°C, ensuring that the curing temperature requirement of 130°C can be achieved.

[0054] According to a method for manufacturing ophthalmic vision lenses disclosed in the embodiments of the present invention above, a plastic mold is used instead of a glass mold. In the preparation stage, a metal mold is used to prepare the plastic mold, so that the surface of the plastic mold has an uneven microstructure. By using the above plastic mold to prepare the lens, an ophthalmic vision lens with a microstructure on the surface can be obtained. The plastic mold is obtained by a vacuum molding process, which can improve the strength and accuracy of the microstructure on the surface of the plastic mold. In addition to the microstructure, the preparation process of the present invention can improve the roughness and surface finish of the surface of the plastic mold, improve the quality of the plastic mold, and further improve the quality of the ophthalmic vision lens. At the same time, the above vacuum molding preparation process can realize the large-scale production of the plastic mold. In addition, by restricting the raw materials for preparing the plastic preform, good dimensional stability of the plastic mold can be maintained at high temperatures, so as to ensure the structural strength of the plastic mold during the curing of the ophthalmic vision lens, and enable the ophthalmic vision lens to obtain high accuracy of the microstructure from the surface of the plastic mold.

[0055] Based on the above disclosure, an embodiment of the present invention also discloses a combined mold for manufacturing ophthalmic vision lenses. The combined mold is used for the above method for manufacturing ophthalmic vision lenses. Refer to the attached Figure 6 , which shows a schematic structural diagram of the combined mold 60. The combined mold 60 is generally lens-shaped, and includes a first mold 61 and a second mold 62 corresponding to each other, and a seal 63 surrounding the outer diameter surfaces of the first mold 61 and the second mold 62. The first mold 61 has a shaping end face A, and the surface of the shaping end face A has an uneven microstructure. One end of the second mold 62 has a second end face B corresponding to the shaping end face A. Among them, the first mold 61 is made by a metal mold in a vacuum molding manner, and the preparation process of the first mold 61 is as described in the manufacturing process disclosed in a method for manufacturing ophthalmic vision lenses disclosed in the present invention, which will not be elaborated here.

[0056] Refer to the attached Figure 6, the seal 63 extends circumferentially and integrally in structure such that the seal 63 can surround the outer peripheral surfaces of the first mold 61 and the second mold 62. In other words, the first mold 61 and the second mold 62 are respectively placed in the columnar inner diameter surface of the cylindrical seal 63, and the shaping end face A and the second end face B are arranged opposite to each other, thereby forming a gap between the first mold 61 and the second mold 62 to constitute a casting cavity P. The first mold 61, the second mold 62 and the seal 63 form a sealed casting cavity P to prepare ophthalmic lenses by casting. It should be noted that the shaping end face A is preferably configured to have a surface with an inwardly concave arc, and the corresponding second end face B is configured to have a surface with the same or different outwardly protruding arc as the shaping end face A. The combined mold 60 is used for the method for manufacturing ophthalmic lenses disclosed in the present invention. Therefore, the process flow and usage method of preparing ophthalmic lenses using the combined mold 60 are as described in the method for manufacturing ophthalmic lenses. By the above method, the roughness of the shaping end face of the first mold can be reduced. In the present invention, the roughness of the shaping end face A of the first mold 61 in the combined mold 60 is less than 10 nm.

[0057] Preferably, in order to ensure that the combined mold 60 can maintain good strength and dimensional stability at high temperatures, the raw material for preparing the combined mold is selected as a material with a Tg (glass transition temperature) > 180 °C. By the above limitation of the raw material, it can be ensured that the combined mold 60 has good dimensional stability below 150 °C and meets the curing temperature requirement of 130 °C for ophthalmic lenses.

[0058] Preferably, the combined mold 60 is configured to grow one or more dense films on all or part of the surface of the casting cavity P. The shaping end face A is formed with a microstructure, which is used to form a microstructure on the surface of the lens during the process of preparing the lens. That is to say, the shaping end face A is the working face for preparing the lens. Coating the above-mentioned shaping end face A with at least one preset film layer by chemical or physical growth methods can improve the performance of the lens product or improve the process flow. For example, coating a waterproof layer, an anti-fouling layer or an anti-adhesion layer on the shaping end face. Exemplarily, silica, titanium oxide, magnesium fluoride and a waterproof layer, etc. are coated on the shaping end face A by chemical or physical methods; or, Au, Ag, Sn, etc. are coated on the shaping end face A to improve the sticking of resin lenses to the mold. Among them, when the pre-film layer is multiple layers, the multiple film layers can include different types of film layers, and the multiple film layers can be deposited in a stacked manner in sequence. It should be noted that the above-mentioned preset film layer can remain on the first mold 61 during the lens demolding process to improve the demolding process, or can directly adhere to the lens product with the lens demolding to improve the lens quality.

[0059] Based on the above method for manufacturing ophthalmic vision lenses, the present invention also discloses a myopia lens, which is prepared according to the above method for manufacturing ophthalmic vision lenses. Preferably, the myopia lens is made of polyurethane (MR series), acrylic and photocurable resin.

[0060] It should be noted that: among the technical solutions described in the embodiments of the present invention, any combination can be made without conflict.

[0061] As mentioned above, the above are only specific embodiments of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention can easily think of changes or substitutions, which should all be covered within the protection scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims.

Claims

1. A method for manufacturing ophthalmic vision lenses, characterized in that, The method includes:

101. Manufacturing a first mold by vacuum molding using a metal mold, the first mold having a shaping end face that receives an uneven microstructure from the metal mold; 102. The first mold and a second mold define a casting cavity for casting the ophthalmic lens through a seal, wherein the shaping end face is located within the casting cavity; 103. Pouring a thermosetting resin or a photocurable resin into the casting cavity to form the ophthalmic lens, wherein the microstructure is integrally formed on the ophthalmic lens.

2. The method according to claim 1, wherein The "manufacturing a first mold by vacuum molding using a metal mold" specifically includes the following steps:

201. Placing a metal lower mold with an arc-shaped groove into the bottom opening of a cylindrical mold, and placing a plastic preform for manufacturing the first mold on the arc-shaped groove, wherein the shape of the plastic preform is close to the shape of the final product; 202. Placing a metal upper mold into the top opening of the cylindrical mold, wherein one end of the metal upper mold facing the metal lower mold has an arc-shaped boss, and the arc-shaped boss is processed with a microstructure by ultra-precision machining, and the arc-shaped boss holds the plastic preform correspondingly with the arc-shaped groove; 203. Placing the metal mold composed of the metal upper mold, the metal lower mold, and the cylindrical mold into a vacuum environment; 204. A driving device drives the metal upper mold and the metal lower mold to approach each other, and the plastic preform is extruded to extend in the space between the arc-shaped boss and the arc-shaped groove to form the first mold, wherein one face of the plastic preform facing the arc-shaped boss is the shaping end face, and the microstructure is integrally formed on the shaping end face.

3. The method according to claim 2, wherein The "manufacturing a first mold by vacuum molding using a metal mold" further includes:

205. Coating the shaping end face.

4. The method according to claim 1, characterized in that, The "the first mold and a second mold define a casting cavity for casting the ophthalmic lens through a seal" specifically includes the following steps:

401. Keeping a gap between the first mold and the second mold, wherein the shaping end face is arranged to face a second end face of the second mold; 402. Fixing the seal to the outer diameter surfaces of both the first mold and the second mold simultaneously, so that a casting cavity is formed between the first mold and the second mold.

5. The method according to claim 1, wherein The "pouring a thermosetting resin or a photocurable resin into the casting cavity to form the ophthalmic lens" specifically includes the following steps:

501. Pouring a thermosetting resin or a photocurable resin into the interior of the casting cavity; 502. Placing the module for manufacturing the ophthalmic lens at the curing temperature required for the ophthalmic lens for curing; 503. After the resin cools and solidifies into a shape, taking out the ophthalmic lens from the casting cavity.

6. A combined mold for manufacturing ophthalmic vision lenses, characterized in that, The combined mold is configured to replicate an uneven microstructure onto the surface of a resin lens by casting, and the combined mold includes: The first mold, which is made by a metal mold through vacuum molding. The first mold has a shaping end face, and the shaping end face has an uneven microstructure. Among them, the roughness of the shaping end face is less than 10 nm; The second mold, which has a second end face; And a seal, which is detachably fixed to the outer diameter surfaces of the first mold and the second mold. Among them, the shaping end face, the second end face and the inner surface of the seal form a casting cavity that can be sealed.

7. The combined mold according to claim 6, characterized in that, The combined mold is configured to grow one or more dense films on all or part of the surfaces of the casting cavity.

8. The combined mold according to claim 6, characterized in that, The combined mold is made of a material with a glass transition temperature > 180 °C.

9. A myopia lens, characterized in that, The myopia lens is made by the method described in any one of the above claims 1-5.

10. The myopia lens according to claim 9, wherein, The myopia lens is made of polyurethane or acrylic or photocurable resin material.

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