Manufacturing method and manufacturing apparatus of spectacle lens

Abstract

To provide a manufacturing method and a manufacturing apparatus of a spectacle lens, capable of satisfactorily coating a lens surface with coating liquid.SOLUTION: The manufacturing method of spectacle lens includes a coating process for relatively moving a lens base material L and a jet nozzle 22 in a lens diameter direction X, and simultaneously ejecting from the jet nozzle 22 coating liquid to a lens surface L1 of the lens base material L rotating about a rotation axis La extending through the lens base material L in a lens thickness direction Y. In the coating process, coating liquid is ejected from the jet nozzle 22 with a nozzle axis 22a of the jet nozzle 22 being inclined to the rotation axis La.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method and an apparatus for manufacturing eyeglass lenses. [Background technology]

[0002] Conventionally, a method for manufacturing eyeglass lenses is known that includes a coating step in which a lens substrate and a spray nozzle are moved relative to each other in the lens radial direction, and a coating liquid is sprayed from the spray nozzle onto the lens surface of the lens substrate that rotates around a rotation axis that extends through the lens substrate in the lens thickness direction (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-85610 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in such a coating process, centrifugal force caused by the rotation of the lens substrate acts on the coating liquid placed on the lens surface, and if the lens surface to which the coating liquid is to be applied has poor compatibility with the coating liquid, it may be difficult to apply the coating liquid well onto the lens surface.

[0005] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a method and apparatus for manufacturing eyeglass lenses that are simple in construction and that are capable of applying a coating liquid to the lens surface in a satisfactory manner. [Means for solving the problem]

[0006] The method for manufacturing eyeglass lenses of the present invention includes a coating step in which a lens substrate and a spray nozzle are moved relative to each other in the lens radial direction, and a coating liquid is sprayed from the spray nozzle onto the lens surface of the lens substrate, which rotates around a rotation axis that extends through the lens substrate in the lens thickness direction, and the above-mentioned problem is solved by spraying the coating liquid from the spray nozzle in the coating step while the nozzle axis of the spray nozzle is inclined with respect to the rotation axis. The eyeglass lens manufacturing apparatus of the present invention comprises a lens rotation support unit that supports the lens substrate rotatably around a rotation axis that extends through the lens substrate in the lens thickness direction, an ejection nozzle that ejects a coating liquid onto the lens surface of the lens substrate, and a radial relative movement unit that moves the lens substrate and the ejection nozzle relatively in the lens radial direction, and the ejection nozzle is installed with the nozzle axis of the ejection nozzle inclined with respect to the rotation axis during the coating process, thereby solving the above problem. [Effects of the Invention]

[0007] In the present invention, the coating liquid can be applied to the lens surface satisfactorily. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is an explanatory diagram showing a schematic configuration of a spectacle lens manufacturing apparatus according to an embodiment of the present invention; [Figure 2] FIG. 10 is an explanatory diagram showing one embodiment of a coating step as viewed from the side. [Figure 3] FIG. 10 is an explanatory diagram showing one embodiment of a coating step as viewed from above. [Figure 4] FIG. 4 is an explanatory diagram illustrating one embodiment of a coating step. DETAILED DESCRIPTION OF THE INVENTION

[0009] An eyeglass lens manufacturing apparatus 10 and manufacturing method according to one embodiment of the present invention will be described below with reference to the drawings. [Eyeglass lens manufacturing equipment]

[0010] First, the eyeglass lens manufacturing apparatus 10 of this embodiment will be described below.

[0011] The manufacturing apparatus 10 manufactures eyeglass lenses by performing various processes on a transparent lens substrate L, and as shown in Figures 1 and 2, it is equipped with an application device 20 that applies a coating liquid to the lens surface L1 of the lens substrate L, and a UV irradiation device 30 that hardens the coating liquid.

[0012] Each component of the manufacturing apparatus 10 will be specifically described below.

[0013] First, in this embodiment, as shown in Figure 1, multiple (three) coating devices 20 are provided. Specifically, there are provided a first coating device 20 that applies a coating liquid (primer liquid) for forming a primer layer on the lens surface L1, a second coating device 20 that applies a coating liquid (photochromic liquid) for forming a photochromic layer on the primer layer formed on the lens surface L1, and a third coating device 20 that applies a coating liquid for forming a protective layer on the photochromic layer formed on the lens surface L1.

[0014] Hereinafter, the common aspects of the coating apparatuses 20 will be specifically described.

[0015] Each coating device 20 coats the lens surface L1 of the lens substrate L with a coating liquid, and as shown in FIG. 2, is equipped with a lens rotation support section 21 that rotatably supports the lens substrate L, a spray nozzle 22 that sprays the coating liquid onto the lens surface L1 of the lens substrate L, a thickness direction relative movement section (not shown) that moves the lens substrate L and the spray nozzle 22 relatively in the lens thickness direction Y, and a radial direction relative movement section (not shown) that moves the lens substrate L and the spray nozzle 22 relatively in the lens radial direction X.

[0016] As shown in Figures 2 and 3, the lens rotation support part 21 adsorbs and holds the lens back surface L2 opposite to the lens surface L1 of the lens substrate L, and supports the lens substrate L rotatably around a rotation axis La that passes through the lens substrate L (specifically, the center of the lens surface L1) and extends in the lens thickness direction Y. In this embodiment, the lens rotation support section 21 supports the lens substrate L so that the lens surface L1 faces upward, as shown in FIG.

[0017] As shown in FIG. 2, in the coating process, the spray nozzle 22 is arranged above the lens substrate L supported by the lens rotation support part 21, and is configured to spray the coating liquid downward onto the lens surface L1 of the lens substrate L in a pulsed or continuous manner. As shown in Figures 2 and 3, during the coating process, the spray nozzle 22 is configured to spray the coating liquid with its nozzle axis 22a (the direction in which the coating liquid is sprayed) inclined with respect to the rotation axis La of the lens substrate L, as will be described in detail later. In the example shown in FIGS. 2 to 4, as can be seen from FIG. 2, within the plane defined by the lens radial direction X and the lens thickness direction Y (i.e., when viewed in a direction perpendicular to the lens radial direction X and the lens thickness direction Y), the nozzle axis 22a is inclined with respect to the rotation axis La, and as can be seen from FIG. 3 (and FIG. 2), when viewed in the lens thickness direction Y, the extension direction of the nozzle axis 22 overlaps with the lens radial direction X. Note that the symbol 22b in FIG. 3 indicates the tip (lower end) of the ejection nozzle 22, and the symbol 22c in FIG. 3 indicates a portion of the ejection nozzle 22 located above the tip 22b.

[0018] As shown in Figures 2 and 3, the radial relative movement unit (not shown) moves the lens substrate L and the ejection nozzle 22 relatively in the lens radial direction X, and in this embodiment, it is configured to move the lens rotation support unit 21 in the lens radial direction X.

[0019] As shown in FIG. 2, the thickness direction relative movement unit (not shown) moves the lens substrate L and the ejection nozzle 22 relatively in the lens thickness direction Y, and in this embodiment, it is configured to move the ejection nozzle 22 in the lens thickness direction Y.

[0020] The UV irradiation device 30 cures the photocurable coating liquid applied to the lens surface L1 of the lens substrate L by each coating device 20 by irradiating it with UV light, and in this embodiment, as shown in Figure 1, it is provided downstream of each of the multiple (three) coating devices 20.

[0021] In addition to the devices 20 and 30 described above, the eyeglass lens manufacturing apparatus in this embodiment also includes devices installed downstream of devices 20 and 30, such as a back-side cutting device (not shown) that cuts the lens back surface L2 side of the lens substrate L to form a shape that satisfies the prescription of the eyeglass lens wearer, a polishing device (not shown) that polishes the lens back surface L2 of the lens substrate L after the back-side cutting process, and an edge processing device (not shown) that cuts the outer edge of the lens substrate L into a shape that will fit into the periphery of an eyeglass frame. [Method of manufacturing eyeglass lenses]

[0022] Next, a method for manufacturing a spectacle lens using the manufacturing apparatus 10 of this embodiment will be described below.

[0023] The method for manufacturing a spectacle lens includes a coating step of applying a coating liquid to the lens surface L1 of the lens substrate L, and a UV irradiation step of curing the coating liquid.

[0024] Each step of the method for manufacturing eyeglass lenses will be specifically described below.

[0025] First, in this embodiment, the coating process is performed multiple times (three times). Specifically, in this embodiment, there are provided a first coating process of applying a coating liquid (primer liquid) for forming a primer layer on the lens surface L1, a second coating process of applying a coating liquid (photochromic liquid) for forming a photochromic layer on the primer layer formed on the lens surface L1, and a third coating process of applying a coating liquid for forming a protective layer on the photochromic layer formed on the lens surface L1.

[0026] The coating method common to each coating step will be specifically described below.

[0027] First, in the coating step, the lens substrate L and the spray nozzle 22 are moved relative to each other in the lens radial direction X, and the coating liquid is sprayed from the spray nozzle 22 onto the lens surface L1 of the lens substrate L rotating about the rotation axis La. Specifically, in this embodiment, the lens substrate L (lens rotation support part 21) is moved in the lens radial direction X relative to the ejection nozzle 22, which is fixed in the lens radial direction X, so that the application area R where the application liquid is applied to the lens surface L1 moves from the outer periphery side toward the inner periphery side (center side) of the lens surface L1, and the application liquid is ejected from the ejection nozzle 22 onto the lens surface L1 of the rotating lens substrate L. By applying the coating liquid in this manner, in this embodiment, the coating area R where the coating liquid is applied to the lens surface L1 starts from the outer periphery of the lens surface L1 and moves spirally toward the center of the lens surface L1, as can be seen from the trajectory T of the nozzle axis 22a on the lens surface L1 shown in Figure 4.

[0028] Furthermore, in the coating process, as shown in FIG. 2, the coating liquid is sprayed from the spray nozzle 22 with the nozzle axis 22a tilted relative to the rotation axis La so that the angle θ between the lens surface L1 and the nozzle axis 22a is smaller than when the nozzle axis 22a of the spray nozzle 22 is set parallel to the rotation axis La. More specifically, in this embodiment, as shown in FIGS. 2 and 3, the application liquid is sprayed in a state in which the nozzle axis 22a is inclined so as to move closer to the lens substrate L in the relative movement direction X of the spray nozzle 22 with respect to the lens substrate L (rearward, in the example shown in FIG. 2, to the left side of the drawing). Here, the inclination angle of the nozzle axis 22a with respect to the rotation axis La is preferably set to 3 to 20°, and more preferably set to 8 to 12°. Furthermore, the angle θ formed between the lens surface L1 and the nozzle axis 22a is preferably set to 39 to 81°, and more preferably 72 to 76°. The inclination angle of the nozzle axis 22a relative to the rotation axis La and the inclination angle θ are both inclination angles within a plane defined by the lens radial direction X and the lens thickness direction Y (when viewed in a direction perpendicular to the lens radial direction X and the lens thickness direction Y), as shown in FIG. Furthermore, when the coating liquid ejected from ejection nozzle 22 reaches lens surface L1, the momentum of the coating liquid is maintained (without dripping) and the angle range above (39 to 81°, more preferably 72 to 76°) is maintained; in other words, to ensure that the angle of incidence of the coating liquid with respect to lens surface L1 falls within the above angle range, it is preferable to set the nozzle inner diameter (diameter) of ejection nozzle 22 to 0.35 mm or less, the coating pressure (pressure applied to the coating liquid when ejected) to 0.055 MPa or more, the ejection rate of the coating liquid to 0.12 g / sec or more, and the distance between the tip of ejection nozzle 22 and lens surface L1 in the lens thickness direction Y to 3 to 5 mm.

[0029] Furthermore, in the application process, in order to maintain the distance between the lens surface L1 and the ejection nozzle 22 in the lens thickness direction Y within a predetermined range (specifically, 3.0 to 5.0 mm), the lens surface L1 and the ejection nozzle 22 are moved relative to each other in the lens thickness direction Y depending on the relative positional relationship between the lens surface L1 and the ejection nozzle 22 in the lens radial direction X. In this embodiment, the ejection nozzle 22 is moved in the lens thickness direction Y with respect to the lens substrate L which is fixed in the lens thickness direction Y.

[0030] The UV irradiation process is a process in which the coating liquid applied to the lens surface L1 in each coating process is cured by irradiating it with UV light. In this embodiment, as can be seen from Figure 1, this process is performed after each of the multiple (three) coating processes.

[0031] In addition to the above-mentioned steps, the manufacturing method for eyeglass lenses in this embodiment also includes, as downstream steps of the coating step, a back-side cutting step in which the lens back surface L2 of the lens substrate L is cut using a back-side cutting device (not shown) to form a shape that satisfies the prescription of the eyeglass lens wearer, a polishing step in which the lens back surface L2 of the lens substrate L is polished using a polishing device (not shown) after the back-side cutting step, and an edging step in which the outer edge of the lens substrate L is cut using an edging device (not shown) into a shape that will fit into the periphery of an eyeglass frame.

[0032] In the eyeglass lens manufacturing apparatus 10 and manufacturing method of the present embodiment obtained in this manner, during the coating process, the coating liquid is sprayed from the spray nozzle 22 with the nozzle axis 22a of the spray nozzle 22 tilted with respect to the rotation axis La.This reduces the angle θ between the lens surface L1 and the nozzle axis 22a, and increases the range (area) over which the coating liquid sprayed from the spray nozzle 22 hits the lens surface L1, compared to when the coating liquid is sprayed with the spray nozzle 22 positioned so that the nozzle axis 22a is parallel to the rotation axis La.As a result, even if the compatibility between the lens surface L1 and the coating liquid is poor, the coating liquid can be applied to the lens surface L1 well in a short time. That is, if the compatibility between the lens surface L1 and the coating liquid is poor (the coating liquid does not easily wet the lens surface L1), there is a risk that the coating liquid will not be applied well to the lens surface L1, for example, because the rotation of the lens substrate L during application causes the centrifugal force acting on the coating liquid on the lens surface L1 to fly off the coating liquid. However, in this embodiment, the nozzle axis 22a of the spray nozzle 22 is tilted with respect to the rotation axis La to reduce the angle θ between the lens surface L1 and the nozzle axis 22a, and widen the area over which the coating liquid sprayed from the spray nozzle 22 hits the lens surface L1. This makes it easier for the subsequently sprayed coating liquid to connect to the coating liquid that was previously deposited on the lens surface L1, thereby increasing the connectivity between the coating liquids and improving the applyability of the coating liquid to the lens surface L1. Furthermore, by improving the connection between the coating liquids in this way and improving the adhesion of the coating liquid to the lens surface L1, the adhesion of the coating liquid can be improved without reducing the rotation speed of the lens substrate L or the relative movement speed between the lens substrate L and the ejection nozzle 22.

[0033] Furthermore, in the coating process, by spraying the coating liquid from the spray nozzle 22 in a state in which the nozzle axis 22a is tilted so that it moves closer to the front side in the direction of relative movement of the spray nozzle 22 with respect to the lens substrate L as it approaches the lens substrate L, the momentum of the coating liquid can be used to more easily connect the subsequently sprayed coating liquid (the coating liquid in the coating region R2 shown in FIG. 4) to the coating liquid that is adjacent in the lens radial direction X and that has just adhered to the lens surface L1 (the coating liquid in the coating region R1 shown in FIG. 4), thereby increasing the connectivity between the coating liquids and improving the applicability of the coating liquid to the lens surface L1.

[0034] Furthermore, by setting the inclination angle of the nozzle axis 22a relative to the rotation axis La to 3 to 20°, it is possible to improve the application properties of the application liquid while ensuring ease of position adjustment of the application end point position. In other words, if the tilt angle is set to be greater than 20°, it becomes difficult to adjust the position of the application end point (in this embodiment, near the center of the lens surface L1) (i.e., it becomes difficult to adjust the position so that the application of the coating liquid ends at the intended application end point), but by setting the tilt angle to 20° or less, it becomes easy to adjust the position of the application end point. Furthermore, when the inclination angle is set to 3° or more, the area over which the coating liquid sprayed from the spray nozzle 22 hits the lens surface L1 becomes significantly wider, making it easier for the subsequently sprayed coating liquid to connect to the coating liquid that has just adhered to the lens surface L1, thereby increasing the connectivity between the coating liquids and improving the adhesion of the coating liquid to the lens surface L1.

[0035] Furthermore, when the coating process is a process of applying a coating liquid (in this embodiment, a photochromic liquid) to a lens surface L1 on whose surface a primer layer formed from a solvent-based primer liquid is formed, the effect of improving the coating properties of the coating liquid described above becomes more pronounced. That is, compared to a primer layer formed from a water-based primer liquid, a primer layer formed from a solvent-based primer liquid has a larger contact angle and poorer compatibility with the coating liquid (light-controlling liquid), and therefore the effect of improving the coating properties of the coating liquid described above becomes more pronounced. The solvent-based primer liquid mentioned above is a primer liquid such as TR-SC-P (manufactured by Tokuyama Corporation) which is prepared by dissolving various raw materials such as polyurethane resin in a hydrocarbon organic solvent or a hydrocarbon ester, and the water-based primer liquid mentioned above is a primer liquid such as NJ-321A (manufactured by Tokuyama Corporation) which is prepared by dissolving various raw materials such as polyurethane resin in water as a solvent.

[0036] Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments, and various design modifications can be made without departing from the present invention as defined in the claims, such as configuring an eyeglass lens manufacturing apparatus 10 and manufacturing method by arbitrarily combining each configuration of the above or following embodiments and variations.

[0037] For example, in the above-described embodiment, the lens substrate L is described as a semi-finished lens, that is, a semi-finished lens that is a semi-finished product in which the shape of the lens front surface side, which has a convex curved surface (facing outward when worn) (a convex curved surface near the center) is in a completed state, and the shape of the lens back surface L2, which has a concave curved surface (facing the eyeball when worn) (a concave curved surface near the center), is processed in the above-described grinding process to achieve a shape that satisfies the prescription of the eyeglass lens wearer, but the specific form of the lens substrate L is not limited to the above. Furthermore, in the above-described embodiment, the lens surface L1 of the lens substrate L to which the coating liquid is applied is described as the lens surface, but the lens surface L1 to which the coating liquid is applied is not limited to the above.

[0038] Furthermore, in the above-described embodiment, the coating liquid applied to the lens surface L1 of the lens substrate L has been described as being a photochromic liquid or the like for forming a photochromic layer, but the specific type of coating liquid may be any type that can be applied to the lens surface L1 of the lens substrate L.

[0039] Furthermore, in the above-described embodiment, the application process has been described as moving the lens substrate L (lens rotation support part 21) in the lens radial direction X relative to the ejection nozzle 22, which is fixed in the lens radial direction X. However, the manner of relative movement between the lens substrate L and the ejection nozzle 22 in the lens radial direction X in the application process is not limited to the above. Specifically, the ejection nozzle 22 may be moved in the lens radial direction X relative to the lens substrate L (lens rotation support part 21), which is fixed in the lens radial direction X, or both the lens substrate L and the ejection nozzle 22 may be moved in the lens radial direction X.

[0040] Furthermore, in the above-described embodiment, in the coating process, the lens substrate L and the ejection nozzle 22 are moved relative to each other in the lens radial direction X so that the coating area R, where the coating liquid is applied to the lens surface L1, moves from the outer periphery side toward the inner periphery side of the lens surface L1. However, the specific manner in which the coating area R moves is not limited to the above, and for example, the lens substrate L and the ejection nozzle 22 may be moved relative to each other so that the coating area R moves from the inner periphery side toward the outer periphery side of the lens surface L1.

[0041] Furthermore, in the above-described embodiment, it has been described that in the coating process, the coating liquid is sprayed from the spray nozzle 22 in a state in which the nozzle axis 22a is tilted so as to move closer to the front side in the relative movement direction of the spray nozzle 22 with respect to the lens substrate L as it approaches the lens substrate L. However, the manner in which the nozzle axis 22a is tilted is not limited to the above, and any tilt is possible as long as the nozzle axis 22a is tilted with respect to the rotation axis La of the lens substrate L in the coating process.

[0042] Furthermore, in the above-described embodiment, the coating liquid is sprayed downward from the spray nozzle 22 arranged above the lens substrate L during the coating process. However, the positional relationship between the lens substrate L and the spray nozzle 22 during the coating process is not limited to the above. For example, the coating liquid may be sprayed sideways from the spray nozzle 22 arranged horizontally to the side of the lens substrate L, or the coating liquid may be sprayed upward from the spray nozzle 22 arranged below the lens substrate L.

[0043] Furthermore, in the above-described embodiment, in the coating process, in order to maintain the distance between the lens substrate L and the ejection nozzle 22 in the lens thickness direction Y within a predetermined range, the ejection nozzle 22 is moved in the lens thickness direction Y relative to the lens substrate L, which is fixed in the lens thickness direction Y, depending on the relative positional relationship between the lens surface L1 and the ejection nozzle 22 in the lens radial direction X. However, the manner of relative movement between the lens substrate L and the ejection nozzle 22 in the lens thickness direction Y in the coating process is not limited to the above. Specifically, the lens substrate L may be moved in the lens radial direction X relative to the ejection nozzle 22, which is fixed in the lens thickness direction Y, or both the lens substrate L and the ejection nozzle 22 may be moved in the lens thickness direction Y. [Explanation of symbols]

[0044] 10... Manufacturing equipment 20 Coating device 21 Lens rotation support part 22 Spout nozzle 22a Nozzle axis 30...UV irradiation equipment L: Lens substrate L1: Lens surface L2: Back of lens La Rotation axis X: Lens radial direction Y: Lens thickness direction R: Area where coating liquid is applied

Claims

1. A method for manufacturing eyeglass lenses, The coating process includes a step of spraying a coating liquid from the spray nozzle onto the lens surface of the lens substrate, which rotates around a rotation axis extending in the lens thickness direction through the lens substrate, while moving the lens substrate and the spray nozzle relatively in the lens diameter direction. A method for manufacturing eyeglass lenses, characterized in that, in the coating step, the coating liquid is ejected from the ejection nozzle with the nozzle axis of the ejection nozzle inclined with respect to the rotation axis.

2. The method for manufacturing eyeglass lenses according to claim 1, characterized in that, in the coating step, the nozzle axis is tilted so that as it approaches the lens substrate, it moves towards the front side in the relative movement direction of the nozzle in the lens diameter direction with respect to the lens substrate, and the coating liquid is ejected from the nozzle.

3. The method for manufacturing eyeglass lenses according to claim 1, wherein the inclination angle of the nozzle axis with respect to the rotation axis is set to 3 to 20°.

4. The method for manufacturing eyeglass lenses according to claim 1, characterized in that, in the coating step, the lens substrate and the ejection nozzle are moved relative to each other in the radial direction of the lens so that the coating area on the lens surface moves from the outer circumference to the inner circumference of the lens surface.

5. The method for manufacturing eyeglass lenses according to claim 1, characterized in that, in the coating step, the lens substrate is moved in the lens diameter direction relative to the spray nozzle which is fixed in the lens diameter direction.

6. The method for manufacturing eyeglass lenses according to claim 1, characterized in that, in the coating step, the coating liquid is ejected from the ejection nozzle positioned above the lens substrate.

7. The method for manufacturing eyeglass lenses according to claim 1, characterized in that, in the coating step, the lens surface and the ejection nozzle are moved relative to each other in the lens thickness direction according to the relative positional relationship between the lens surface and the ejection nozzle in the lens diameter direction.

8. The lens substrate has a convex curved surface and a concave curved surface. The method for manufacturing eyeglass lenses according to claim 1, characterized in that the coating step involves applying a coating solution to the lens surface, which is the lens surface.

9. The method for manufacturing eyeglass lenses according to claim 1, characterized in that the coating step is a step of applying a coating solution to the lens surface on which a primer layer formed from a solvent-based primer solution has been formed.

10. A device for manufacturing eyeglass lenses, A lens rotation support portion that supports the lens substrate so as to be rotatable about a rotation axis that extends through the lens substrate in the direction of the lens thickness, A spray nozzle for spraying the coating liquid onto the lens surface of the lens substrate, It comprises a radial relative movement unit that moves the lens substrate and the ejection nozzle relative to each other in the radial direction of the lens, The apparatus for manufacturing eyeglass lenses is characterized in that, during the coating process, the nozzle axis of the nozzle is installed in an inclined position with respect to the rotation axis.

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