Method for manufacturing an optical component and optical component

Abstract

The present invention provides a method for manufacturing an optical component and an optical component that can produce an optical component in which prisms are suppressed. [Solution] A method for manufacturing an optical component, comprising: a space formation step of forming a space surrounded by a molded substrate, a resin substrate, and a film by attaching a film to the outer circumferential surfaces of a molded substrate and a resin substrate arranged opposite each other at a predetermined interval; an injection step of injecting a polymerizable composition into the space; and a curing step of curing the polymerizable composition injected into the space to obtain a cured product, wherein the film satisfies at least one of the following conditions: when attached to the resin substrate and subjected to a heat resistance index test at 50°C, it does not peel off the resin substrate even when held for 3 minutes; and when attached to the resin substrate and subjected to a heat resistance index test at 50°C, its elongation rate is greater than 0% for 3 minutes.

Description

[Technical Field]

[0001] This disclosure relates to a method for manufacturing an optical component and to an optical component. [Background technology]

[0002] One method for manufacturing resins used in optical materials for plastic lenses is the casting polymerization method, in which a polymerizable composition containing monomers is injected into a mold and heated to cure. In the casting polymerization method, a polymerizable composition is prepared and degassed, then injected into a mold, heated and cured (polymerization reaction), the product is removed from the mold (release), and annealed to obtain optical materials (e.g., lenses, semi-finished blanks, etc.).

[0003] For example, Patent Document 1 describes a plastic lens manufacturing tape for which a plastic lens made of a polymerizable composition is manufactured by attaching it to the outer circumferential surfaces of two opposing substantially circular mold substrates and forming a space between the two mold substrates for manufacturing a plastic lens. The plastic lens manufacturing tape comprises a base material and an adhesive layer laminated together, has a heat resistance index greater than 0 mm and less than or equal to 10 mm, and a maximum tensile load measured in accordance with JIS Z0237 of 50 N / 10 mm or more and less than or equal to 100 N / 10 mm.

[0004] For example, Patent Document 2 describes a method for manufacturing a plastic lens for eyeglasses, comprising: a mold substrate assembly step of forming a cavity for molding a lens surrounded by two mold substrates and adhesive tape by wrapping adhesive tape around the sides of two mold substrates arranged opposite each other at a predetermined interval and fixing these mold substrates with the adhesive tape; an injection step of injecting a polymerizable composition into the cavity; and a curing step of curing the polymerizable composition to obtain a plastic lens, wherein the holding force of the adhesive tape in accordance with JIS Z 0237 is 10 mm or more or drop, and in the curing step, one or both of the two mold substrates move along the inner surface of the adhesive tape from the position fixed in the mold substrate assembly step to narrow the distance between them.

[0005] For example, Patent Document 3 describes a method for manufacturing a plastic lens for eyeglasses, comprising: a mold substrate assembly step of forming a cavity for molding a lens surrounded by the two mold substrates and adhesive tape by wrapping adhesive tape around the sides of two mold substrates arranged opposite each other at a predetermined interval and fixing these mold substrates with the adhesive tape; an injection step of injecting a polymerizable composition into the cavity; and a curing step of curing the polymerizable composition to obtain a plastic lens, wherein the adhesive tape has a structure in which an adhesive layer is formed on a tape substrate, and the elastic modulus gradient of the tape substrate perpendicular to the tape surface is 10 N / mm or less.

[0006] For example, Patent Document 4 describes a method for manufacturing a plastic lens, comprising: a mold substrate assembly step of forming a cavity for molding a lens surrounded by two mold substrates and adhesive tape by wrapping adhesive tape around the sides of two mold substrates arranged opposite each other at a predetermined distance apart and fixing these mold substrates with the adhesive tape; an injection step of injecting a polymerizable composition into the cavity; and a curing step of curing the polymerizable composition to obtain a plastic lens, wherein in the curing step, one or both of the two mold substrates move along the inner surface of the adhesive tape from the position fixed in the mold substrate assembly step, thereby narrowing the distance between them.

[0007] Patent Document 1: Japanese Unexamined Patent Publication No. 2019-162848 Patent Document 2: Japanese Unexamined Patent Publication No. 2012-196933 Patent Document 3: Japanese Unexamined Patent Publication No. 2012-196934 Patent Document 4: Japanese Unexamined Patent Publication No. 2002-248636 [Overview of the project] [Problems that the invention aims to solve]

[0008] When manufacturing optical components by curing polymerizable compositions, the cured material immediately after curing often has an uneven thickness or other characteristics. Therefore, since the hardened material immediately after curing does not meet the quality standards for optical components, conventional methods have involved polishing or other processes to ensure uniform thickness and guarantee quality. However, in order to achieve the desired size of the optical component, it is necessary to calculate in advance that polishing will be required and set the size of the hardened material before polishing to be larger. Also, the shavings generated during the polishing process are often disposed of as waste.

[0009] The prism of a hardened material is often large immediately after curing. In this disclosure, "prism" represents the non-uniformity of thickness within the cured material. For example, a large difference in thickness between the thicker and thinner parts of the cured material indicates a large prism. Even hardened materials with large prisms typically require polishing because they do not meet the quality standards for optical components. Therefore, there is a need for a method of manufacturing optical components that can produce optical components with suppressed prisms without or with minimal polishing for prism correction.

[0010] One embodiment of this disclosure aims to solve the problem of manufacturing an optical component and an optical component that can produce an optical component in which prisms are suppressed. [Means for solving the problem]

[0011] The specific means for solving the problem include the following: <1> A method for manufacturing an optical component, comprising: a space formation step of forming a space surrounded by a mold substrate, a resin substrate and a film by attaching a film to the outer circumferential surfaces of a mold substrate and a resin substrate arranged opposite each other at a predetermined interval; an injection step of injecting a polymerizable composition into the space; and a curing step of curing the polymerizable composition injected into the space to obtain a cured product, wherein the film satisfies at least one of the following conditions: when attached to the resin substrate and subjected to a heat resistance index test at 50°C, it does not peel off the resin substrate even when held for 3 minutes, and when attached to the resin substrate and subjected to a heat resistance index test at 50°C, its elongation rate is greater than 0% for 3 minutes. <2> The film satisfies both of the following conditions: when attached to the resin substrate and subjected to a heat resistance index test at 50°C, it does not peel off the resin substrate even after being held for 3 minutes; and when attached to the resin substrate and subjected to a heat resistance index test at 50°C, its elongation rate is greater than 0% after 3 minutes. <1> A method for manufacturing optical components as described above. <3> The aforementioned film exhibits a glass ball tack test at 80°C, where the distance the glass ball travels is 200 mm or less. <1> or <2> A method for manufacturing optical components as described above. <4> The polymerizable composition comprises two or more different monomers for optical materials and a polymerization catalyst, wherein the content of the polymerization catalyst is 0.01 parts by mass to 0.1 parts by mass per 100 parts by mass of the total of the two or more different monomers for optical materials, and the viscosity measured with a B-type viscometer at 25°C and 60 rpm is 30 mPa·s to 1000 mPa·s. <1> ~ <3> A method for manufacturing an optical component as described in any one of the following. <5> The polymerizable composition further comprises at least one selected from the group consisting of photochromic compounds, alcohol compounds, and visible light absorbing dyes. <4> A method for manufacturing optical components as described above. <6> The two or more different monomers for optical materials include an isocyanate compound and an active hydrogen compound which is at least one selected from the group consisting of a polythiol compound containing two or more mercapto groups, a hydroxythiol compound containing one or more mercapto groups and one or more hydroxyl groups, a polyol compound containing two or more hydroxyl groups, and an amine compound. <4> or <5> A method for manufacturing optical components as described above. <7> An optical member comprising a first layer and a second layer, wherein the average thickness of the second layer is greater than the average thickness of the first layer, and the first layer comprises a photochromic compound, an alcohol compound, and a visible light absorbing dye, has a prism difference of 0.25 mm or less, and is free from striations of 1.0 mm or longer within a radius of 15 mm from the center. <8> The second layer has a stepped shape in part of its outer periphery. <7> Optical components as described above. <9> At the center of the optical material, the value H1, which is the haze of the first layer divided by the thickness of the first layer, is higher than the value H2, which is the haze of the second layer divided by the thickness of the second layer. <7> or <8> Optical components as described above. <10> The ratio of the value H1 to the value H2 is between 1.001 and 1.500. <9> Optical components as described above. <11> A space forming step of forming a space surrounded by the pair of mold substrates and the film by attaching a film to the outer peripheral surfaces of the pair of mold substrates arranged to face each other at a predetermined interval, an injection step of injecting a polymerizable composition into the space, and a curing step of curing the polymerizable composition injected into the space to obtain a cured product. The film has a ratio of the heat resistance index measured at 30°C for 30 minutes to the heat resistance index measured at 20°C for 30 minutes of more than 0.1. In the curing step, a method for manufacturing an optical member in which the degree of polymerization of the polymerizable composition is 15% or more at 30°C. <12> The method for manufacturing an optical member according to <11>, wherein in the curing step, the degree of polymerization of the polymerizable composition is 75% or less at 30°C. <13> The method for manufacturing an optical member according to <11> or <12>, wherein the film includes an adhesive layer, and in the curing step, the degree of polymerization of the polymerizable composition is 30% or more at the elution temperature of the adhesive layer. <14> The polymerizable composition includes two or more different optical material monomers and a polymerization catalyst. The content of the polymerization catalyst with respect to a total of 100 parts by mass of the two or more different optical material monomers is 0.015 parts by mass to 0.080 parts by mass, and the viscosity measured at 25°C and 60 rpm with a B-type viscometer is 10 mPa·s to 200 mPa·s. The method for manufacturing an optical member according to any one of <11> to <13>. <15> The method for manufacturing an optical member according to <14>, wherein the two or more different optical material monomers include at least one active hydrogen compound selected from the group consisting of a polythiol compound containing two or more mercapto groups, a hydroxy thiol compound containing one or more mercapto groups and one or more hydroxyl groups, a polyol compound containing two or more hydroxyl groups, and an amine compound. <16> The monomer for two or more different optical materials contains an isocyanate compound, and the isocyanate compound is at least one selected from the group consisting of isophorone diisocyanate, 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, m-xylene diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, dicyclohexylmethane diisocyanate, 1,3-bis(isocyanatomethyl)cyclohexane, 1,4-bis(isocyanatomethyl)cyclohexane, 1,6-hexamethylene diisocyanate, and 1,5-pentamethylene diisocyanate, and is the manufacturing method of the optical member according to <14> or <15>. <17> The polymerization catalyst contains at least one selected from the group consisting of an amine-based catalyst and an organotin-based catalyst, and is the manufacturing method of the optical member according to any one of <14> to <16>.

Effects of the Invention

[0012] According to an embodiment of the present disclosure, a manufacturing method of an optical member capable of manufacturing an optical member with suppressed prisms and an optical member can be provided.

Brief Description of the Drawings

[0013] [Figure 1] It is a schematic diagram for explaining the space formation process. [Figure 2] It is a schematic diagram for explaining the injection process. [Figure 3] It is a schematic diagram for explaining the space formation process. [Figure 4] It is a schematic diagram for explaining the injection process.

Modes for Carrying Out the Invention

[0014] In the present disclosure, the numerical range represented by "~" means a range including the numerical values described before and after "~" as the lower limit value and the upper limit value. In this disclosure, the amount of each component in a composition means the total amount of any multiple substances present in the composition, unless otherwise specified, if there are multiple substances corresponding to each component in the composition. In numerical ranges described in stages within this disclosure, the upper or lower limit of one numerical range may be replaced with the upper or lower limit of another numerical range described in stages. Furthermore, in numerical ranges described within this disclosure, the upper or lower limit of that range may be replaced with the values ​​shown in the examples. In this disclosure, the term "process" includes not only independent processes but also processes that cannot be clearly distinguished from other processes, as long as their intended purpose is achieved. In this disclosure, "film" is a concept that generally includes what is referred to as a sheet, tape, laminated film, adhesive film, etc.

[0015] This disclosure includes the following first and second embodiments. The first and second embodiments will be described in detail below.

[0016] ≪Method for manufacturing optical components≫ The method for manufacturing an optical component according to the first embodiment includes a space formation step of forming a space surrounded by a mold substrate, a resin substrate and a film by attaching a film to the outer circumferential surfaces of a mold substrate and a resin substrate arranged opposite each other at a predetermined interval, an injection step of injecting a polymerizable composition into the space, and a curing step of curing the polymerizable composition injected into the space to obtain a cured product, wherein the film satisfies at least one of the following: when attached to the resin substrate and subjected to a heat resistance index test at 50°C, it does not peel off the resin substrate even when held for 3 minutes, and when attached to the resin substrate and subjected to a heat resistance index test at 50°C, its elongation rate is greater than 0% for 3 minutes.

[0017] The manufacturing method of the optical component according to the first embodiment includes a space formation step in which a film is attached to the outer circumferential surfaces of a molded substrate and a resin substrate that are arranged facing each other at a predetermined interval, thereby forming a space surrounded by the molded substrate, the resin substrate and the film. Typically, when manufacturing lenses, a polymerizable composition is injected between two mold substrates positioned opposite each other at a predetermined distance and then cured. The cured material can then be used as the lens material (also known as the single-cast method). In the first embodiment, for example, a polymerizable composition containing a compound such as a photochromic compound may be injected between the molded substrate and the lens material obtained above (corresponding to the resin substrate in the first embodiment) and cured. The cured product obtained after curing is a product in which a layer containing the photochromic compound and a layer of the lens material are laminated (also known as the double-cast method). In other words, the method for manufacturing the optical component of the first embodiment is a method suitably used for optical materials obtained by a method that involves multiple castings (for example, a double casting method) (i.e., a laminated body with layers stacked on top of each other).

[0018] In this case, the cured material obtained by the single-cast method and the cured material obtained by the double-cast method often have uneven thickness. When using only the single-cast method, thickness inconsistencies can be eliminated simply by polishing the thicker sections. Generally, polishing should be performed from the eye side (also called the back side) rather than from the object side (also called the front side). However, because the hardened material obtained by the double-cast method is a laminate with layers stacked on top of each other, it is difficult to polish the layer located on the front side from the back side. Therefore, it is difficult to eliminate the uneven thickness of the layer located on the front side.

[0019] Furthermore, we will describe a case in which, for example, a film is attached to the outer circumferential surfaces of two mold substrates arranged opposite each other at a predetermined interval, thereby forming a space surrounded by the two mold substrates and the film, and a polymerizable composition is injected into this space and cured. In this case, the films attached to the outer circumferential surfaces will overlap in some areas. Generally, when polymerizing and curing the polymerizable composition, it is preferable that the polymerizable composition undergoes polymerization shrinkage, causing the distance between the molds to shorten uniformly. However, in the overlapping portion mentioned above, the strength of the film increases, making it difficult for the distance between molds to shorten when the polymerizable composition undergoes polymerization shrinkage. As a result, the thickness of the cured material increases around the overlapping portion mentioned above, while it decreases around the non-overlapping portion. Consequently, the overall thickness of the cured material becomes uneven.

[0020] The method for manufacturing the optical component according to the first embodiment can solve the above-mentioned problems. The method for manufacturing an optical component according to the first embodiment, by including the above configuration, can manufacture an optical component in which prisms are suppressed. Furthermore, the manufacturing method of the optical component according to the first embodiment makes it possible to manufacture an optical component with suppressed prism without performing polishing work for prism correction, or with a small amount of polishing.

[0021] Furthermore, the adhesive in the film may leach into the polymerizable composition. The adhesive that leaches into the polymerizable composition may cause clouding, voids, and other problems in the resulting cured product. The manufacturing method for the optical component of the first embodiment can effectively suppress the above-mentioned clouding, voids, etc., by combining the above-mentioned components. Particularly preferable, in the curing process of the first embodiment, if the curing time is 20 hours or less, the above-mentioned wrinkles, clouding, voids, etc. can be suppressed more effectively.

[0022] <Space formation process> The space formation process involves forming a space surrounded by a molded substrate, a resin substrate, and a film by attaching a film to the outer surfaces of a molded substrate and a resin substrate that are arranged facing each other at a predetermined interval. An example of the space formation process will be explained using Figure 1. Figure 1 is a schematic diagram illustrating the space formation process.

[0023] First, as shown in Figure 1, a lens casting polymerization mold 10 is prepared. For example, a glass mold substrate 11 for forming a convex surface and a resin substrate 12 for forming a concave surface are prepared. The outer diameters of the mold substrate 11 and the resin substrate 12 may be the same as the finished outer diameter of the plastic lens. The resin substrate 12 may be an SF lens (semi-finished lens) manufactured in advance by the single-cast method. With the mold substrate 11 and the resin substrate 12 positioned opposite each other at a predetermined distance, a film (e.g., adhesive tape) 13 is wrapped around the outer circumferential surfaces of the mold substrate 11 and the resin substrate 12 slightly more than one full turn, fixing the mold substrate 11 and the resin substrate 12 with the adhesive tape and closing the gap between the mold substrate 11 and the resin substrate 12. This forms a space (i.e., a cavity 14 for molding the lens) surrounded by the mold substrate, the resin substrate, and the film. The film 13 may be a heat-release or re-peelable adhesive tape.

[0024] In the manufacturing method of the optical component according to the first embodiment, a molded substrate and a resin substrate are used. The mold in the first embodiment (also referred to as a mold for manufacturing optical components) is preferably a mold for manufacturing optical components by forming a space surrounded by a mold substrate, a resin substrate, and a film by attaching a film to the outer circumferential surfaces of a mold substrate and a resin substrate arranged opposite each other at a predetermined interval, placing a polymerizable composition in the space, and curing the polymerizable composition to obtain a cured product. In the first embodiment, the mold preferably has a main surface diameter of approximately 60 cm to 80 cm. As described above, when using the manufacturing method for optical components of the first embodiment, it is possible to manufacture optical components with suppressed prisms without polishing, or with a small amount of polishing. Therefore, the approximate diameter of the main surface of the mold and resin substrate can be reduced by eliminating the need for polishing.

[0025] The resin substrate in the first embodiment is a substrate formed of resin. The resin substrate may be, for example, an optical element such as a lens, or it may be a semi-finished lens. In other words, the optical member obtained by the manufacturing method of the optical member of the first embodiment may include a layer of a semi-finished lens and a layer of a cured polymerizable composition from the first embodiment. In this case, the resin substrate is preferably a cured product of a polymerizable composition containing, for example, two or more different monomers for optical materials, as described later, and a polymerization catalyst, as described later.

[0026] <film> The method for manufacturing the optical component of the first embodiment uses the film of the first embodiment (also referred to as the film for manufacturing optical components). In the first embodiment, the film is preferably a film for manufacturing optical components, which is used to manufacture optical components by attaching the film to a molded substrate and a resin substrate arranged opposite each other at a predetermined interval to form a space surrounded by the molded substrate, the resin substrate and the film, placing a polymerizable composition in the space, and curing the polymerizable composition to obtain a cured product. The film in the first embodiment satisfies at least one of the following conditions: when attached to a resin substrate and subjected to a heat resistance index test at 50°C, it does not peel off the resin substrate even after being held for 3 minutes; and when attached to a resin substrate and subjected to a heat resistance index test at 50°C, its elongation rate is greater than 0% after 3 minutes.

[0027] The film in the first embodiment preferably includes at least a base layer and an adhesive layer. The film in the first embodiment may consist only of a single substrate layer, or it may be a laminate in which a substrate layer and an adhesive layer are laminated together.

[0028] In the first embodiment, the film has high adhesive strength at temperatures (around 25°C) when operations such as injecting a polymerizable composition into a space surrounded by a mold substrate, a resin substrate, and the film are performed (casting), and therefore can maintain the shape of the space. On the other hand, at temperatures higher than room temperature when polymerizing the polymerizable composition, the film becomes more stretchable, or the mold becomes more slippery on the film. This allows the polymerization shrinkage caused by the polymerization of the polymerizable composition to be absorbed by narrowing the gap between the mold substrate and the resin substrate in the aforementioned space. As a result, it is possible to suppress the generation of prisms, particularly those caused by differences in hardness between the overlapping and non-overlapping parts of the film.

[0029] [Heat resistance index test] In the first embodiment, it is preferable that the film does not peel off the resin substrate even after being attached to the resin substrate and subjected to a heat resistance index test at 50°C for 3 minutes. The static adhesive strength of a film can be measured by a heat resistance index test. In the first embodiment, the film does not peel off the resin substrate even after being held for 3 minutes when attached to the resin substrate and subjected to a heat resistance index test at 50°C, thus allowing for good adjustment of static adhesive strength.

[0030] In the first embodiment, when the film is attached to a resin substrate and subjected to a heat resistance index test at 50°C, it may peel off the resin substrate in 20 minutes or less, or in 10 minutes or less.

[0031] In the first embodiment, the film peels off from the resin substrate within the time period described above, thereby suppressing leakage of the polymerizable composition from the space when the polymerizable composition is injected.

[0032] The specific method for the heat resistance index test is as follows: (method) At room temperature, of the exposed surface area of ​​the adhesive layer of a film with a width of 20 mm ± 0.5 mm and a length of 150 mm ± 0.5 mm, the area is 55 mm². 2 ±10mm 2 The part is brought into close contact with the resin substrate, and a load of 1 kg / cm is applied. 2 The film is then pressed down. A 1kg weight is attached to the edge of the folded portion of the film that is not in close contact with the resin substrate, and the resin substrate is placed in a constant temperature bath at 50°C so that it is oriented vertically. Three minutes after being placed in the constant temperature bath, it is checked whether the film (i.e., tape) has completely peeled off from the resin substrate. If it has not completely peeled off, the point at which the film (i.e., tape) has completely peeled off from the resin substrate is checked continuously thereafter.

[0033] The statement "When attached to a resin substrate and subjected to a heat resistance index test at 50°C, it does not peel off the resin substrate even after being held for 3 minutes" means that, even after being attached to a resin substrate and subjected to a heat resistance index test at 50°C for 3 minutes, at least a portion of the film and the resin substrate remain bonded together. "When attached to a resin substrate and subjected to a heat resistance index test, it completely peels off from the resin substrate" means that, when the above heat resistance index test is performed, the film attached to the resin substrate separates from the resin substrate within 3 minutes of being placed in a constant temperature bath, and the portion that is in contact with the glass plate disappears.

[0034] (Growth rate) In the first embodiment, it is preferable that the film, when attached to a resin substrate and subjected to a heat resistance index test at 50°C, exhibits an elongation rate of more than 0% in 3 minutes. From the viewpoint of suppressing prism in the resulting optical component, the film in the first embodiment preferably has an elongation rate of 1% or more, more preferably 5% or more, and even more preferably 10% or more in 3 minutes when attached to a resin substrate and subjected to a heat resistance index test at 50°C. From the viewpoint of suppressing prisms in the resulting optical component, the film in the first embodiment preferably has an elongation rate of 70% or less, more preferably 50% or less, and even more preferably 30% or less in 3 minutes when attached to a resin substrate and subjected to a heat resistance index test at 50°C.

[0035] The method for conducting the heat resistance index test at 50°C in measuring the elongation rate of the film is as described above. The elongation rate of the film is measured with the 1kg weight still attached, 3 minutes after the weight has been attached. The elongation rate of the film is expressed as ((length of film after 3 minutes - initial length of film) / (initial length of film)) × 100. However, if the film separates from the resin substrate before 3 minutes have elapsed and there is no longer any part in contact with the resin substrate, the elongation rate of the film is expressed as (length of the film just before it separates from the resin substrate - initial length of the film) / (initial length of the film) × 100.

[0036] In the first embodiment, it is preferable that the film satisfies both of the following conditions: it does not peel off the resin substrate even when held for 3 minutes when attached to a resin substrate and subjected to a heat resistance index test at 50°C, and its elongation rate is greater than 0% after 3 minutes when attached to a resin substrate and subjected to a heat resistance index test at 50°C.

[0037] [Glass ball tack test] In the first embodiment, it is preferable that the film exhibits a glass ball tack test at 80°C, with the glass ball traveling 200 mm or less. The dynamic adhesive strength of a film can be measured using a glass ball tack test. The film in the first embodiment exhibits excellent dynamic adhesion, as evidenced by the fact that the distance the glass ball travels is 200 mm or less when a glass ball tack test is performed at 80°C. As a result, the film in the first embodiment can fix the molded substrate more securely. In addition, when peeling off the film and removing the cured product, less adhesive residue from the film is left behind.

[0038] The glass ball tack test in the first embodiment is performed using a ball tack tester in accordance with JIS-Z0237. First, prepare a board with the film on its surface. Tilt the prepared board at a 30° angle so that the adhesive side of the film is facing upwards. Next, under a predetermined temperature, a measuring glass ball (4.65 ± 0.03 g) is rolled from a predetermined position on the film, and the distance traveled until the glass ball stops is measured.

[0039] In the first embodiment, it is preferable that the film exhibits a glass ball tack test at 25°C to 80°C, with the glass ball traveling 200 mm or less. In other words, when a glass ball tack test is performed at temperatures between 25°C and 80°C, it is preferable that the distance the glass ball travels is 200 mm or less in the entire temperature range from 25°C to 80°C. In the first embodiment, it is also preferable that the film exhibits a glass ball tack test at 120°C, with the glass ball traveling 200 mm or less.

[0040] In the first embodiment, when a glass ball tack test is performed at 25°C, 80°C, or 120°C, the film preferably has a glass ball migration distance of 10 mm or more, more preferably 20 mm or more, and even more preferably 30 mm or more.

[0041] [Tensile modulus of elasticity] The film in the first embodiment has a tensile modulus of 1.0 × 10 at 80°C. 10 It is preferable that it be Pa or higher, 3.0 × 10 10 It is more preferable that it be Pa or higher, 5.0 × 10 10 It is even more preferable that it be Pa or higher, 7.0 × 10 10It is particularly preferred that it is above Pa. The film in the first embodiment has a tensile elastic modulus at 80 °C of 40.0×10 10 Pa or less, preferably 30.0×10 10 Pa or less, more preferably 20.0×10 10 Pa or less, even more preferably. The film in the first embodiment, for example, has a tensile elastic modulus at 80 °C of 1.0×10 10 Pa to 40.0×10 10 Pa is preferable.

[0042] Specific examples of the detailed conditions of the tensile elastic modulus measurement test include the following. Measurement method: DMA single cantilever measurement · Test model: DMA8000 · Test temperature: 0 °C to 180 °C · Frequency: 1.0 Hz · Heating rate: 3 °C / min · Measurement area: 1.2 (cm 2 ) · Distance between chucks: 12.5 mm

[0043] 〔Adhesive force〕 When the film in the first embodiment includes at least a base material layer and an adhesive layer, the adhesive force of the adhesive layer is preferably 1.0 N / 10 mm to 10.0 N / 10 mm, more preferably 2.0 N / 10 mm to 7.0 N / 10 mm, and even more preferably 3.0 N / 10 mm to 5.0 N / 10 mm. The adhesive force is measured in accordance with JIS Z 0237:2009.

[0044] The film in the first embodiment may contain an adhesive. The adhesive may be contained in the adhesive layer. As the adhesive, known adhesives can be used, for example, acrylic resins, rubbers, etc. can be mentioned. Also, as the adhesive, the adhesives described in PCT / JP2021 / 042848 can be used.

[0045] <Injection process> The injection step in the first embodiment is a step of injecting a polymerizable composition into a space. An example of the injection process will be explained using Figure 2. Figure 2 is a schematic diagram illustrating the injection process.

[0046] As shown in Figure 2, in the injection process, the adhesive tape 13 is peeled back to the extent that a gap is created in the cavity 14 through which the polymerizable composition can be injected. The polymerizable composition 20 is then injected into the cavity 14 through this gap, and the gap is sealed again with the adhesive tape 13.

[0047] The temperature during the injection process is preferably 30°C or lower, more preferably 27°C or lower, and even more preferably 25°C or lower. The temperature during the injection process is preferably 15°C or higher, more preferably 18°C ​​or higher, and even more preferably 20°C or higher.

[0048] <Polymerizable composition> The polymerizable composition of the first embodiment may be a polymerizable composition comprising two or more different monomers for optical materials and a polymerization catalyst. The polymerizable composition of the first embodiment comprises two or more different monomers for optical materials and a polymerization catalyst, wherein the content of the polymerization catalyst is preferably 0.010 parts by mass to 0.1 parts by mass per 100 parts by mass of the total of the two or more different monomers for optical materials, and the viscosity measured with a B-type viscometer at 25°C and 60 rpm is preferably 30 mPa·s to 1000 mPa·s. When measuring viscosity with a Type B viscometer under conditions of 25°C and 60 rpm, the rotor number is 2. The viscosity measured with a Type B viscometer at 25°C and 60 rpm may be the viscosity immediately before the polymerizable composition is injected into the aforementioned space.

[0049] (Monomers for optical materials) The polymerizable composition of the first embodiment may contain two or more different monomers for optical materials. The monomer used for optical materials can be any monomer used for optical purposes, and is not particularly limited. For example, a monomer used to manufacture an optical material having any of the following properties: Optical materials obtained using monomers for optical materials may have a total light transmittance of 10% or more. The total light transmittance of the above optical material may be measured in accordance with JIS K 7361-1 (1997). The optical material obtained using the monomer for optical materials has a haze (i.e., total haze) of 10% or less, preferably 1% or less, and more preferably 0.5% or less. The haze of the optical material is a value measured at 25°C using a haze measuring instrument [(Tokyo Denshoku Co., Ltd., TC-HIII DPK)] in accordance with JIS-K7105. The optical material obtained using the monomer for optical materials preferably has a refractive index of 1.58 or higher. The refractive index of the optical material obtained using the monomer for optical materials may also be 1.80 or lower, or 1.75 or lower. The refractive index of the optical material may be measured in accordance with JIS K7142 (2014).

[0050] The shape of the optical material obtained using the monomer for optical materials is not particularly limited and may be plate-shaped, cylindrical, rectangular, or the like.

[0051] Examples of monomers for optical materials include polymerizable monomers that polymerize when a polymerization catalyst is used, as described later. Specifically, examples include isocyanate compounds, polythiol compounds having two or more mercapto groups, hydroxythiol compounds containing one or more mercapto groups and one or more hydroxyl groups, polyol compounds containing two or more hydroxyl groups, amine compounds, and the like.

[0052] Preferably, the monomers for optical materials include two or more different isocyanate compounds and active hydrogen compounds, which are at least one selected from the group consisting of polythiol compounds containing two or more mercapto groups, hydroxythiol compounds containing one or more mercapto groups and one or more hydroxyl groups, polyol compounds containing two or more hydroxyl groups, and amine compounds.

[0053] [Isocyanate compounds] Examples of isocyanate compounds include aliphatic isocyanate compounds, alicyclic isocyanate compounds, aromatic isocyanate compounds, and heterocyclic isocyanate compounds, which are used individually or in combination of two or more. These isocyanate compounds may include dimers, trimers, and prepolymers. Examples of these isocyanate compounds include those exemplified in International Publication No. 2011 / 055540. Furthermore, as isocyanate compounds, halogen-substituted compounds (e.g., chlorine-substituted compounds, bromine-substituted compounds, etc.), alkyl-substituted compounds, alkoxy-substituted compounds, carbodiimide-modified compounds, urea-modified compounds, and biuret-modified compounds of the above-mentioned compounds are also available. The above-mentioned compounds are used to create prepolymer-type modified products with nitro-substituted compounds, polyhydric alcohols, etc. The dimerization or trimmerization reaction products of the above-mentioned compounds can also be used. These compounds may be used individually or in combination of two or more.

[0054] In the first embodiment, the alicyclic isocyanate compound refers to an isocyanate compound that includes an alicyclic structure and may also include structures other than alicyclic structures, such as heterocyclic structures. Aromatic isocyanate compounds refer to isocyanate compounds that contain an aromatic structure and may also contain one or a combination thereof of an aliphatic structure, an alicyclic structure, and a heterocyclic structure. Heterocyclic isocyanate compounds refer to isocyanate compounds that contain a heterocyclic structure but do not contain alicyclic or aromatic structures. Aliphatic isocyanate compounds refer to isocyanate compounds that do not contain aromatic, alicyclic, or heterocyclic structures.

[0055] The isocyanate compound preferably includes at least one selected from the group consisting of aliphatic isocyanate compounds, alicyclic isocyanate compounds, aromatic isocyanate compounds, and heterocyclic isocyanate compounds.

[0056] At least one of the monomers for the optical material in the first embodiment may be an isocyanate compound having an aromatic ring. Specifically, examples of isocyanate compounds having an aromatic ring include aromatic isocyanate compounds, and more specifically, isocyanate compounds in which an isocyanate group is directly bonded to the aromatic ring, and isocyanate compounds in which an isocyanate group is bonded to the benzyl position of the aromatic ring. Monomers for optical materials may include isocyanate compounds other than those having an aromatic ring, i.e., isocyanate compounds that do not have an aromatic ring.

[0057] There are no particular restrictions on isocyanate compounds other than those having an aromatic ring, but examples include isocyanate compounds that do not have an aromatic ring.

[0058] In the first embodiment, from the viewpoint of maintaining the quality of the optical material and shortening the manufacturing time of the optical material, the isocyanate compound preferably contains at least one selected from the group consisting of isophorone diisocyanate, 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, m-xylylene diisocyanate, 2,4-tole diisocyanate, 2,6-tole diisocyanate, dicyclohexylmethane diisocyanate, 1,3-bis(isocyanatomethyl)cyclohexane, 1,4-bis(isocyanatomethyl)cyclohexane, 1,6-hexamethylene diisocyanate, and 1,5-pentamethylene diisocyanate. It is more preferable to include at least one selected from the group consisting of isophorone diisocyanate, 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, m-xylylene diisocyanate, 2,4-tole diisocyanate, 2,6-tole diisocyanate, dicyclohexylmethane diisocyanate, and 1,3-bis(isocyanatomethyl)cyclohexane. It is even more preferable to include at least one selected from the group consisting of 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, and 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane and m-xylylene diisocyanate.

[0059] [Active hydrogen compounds] Examples of active hydrogen compounds include polythiol compounds having two or more mercapto groups, hydroxythiol compounds containing one or more mercapto groups and one or more hydroxyl groups, polyol compounds containing two or more hydroxyl groups, and amine compounds. As the active hydrogen compound, oligomers of the above-mentioned active hydrogen compound or halogen-substituted derivatives of the above-mentioned active hydrogen compound (e.g., chlorine-substituted derivatives, bromine-substituted derivatives, etc.) may be used. Furthermore, the active hydrogen compounds may be used individually or in mixtures of two or more types.

[0060] (Polythiol compounds having two or more mercapto groups) Examples of polythiol compounds having two or more mercapto groups include those exemplified in International Publication No. 2016 / 125736. In the first embodiment, from the viewpoint of maintaining the quality of the optical material and shortening the manufacturing time of the optical material, the polythiol compound is 4-mercaptomethyl-1,8-dimercapto-3,6-dithiaoctane, 5,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,8-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, pentaerythritol Preferably, it contains at least one selected from the group consisting of tetrakis(3-mercaptopropionate), bis(mercaptoethyl)sulfide, pentaerythritoltetrakis(2-mercaptoacetate), 2,5-bis(mercaptomethyl)-1,4-dithiane, 1,1,3,3-tetrakis(mercaptomethylthio)propane, 4,6-bis(mercaptomethylthio)-1,3-dithiane, and 2-(2,2-bis(mercaptomethylthio)ethyl)-1,3-dithiane. It is more preferable to include at least one selected from the group consisting of 4-mercaptomethyl-1,8-dimercapto-3,6-dithiaoctane, 5,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,8-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, pentaerythritol tetrakis(3-mercaptopropionate), pentaerythritol tetrakis(2-mercaptoacetate), and 2,5-bis(mercaptomethyl)-1,4-dithiane. It is even more preferable to include at least one selected from the group consisting of 4-mercaptomethyl-1,8-dimercapto-3,6-dithiaoctane, 5,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,8-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, and pentaerythritol tetrakis(3-mercaptopropionate).

[0061] (Hydroxythiol compounds containing one or more mercapto groups and one or more hydroxyl groups) Examples of thiol compounds having a hydroxyl group include 2-mercaptoethanol, 3-mercapto-1,2-propanediol, glycerin bis(mercaptoacetate), 4-mercaptophenol, 2,3-dimercapto-1-propanol, pentaerythritol tris(3-mercaptopropionate), and pentaerythritol tris(thioglycolate), but the list is not limited to these example compounds.

[0062] (Polyol compounds containing two or more hydroxyl groups) Examples of polyol compounds include one or more aliphatic or alicyclic alcohols. Specifically, examples include linear or branched aliphatic alcohols, alicyclic alcohols, and alcohols obtained by adding at least one substance selected from the group consisting of ethylene oxide, propylene oxide, and ε-caprolactone to these alcohols. More specifically, examples include the compounds exemplified in International Publication No. 2016 / 125736.

[0063] The polyol compound is preferably at least one selected from the group consisting of ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, 1,3-propanediol, 1,2-cyclopentanediol, 1,3-cyclopentanediol, 1,2-cyclohexanediol, 1,3-cyclohexanediol, and 1,4-cyclohexanediol.

[0064] (Amine compounds) Examples of amine compounds include ethylenediamine, 1,2- or 1,3-diaminopropane, 1,2-, 1,3- or 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,7-diaminoheptane, 1,8-diaminooctane, 1,10-diaminodecane, 1,2-, 1,3- or 1,4-diaminocyclohexane, o-, m- or p-diaminobenzene, 3,4- or 4,4'-diaminobenzophenone, 3,4- or 4,4'-diaminodiphenyl ether, 4,4'-diaminodiphenylmethane, 4,4'-diaminodiphenyl sulfide, 3,3' or primary polyamine compounds such as 4,4'-diaminodiphenylsulfone, 2,7-diaminofluorene, 1,5-, 1,8- or 2,3-diaminonaphthalene, 2,3-, 2,6- or 3,4-diaminopyridine, 2,4- or 2,6-diaminotoluene, m- or p-xylylenediamine, isophoronediamine, diaminomethylbicycloheptane, 1,3- or 1,4-diaminomethylcyclohexane, 2- or 4-aminopiperidine, 2- or 4-aminomethylpiperidine, 2- or 4-aminoethylpiperidine, N-aminoethylmorpholine, N-aminopropylmorpholine, etc. Monofunctional secondary amine compounds such as diethylamine, dipropylamine, di-n-butylamine, di-sec-butylamine, diisobutylamine, di-n-pentylamine, di-3-pentylamine, dihexylamine, dioctylamine, di(2-ethylhexyl)amine, methylhexylamine, diallylamine, N-methylallylamine, piperidine, pyrrolidine, diphenylamine, N-methylamine, N-ethylamine, dibenzylamine, N-methylbenzylamine, N-ethylbenzylamine, dicyclohexylamine, N-methylaniline, N-ethylaniline, dinaphthylamine, 1-methylpiperazine, and morpholine; N,N'-dimethylethylenediamine, N,N'-dimethyl-1,2-diaminopropane, N,N'-dimethyl-1,3-diaminopropane, N,N'-dimethyl-1,2-diaminobutane, N,N'-dimethyl-1,3-diaminobutane, N,N'-dimethyl-1,4-diaminobutane, N,N'-dimethyl-1,5-diaminopentane, N,N'-dimethyl-1,6-diaminohexane, N,N'-dimethyl-1,7-diaminoheptane, N,N'-diethylethylenediamine, N,N'-diethyl-1,2-diaminopropane, N,N'-diethyl-1,3-diaminopropane, N,N'-diethyl-1,2-diamino Examples include secondary polyamine compounds such as nobutane, N,N'-diethyl-1,3-diaminobutane, N,N'-diethyl-1,4-diaminobutane, N,N'-diethyl-1,5-diaminopentane, N,N'-diethyl-1,6-diaminohexane, N,N'-diethyl-1,7-diaminoheptane, piperazine, 2-methylpiperazine, 2,5-dimethylpiperazine, 2,6-dimethylpiperazine, homopiperazine, 1,1-di-(4-piperidyl)methane, 1,2-di-(4-piperidyl)ethane, 1,3-di-(4-piperidyl)propane, 1,4-di-(4-piperidyl)butane, and tetramethylguanidine.

[0065] Among the above, the active hydrogen compound is preferably a polythiol compound having two or more mercapto groups, from the viewpoint of improving the heat resistance and refractive index of the cured product. The content of the polythiol compound having two or more mercapto groups is preferably 60% by mass or more, more preferably 70% by mass or more, and even more preferably 80% by mass or more, based on the total mass of the active hydrogen compound.

[0066] Furthermore, in the first embodiment, the total content of the active hydrogen compound, including 4-mercaptomethyl-1,8-dimercapto-3,6-dithiaoctane, 5,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,8-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, and pentaerythritol tetrakis(3-mercaptopropionate), is preferably 60% by mass or more, more preferably 70% by mass or more, and even more preferably 80% by mass or more, based on the total mass of the active hydrogen compound.

[0067] <Polymerization catalyst> The polymerizable composition of the first embodiment preferably contains at least one polymerization catalyst. There are no particular restrictions on the polymerization catalyst, but for example, basic catalysts, organometallic catalysts, zinc carbamate salts, ammonium salts, sulfonic acids, etc., can be used. The polymerization catalysts described above may be used individually or in appropriate combinations of two or more types.

[0068] (Basic catalyst) Examples of basic catalysts include amine-based catalysts (including imidazole-based catalysts). Specifically, examples include tertiary amine catalysts such as triethylenediamine, N,N-dimethylethanolamine, triethylamine, and N-ethylmorpholine; and 2-methylpyrazine, pyridine, α-picoline, β-picoline, γ-picoline, 2,6-lutidine, 3,5-lutidine, 2,4,6-collidine, 3-chlorpyridine, N,N-diethylaniline, N,N-dimethylaniline, hexamethylenetetramine, quinoline, isoquinoline, N,N-dimethyl-p-toluidine, N,N-dimethylpiperazine, quinaldine, 4-methylmorpholine, triallylamine, trioctylamine, 1,2-dimethylimidazole, and 1-benzyl-2-methylimidazole.

[0069] Among the above, amine-based catalysts are preferred as basic catalysts. Examples of amine-based catalysts include tertiary amine catalysts such as 3,5-lutidine, 2,4,6-collidine, triethylenediamine, N,N-dimethylethanolamine, triethylamine, and N-ethylmorpholine.

[0070] The amine catalyst preferably contains at least one selected from the group consisting of 3,5-lutidine, 2,4,6-collidine, triethylenediamine, N,N-dimethylethanolamine, and N-ethylmorpholine.

[0071] The basic catalyst may also preferably contain a compound represented by the following general formula (2) and / or a compound represented by the following general formula (3).

[0072] [ka]

[0073] In general formula (2), R1 represents a linear alkyl group having 1 to 20 carbon atoms, a branched alkyl group having 3 to 20 carbon atoms, a cycloalkyl group having 3 to 20 carbon atoms, or a halogen atom. Multiple R1 atoms may be the same or different. Q represents a carbon atom or a nitrogen atom. m represents an integer from 0 to 5.

[0074] [ka]

[0075] In general formula (3), R2, R3, and R4 each independently represent a linear alkyl group having 1 to 20 carbon atoms, a branched alkyl group having 3 to 20 carbon atoms, a cycloalkyl group having 3 to 20 carbon atoms, an allyl group, or a hydrocarbon group containing a hydroxyl group.

[0076] The basic catalyst is preferably one with a pKa value of 1 or higher, more preferably one with a pKa value of 3 or higher, and even more preferably one with a pKa value of 4 or higher. As a basic catalyst, a pKa value of 9 or less is preferred, and a pKa value of 8 or less is more preferred.

[0077] The pKa value (acid dissociation index) can be measured, for example, by (a) the method described in The Journal of Physical Chemistry vol.68, number 6, page 1560 (1964), (b) a method using a potentiometric automatic titrator manufactured by Kyoto Electronics Manufacturing Co., Ltd. (such as AT-610 (product name)), or (c) the acid dissociation index described in the Chemical Handbook edited by the Chemical Society of Japan (3rd revised edition, June 25, 1984, published by Maruzen Co., Ltd.).

[0078] (organometallic catalyst) Examples of organometallic catalysts include organotin catalysts; organic acid salts of iron, nickel, zinc, etc.; acetylacetonate complexes; catalyst compositions consisting of carboxylate metal compounds and quaternary ammonium salt compounds; catalyst compositions consisting of bicyclic tertiary amine compounds and quaternary ammonium salt compounds; and metal catalysts in which alkoxy groups, carboxyl groups, etc., are coordinated to titanium or aluminum. Among the organometallic catalysts mentioned above, organotin catalysts are preferred. Examples of organotin catalysts include dibutyltin dichloride (DBC), dimethyltin dichloride (DMC), dibutyltin dilaurate (DBTDL), and dibutyltin diacetate.

[0079] It is preferable that the organotin catalyst includes at least one selected from the group consisting of dibutyltin dichloride, dimethyltin dichloride, dibutyltin dilaurate, and dibutyltin diacetate.

[0080] The polymerization catalyst preferably includes at least one selected from the group consisting of a basic catalyst with a pKa value of 4 to 8 and an organometallic catalyst.

[0081] The polymerization catalyst may also preferably include at least one selected from the group consisting of amine-based catalysts and organotin-based catalysts.

[0082] The polymerization catalyst preferably contains at least one selected from the group consisting of 3,5-lutidine, 2,4,6-collidine, triethylenediamine, N,N-dimethylethanolamine, triethylamine, N-ethylmorpholine, dibutyltin dichloride, dimethyltin dichloride, dibutyltin dilaurate, and dibutyltin diacetate.

[0083] In the polymerizable composition of the first embodiment, from the viewpoint of effectively promoting the polymerization reaction, the content of the polymerization catalyst per 100 parts by mass of the total of two or more different monomers for optical materials is preferably 0.010 parts by mass or more, more preferably 0.020 parts by mass or more, and even more preferably 0.030 parts by mass or more.

[0084] In the polymerizable composition of the first embodiment, from the viewpoint of improving handling when injecting the polymerizable composition into a mold, the content of the polymerization catalyst per 100 parts by mass of the total of two or more different monomers for optical materials is preferably 0.10 parts by mass or less, and more preferably 0.090 parts by mass or less.

[0085] (Other additives) The polymerizable composition of the first embodiment may contain any additives. Optional additives include photochromic compounds, alcohol compounds, visible light absorbing dyes, internal mold release agents, bluing agents, and ultraviolet absorbers.

[0086] (Photochromic compounds) Photochromic compounds are compounds whose molecular structure reversibly changes upon irradiation with light of a specific wavelength, and whose absorption properties (absorption spectrum) change accordingly. Examples of photochromic compounds used in the first embodiment include compounds whose absorption characteristics (absorption spectrum) change in response to light of a specific wavelength.

[0087] In the first embodiment, there are no particular restrictions on the photochromic compound, and any conventionally known compound that can be used in photochromic lenses can be appropriately selected and used. For example, one or more compounds can be used from spiropyran compounds, spirooxazine compounds, fulgide compounds, naphthopyran compounds, bisimidazole compounds, etc., depending on the desired coloration. Photochromic compounds can be obtained, for example, by the methods described in WO2009 / 146509, WO2010 / 20770, WO2012 / 149599, and WO2012 / 162725.

[0088] (Visible light absorbing dye) Commercially available visible light absorbing dyes may be used, and organic dye compounds are preferred. Specifically, porphyrin compounds or tetraazaporphyrin compounds are examples. More specifically, PD-311S (manufactured by Yamamoto Kasei Co., Ltd.) is an example of a visible light absorbing dye.

[0089] (Internal release agent) Examples of internal mold release agents include acidic phosphate esters. Examples of acidic phosphate esters include phosphate monoesters and phosphate diesters, which can be used individually or in combination of two or more types.

[0090] (Bluing agent) Examples of bluing agents include those that have an absorption band in the orange to yellow wavelength range within the visible light spectrum and have the function of adjusting the hue of optical materials made of resin. More specifically, bluing agents include substances that exhibit blue to purple colors.

[0091] (UV absorber) Examples of UV absorbers used include benzophenone-based UV absorbers such as 2,2'-dihydroxy-4-methoxybenzophenone, triazine-based UV absorbers such as 2-[4-[(2-hydroxy-3-dodecyloxypropyl)oxy]-2-hydroxyphenyl]4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and benzotriazole-based UV absorbers such as 2-(2H-benzotriazole-2-yl)-4-methylphenol and 2-(2H-benzotriazole-2-yl)-4-tert-octylphenol. Preferably, benzotriazole-based UV absorbers such as 2-(2H-benzotriazole-2-yl)-4-tert-octylphenol and 2-(5-chloro-2H-benzotriazole-2-yl)-4-methyl-6-tert-butylphenol are used. These UV absorbers can be used alone or in combination of two or more.

[0092] Compounds that absorb and block light of specific wavelengths include dyes, UV absorbers, and other compounds described in International Publication Nos. 2017 / 047684 and 2015 / 037628.

[0093] (Alcohol compounds) The polymerizable composition of the first embodiment may contain an alcohol compound. The polymerizable composition of the first embodiment, by containing an alcohol compound, can impart good light-adjusting properties to the resin. Examples of alcohol compounds include the Pluronic® series manufactured by BASF. The structures of the compounds contained in Pluronic® are illustrated, for example, in non-patent literature (P. Alexandridis, TA Hatton / Colloids Surfaces A: Physicochem. Eng. Aspects 96 (1995) 1-46).

[0094] The polymerizable composition of the first embodiment further includes, in addition to the two or more different monomers and polymerization catalysts for optical materials described above, Preferably, it contains at least one selected from the group consisting of photochromic compounds, alcohol compounds, and visible light absorbing dyes. It is more preferable to include a combination of a photochromic compound and an alcohol compound, and at least one of a visible light absorbing dye.

[0095] (viscosity) The polymerizable composition of the first embodiment has a viscosity of 30 mPa·s or more, preferably 40 mPa·s or more, more preferably 70 mPa·s or more, even more preferably 80 mPa·s or more, particularly preferably 100 mPa·s or more, and even more preferably 120 mPa·s or more, as measured with a B-type viscometer at 25°C and 60 rpm, from the viewpoint of suppressing striation and suppressing the elution of the adhesive. From the viewpoint of maintaining good handling properties when molding optical materials into a desired shape, the polymerizable composition of the first embodiment has a viscosity of 1000 mPa·s or less, preferably 700 mPa·s or less, and more preferably 400 mPa·s or less, as measured with a B-type viscometer at 25°C and 60 rpm.

[0096] <Curing process> The curing step in the first embodiment is a step of curing a polymerizable composition injected into a space to obtain a cured product. The method for manufacturing an optical component according to the first embodiment, by including a curing step, allows for the polymerization of a polymerizable composition and the production of an optical material.

[0097] In the curing process, the curing time is preferably 20 hours or less. In particular, in the curing process of the first embodiment, when the curing time is 20 hours or less, the amount of adhesive elution tends to be significantly suppressed, and the above-mentioned clouding, voids, etc. can be suppressed more effectively.

[0098] In the first embodiment, the curing time refers to the time from when the temperature of the polymerizable composition reaches 30°C until the polymerizable composition is completely cured.

[0099] From the above perspective, a curing time of 7 hours or less is more preferable, and 5 hours or less is even more preferable.

[0100] From the viewpoint of the curability of the polymerizable composition, a curing time of 1 hour or more is preferable, and a curing time of 3 hours or more is more preferable.

[0101] The maximum curing temperature in the curing process is preferably 150°C or lower, more preferably 130°C or lower, even more preferably 100°C or lower, and particularly preferably 80°C or lower. The maximum curing temperature in the curing process is preferably 50°C or higher, more preferably 60°C or higher, and even more preferably 70°C or higher.

[0102] In the curing process, a microwave irradiation step may be provided, if necessary, in which the polymerizable composition is irradiated with microwaves for a predetermined time.

[0103] <Cured product> The cured product of the first embodiment is the cured product of the polymerizable composition in the first embodiment. The cured product in the first embodiment can be suitably used as an optical component.

[0104] The cured product of the first embodiment is Preferably, it contains at least one selected from the group consisting of photochromic compounds, alcohol compounds, and visible light absorbing dyes. It is more preferable to include a combination of a photochromic compound and an alcohol compound, and at least one of a visible light absorbing dye.

[0105] <Optical components> The optical component in the first embodiment is manufactured by the method for manufacturing the optical component in the first embodiment. The optical component to be manufactured may include a first layer and a second layer, wherein the first layer may be a cured product of the polymerizable composition in the first embodiment, and the second layer may be a resin substrate in the first embodiment.

[0106] The optical member in the first embodiment preferably comprises a first layer and a second layer, wherein the average thickness of the second layer is greater than the average thickness of the first layer, and the first layer comprises at least one selected from the group consisting of a photochromic compound, an alcohol compound, and a visible light absorbing dye (more preferably a combination of a photochromic compound and an alcohol compound, and at least one of a visible light absorbing dye), has a prism difference of 0.25 mm or less, and is free from striations of 1.0 mm or longer within a radius of 15 mm from the center.

[0107] The prism difference is measured by the following method. The thickness of the optical element is measured at a total of five points: the center, two midpoints of the radius on the diameter line, and two midpoints of the radius on a line perpendicular to the diameter line and passing through the center. Next, we calculate the difference in thickness from the center of the optical element (also called the center thickness difference) by subtracting the thicknesses at four points other than the center of the optical element from the thickness at the center of the optical element. In other words, we obtain four center thickness differences. The center thickness difference will be negative at points where the thickness is less than the center, and positive at points where the thickness is greater than the center. The maximum thickness difference is calculated by subtracting the minimum value from the maximum value of the four obtained central thickness differences, and this is considered the prism difference.

[0108] The second layer preferably has a stepped shape on part of its outer periphery. For example, a case will be described in which a film is attached to the outer periphery of two mold substrates arranged opposite each other at a predetermined distance, thereby forming a space surrounded by the two mold substrates and the film, and a polymerizable composition is injected into the space and cured. In this case, the film attached to the outer periphery overlaps in some areas. Due to the existence of these overlapping areas, a stepped shape is formed on a part of the outer periphery of the resulting optical component. The stepped shape described above can be eliminated by minor polishing. In an optical component including a cured product immediately after hardening, it is preferable that the optical component includes a first layer and a second layer, and that the second layer has a stepped shape on a part of its outer periphery.

[0109] In the first embodiment, it is preferable that the value H1, which is the value obtained by dividing the haze of the first layer by the thickness of the first layer, at the center of the optical material, is higher than the value H2, which is the value obtained by dividing the haze of the second layer by the thickness of the second layer. This improves the performance of the optical material imparted by the first layer. For example, when the first layer contains a photochromic compound, the photochromic performance of the optical material imparted by the first layer is further improved (for example, the color development is more intense and the fading half-life is shorter). According to the manufacturing method of the optical member of the first embodiment, it is easy to manufacture an optical member in which the value H1 is higher than the value H2.

[0110] From the viewpoint of further improving the performance of the optical element by the first layer, in the optical element of the first embodiment, the ratio of value H1 to value H2 is preferably 1.001 to 1.500, more preferably 1.100 to 1.500, and even more preferably 1.200 to 1.400. According to the manufacturing method of the optical member of the first embodiment, it is easy to manufacture an optical member in which the ratio of value H1 to value H2 is within the above preferred range.

[0111] <Applications of optical components> The optical component in the first embodiment can be used as a plastic lens, prism, optical fiber, information recording substrate, filter, light-emitting diode, etc. Among the above, the optical component in the first embodiment can be suitably used in lenses, more suitably used in plastic lenses, and even more suitably used in plastic lenses for eyeglasses.

[0112] <Annealing process> The method for manufacturing the optical component of the first embodiment may optionally include an annealing step of annealing the cured polymerizable composition. The annealing process is typically carried out at a temperature of 50-150°C, but is preferably carried out at 90-140°C, and more preferably at 100-130°C.

[0113] The specific means of the first embodiment include the following aspects. <1A> A space formation step in which a film is attached to the outer circumferential surfaces of a mold substrate and a resin substrate arranged opposite each other at a predetermined interval, thereby forming a space surrounded by the mold substrate, the resin substrate and the film; an injection step in which a polymerizable composition is injected into the space; and a curing step in which the polymerizable composition injected into the space is cured to obtain a cured product. A method for manufacturing an optical component, comprising: a film that does not peel off the resin substrate even when held for 3 minutes after being attached to the resin substrate and subjected to a heat resistance index test at 50°C; and a film that has an elongation rate of more than 0% after 3 minutes after being attached to the resin substrate and subjected to a heat resistance index test at 50°C. <2A> The method for manufacturing an optical component according to <1A>, wherein the film satisfies both of the following conditions: when attached to the resin substrate and subjected to a heat resistance index test at 50°C, it does not peel off the resin substrate even when held for 3 minutes, and when attached to the resin substrate and subjected to a heat resistance index test at 50°C, its elongation rate is greater than 0% for 3 minutes. <3A> The method for manufacturing an optical component according to <1A> or <2A>, wherein the film is such that when a glass ball tack test is performed at 80°C, the distance the glass ball moves is 200 mm or less. <4A> The polymerizable composition comprises two or more different monomers for optical materials and a polymerization catalyst, wherein the content of the polymerization catalyst is 0.01 parts by mass to 0.1 parts by mass per 100 parts by mass of the total of the two or more different monomers for optical materials, and is measured with a B-type viscometer at 25°C and 60 rpm. A method for manufacturing an optical component as described in any one of <1A> to <3A>, wherein the viscosity measured under the conditions is 30 mPa·s to 1000 mPa·s. <5A> The method for producing an optical member according to <4A>, wherein the polymerizable composition further comprises at least one selected from the group consisting of photochromic compounds and alcohol compounds. <6A> A method for producing an optical member according to <4A> or <5A>, wherein the two or more different monomers for optical materials are an isocyanate compound and an active hydrogen compound which is at least one selected from the group consisting of a polythiol compound containing two or more mercapto groups, a hydroxythiol compound containing one or more mercapto groups and one or more hydroxyl groups, a polyol compound containing two or more hydroxyl groups, and an amine compound. <7A> An optical member comprising a first layer and a second layer, wherein the average thickness of the second layer is greater than the average thickness of the first layer, the first layer comprises at least one selected from the group consisting of photochromic compounds and alcohol compounds, the prism difference is 0.25 mm or less, and there are no striations of a length of 1.0 mm or more within a radius of 15 mm from the center. <8A> The optical member described in <7A>, wherein the second layer has a stepped shape on a part of its outer periphery.

[0114] ≪Method for manufacturing optical components≫ The method for manufacturing an optical member according to the second embodiment includes a space formation step of forming a space surrounded by a pair of mold substrates and a film by attaching a film to the outer circumferential surfaces of a pair of mold substrates arranged facing each other at a predetermined interval; an injection step of injecting a polymerizable composition into the space; and a curing step of curing the polymerizable composition injected into the space to obtain a cured product. The film has a ratio of the heat resistance index measured at 30°C for 30 minutes to the heat resistance index measured at 20°C for 30 minutes which is greater than 0.1, and in the curing step, the degree of polymerization of the polymerizable composition is 15% or more at 30°C.

[0115] The method for manufacturing an optical component according to the second embodiment, by including the above configuration, can manufacture an optical component in which prisms are suppressed.

[0116] When manufacturing optical components by curing a polymerizable composition, the cured product immediately after curing often has an uneven outer surface with wrinkles, including an uneven shape. One reason for this is that polymerization shrinkage causes the surrounding film (e.g., tape) to be pulled by the polymerization shrinkage of the polymerizable composition, resulting in wrinkles that are then transferred to the side surface of the cured product. In the second embodiment, wrinkles caused by polymerization shrinkage are also called polymerization wrinkles. For hardened products with polymerization wrinkles on the outer surface, similar to the case where the thickness is not uniform as described above, the outer surface has traditionally been smoothed by polishing or other methods to ensure quality. However, this has disadvantages, such as requiring the size of the hardened product to be larger before polishing in anticipation of the polishing work, and requiring the disposal of the shavings. Therefore, there is a need for a method for manufacturing optical components that can produce optical components with smooth outer surfaces without polishing, or with minimal polishing. The manufacturing method of the optical member according to the second embodiment can also suppress polymerization wrinkles on the outer surface.

[0117] Typically, when manufacturing lenses, a polymerizable composition (which may include compounds such as photochromic compounds) is injected between two mold substrates positioned opposite each other at a predetermined distance and then cured. The cured material can then be used as the lens material (also known as the single-cast method). Furthermore, for example, a polymerizable composition may be injected between the molded substrate and the lens material obtained above and cured (also known as the double-cast method). In this case, the cured product obtained after curing is a product in which a layer containing a photochromic compound and a layer of the lens material are laminated together, by injecting a polymerizable composition containing a photochromic compound between the molded substrate and the lens material obtained above. The manufacturing method for optical components of the second embodiment can be suitably used for optical materials obtained by methods involving multiple castings (e.g., double casting) (i.e., laminates with stacked layers) because the resulting cured product has a small prism and there is little need to polish and correct the prism.

[0118] As mentioned above, the cured products obtained by the single-cast method and the cured products obtained by the double-cast method often have uneven thickness. When using only the single-cast method, thickness inconsistencies can be eliminated simply by polishing the thicker sections. Generally, polishing should be performed from the eye side (also called the back side) rather than from the object side (also called the front side). However, because the cured material obtained by the double-cast method is a laminate with layers stacked on top of each other, it is difficult to polish the layer located on the front side from the back side. Therefore, it is difficult to eliminate the uneven thickness of the layer located on the front side by polishing the cured material.

[0119] For example, a case will be described in which a film is attached to the outer circumferential surface of a pair of mold substrates arranged facing each other at a predetermined interval, thereby forming a space surrounded by the pair of mold substrates and the film, and a polymerizable composition is injected into the space and cured. In this case, the film attached to the outer circumferential surface overlaps to prevent leakage of the polymerizable composition. Generally, when polymerizing and curing the polymerizable composition, it is preferable that the polymerizable composition shrinks during polymerization, causing the distance between the molds to decrease uniformly. However, in the overlapping portion mentioned above, the strength of the film increases, making it difficult for the distance between molds to shorten when the polymerizable composition undergoes polymerization shrinkage. As a result, the thickness of the cured material around the overlapping portion is greater than that around the non-overlapping portion. Consequently, the overall thickness of the cured material becomes uneven, and the prism becomes larger.

[0120] The method for manufacturing the optical component according to the second embodiment can solve the above-mentioned problems. The method for manufacturing an optical component according to the second embodiment, by including the above configuration, can manufacture an optical component in which prisms are suppressed. Furthermore, the manufacturing method of the optical component according to the second embodiment makes it possible to manufacture an optical component with suppressed prism without performing polishing work for prism correction, or with a small amount of polishing.

[0121] Furthermore, the method for manufacturing the optical member of the second embodiment, by including the above configuration, can suppress polymerization wrinkles in the tape during polymerization shrinkage, thus enabling the manufacture of an optical member in which polymerization wrinkles on the outer surface are suppressed.

[0122] The above advantages are considered particularly beneficial when using the double-cast method, for example. The optical component obtained by the manufacturing method of the second embodiment can be manufactured as a high-quality optical component with suppressed prism without or with minimal polishing for prism correction. Therefore, when performing the double-cast method in which another optical component is laminated on top of the optical component of the second embodiment, the workload of polishing can be reduced by using the optical component of the second embodiment without or with minimal polishing for prism correction. In addition, it becomes possible to eliminate or reduce the amount of shavings generated by polishing.

[0123] Furthermore, the adhesive in the film may leach into the polymerizable composition. The adhesive that leaches into the polymerizable composition may cause clouding, voids, and other problems in the resulting cured product. The manufacturing method for the optical component of the second embodiment can also effectively suppress the above-mentioned clouding, voids, etc., by combining the above-mentioned components. Particularly preferable, in the curing process of the second embodiment, if the curing time is 20 hours or less, the above-mentioned wrinkles, cloudiness, voids, etc. can be suppressed more effectively.

[0124] <Space formation process> The space formation process involves forming a space surrounded by a pair of molded substrates and a film by attaching a film to the outer surfaces of a pair of molded substrates that are arranged facing each other at a predetermined interval. An example of the space formation process will be explained using Figure 3. Figure 3 is a schematic diagram illustrating the space formation process.

[0125] First, as shown in Figure 3, a lens casting polymerization mold 110 is prepared. For example, a glass mold substrate 111 for forming a convex surface and a mold substrate 112 for forming a concave surface are prepared. The outer diameters of the mold substrates 111 and 112 may be the same as the finished outer diameter of the plastic lens. With the mold substrates 111 and 112 positioned opposite each other at a predetermined distance, a film (e.g., adhesive tape) 113 is wrapped around the outer periphery of the mold substrates 111 and 112 slightly more than once, fixing the mold substrates 111 and 112 with the adhesive tape and closing the gap between the mold substrates 111 and 112. This forms a space surrounded by the mold substrates and the film (i.e., a cavity 114 for forming the lens). The film 113 may be a heat-release or re-peelable adhesive tape.

[0126] In the manufacturing method of the optical component of the second embodiment, a pair of molded substrates is used. The pair of molded substrates may be a pair of molded substrates. The mold in the second embodiment (also referred to as a mold for manufacturing optical components) is preferably a mold for manufacturing optical components by forming a space surrounded by a pair of mold substrates and a film by attaching a film to the outer circumferential surface of a pair of mold substrates arranged facing each other at a predetermined interval, placing a polymerizable composition in the space, and curing the polymerizable composition to obtain a cured product. In the second embodiment, the mold preferably has a main surface diameter of approximately 60 cm to 80 cm. As described above, when using the manufacturing method for the optical component of the second embodiment, an optical component with suppressed prism can be manufactured without polishing, or with a small amount of polishing. Therefore, the approximate diameter of the main surface of the mold and resin substrate can be reduced by eliminating the need for polishing.

[0127] Furthermore, we will also explain the case in which a double-casting method is used to obtain a cured product in which a layer containing a photochromic compound and the above-mentioned lens material are laminated together. When performing the double casting method, in the second and subsequent casts, the method for manufacturing the optical component of the second embodiment may include a step of forming a space surrounded by the mold substrate, the cured material, and the film by attaching a film to the outer surface of the mold substrate and the cured material obtained in the curing step, which are arranged to face each other at a predetermined interval. In this case, the method for manufacturing the optical member of the second embodiment may further include an injection step of injecting a polymerizable composition into the space, and a curing step of curing the polymerizable composition injected into the space to obtain a cured product.

[0128] When the double-cast method is performed, the cured product obtained in the curing process may be a resin substrate. In the second embodiment, the resin substrate is a substrate formed of resin. The resin substrate may be, for example, an optical element such as a lens, a semi-finished lens, or may contain a photochromic compound. The optical component obtained by the double-casting method may include a first layer and a second layer. For example, either the first layer or the second layer may contain a photochromic compound or the like.

[0129] <film> The method for manufacturing the optical component of the second embodiment uses the film of the second embodiment (also referred to as the film for manufacturing optical components). In the second embodiment, the film has a ratio (also called the heat resistance index ratio) of the heat resistance index measured at 30°C for 30 minutes to the heat resistance index measured at 20°C for 30 minutes, which is greater than 0.1. This allows the mold to slide appropriately across the film surface during polymerization shrinkage in the curing process. Therefore, polymerization wrinkles in the film can be suppressed, and the occurrence of polymerization wrinkles on the outer surface of the resulting cured product can be reduced. Furthermore, the spacing between molds can be uniformly narrowed during polymerization shrinkage in the curing process. As a result, prism formation can be suppressed. In the second embodiment, the film preferably includes at least a base layer and an adhesive layer. The film in the second embodiment may consist only of a single substrate layer, or it may be a laminate in which a substrate layer and an adhesive layer are laminated together.

[0130] (Heat resistance index ratio) In the second embodiment, the film has a ratio (also called the heat resistance index ratio) of the heat resistance index measured at 30°C for 30 minutes to the heat resistance index measured at 20°C for 30 minutes, which is greater than 0.1. A heat resistance index ratio greater than 0.1 makes the film less slippery at around 20°C, when the polymerizable composition is typically injected into the space between molds, thus preventing leakage of the polymerizable composition. Furthermore, a heat resistance index ratio greater than 0.1 makes the film more slippery when the temperature rises to around 30°C, where polymerization of the polymerizable composition begins. Making the film more slippery near the polymerization start temperature allows for easier absorption of polymerization shrinkage of the polymerizable composition by reducing the distance between molds. This also helps to suppress polymerization wrinkles, resulting in a smoother outer surface and reduced prism formation. From the above viewpoint, the heat resistance index ratio is preferably 0.2 or higher, more preferably 1.0 or higher, and even more preferably 2.0 or higher. From the viewpoint of suppressing the whitening of the resin due to the elution of tape adhesive, the heat resistance index ratio is preferably 20.0 or less, more preferably 15.0 or less, and even more preferably 10.0 or less.

[0131] [Heat resistance index test] The heat resistance index of the film in the second embodiment can be measured by a heat resistance index test. The static adhesive strength of a film can be measured by a heat resistance index test.

[0132] The specific method for the heat resistance index test is as follows: (method) At room temperature, of the exposed surface area of ​​the adhesive layer of a film measuring 25 mm ± 6 mm in width and 80 mm ± 0.5 mm in length, the area is 625 mm². 2 ±25mm2 Press this part firmly against the glass plate and apply a load of 1 kg / cm². 2 The film is then pressed together. A 1 kg weight is attached to the edge of the folded portion of the film that is not in close contact with the glass plate, and the glass plate is placed vertically in a constant temperature bath adjusted to a predetermined temperature (20°C or 30°C). After a predetermined time (30 minutes) has elapsed since being placed in the constant temperature bath, the position of the upper edge of the adhesive layer is measured, and the distance moved from the upper edge position immediately after the weight was attached is calculated to determine the heat resistance index.

[0133] [Tensile modulus of elasticity] The film in the second embodiment has a tensile modulus of 1.0 × 10 at 80°C. 10 It is preferable that it be Pa or higher, 2.0 × 10 10 It is more preferable that it be Pa or higher, 5.0 × 10 10 It is even more preferable that it be Pa or higher, 4.0 × 10 10 It is particularly preferable that the value be Pa or higher. The film in the second embodiment has a tensile modulus of 40.0 × 10 at 80°C. 10 It is preferable that it is less than or equal to Pa, 30.0 × 10 10 It is more preferable that it be less than or equal to Pa, 20.0 × 10 10 It is even more preferable that it be Pa or less. The film in the second embodiment has, for example, a tensile modulus of elasticity at 80°C of 1.0 × 10 10 Pa~40.0×10 10 Pa is preferable.

[0134] The tensile modulus measurement test shall be conducted in accordance with JIS Z0237. The detailed conditions are as follows: • Test model: AG-X-5 • Test temperature: 23℃ • Load cell capacity: 500N • Test speed: 5 mm / min ·Measurement area: 0.5(cm 2 ) • Chuck spacing: 10.0 mm • Chuck shape: Flat (width 50mm, depth 30mm)

[0135] [Adhesive strength] In the second embodiment, if the film includes at least a base layer and an adhesive layer, the adhesive strength of the adhesive layer is preferably 1.0 N / 10 mm to 10.0 N / 10 mm, more preferably 2.0 N / 10 mm to 7.0 N / 10 mm, and even more preferably 3.0 N / 10 mm to 5.0 N / 10 mm. Adhesion strength is measured in accordance with JIS Z 0237:2009.

[0136] The film in the second embodiment may contain an adhesive. The adhesive may be included in the adhesive layer. As the adhesive, known adhesives can be used, such as acrylic resin and rubber. Alternatively, adhesives described in PCT / JP2021 / 042848 can be used.

[0137] <Injection process> The injection step in the second embodiment is the step of injecting the polymerizable composition into the space described above. An example of the injection process will be explained using Figure 4. Figure 4 is a schematic diagram illustrating the injection process.

[0138] As shown in Figure 4, in the injection process, the adhesive tape 113 is peeled back to the extent that a gap is created in the cavity 114 through which the polymerizable composition can be injected. The polymerizable composition 120 is then injected into the cavity 114 through this gap, and the gap is sealed again with the adhesive tape 113.

[0139] The temperature during the injection process is preferably 30°C or lower, more preferably 27°C or lower, and even more preferably 25°C or lower. The temperature during the injection process is preferably 15°C or higher, more preferably 18°C ​​or higher, and even more preferably 20°C or higher.

[0140] <Polymerizable composition> The polymerizable composition in the second embodiment is a composition containing polymerizable monomers. A cured product is obtained by curing a polymerizable composition.

[0141] The polymerizable composition of the second embodiment may be a polymerizable composition comprising two or more different monomers for optical materials and a polymerization catalyst.

[0142] The polymerizable composition of the second embodiment comprises two or more different monomers for optical materials and a polymerization catalyst, wherein the content of the polymerization catalyst is preferably 0.015 to 0.080 parts by mass per 100 parts by mass of the total of the two or more different monomers for optical materials, and the viscosity measured with a B-type viscometer at 25°C and 60 rpm is preferably 10 mPa·s to 200 mPa·s. When measuring viscosity with a Type B viscometer under conditions of 25°C and 60 rpm, the rotor number is 2. The viscosity measured with a Type B viscometer at 25°C and 60 rpm is the viscosity (also called casting viscosity) immediately before injecting the polymerizable composition into the aforementioned space.

[0143] (Monomers for optical materials) The polymerizable composition of the second embodiment may contain two or more different monomers for optical materials. Details of specific examples of monomers for optical materials in the second embodiment, preferred examples, and preferred embodiments such as total light transmittance, haze, refractive index, and shape of the optical material are the same as those of specific examples of monomers for optical materials in the first embodiment, preferred examples, and preferred embodiments such as total light transmittance, haze, and refractive index.

[0144] [Isocyanate compounds] Details of specific examples, preferred examples, and preferred embodiments of the isocyanate compound in the second embodiment are the same as details of specific examples, preferred examples, and preferred embodiments of the isocyanate compound in the first embodiment.

[0145] [Active hydrogen compounds] Examples of active hydrogen compounds include polythiol compounds having two or more mercapto groups, hydroxythiol compounds containing one or more mercapto groups and one or more hydroxyl groups, polyol compounds containing two or more hydroxyl groups, and amine compounds. As the active hydrogen compound, oligomers of the above-mentioned active hydrogen compound or halogen-substituted derivatives of the above-mentioned active hydrogen compound (e.g., chlorine-substituted derivatives, bromine-substituted derivatives, etc.) may be used. Furthermore, the active hydrogen compounds may be used individually or in mixtures of two or more types.

[0146] (Polythiol compounds having two or more mercapto groups) Details of specific examples, preferred examples, and preferred embodiments of polythiol compounds having two or more mercapto groups in the second embodiment are the same as details of specific examples, preferred examples, and preferred embodiments of polythiol compounds having two or more mercapto groups in the first embodiment.

[0147] (Hydroxythiol compounds containing one or more mercapto groups and one or more hydroxyl groups) Details of specific examples, preferred examples, and preferred embodiments of hydroxythiol compounds containing one or more mercapto groups and one or more hydroxyl groups in the second embodiment are the same as details of specific examples, preferred examples, and preferred embodiments of hydroxythiol compounds containing one or more mercapto groups and one or more hydroxyl groups in the first embodiment.

[0148] (Polyol compounds containing two or more hydroxyl groups) Details of specific examples, preferred examples, and preferred embodiments of polyol compounds containing two or more hydroxyl groups in the second embodiment are the same as details of specific examples, preferred examples, and preferred embodiments of polyol compounds containing two or more hydroxyl groups in the first embodiment.

[0149] (Amine compounds) Details regarding specific examples, preferred examples, and preferred embodiments of the amine compound in the second embodiment are the same as those regarding specific examples, preferred examples, and preferred embodiments of the amine compound in the first embodiment.

[0150] The details of preferred specific examples and preferred content of the active hydrogen compound in the second embodiment are the same as those of the preferred specific examples and preferred content of the active hydrogen compound in the first embodiment.

[0151] <Polymerization catalyst> The polymerizable composition of the second embodiment preferably contains at least one polymerization catalyst. There are no particular restrictions on the polymerization catalyst, but for example, basic catalysts, organometallic catalysts, zinc carbamate salts, ammonium salts, sulfonic acids, etc., can be used. The polymerization catalysts described above may be used individually or in appropriate combinations of two or more types.

[0152] (Basic catalyst) Details regarding specific examples of basic catalysts in the second embodiment, preferred examples of compounds represented by general formula (2), preferred embodiments of compounds represented by general formula (3), preferred pKa values, and definitions of pKa values ​​are the same as those regarding specific examples of basic catalysts, preferred examples, preferred embodiments, preferred pKa values, and definitions of pKa values ​​in the first embodiment.

[0153] (organometallic catalyst) Details of specific examples, preferred examples, and preferred embodiments of the organometallic catalyst in the second embodiment are the same as details of specific examples, preferred examples, and preferred embodiments of the organometallic catalyst in the first embodiment.

[0154] Details of specific examples, preferred examples, and preferred embodiments of the polymerization catalyst in the second embodiment are the same as details of specific examples, preferred examples, and preferred embodiments of the polymerization catalyst in the first embodiment.

[0155] In the polymerizable composition of the second embodiment, from the viewpoint of effectively promoting the polymerization reaction, the content of the polymerization catalyst per 100 parts by mass of the total of two or more different monomers for optical materials is preferably 0.015 parts by mass or more, more preferably 0.020 parts by mass or more, and even more preferably 0.030 parts by mass or more.

[0156] In the polymerizable composition of the second embodiment, from the viewpoint of improving handling when injecting the polymerizable composition into a mold, the content of the polymerization catalyst per 100 parts by mass of the total of two or more different monomers for optical materials is preferably 0.080 parts by mass or less, more preferably 0.060 parts by mass or less, and more preferably 0.040 parts by mass or less.

[0157] (Other additives) The polymerizable composition of the second embodiment may contain any additives. Optional additives include photochromic compounds, alcohol compounds, visible light absorbing dyes, internal mold release agents, bluing agents, and ultraviolet absorbers.

[0158] (Photochromic compounds) Photochromic compounds are compounds whose molecular structure reversibly changes upon irradiation with light of a specific wavelength, and whose absorption properties (absorption spectrum) change accordingly. Details of specific examples, preferred examples, and preferred embodiments of the photochromic compound in the second embodiment are the same as details of specific examples, preferred examples, and preferred embodiments of the photochromic compound in the first embodiment. Examples of photochromic compounds used in the second embodiment include compounds whose absorption characteristics (absorption spectrum) change in response to light of a specific wavelength.

[0159] (Visible light absorbing dye) Commercially available visible light absorbing dyes may be used, and organic dye compounds are preferred. Specifically, porphyrin compounds or tetraazaporphyrin compounds are examples. More specifically, PD-311S (manufactured by Yamamoto Kasei Co., Ltd.) is an example of a visible light absorbing dye.

[0160] (Internal release agent) Examples of internal mold release agents include acidic phosphate esters. Examples of acidic phosphate esters include phosphate monoesters and phosphate diesters, which can be used individually or in combination of two or more types.

[0161] (Bluing agent) Examples of bluing agents include those that have an absorption band in the orange to yellow wavelength range within the visible light spectrum and have the function of adjusting the hue of optical materials made of resin. More specifically, bluing agents include substances that exhibit blue to purple colors.

[0162] (UV absorber) Details regarding specific examples, preferred examples, and preferred embodiments of the ultraviolet absorber in the second embodiment are the same as those regarding specific examples, preferred examples, and preferred embodiments of the ultraviolet absorber in the first embodiment.

[0163] (Alcohol compounds) The polymerizable composition of the second embodiment may contain an alcohol compound. Details regarding specific examples, preferred examples, and preferred embodiments of alcohol compounds in the second embodiment are the same as those regarding specific examples, preferred examples, and preferred embodiments of alcohol compounds in the first embodiment.

[0164] The polymerizable composition of the second embodiment further includes, in addition to the two or more different monomers and polymerization catalysts for optical materials described above, Preferably, it contains at least one selected from the group consisting of photochromic compounds, alcohol compounds, and visible light absorbing dyes. It is more preferable to include at least one selected from the group consisting of photochromic compounds and alcohol compounds, and / or at least one selected from visible light absorbing dyes.

[0165] (viscosity) The polymerizable composition of the second embodiment preferably has a viscosity of 10 mPa·s or more, more preferably 15 mPa·s or more, even more preferably 20 mPa·s or more, particularly preferably 25 mPa·s or more, even more preferably 35 mPa·s or more, and even more preferably 40 mPa·s or more, as measured with a B-type viscometer at 25°C and 60 rpm, from the viewpoint of suppressing striation and suppressing the elution of the adhesive. In the second embodiment, the polymerizable composition preferably has a viscosity of 200 mPa·s or less, more preferably 150 mPa·s or less, and even more preferably 100 mPa·s or less, as measured with a B-type viscometer at 25°C and 60 rpm, from the viewpoint of maintaining good handling when molding the optical material into a desired shape. The viscosity measured with a Type B viscometer at 25°C and 60 rpm is the viscosity (also called casting viscosity) immediately before injecting the polymerizable composition into the aforementioned space.

[0166] <Curing process> The curing step in the second embodiment is a step of curing a polymerizable composition injected into a space to obtain a cured product. The method for manufacturing an optical component according to the second embodiment includes a curing step, which allows the polymerizable composition to be polymerized and an optical material to be manufactured.

[0167] (Degree of polymerization) During the curing process, the degree of polymerization of the polymerizable composition is 15% or more at 30°C. By achieving a polymerization degree of 15% or higher, prisms and striations in the resulting cured product can be suppressed. In the curing process, it is preferable that the degree of polymerization of the polymerizable composition is 15% or more at 30°C.

[0168] In the curing process, it is preferable that the degree of polymerization of the polymerizable composition is 75% or less at 30°C. By keeping the degree of polymerization below 75%, polymerization of the polymerizable composition can be prevented at low temperatures while the mold does not slip excessively on the film surface. This further suppresses the occurrence of polymerization wrinkles. In addition, it can also suppress striations in the resulting cured product. The degree of polymerization is preferably 65% ​​or less, more preferably 55% or less, and even more preferably 45% or less.

[0169] In the second embodiment, the method for manufacturing the optical member is such that the film includes an adhesive layer, and in the curing step, the degree of polymerization of the polymerizable composition at the dissolution temperature of the adhesive layer is preferably 30% or more, more preferably 35% or more, and even more preferably 40% or more. This makes it possible to suppress the whitening of the cured product due to the elution of the adhesive layer. In the second embodiment, the method for manufacturing the optical member is such that the film includes an adhesive layer, and in the curing step, the degree of polymerization of the polymerizable composition at the dissolution temperature of the adhesive layer is preferably 75% or less, more preferably 65% ​​or less, and even more preferably 55% or less. The elution temperature refers to the temperature at which cloudiness is visually observed during the curing process after the polymerizable composition is injected into the space surrounded by the mold substrate and film.

[0170] The degree of polymerization is measured by the following method. Equipment used: Shimadzu DSC-60Plus Cells used: Pressure-resistant cell assembly, gold-plated. Filling gas: Air Measurement temperature conditions: Start temperature 20°C, end temperature 300°C After the mixing process is complete, the total heat generated from the exothermic behavior of the mixed liquid under the above conditions is measured and defined as the total heat of reaction (A). Next, the mixture being heated and polymerized in the oven is removed after a predetermined time, and the total heat generated is measured in the same manner and defined as the residual heat generated (B). In the second embodiment, the degree of polymerization (%) is calculated as B / A × 100.

[0171] In the curing process, the curing time is preferably 40 hours or less. In particular, in the curing process of the second embodiment, when the curing time is 40 hours or less, the amount of adhesive elution tends to be significantly suppressed, and the above-mentioned clouding, voids, etc. can be suppressed more effectively.

[0172] In the second embodiment, the curing time refers to the time from when the temperature of the polymerizable composition reaches 30°C until the polymerizable composition is completely cured.

[0173] From the viewpoint of the curability of the polymerizable composition, a curing time of 1 hour or more is preferable, and a curing time of 3 hours or more is more preferable.

[0174] The maximum curing temperature in the curing process is preferably 150°C or lower, and more preferably 130°C or lower. The maximum curing temperature in the curing process is preferably 50°C or higher, more preferably 60°C or higher, and even more preferably 70°C or higher.

[0175] In the curing process, a microwave irradiation step may be provided, if necessary, in which the polymerizable composition is irradiated with microwaves for a predetermined time.

[0176] <Cured product> The cured product of the second embodiment is the cured product of the polymerizable composition in the second embodiment. The cured product in the second embodiment can be suitably used as an optical component.

[0177] The cured product of the second embodiment preferably contains at least one selected from the group consisting of photochromic compounds and alcohol compounds.

[0178] <Optical components> The optical member in the second embodiment is manufactured by the manufacturing method of the optical member of the second embodiment. In the optical member of the second embodiment, polymerization wrinkles on the outer peripheral surface are suppressed and prisms are suppressed. Generally, cured products obtained by the single casting method often have non-uniform thicknesses, and the outer peripheral surfaces also have uneven shapes such as unevenness and are not smooth. Conventionally, these thickness non-uniformities and unevenness of the outer peripheral surface have been eliminated by polishing. In contrast, the optical member of the second embodiment can manufacture a high-quality optical member with suppressed prisms without performing polishing operations for prism correction and elimination of unevenness of the outer peripheral surface, or with a small polishing amount.

[0179] As described above, the manufacturing method of the optical member of the second embodiment can also be used for the double casting method. By using the double casting method, for example, a second layer made of the optical member of the second embodiment (for example, a lens) and a first layer laminated on the second layer and made of an optical member α (for example, a lens) other than the optical member of the second embodiment can be obtained. In this case, the second layer made of the optical member of the second embodiment (for example, a lens) may be disposed on the back surface side (the side opposite to the eye in the lens). In this case, the average thickness of the first layer may be thicker than the average thickness of the second layer. The first layer may contain at least one selected from the group consisting of a photochromic compound, an alcohol compound, and a visible light absorbing dye. It may contain at least one selected from the group consisting of a photochromic compound and an alcohol compound, and / or at least one selected from visible light absorbing dyes.

[0180] (Prismatic difference) From the viewpoint of suppressing non-uniformity in thickness and exhibiting high quality, the prismatic difference of the optical member of the second embodiment is preferably 0.20 mm or less, more preferably 0.15 mm or less, and even more preferably 0.10 mm or less.

[0181] The prism difference is measured by the following method. The thickness of the optical element is measured at a total of five points: the center (i.e., the area center), two midpoints of the radius on the diameter line, and two midpoints of the radius on a line perpendicular to the diameter line and passing through the center. Next, we calculate the difference in thickness from the center of the optical element (also called the center thickness difference) by subtracting the thicknesses at four points other than the center of the optical element from the thickness at the center of the optical element. In other words, we obtain four center thickness differences. The center thickness difference will be negative at points where the thickness is less than the center, and positive at points where the thickness is greater than the center. The maximum thickness difference is calculated by subtracting the minimum value from the maximum value of the four obtained central thickness differences, and this is considered the prism difference.

[0182] From a quality standpoint, it is preferable that the optical component of the second embodiment does not have striations of 1.0 mm or longer within a radius of 15 mm from the center.

[0183] In the second embodiment, it is preferable that the optical member has a stepped shape on a part of its outer circumference. For example, a case will be described in which a film is attached to the outer periphery of a pair of molded substrates arranged opposite each other at a predetermined interval, thereby forming a space surrounded by the pair of molded substrates and the film, and a polymerizable composition is injected into the space and cured. In this case, the film attached to the outer periphery overlaps in some areas. Due to the existence of these overlapping areas, a stepped shape is formed on a part of the outer periphery of the resulting optical component. The stepped shape described above can be eliminated by minor polishing.

[0184] <Applications of optical components> Details regarding specific examples and preferred examples of applications for the optical components in the second embodiment are the same as those regarding specific examples and preferred examples of applications for the optical components in the first embodiment.

[0185] <Annealing process> Details of the specific and preferred embodiments of the annealing process in the second embodiment are the same as those of the specific and preferred embodiments of the annealing process in the first embodiment.

[0186] The specific means of the second embodiment include the following aspects. <1B> A method for manufacturing an optical component, comprising: a space formation step of forming a space surrounded by a pair of mold substrates and a film by attaching a film to the outer circumferential surfaces of a pair of mold substrates arranged facing each other at a predetermined interval; an injection step of injecting a polymerizable composition into the space; and a curing step of curing the polymerizable composition injected into the space to obtain a cured product, wherein the film has a ratio of a heat resistance index measured at 30°C for 30 minutes to a heat resistance index measured at 20°C for 30 minutes of greater than 0.1, and in the curing step, the degree of polymerization of the polymerizable composition at 30°C is 15% or more. <2B> The method for manufacturing an optical component according to <1B>, wherein in the curing step, the degree of polymerization of the polymerizable composition is 75% or less at 30°C. <3B> The method for manufacturing an optical member according to <1B> or <2B>, wherein the film includes an adhesive layer, and in the curing step, the degree of polymerization of the polymerizable composition is 30% or more at the dissolution temperature of the adhesive layer. <4B> The polymerizable composition comprises two or more different monomers for optical materials and a polymerization catalyst, wherein the content of the polymerization catalyst is 0.015 parts by mass to 0.080 parts by mass per 100 parts by mass of the total of the two or more different monomers for optical materials, and the viscosity measured with a B-type viscometer at 25°C and 60 rpm is 10 mPa·s to 200 mPa·s, the method for producing an optical component according to any one of <1B> to <3B>. <5B> The method for producing an optical component according to <4B>, wherein the two or more different monomers for optical materials comprises at least one active hydrogen compound selected from the group consisting of a polythiol compound containing two or more mercapto groups, a hydroxythiol compound containing one or more mercapto groups and one or more hydroxyl groups, a polyol compound containing two or more hydroxyl groups, and an amine compound. <6B> A method for producing an optical component according to <4B> or <5B>, wherein the two or more different monomers for optical materials include an isocyanate compound, and the isocyanate compound includes at least one selected from the group consisting of isophorone diisocyanate, 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, m-xylylene diisocyanate, 2,4-tole diisocyanate, 2,6-tole diisocyanate, dicyclohexylmethane diisocyanate, 1,3-bis(isocyanatomethyl)cyclohexane, 1,4-bis(isocyanatomethyl)cyclohexane, 1,6-hexamethylene diisocyanate, and 1,5-pentamethylene diisocyanate. <7B> A method for manufacturing an optical component according to any one of <4B> to <6B>, wherein the polymerization catalyst comprises at least one selected from the group consisting of amine-based catalysts and organotin-based catalysts. [Examples]

[0187] Hereinafter, one embodiment of the first embodiment will be specifically described with reference to examples, but the first embodiment is not limited to these examples. The method for measuring viscosity in the examples is the same as the method described in the section on the first embodiment above. The method for the heat resistance index test in the examples is the same as the method described in the section on the first embodiment above. The method for measuring the tensile modulus in the embodiment is the same as the method described in the section on the first embodiment above. The method for performing the glass ball tack test in the examples is the same as the method described in the section on the first embodiment above. The method for measuring adhesive strength in the examples is the same as the method described in the section on the first embodiment above.

[0188] The following evaluations were performed on the cured products (i.e., lenses) obtained in each example or comparative example.

[0189] [prism] Set the prism difference in the same manner as the above method. Evaluate the prism of the optical member from the obtained prism difference. In addition, when the prism difference is 0.25 mm or less, it can be said that the prism of the optical member is small.

[0190] [Adhesive residue] After the curing of the polymerizable composition was completed and the cured product was removed from the mold and the resin substrate, after peeling off the film (i.e., tape), it was visually confirmed whether or not the tape adhesive remained on the mold and the resin substrate. The case where no adhesive residue occurred was designated as A, and the case where adhesive residue occurred was designated as B.

[0191] [Void] In the cured product, it was visually confirmed whether or not voids occurred. The case where no voids occurred was designated as A, and the case where voids occurred was designated as B.

[0192] [Leakage] After injecting the polymerizable composition, it was confirmed whether or not "monomer leakage", in which the monomer leaked from the mold in the oven, occurred. The amount of monomer injected into the mold and the resin mass after polymerization were measured, and the ratio of the monomer leaked from the mold in the oven after injection was defined as the monomer leakage rate and obtained by the following formula. The case where the monomer leakage rate was 1% or less was designated as A, and the case where it was greater than 1% was designated as B. Monomer injection amount = X (g) Resin mass after polymerization = Y (g) Monomer leakage amount = X - Y (g) Monomer leakage rate = (X - Y) / X × 100 (%)

[0193] [Cloudiness / Elution] In the cured product, it was visually confirmed whether or not cloudiness or elution of the adhesive occurred. The case where neither cloudiness nor elution of the adhesive was confirmed was designated as A, and the case where cloudiness or elution of the adhesive was confirmed was designated as B.

[0194] [Haze] The haze of a 9.0 mm thick flat resin plate, as a cured product, was measured using a haze meter (model number: NDH 2000) manufactured by Nippon Denshoku Industries Co., Ltd. A lower haze value indicates better transparency as a lens.

[0195] [Photochromic performance] (a) Light transmittance during color development (T%max) Using a xenon lamp light source, a 0.7 mm thick molded sample, intended as a cured material, was irradiated for 15 minutes at a temperature of 23°C and an illuminance of 50,000 lux, and the spectrum was continuously measured during this time. From the spectrum after 15 minutes of irradiation, the light transmittance (T%max) at the maximum absorption wavelength (λmax) at that time was determined. A lower transmittance indicates a deeper color development (i.e., superior photochromic performance). (b) Fading half-life (F1 / 2): After the 15 minutes of color development, the spectrum of the cured material (molded sample) was measured continuously for another 15 minutes after stopping the light irradiation. From the spectral data, the time required for the absorbance at λmax of the molded sample to return to the midpoint of the absorbance before and after color development was determined and defined as the fading half-life (F1 / 2). A shorter fading half-life (F1 / 2) indicates a faster fading rate (i.e., superior photochromic performance). • Light source: Ushio Electric Co., Ltd. MS-35AAF / FB • Lamp: Ushio Electric Co., Ltd. Xenon Lamp UXL-300SX2 • Spectroscopic measurement device: Otsuka Electronics Co., Ltd. Instant Multi-Photometric System MSPD-7700

[0196] <film> The film used in this embodiment is as follows: A: Scotch® Removable Tape 821-3-24 (Manufactured by 3M Japan Limited) B: Packaging sealing tape (non-PVC type) No. 33T (manufactured by Nitto Denko Corporation) C: Packaging sealing vinyl tape No. 23S (manufactured by Nitto Denko Corporation) D:6263-73 (Manufactured by Sliontec Co., Ltd.) Details of each film are shown in Table 1.

[0197] (Examples 1A to 3A, Comparative Example 1A) <Fabrication of resin substrates> A mixed solution was prepared by charging 0.008 parts by mass of dimethyltin(II) dichloride, 0.1 parts by mass of Mitsui Chemicals' internal mold release agent for MR, 0.6 parts by mass each of the ultraviolet absorbers Tinuvin 329 and Seesorb 709, and 50.7 parts by mass of m-xylylene diisocyanate. This mixed solution was stirred at 25°C for 1 hour to completely dissolve the substances. Then, 49.3 parts by mass of a mixture of 5,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, 4,7-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane, and 4,8-dimercaptomethyl-1,11-dimercapto-3,6,9-trithiaundecane into this solution, and stirring at 25°C for 30 minutes to obtain a homogeneous solution. This solution was degassed at 400 Pa for 1 hour, filtered through a 1 μm PTFE filter, and then poured into a glass mold for flat plates. The glass mold was heated from 25°C to 120°C over 20 hours. After cooling to room temperature, it was removed from the glass mold to obtain a flat plate lens. The obtained flat plate lens was further annealed at 120°C for 2 hours to obtain a molded body (lens) having the center thickness and base curve described in Table 1. The resulting molded body is used as a resin substrate.

[0198] <Preparation of polymerizable compositions> A master solution was prepared by dissolving 0.02 parts by mass of Reversacol Wembley Grey, manufactured by Vivimed, as a photochromic compound, 0.02 parts by mass of Reversacol Jalapeno Red, manufactured by Vivimed, 0.02 parts by mass of Reversacol Marine Blue, manufactured by Vivimed, 0.05 parts by mass of Reversacol Adriatic Blue, manufactured by Vivimed, and 0.08 parts by mass of Reversacol Mendip Green, manufactured by Vivimed, as well as 0.075 parts by mass of HOSTAVIN PR-25 as an ultraviolet absorber, in 9.73 parts by mass of a composition containing 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane and 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, and in 0.08 parts by mass of Reversacol Mendip Green, manufactured by Vivimed, as photochromic compounds, and 0.075 parts by mass of HOSTAVIN PR-25 as an ultraviolet absorber. 30.28 parts by mass of a composition containing 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane and 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane were added to 10 parts by mass of the obtained master solution and stirred. Then, 2.52 parts by mass of ADEKA Pluronic® L-64 manufactured by ADEKA Corporation, 0.4 parts by mass of Polyflow KL-100 manufactured by Kyoeisha Chemical Co., Ltd., and 0.05 parts by mass of JP-506H manufactured by Johoku Chemical Industry Co., Ltd. as an acidic phosphate ester were added and stirred for 30 minutes at 15°C to 20°C to obtain a mixed solution (mixing step A). To the mixture obtained in mixing step A, 19.97 parts by mass of pentaerythritol tetrakis(3-mercaptopropionate) and 27.23 parts by mass of 4-mercaptomethyl-1,8-dimercapto-3,6-dithiaoctane were added, and the mixture was stirred for 15 minutes at 15°C to 20°C to obtain a mixed solution (mixing step B). A solution was prepared by adding 0.015 parts by mass of dimethyl tin dichloride to 10 parts by mass of a composition containing 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane and 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane and dissolving it uniformly. This solution was added to the mixture obtained in mixing step B and stirred for 15 minutes at a temperature of 15°C to 20°C to obtain a polymerizable composition.

[0199] <Preparation of hardened material> A casting mold was created by attaching the film (or tape) described in Table 1 to the outer surfaces of a mold substrate and a resin substrate arranged opposite each other at a predetermined interval, thereby forming a space surrounded by the mold substrate, resin substrate, and film. The distance between the mold substrate and the resin substrate (i.e., the space) at the center of the lens was set to 0.8 mm.

[0200] The obtained polymerizable composition was injected into the aforementioned space at a rate of 6 g / second while being remixed in a stationary mixer. The viscosity (also called casting viscosity) of the polymerizable composition when it is delivered to the mold and cast was adjusted to the values ​​shown in Table 1.

[0201] The cast material was heated in an oven at the temperatures and times listed in Table 1 to carry out polymerization. The hardened material was released from the casting mold, and then annealed at 120°C for 2 hours to obtain a hardened product (lens).

[0202] The cured products (lenses) obtained in Examples 1A to 3A did not have striations longer than 1.0 mm within a radius of 15 mm from the center. Furthermore, the cured products (lenses) obtained in Examples 1A to 3A had a stepped shape in a part of the outer periphery of the second layer (i.e., the resin substrate layer).

[0203] [Table 1]

[0204] As shown in Table 1, the method for manufacturing an optical component, which includes a space formation step of forming a space surrounded by a molded substrate, a resin substrate, and a film by attaching a film to the outer circumferential surfaces of a molded substrate and a resin substrate arranged opposite each other at a predetermined interval, an injection step of injecting a polymerizable composition into the space, and a curing step of curing the polymerizable composition injected into the space to obtain a cured product, wherein the film satisfies at least one of the following conditions: it does not peel off the resin substrate even when held for 3 minutes when attached to the resin substrate and subjected to a heat resistance index test at 50°C, and the elongation rate is greater than 0% in 3 minutes when attached to the resin substrate and subjected to a heat resistance index test at 50°C, the resulting optical component had a prism difference of 0.25 mm or less. Therefore, it was possible to manufacture an optical component with suppressed prism. In addition, the results for leakage and turbidity / elution were also excellent. On the other hand, Comparative Example 1A, which used a film that did not satisfy both conditions—that it did not peel off the resin substrate even after being held for 3 minutes when attached to a resin substrate and subjected to a heat resistance index test at 50°C, and that its elongation rate was greater than 0% after 3 minutes when attached to a resin substrate and subjected to a heat resistance index test at 50°C—resulted in an optical component with a prism difference of more than 0.25 mm. Therefore, it was not possible to manufacture an optical component with suppressed prism. In particular, Example 2A, which satisfies both conditions that the film does not peel off the resin substrate even after being held for 3 minutes when attached to a resin substrate and subjected to a heat resistance index test at 50°C, and that the elongation rate is greater than 0% after 3 minutes when attached to a resin substrate and subjected to a heat resistance index test at 50°C, resulted in an optical component with a particularly small prism difference, making it possible to manufacture an optical component with better prism suppression. Furthermore, Example 2A showed superior results in all aspects, including adhesive residue, voids, leakage, and turbidity / elution.

[0205] Next, the haze (%) of the first layer, the thickness (mm) of the first layer, the haze (%) of the second layer, and the thickness (mm) of the second layer were measured at the center of the cured product (lens) obtained in Example 2A. Based on the measurement results, the value H1 (% / mm), which is the value obtained by dividing the haze (%) of the first layer by the thickness (mm) of the first layer, and the value H2 (% / mm), which is the value obtained by dividing the haze (%) of the second layer by the thickness (mm) of the second layer, were determined. As a result, the value H1 was found to be 0.069% / mm and the value H2 was found to be 0.052% / mm, confirming that the value H1 was higher than the value H2. Furthermore, the ratio of value H1 to value H2 was 1.327 (=0.069 / 0.052). When the photochromic performance of the cured product (lens) obtained in Example 2A was evaluated, it was confirmed that the light transmittance during color development was 20% or less, indicating deep color development, and the fading half-life (F1 / 2) was 60 seconds or less, indicating a fast fading rate, thus confirming that a cured product (lens) with good photochromic performance was obtained.

[0206] The following describes in detail one embodiment of the second embodiment with reference to examples, but the second embodiment is not limited to these examples. The method for measuring viscosity in the examples is the same as the method described in the section on the second embodiment above. The method for the heat resistance index test in the examples is the same as the method described in the section on the second embodiment above. The method for measuring the tensile modulus in the embodiment is the same as the method described in the section on the second embodiment above.

[0207] The following evaluations were performed on the cured products (i.e., lenses) obtained in each example or comparative example.

[0208] [prism] The prism difference was measured using the same method as described above. The prism of the optical component was evaluated based on the obtained prism difference. Furthermore, if the prism difference is 0.20 mm or less, it can be said that the prism of the optical component is small.

[0209] [polymer wrinkles] After the polymerizable composition had cured and was removed from the mold, the side surface of the cured product was visually inspected for the presence or absence of polymerization wrinkles (i.e., polymerization shrinkage marks). If irregularities with an average depth of 0.4 mm or more were observed on the outer surface, the result was classified as B; if no irregularities were observed, the result was classified as A.

[0210] [Glue residue] After the polymerizable composition had cured and the cured product was removed from the mold, the film (i.e., tape) was peeled off. A visual inspection was then conducted to confirm whether any adhesive residue from the tape remained on the mold and the cured product. Case A was defined as having no adhesive residue, and case B was defined as having adhesive residue.

[0211] [Void] We visually inspected the cured material to see if voids had formed. Case A was defined as no voids occurring, and case B was defined as voids occurring.

[0212] [leak] We checked whether "monomer leakage," where monomers leak out of the mold in the oven after the polymerizable composition is injected, is occurring. The amount of monomer injected into the mold and the mass of the polymerized resin were measured, and the percentage of monomer that leaked out of the mold in the oven after injection was defined as the monomer leakage rate and calculated using the following formula. Case A was defined as having a monomer leakage rate of 1% or less, and case B was defined as having a rate greater than 1%. Monomer injection amount = X (g) Resin mass after polymerization = Y (g) Monomer leakage amount = XY(g) Monomer leakage rate = (XY) / X × 100 (%)

[0213] [Cloudiness / elution] The cured product was visually inspected to see if any clouding or leaching of the adhesive had occurred. Cases where no clouding or leaching of adhesive was observed were classified as A, and cases where clouding or leaching of adhesive was observed were classified as B.

[0214] <film> The film used in this embodiment is as follows: A: KC2 (manufactured by YOUNGWOO Co., Ltd.) B: YT-7107C (Manufactured by YOUNGWOO Co., Ltd.) C:6263-00 (Manufactured by Sliontec Co., Ltd.) D:6263-73 (Manufactured by Sliontec Co., Ltd.) Details of each film are shown in Table 2.

[0215] <Preparation of polymerizable compositions> 50.6 parts by mass of a composition containing 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane and 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane were mixed with 0.125 parts by mass of Zelec-UN and 0.05 parts by mass of Viosorb 583, and the mixture was stirred at 10°C to 20°C for 10 to 20 minutes to obtain a mixed solution (mixing step A). In mixing step A, 23.9 parts by mass of pentaerythritol tetrakis(3-mercaptopropionate) were added to the mixture obtained, and the mixture was stirred at 10°C to 20°C for 10 to 20 minutes to obtain the final mixture (mixing step B). A solution was prepared by adding 0.03 parts by mass of dimethyl tine dichloride to 25.5 parts by mass of 4-mercaptomethyl-1,8-dimercapto-3,6-dithiaoctane and dissolving it uniformly. This solution was added to the mixture obtained in mixing step B and stirred for 10 to 20 minutes at a temperature of 10°C to 20°C to obtain a polymerizable composition.

[0216] [Examples 1B to 3B, Comparative Examples 1B to 3B] <Preparation of hardened material> A casting mold was created by attaching the film (or tape) described in Table 2 to the outer surfaces of a pair of mold substrates arranged opposite each other at a predetermined interval, thereby forming a space surrounded by the pair of mold substrates and the film.

[0217] The obtained polymerizable composition was injected into the aforementioned space at a rate of 6 g / second while being remixed in a stationary mixer. The viscosity (also called casting viscosity) of the polymerizable composition when it is delivered to the mold and cast was adjusted to the values ​​shown in Table 2.

[0218] Polymerization was carried out by heating the cast material in an oven at the temperatures and times specified in Table 2. The hardened material was released from the casting mold, and then annealed at 120°C for 2 hours to obtain a hardened product (lens).

[0219] [Table 2]

[0220] As shown in Table 2, the method for manufacturing optical components includes a space formation step of forming a space surrounded by a pair of molded substrates and a film by attaching a film to the outer circumferential surfaces of a pair of molded substrates arranged opposite each other at a predetermined interval, an injection step of injecting a polymerizable composition into the space, and a curing step of curing the polymerizable composition injected into the space to obtain a cured product, wherein the film has a ratio of the heat resistance index measured at 30°C for 30 minutes to the heat resistance index measured at 20°C for 30 minutes (also called the heat resistance index ratio) of more than 0.1, and in the curing step, the degree of polymerization of the polymerizable composition at 30°C is 15% or more. In the example using this method for manufacturing optical components, polymerization wrinkles on the outer circumferential surface were suppressed, and an optical component with suppressed prism formation was produced. On the other hand, Comparative Example 1B, which did not have a heat resistance index ratio greater than 0.1, performed poorly in the evaluation of prisms and polymerization wrinkles, and therefore could not suppress polymerization wrinkles on the outer surface of the optical component, nor could it suppress prisms. Furthermore, Comparative Examples 2B and 3B, in which the degree of polymerization of the polymerizable composition was not 15% or more at 30°C, performed poorly in prism evaluation and therefore could not suppress prism formation.

[0221] The disclosures of Japanese Patent Application No. 2022-028598, filed on 25 February 2022, and Japanese Patent Application No. 2022-120906, filed on 28 July 2022, are incorporated herein by reference in their entirety. All documents, patent applications, and technical standards described herein are incorporated by reference to the same extent as if each individual document, patent application, and technical standard were specifically and individually noted to be incorporated by reference. [Explanation of symbols]

[0222] 10 Lens casting polymerization type 11 Molded circuit board 12 Resin substrate 13. Film (adhesive tape) 14. Space (cavity) 20 Polymerizable composition 110 Lens casting polymerization type 111 Molded substrate for convex surface formation 112 Molding substrate for concave surface formation 113 Film (adhesive tape) 114 Space (cavity) 120 Polymerizable composition

Claims

1. A space formation step is to form a space surrounded by the mold substrate, the resin substrate and the film by attaching a film to the outer circumferential surfaces of a mold substrate and a resin substrate arranged facing each other at a predetermined interval, An injection step of injecting a polymerizable composition into the aforementioned space, A curing step is performed to cure the polymerizable composition injected into the space to obtain a cured product. Includes, A method for manufacturing an optical component, wherein the film satisfies at least one of the following conditions: when attached to the resin substrate and subjected to a heat resistance index test at 50°C, it does not peel off the resin substrate even when held for 3 minutes; and when attached to the resin substrate and subjected to a heat resistance index test at 50°C, its elongation rate is greater than 0% for 3 minutes.

2. The method for manufacturing an optical member according to claim 1, wherein the film satisfies both of the following conditions: when attached to the resin substrate and subjected to a heat resistance index test at 50°C, it does not peel off the resin substrate even when held for 3 minutes; and when attached to the resin substrate and subjected to a heat resistance index test at 50°C, its elongation rate is greater than 0% after 3 minutes.

3. The method for manufacturing an optical component according to claim 1, wherein the film is such that when a glass ball tack test is performed at 80°C, the distance the glass ball moves is 200 mm or less.

4. The method for producing an optical member according to claim 1, wherein the polymerizable composition comprises two or more different monomers for optical materials and a polymerization catalyst, wherein the content of the polymerization catalyst is 0.01 parts by mass to 0.1 parts by mass per 100 parts by mass of the total of the two or more different monomers for optical materials, and the viscosity measured with a B-type viscometer at 25°C and 60 rpm is 30 mPa·s to 1000 mPa·s.

5. The method for producing an optical member according to claim 4, wherein the polymerizable composition further comprises at least one selected from the group consisting of photochromic compounds, alcohol compounds, and visible light absorbing dyes.

6. The method for producing an optical member according to claim 4, wherein the two or more different monomers for optical materials include an isocyanate compound and an active hydrogen compound which is at least one selected from the group consisting of a polythiol compound containing two or more mercapto groups, a hydroxythiol compound containing one or more mercapto groups and one or more hydroxyl groups, a polyol compound containing two or more hydroxyl groups, and an amine compound.

7. It includes the first layer and the second layer, The average thickness of the second layer is greater than the average thickness of the first layer. The first layer comprises at least one selected from the group consisting of photochromic compounds, alcohol compounds, and visible light absorbing dyes. An optical element having a prism difference of 0.25 mm or less, and no striations of 1.0 mm or longer within a radius of 15 mm from the center.

8. The optical member according to claim 7, wherein the second layer has a stepped shape on a part of its outer periphery.

9. The optical member according to claim 7, wherein, at the center of the optical material, a value H1 obtained by dividing the haze of the first layer by the thickness of the first layer is higher than a value H2 obtained by dividing the haze of the second layer by the thickness of the second layer.

10. The optical member according to claim 9, wherein the ratio of the value H1 to the value H2 is 1.001 to 1.

500.

11. A space formation step is to form a space surrounded by the pair of molded substrates and the film by attaching a film to the outer circumferential surface of a pair of molded substrates arranged facing each other at a predetermined interval, An injection step of injecting a polymerizable composition into the aforementioned space, A curing step is performed to cure the polymerizable composition injected into the space to obtain a cured product. Includes, The aforementioned film has a ratio of the heat resistance index measured at 30°C for 30 minutes to the heat resistance index measured at 20°C for 30 minutes that is greater than 0.

1. A method for manufacturing an optical component, wherein in the curing step, the degree of polymerization of the polymerizable composition is 15% or more at 30°C.

12. The method for manufacturing an optical member according to claim 11, wherein in the curing step, the degree of polymerization of the polymerizable composition is 75% or less at 30°C.

13. The film includes an adhesive layer, The method for manufacturing an optical member according to claim 11, wherein in the curing step, the degree of polymerization of the polymerizable composition is 30% or more at the dissolution temperature of the adhesive layer.

14. The polymerizable composition is, It comprises two or more different monomers for optical materials and a polymerization catalyst, The content of the polymerization catalyst is 0.015 parts by mass to 0.080 parts by mass relative to a total of 100 parts by mass of the two or more different monomers for optical materials. The viscosity measured with a Type B viscometer at 25°C and 60 rpm is between 10 mPa·s and 200 mPa·s. The method for manufacturing an optical member according to claim 11.

15. The method for producing an optical member according to claim 14, wherein the two or more different monomers for optical materials include at least one active hydrogen compound selected from the group consisting of a polythiol compound containing two or more mercapto groups, a hydroxythiol compound containing one or more mercapto groups and one or more hydroxyl groups, a polyol compound containing two or more hydroxyl groups, and an amine compound.

16. The two or more different monomers for optical materials include an isocyanate compound. The method for producing an optical member according to claim 14, wherein the isocyanate compound comprises at least one selected from the group consisting of isophorone diisocyanate, 2,5-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, 2,6-bis(isocyanatomethyl)bicyclo-[2.2.1]-heptane, m-xylylene diisocyanate, 2,4-tole diisocyanate, 2,6-tole diisocyanate, dicyclohexylmethane diisocyanate, 1,3-bis(isocyanatomethyl)cyclohexane, 1,4-bis(isocyanatomethyl)cyclohexane, 1,6-hexamethylene diisocyanate, and 1,5-pentamethylene diisocyanate.

17. The method for producing an optical member according to claim 14, wherein the polymerization catalyst comprises at least one selected from the group consisting of amine-based catalysts and organotin-based catalysts.

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