Matt coated lens and manufacturing method thereof

Abstract

According to the matte coated lens and the manufacturing method thereof provided by the invention, the matte coated lens is manufactured through an AG membrane material which is widely applied at present, and an atomizing mold with high manufacturing cost does not need to be adopted, so that on one hand, the manufacturing cost is greatly reduced, the processing technology can be simplified to a certain extent, and the production efficiency is improved; and on the other hand, the manufactured matte coated lens also has good optical characteristics.

Description

Technical Field

[0001] The present invention relates to the technical field of lenses, and in particular to a matte coated lens and a manufacturing method thereof. Background Art

[0002] The basic principle behind common goggles and sunglasses on the market is to create tinted lenses by adding different colors to transparent lens materials. This tinting process effectively filters out harmful ultraviolet rays and overly intense visible light (glare), significantly reducing eye strain and fatigue for the wearer, providing a more comfortable and safer field of vision.

[0003] A further advancement is coated lenses. These lenses are coated with a special metallic reflective film, giving them a unique luster and reflecting most incoming light like a mirror. As a result, when viewed from the outside, the lenses reflect light strongly, reflecting the surroundings and cleverly concealing the wearer's eyes from prying eyes. This mirrored design is not only stylish but also provides privacy while effectively blocking glare, enhancing the wearing experience.

[0004] The conventional manufacturing process of the existing coated lenses is as follows: Figure 1 As shown in (a), first, a lens body layer 1 with an atomized surface is injection-molded in an atomizing mold, and the surface of the lens body layer 1 has a concave-convex atomized surface 1a; secondly, a film is coated on the atomized surface 1a of the lens body layer 1 to form a coating layer 2, and the coating layer 2 is a thin layer with an almost uniform thickness, so the outer surface of the coating layer 2 is formed with a concave-convex surface 2a, and the coating layer 2 with the concave-convex surface 2a diffusely reflects light, so that the external appearance has a metallic foggy luster; thirdly, a glue layer 3 is coated on the concave-convex surface 2a of the coating layer 2, and the glue layer 3 can fill the concave-convex surface 2a, so that the lens becomes transparent, so as to obtain a lens with both a transparent field of view and a metallic foggy luster; finally, the second lens layer 4 is bonded to the concave-convex surface 2a of the coating layer 2 through the glue layer 3, and the second lens layer 4 can play a role of reinforcement and protection; of course, in another existing embodiment, as Figure 1 As shown in (b), the adhesive layer 3 can be omitted, and a strengthening layer 4' can be formed on the uneven surface 2a of the coating layer 2, thereby leveling the uneven surface 2a. The strengthening layer 4' can be formed using existing technologies, such as by dipping the lens into a pool of hardening liquid to adhere the strengthening layer 4' to the surface. The coated lens formed by the above-described process can achieve the effect of reflecting external light while also having a matte visual appearance. However, the existing process flow is relatively complex, and production efficiency is not high enough. Furthermore, the cost of the atomization mold is relatively high, resulting in high overall costs. Summary of the Invention

[0005] To address at least one of the above problems, the present invention provides a matte coated lens and a method for manufacturing the same.

[0006] The present invention is implemented by the following scheme:

[0007] The present invention proposes a matte coated lens, including a lens substrate, which is an optical lens made of a translucent material, and also includes an AG film, a coating layer and a filling protective layer. The AG film is a film material, including a first surface and a second surface opposite to the first surface, wherein the first surface is a concave-convex surface; the coating layer is bonded to the first surface of the AG film, and the lens substrate is bonded to the second surface of the AG film, defining that the coating layer is located on the outside of the AG film, and the filling protective layer is at least bonded to the outer surface of the coating layer, and the filling protective layer has a flat outer surface.

[0008] In one embodiment, the filling and protective layer is an adhesive layer bonded to a protective lens layer; or, the filling and protective layer is a strengthening treatment layer.

[0009] In one embodiment, the lens substrate is formed by injection molding a high-temperature molten material into a mold cavity where the AG film is positioned, so that the lens substrate is directly bonded to the second surface of the AG film.

[0010] In one embodiment, an adhesive layer is further included, and the adhesive layer is used to bond the lens substrate to the second surface of the AG film.

[0011] In one embodiment, the filling protective layer is a strengthening treatment layer, and the strengthening treatment layer is combined with the outer surface of the lens combination composed of the lens substrate, the AG film and the coating layer to form an overall outer covering.

[0012] In one embodiment, the lens substrate is made of PC or PA material.

[0013] In one embodiment, the lens substrate and the AG film are made of the same material.

[0014] In one embodiment, a functional layer is further included, and the functional layer is combined with the lens substrate. The functional layer includes: one or more of: a polarizing layer, a color-changing layer, an ultraviolet light filtering layer, and a blue light filtering layer.

[0015] The present invention also provides a method for manufacturing a matte coated lens, wherein the matte coated lens is the matte coated lens as described above, comprising the following steps:

[0016] S1: providing an AG film and a molding die having a cavity; the AG film is a membrane material, comprising a first surface and a second surface opposite to the first surface, wherein the first surface is a concave-convex surface;

[0017] S2: Positioning an AG film in a mold cavity, wherein a first surface of the AG film is positioned away from the mold cavity;

[0018] S3: using a high-temperature molten material to form a lens substrate attached to the AG film by an intramold injection molding method into a mold cavity where the AG film is positioned; the lens substrate is attached to the second surface of the AG film;

[0019] S4: forming a coating layer on the first surface of the AG film through a coating process;

[0020] S5: forming a strengthening treatment layer by at least partially immersing the lens produced in step S4 in a container filled with a strengthening coating solution and subjecting the lens to a strengthening process, wherein the strengthening treatment layer is at least formed on the coating layer; the strengthening treatment layer serves as a filling and protective layer.

[0021] In one embodiment, in step S5, the strengthening treatment layer is formed on the surface of the lens assembly consisting of the lens substrate, the AG film and the coating layer to form an overall outer covering.

[0022] In one embodiment,

[0023] In step S2: positioning the AG film in the mold cavity further includes pre-bending the AG film to fit the mold cavity; and / or

[0024] In step S3: the high temperature melting material is a high temperature melting polymer material; and / or

[0025] In step S4: the coating process adopts vacuum evaporation method.

[0026] The technical solution provided by the present invention has the following technical effects:

[0027] The present invention proposes a matte-coated lens and a manufacturing method thereof. The matte-coated lens is manufactured using the widely used AG diaphragm material, without the need for expensive atomizing molds. On the one hand, this greatly reduces manufacturing costs and can also simplify the processing technology to a certain extent, thereby improving production efficiency. On the other hand, the matte-coated lens obtained also has good optical properties. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the structure of a coated lens in the prior art;

[0029] Figure 2 2 is a schematic structural diagram of a matte coated lens according to a first embodiment of the present invention;

[0030] Figure 3 is a schematic structural diagram of a matte coated lens according to a second embodiment of the present invention;

[0031] Figure 4 is a schematic structural diagram of a matte coated lens according to a third embodiment of the present invention;

[0032] Figure 5 2 is a schematic structural diagram of a matte-coated lens according to a fourth embodiment of the present invention;

[0033] Figure 6 is a schematic structural diagram of a matte-coated lens according to a fifth embodiment of the present invention;

[0034] Figure 7 4 is a flow chart of a method for manufacturing a matte-coated lens according to a sixth embodiment of the present invention. DETAILED DESCRIPTION

[0035] To further illustrate various embodiments, the present invention is provided with accompanying drawings. These drawings form part of the present disclosure and are primarily used to illustrate the embodiments and, in conjunction with the relevant description in the specification, to explain the operating principles of the embodiments. By referring to these drawings, one of ordinary skill in the art will understand other possible embodiments and the advantages of the present invention. The components in the figures are not drawn to scale, and similar reference numerals are generally used to represent similar components.

[0036] The present invention will now be further described with reference to the accompanying drawings and specific embodiments.

[0037] Example 1

[0038] like Figure 2 As shown, this embodiment provides a matte coated lens 100, including a lens substrate 10, an AG film 20, a coating layer 30, and a filling protective layer 40. The lens substrate 10 is an optical lens made of a light-transmitting material, for example, polycarbonate (PC) or nylon (PA). In some other embodiments, the lens substrate 10 can also be made of PMMA or other synthetic resins or glass. In this embodiment, the lens substrate 10 adopts PC plastic or PA resin lens. These two materials are widely used as substitutes for glass eyeglass lenses due to their excellent light transmittance and excellent impact resistance.

[0039] AG (Anti-Glare) film 20, also known as matte or frosted protective film, scatters light through its rough surface texture, reducing specular reflection and thus glare. It is commonly used for surface protection on some computer screens. It can reduce bright spots caused by reflection, allowing the screen to maintain good visibility at different angles and reducing the interference of ambient light on the screen content, making the screen content easier to see. AG film works by scattering light through the tiny concave and convex structures on its surface. These structures cause the incident light to be reflected in different directions, thereby reducing the amount of light directly reflected into the viewer's eyes. This scattering effect ensures that the screen remains highly readable even in direct sunlight. AG film is a currently known membrane material. It can be PET, TAC, PMMA, PC, or PA membrane with AG functionality, manufactured using methods such as particle addition or phase separation technology. Companies such as DNP, Electrical Engineering, 3M, ClearCal, Lexerd, Celicous, iLLumiShield, Skinomi, i-Tronixs, GENERIC, Book Pub, Wing King Technology, and Excelite all have mature products that are now widely used and easily available. Their production process is mature and will not be elaborated on here.

[0040] The AG film 20 is a film material including a first surface 21 and a second surface 22 opposite to the first surface 21. The first surface 21 is a concave-convex surface, while the second surface 22 is a flat surface. Of course, in other embodiments, the second surface 22 of the AG film 20 may also be a concave-convex surface.

[0041] In this embodiment, the lens substrate 10 is bonded to the second surface 22 of the AG film 20. The lens substrate 10 is manufactured using a high-temperature melt-transparent polymer material (such as PC, PA, PMMA, etc.) and subjected to an intramolecular injection molding process into a mold cavity where the AG film 20 is positioned. This allows a layer of the AG film 20 to be directly and firmly attached to the optical polymer lens substrate 10. The polymer materials of the lens substrate 10 are preferably heat-resistant and impact-resistant, such as the PC and PA materials mentioned above, to reduce the safety risks of damage to the lens substrate 10 caused by impact and resulting in eye injury. At the same time, to ensure the reliability of the bond between the lens substrate 10 and the AG film 20 and to ensure the final optical performance of the lens, it is preferred to use the same material for the lens substrate 10 and the AG film 20 for intramolecular injection molding, such as PC.

[0042] This embodiment uses a lens base 10 combined with an AG film 20 to provide the outer surface of the lens body with a frosted surface. Compared to the prior art method of manufacturing a body layer 1 with a frosted surface 11 by injection molding in an atomizing mold, this embodiment not only reduces manufacturing costs, but also, because the AG film 20 can be manufactured using methods such as particle addition, phase separation technology, chemical etching, or physical sandblasting, the performance of the concave and convex surface (atomized surface) of the AG film 20 is better than that of the atomized surface formed by injection molding in an atomizing mold. This also provides a more favorable basic condition for the subsequent coating layer 30 operation, so that the matte coated lens 100 finally manufactured not only has a lower manufacturing cost, but also has excellent optical performance and atomized appearance.

[0043] The coating layer 30 is bonded to the first surface 21 of the AG film 20. The coating layer 30 is defined as being located outside the AG film 20, with the area of the coating layer 30 facing away from the AG film 20 being the exterior. The coating layer 30 can reflect light directed from the exterior toward the matte coated lens 100. The coating layer 30 is formed through a coating process. The coating process, for example, employs vacuum evaporation. Vacuum evaporation involves placing a low-refractive index material (which can be any of silicon dioxide SiO2 and magnesium fluoride MgF2), a high-refractive index material (which can be any of titanium dioxide TiO2, zirconium oxide ZrO2, and tantalum oxide Ta2O5), or a metal material (which can be any of aluminum and indium) into a metal container, creating a vacuum environment within the container, and then vaporizing the coating material through resistance or electron beam heating, depositing it on the surface of the target (lens). Since the vacuum evaporation method can employ well-known methods such as sputtering, electron beam evaporation, and ion beam evaporation, a detailed description thereof will not be provided here.

[0044] The coating layer 30 is a thin layer of nearly uniform thickness. Therefore, the outer surface 31 of the coating layer 30 is formed into a concave and convex surface, giving the lens a metallic, hazy appearance. However, such coated lenses are susceptible to scratching due to their low surface hardness, particularly for lenses made of materials such as PC plastic or PA resin. To address this susceptibility to scratching, a protective layer can be formed on the lens surface. In this embodiment, a leveling protective layer 40 is also incorporated onto the coating layer 30. This leveling protective layer 40 has a smooth outer surface, thereby flattening any uneven outer surface 31 of the coating layer, thereby giving the lens a transparent field of view. The leveling protective layer 40 can be a strengthening layer 41 formed by at least partially immersing the lens in a container containing a strengthening coating solution. Thus, the coating layer 30 is protected by the leveling protective layer 40, and its surface hardness is also increased, thereby enhancing wear resistance. In some other embodiments, the strengthening treatment layer 41 is combined with the surface of the lens combination composed of the lens base 10, the AG film 20 and the coating layer 30 to form an overall outer covering effect. In this way, the lens base 10, the AG film 20 and the coating layer 30 are all protected by the strengthening treatment layer 41, and the protection effect is better.

[0045] The matte-coated lens 100 provided in this embodiment is manufactured using the widely used AG film material. This eliminates the need for expensive atomizing molds, significantly reducing manufacturing costs and simplifying the processing process to a certain extent, further improving production efficiency. The matte-coated lens 100 manufactured using AG film, where the frosted surface of the AG film, combined with the coating layer, reflects external light, thereby cleverly concealing the wearer's eyes from view and protecting their privacy. The matte properties of the AG film's concave and convex surfaces prevent light from being directly reflected back to the viewer, but instead appear soft and glare-free. When used in ordinary glasses, sunglasses, or goggles, such lenses create a softer, more pleasant impression. Furthermore, the wearer's field of view remains clear, significantly enhancing the wearing experience.

[0046] Example 2

[0047] Reference Figure 3In this embodiment, a matte coated lens 100a is provided. The difference between this embodiment and embodiment 1 is that the leveling protective layer 40a in this embodiment is not a strengthening treatment layer formed by immersing the lens in a container filled with a strengthening coating solution. The rest of this embodiment is the same as embodiment 1. In this embodiment, the leveling protective layer 40a includes a first adhesive layer 42 and a protective lens layer 43. The protective lens layer 43 is adhered to the concavo-convex outer surface 31 of the coating layer 30 through the first adhesive layer 42. The protective lens layer 43 can play a role of reinforcement and protection, and the first adhesive layer 42 can level the concavo-convex outer surface 31 of the coating layer 30. This process does not have high requirements for equipment and raw materials, and the operation is also simpler.

[0048] Example 3

[0049] Reference Figure 4 This embodiment provides a matte-coated lens 100b. This embodiment differs from Example 1 in that the lens substrate 10 of this embodiment is not bonded to the AG film 20 using in-film injection molding. Instead, a second adhesive layer 50 is provided to bond the lens substrate 10 to the second surface 22 of the AG film 20. The remainder of this embodiment is the same as Example 1. This embodiment simplifies the manufacturing process for the matte-coated lens. However, because the lens substrate 10 and the AG film 20 are bonded via adhesive, the lens's performance and stability are slightly inferior to that of Example 1.

[0050] Example 4

[0051] Reference Figure 5 In this embodiment, a matte coated lens 100c is provided. The difference between this embodiment and embodiment 3 is that the leveling protective layer 40a in this embodiment is not a strengthening treatment layer formed by immersing the lens in a container filled with a strengthening coating solution. The rest of this embodiment is the same as embodiment 3. In this embodiment, the leveling protective layer 40a includes a first adhesive layer 42 and a protective lens layer 43. The protective lens layer 43 is adhered to the concavo-convex outer surface 31 of the coating layer 30 through the first adhesive layer 42. The protective lens layer 43 can play a role of reinforcement and protection, and the first adhesive layer 42 can level the concavo-convex outer surface 31 of the coating layer 30. This process does not have high requirements for equipment and raw materials, and the operation is also simpler.

[0052] Example 5

[0053] Reference Figure 6In this embodiment, a matte-coated lens 100d is provided. The difference from Example 1 is that a functional layer 60 is incorporated between the lens substrate 10 and the AG film 20, and the remainder is the same as in Example 1. The functional layer 60 may include one or more of a polarizing layer, a color-changing layer, an ultraviolet light filter layer, and a blue light filter layer to provide more functions and further enhance the protective effect. For example, the polarizing layer can impart a polarizing function to the lens, filtering out stray light and reducing glare caused by reflections from water, snow, or sunlight. It can also reduce strong light stimulation, improve visual clarity, and alleviate visual fatigue. The functional layer 60 can be combined with the AG film 20 by the aforementioned intramold injection molding method, or by an adhesive layer. Similarly, the lens substrate 10 can be combined with the functional layer 60 by the aforementioned intramold injection molding method, or by an adhesive layer.

[0054] In this embodiment, the functional layer 60 is bonded between the lens base 10 and the AG film 20 as an example. However, the present invention is not limited thereto. In other embodiments, the functional layer 60 can be bonded to the inner side of the lens base 10, which is also a feasible technical solution.

[0055] Furthermore, the leveling protective layer 40 in this embodiment can be a strengthening treatment layer 41 formed by at least partially immersing the lens in a container containing a strengthening coating solution. Of course, as another embodiment, the leveling protective layer can also include an adhesive layer and a protective lens layer. In this embodiment, the protective lens layer is bonded to the uneven outer surface of the coating layer via the adhesive layer. The protective lens layer can provide both reinforcement and protection, and the adhesive layer can level out the uneven outer surface of the coating layer.

[0056] Example 6

[0057] Reference Figure 7 This embodiment provides a method for manufacturing a matte coated lens 100, wherein the matte coated lens 100 is the matte coated lens 100 provided in Example 1, and the method comprises the following steps:

[0058] S1: Provide an AG film 20 and a molding die with a cavity; the AG film 20 is a membrane material, including a first surface 21 and a second surface 22 opposite to the first surface 21, wherein the first surface 21 is a concave-convex surface;

[0059] S2: Positioning the AG film 20 in the mold cavity, wherein the concavoconvex first surface 21 of the AG film 20 is positioned away from the mold cavity;

[0060] S3: Using a high-temperature molten material into a mold cavity where the AG film 20 is positioned, a lens substrate 10 attached to the AG film 20 is manufactured by an intramold injection molding process; specifically, the lens substrate 10 is attached to the flat second surface 22 of the AG film 20;

[0061] S4: forming a coating layer 30 on the concavo-convex first surface 21 of the AG film 20 by a coating process; the coating process adopts, for example, a vacuum evaporation method;

[0062] S5: The lens produced in step S4 is at least partially immersed in a container containing a strengthening coating solution and subjected to a strengthening process to form a strengthening layer 41. The strengthening layer 41 serves as a filler and protective layer 40. The strengthening layer 41 is formed at least on the coating layer 30. The strengthening process may include baking.

[0063] More specifically, in step S2 , positioning the AG film 20 in the mold cavity further includes pre-bending the AG film 20 to fit the mold cavity, thereby providing the curvature required for the molded lens.

[0064] In some other embodiments, a strengthening treatment layer 41 is formed on the surface of the lens combination composed of the lens substrate 10, the AG film 20 and the coating layer 30 to form a covering effect. In this way, the lens substrate 10, the AG film 20 and the coating layer 30 are all protected by the strengthening treatment layer 41, and the protection effect is better.

[0065] Although the present invention has been particularly shown and described in conjunction with preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made to the present invention without departing from the spirit and scope of the invention as defined in the appended claims, and all such changes are within the scope of protection of the present invention.

Claims

1. A matte coated lens, comprising a lens substrate, wherein the lens substrate is an optical lens made of a light-transmitting material, characterized in that: It also includes an AG film, a coating layer and a filling protective layer. The AG film is a film material, including a first surface and a second surface opposite to the first surface, wherein the first surface is a concave-convex surface; the coating layer is bonded to the first surface of the AG film, and the lens substrate is bonded to the second surface of the AG film. It is defined that the coating layer is located on the outside of the AG film, and the filling protective layer is at least bonded to the outer surface of the coating layer, and the filling protective layer has a flat outer surface.

2. The matte coated lens according to claim 1, characterized in that: The filling and protection layer is a glue layer bonded to a protection lens layer; or, the filling and protection layer is a strengthening treatment layer.

3. The matte coated lens according to claim 1, wherein: The lens substrate is formed by injecting a high-temperature molten material into a mold cavity where the AG film is positioned, so that the lens substrate is directly bonded to the second surface of the AG film.

4. The matte-coated lens according to claim 1, wherein: The invention also includes an adhesive layer, wherein the adhesive layer is used to adhere the lens substrate to the second surface of the AG film.

5. The matte coated lens according to claim 1, wherein: The filling protection layer is a strengthening treatment layer, and the strengthening treatment layer is combined with the outer surface of the lens assembly composed of the lens substrate, the AG film and the coating layer to form an overall outer covering.

6. The matte coated lens according to claim 1, wherein: The lens substrate is made of PC or PA material.

7. The matte coated lens according to claim 1, wherein: The lens substrate and the AG film are made of the same material.

8. The matte coated lens according to claim 1, wherein: It also includes a functional layer, which is combined with the lens substrate. The functional layer includes one or more of: a polarizing layer, a color-changing layer, an ultraviolet light filtering layer, and a blue light filtering layer.

9. A method for manufacturing a matte coated lens, characterized in that: The matte coated lens is the matte coated lens according to claim 1, comprising the following steps: S1: providing an AG film and a molding die having a cavity; the AG film is a membrane material, comprising a first surface and a second surface opposite to the first surface, wherein the first surface is a concave-convex surface; S2: Positioning an AG film in a mold cavity, wherein a first surface of the AG film is positioned away from the mold cavity; S3: using a high-temperature molten material to form a lens substrate attached to the AG film by an intramold injection molding method into a mold cavity where the AG film is positioned; the lens substrate is attached to the second surface of the AG film; S4: forming a coating layer on the first surface of the AG film through a coating process; S5: forming a strengthening treatment layer by at least partially immersing the lens produced in step S4 in a container filled with a strengthening coating solution and subjecting the lens to a strengthening process, wherein the strengthening treatment layer is at least formed on the coating layer; the strengthening treatment layer serves as a filling and protective layer.

10. The method for manufacturing a matte coated lens according to claim 9, wherein: In step S5: the strengthening treatment layer is formed on the surface of the lens assembly consisting of the lens substrate, the AG film and the coating layer to form an overall outer coating.

11. The method for manufacturing a matte coated lens according to claim 9, wherein: In step S2: the positioning of the AG film in the mold cavity further includes pre-bending the AG film to fit the mold cavity; and / or In step S3: the high temperature melting material is a high temperature melting polymer material; and / or In step S4: the coating process adopts vacuum evaporation method.

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