Method for manufacturing spectacle lenses

Abstract

To provide a spectacle lens which exhibits water repellency and capabilities expressed by a metal component included in a water-repellent layer, and is also excellent in durability of those capabilities.SOLUTION: A method for producing a spectacle lens is provided. The spectacle lens has a water-repellent layer. The water-repellent layer is formed as a film by a thermal vapor deposition method. The film formation by the thermal vapor deposition method includes heating a plurality of vapor deposition sources at different respective temperature profiles. Among the plurality of vapor deposition sources, at least one of the vapor deposition sources includes a water-repellent component, and at least one of the vapor deposition sources includes a metal component.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a method for manufacturing spectacle lenses.

Background Art

[0002] Spectacle lenses generally have a structure in which one or more functional layers are formed on the surface of a lens substrate (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the example of Patent Document 1, a water-repellent layer (a water-repellent thin film in Patent Document 1) is provided on a plastic lens as a functional layer to manufacture an optical member that can be used as a spectacle lens. By providing a water-repellent layer on the spectacle lens, water-repellency can be imparted to the spectacle lens. The fact that the spectacle lens has water-repellency is preferable from the viewpoints of suppressing the adhesion of dirt (such as sweat, fingerprints, etc.) to the surface of the spectacle lens and facilitating the removal of the adhered dirt.

[0005] Imparting various performances to spectacle lenses leads to an increase in the added value of the spectacle lenses. In this regard, the present inventor has considered imparting the performance exhibited by a metal component to a spectacle lens by including the metal component in the water-repellent layer.

[0006] In addition, for spectacle lenses, wiping treatment for removing surface dirt is routinely performed by spectacle users. It is also desired that the spectacle lenses have little performance degradation even when such wiping treatment is performed for a long period (that is, excellent durability).

[0007] One aspect of the present invention aims to provide spectacle lenses that can exhibit water repellency and the performance exhibited by the metal components contained in the water-repellent layer, and that also have excellent durability of those performances.

Means for Solving the Problems

[0008] One aspect of the present invention is a method for manufacturing spectacle lenses, comprising the above spectacle lenses having a water-repellent layer, forming the above water-repellent layer by a heat evaporation deposition method, the film formation by the above heat evaporation deposition method includes heating a plurality of evaporation sources with different temperature profiles respectively, the above plurality of evaporation sources include at least one evaporation source containing a water-repellent component and at least one evaporation source containing a metal component, a method for manufacturing spectacle lenses (hereinafter, also simply referred to as the "manufacturing method"), relates to.

[0009] In the above manufacturing method, film formation is performed by a heat evaporation deposition method using the above plurality of evaporation sources and heating those plurality of evaporation sources with different temperature profiles. Normally, the metal component and the water-repellent component have different vaporization temperatures. In vapor deposition by heating with a single temperature profile, it is considered that during the temperature increase, the water-repellent component that vaporizes at a lower temperature mainly vaporizes and deposits first, and then the metal component that vaporizes at a higher temperature mainly vaporizes and deposits. When the metal component and the water-repellent component are deposited in this way to form the water-repellent layer, a bias occurs in the distribution of the metal component and the water-repellent component within the water-repellent layer. Regarding the water-repellent component that is unevenly distributed inside the water-repellent layer, it is considered that the water repellency that the spectacle lenses can exhibit is reduced by the inclusion of this component. On the other hand, it is presumed that the durability of the performance exhibited by the metal component unevenly distributed in the surface layer portion is low. In contrast, in the above manufacturing method, since a plurality of evaporation sources are heated with different temperature profiles in film formation by the heat evaporation method, it is considered that the deviation in the distribution of the metal component and the water-repellent component in the water-repellent layer can be reduced. Thus, the present inventor conjectures that it becomes possible to provide spectacle lenses that can exhibit the performance exerted by the water repellency and the metal component, and that also have excellent durability of those performances. However, the present invention is not limited to the conjecture described in this specification.

Effect of the Invention

[0010] According to one aspect of the present invention, it becomes possible to manufacture spectacle lenses that can exhibit the performance exerted by the water repellency and the metal component contained in the water-repellent layer, and that also have excellent durability of those performances.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Mode for Carrying Out the Invention

[0012] Hereinafter, the above manufacturing method will be described in more detail.

[0013] <Water-repellent layer> The above spectacle lenses have a water-repellent layer. In the present invention and this specification, the "water-repellent layer" refers to a layer that contributes to the water-repellent property of the spectacle lens surface or that contributes to exhibiting better water-repellent property compared to the case where this layer is not present.

[0014] <Metal component> The water-repellent layer contains one or more metal components. The spectacle lens manufactured by the above manufacturing method can exhibit the functions exerted by the metal components contained in the water-repellent layer, and can also exhibit excellent durability with respect to these functions.

[0015] In the present invention and this specification, the "metal component" shall mean a component containing one or more metals. Examples of the form of the metal in the metal component include the form of a simple metal or an alloy, the form of an inorganic compound or an organic compound, the form of metal ions, and the like. Further, as an example of the metal component, a metal complex can also be mentioned.

[0016] As a performance that is desired to be imparted to the spectacle lens, in recent years when the need for antibacterial properties has been increasing, a function capable of suppressing the growth of bacteria (i.e., antibacterial property) can be mentioned. From the viewpoint of also functioning as an antibacterial layer that contributes to imparting antibacterial properties to the spectacle lens with the water-repellent layer, a silver-containing component can be mentioned as a desirable metal component. In the water-repellent layer formed by vapor-depositing a silver-containing component, silver can exist in a plurality of forms. This is the same for other metals. The present inventor believes that at least a part of silver can be ionized by oxidation to exhibit antibacterial properties, and this contributes to the fact that the water-repellent layer containing silver can function as an antibacterial layer. Further, in one form, as the metal component to be contained in the water-repellent layer, one or more components containing a metal selected from the group consisting of platinum (Pt), gold (Au), palladium (Pd), mercury (Hg), cadmium (Cd), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), titanium (Ti), zirconium (Zr), molybdenum (Mo), and lead (Pb) can be mentioned. Forming the water-repellent layer using one or more metal components containing the above other metals together with the silver-containing component may lead to suppressing a decrease in the functions exerted by silver by other metals.

[0017] <Water-repellent component> The water-repellent layer contains one or more water-repellent components. The spectacle lens manufactured by the above manufacturing method can exhibit the water-repellency exerted by the water-repellent components contained in the water-repellent layer and can also exhibit excellent durability with respect to water-repellency.

[0018] In the present invention and this specification, the "water-repellent component" means a component that contributes to the surface of the layer containing this component exhibiting water-repellency or contributes to better water-repellency being exhibited compared to the case where this component is not contained.

[0019] Examples of the water-repellent component can include fluorine-containing components. Examples of the form of fluorine in the fluorine-containing component can include the form of an inorganic compound or an organic compound, and the form of an organic compound is preferred. That is, as one form of the water-repellent component, fluorine-containing organic compounds can be mentioned.

[0020] An example of the fluorine-containing organic compound can include metaxylene hexafluoride (C6H4(CF3)2) and the like.

[0021] In addition, examples of the fluorine-containing organic compound can also include fluorine-containing organosilane compounds represented by the following general formula (1).

[0022]

Chemical formula

[0023] In the above general formula (1), Rf is a linear or branched perfluoroalkyl group having 1 to 16 carbon atoms, preferably CF3-, C2F5-, C3F7-. R1 is a hydrolyzable group, and for example, a halogen atom, -OR3, -OCOR3, -OC(R3)=C(R4)2, -ON=C(R3)2, -ON=CR5 are preferred. More preferably, they are a chlorine atom, -OCH3, -OC2H5. Here, R3 is an aliphatic hydrocarbon group or an aromatic hydrocarbon group, R4 is a hydrogen atom or an aliphatic hydrocarbon group (for example, a lower aliphatic hydrocarbon group), and R5 is a divalent aliphatic hydrocarbon group having 3 to 6 carbon atoms. R2 is a hydrogen atom or a monovalent organic group. The above monovalent organic group is preferably an inert group. The above monovalent organic group is more preferably a monovalent hydrocarbon group having 1 to 4 carbon atoms. X is an iodine atom or a hydrogen atom, Y is a hydrogen atom or an alkyl group (for example, a lower alkyl group). Z is a fluorine atom or a trifluoromethyl group. a, b, c, d are each independently an integer in the range of 0 to 200, preferably an integer in the range of 1 to 50. e is 0 or 1. m, n are each independently an integer in the range of 0 to 2, preferably 0. p is an integer of 1 or more, preferably an integer in the range of 1 to 10.

[0024] Also, the molecular weight (weight average molecular weight Mw) of the fluorine-containing organosilane compound represented by the general formula (1) is not particularly limited. For example, it can be in the range of 5×10 2 ~1×10 5 or in the range of 5×10 2 ~1×10 4 .

[0025] In addition, in one form, the fluorine-containing organosilane compound represented by the above general formula (1) can be a fluorine-containing organosilane compound represented by the following general formula (2).

[0026]

Chemical formula

[0027] In the above general formula (2), R1, Y, and m are defined as the same as in the above general formula (1). q is an integer in the range of 1 to 50, and r is an integer in the range of 1 to 10.

[0028] <Vapor deposition source> In the above manufacturing method, a heating vapor deposition method is used as a film formation method to form a water-repellent layer. The heating vapor deposition method is a method in which the vapor deposition material is heated and vaporized by heating the atmosphere inside the vapor deposition device using a heating means (heater, etc.) arranged in the vapor deposition device. As described above, if a water-repellent layer is formed by heating and vaporizing a metal component and a water-repellent component, which usually have different vaporization temperatures, with a single temperature profile, it is considered that a bias in the distribution of the metal component and the water-repellent component occurs in the water-repellent layer. In contrast, in the above manufacturing method, a plurality of vapor deposition sources are heated with different temperature profiles. This makes it possible to reduce the bias in the distribution of the metal component and the water-repellent component in the water-repellent layer formed by the heating vapor deposition method, and the present inventors speculate that it is possible to manufacture a spectacle lens that can exhibit the performance exhibited by the water-repellent component (i.e., water repellency) and the performance exhibited by the metal component (e.g., antibacterial properties) and also has excellent durability of these performances.

[0029] The deposition source may be a deposition source having one or more metal components and / or one or more water-repellent components supported on a carrier. The deposition sources used in the above-mentioned production method may include a deposition source containing only one of a metal component and a water-repellent component, a deposition source containing both a metal component and a water-repellent component, or the former deposition source and the latter deposition source.

[0030] Examples of the method for supporting the deposition material (metal component and / or water-repellent component) on the carrier include the following methods. A solution containing a vapor deposition material is impregnated into a carrier. Examples of the method for impregnating the solution into the carrier include a method of injecting or spraying the solution onto the carrier, a method of immersing the carrier in the solution, and the like. The carrier can be, for example, a porous body, and can be made of, for example, metal, alloy, or ceramic. A specific example of the porous body can be a sintered filter. The sintered filter can be a sintered body obtained by sintering powder materials such as metal powder, alloy powder, and ceramic powder. After impregnating the solution into the carrier, the vapor deposition material can be supported on the carrier by performing a drying treatment by a known method.

[0031] Regarding the water-repellent component, for example, a commercially available liquid water-repellent agent can be used as it is or diluted and impregnated into the carrier. Regarding the metal component, a solution containing particles of the metal component can be impregnated into the carrier. Such a solution can be, for example, an aqueous solution and can be an aqueous dispersion of particles of the metal component. The concentration of the metal component in the solution can be, for example, in the range of 1000 to 10000 ppm. In the present invention and this specification, ppm is based on mass. Here, when two or more metal components are supported on one carrier, the above concentration refers to the total concentration of those two or more metal components. For example, a commercially available product sold as an aqueous dispersion of a metal component can be used as it is or diluted and impregnated into the carrier. The particle size of the particles of the metal component can be, for example, 1 nm or more and 10 nm or less, or 1 nm or more and 5 nm or less. The liquid volume of each solution to be impregnated into the carrier can be, for example, in the range of 0.10 to 5.00 ml.

[0032] The total number of vapor deposition sources used in the above manufacturing method is two or more, and can be two, three, or four, and can also be, for example, five or less. Among the plurality of vapor deposition sources used in the above manufacturing method, two or more vapor deposition sources having the same types and amounts of components contained therein may be included, or two or more vapor deposition sources having at least one of the types and amounts of components contained therein different may be included.

[0033] <Heating of the vapor deposition source> In the above manufacturing method, a plurality of evaporation sources are heated with different temperature profiles. As described above, it is considered that this can reduce the bias between the metal component and the water-repellent component in the water-repellent layer. When three or more evaporation sources are used, it is only necessary that the temperature profiles for heating at least two evaporation sources are different temperature profiles, and two or more of the three or more evaporation sources may be heated with the same temperature profile.

[0034] The heating of the plurality of evaporation sources can be performed in one form within one chamber. For example, using one vacuum evaporation apparatus, a plurality of evaporation sources can be arranged in the vacuum chamber of this apparatus to deposit a deposition material on the surface to be formed.

[0035] FIG. 1 is a schematic diagram for explaining an example of a method for forming a water-repellent layer by a heat-evaporation method. In FIG. 1, 2A and 2B are evaporation sources, 3A and 3B are heaters, 11 is a lens substrate, and 14 is a formed water-repellent layer.

[0036] The pressure in the chamber during film formation may be determined according to the type of the deposition material. For example, it can be set to 2×10 -2 Pa or less.

[0037] As the heaters 3A and 3B, for example, a halogen heater or the like can be used. The temperature profile of the heater 3A for heating the evaporation source 2A and the temperature profile of the heater 3B for heating the evaporation source 2B are set to different temperature profiles. The temperature profile can be set in a control unit provided in the vacuum evaporation apparatus. The plurality of different temperature profiles can be those in which one or more heating parameters selected from the group consisting of a heating rate, a heating start time, and a heating end time are different.

[0038] Specific examples of the temperature profiles of the heaters 3A and 3B are shown in FIGS. 2 to 4.

[0039] Specific example 1 shown in FIG. 2 is an example where the heating rate is different in the temperature profiles of two heaters. For example, when the vapor deposition source 2A heated by the heater 3A contains a water-repellent component, the vapor deposition source 2B heated by the heater 3B contains a metal component, and the water-repellent component is a component that is more likely to vaporize at a lower temperature than the metal component, by providing a period during which the heating rate of the heater 3A is slower than that of the heater 3B, the period during which the metal component vaporizes and the period during which the water-repellent component vaporizes can be made to be about the same period, or the difference between those periods can be reduced. Note that the heating rate of heating by each heater can be the same heating rate from the start to the end of heating in one mode, and can be changed in two or more stages between the start and the end of heating in another mode.

[0040] Specific example 2 shown in FIG. 3 is an example where the heating rate and the heating end time are different in the temperature profiles of two heaters. For example, when the vapor deposition source 2A heated by the heater 3A contains a water-repellent component, the vapor deposition source 2B heated by the heater 3B contains a metal component, and the water-repellent component is a component that is more likely to vaporize at a lower temperature than the metal component, by providing a period during which the heating rate of the heater 3A is slower than that of the heater 3B and ending the heating of the heater 3B earlier than the heating of the heater A, the period during which the metal component vaporizes and the period during which the water-repellent component vaporizes can be made to be about the same period, or the difference between those periods can be reduced.

[0041] Specific example 3 shown in FIG. 4 is an example where the heating start time and the heating rate are different in the temperature profiles of two heaters. For example, when both the vapor deposition source 2A heated by the heater 3A and the vapor deposition source 2B heated by the heater 3B contain a metal component and a water-repellent component, according to specific example 3, the period during which the water-repellent component vaporizes from the vapor deposition source 2A and the period during which the water-repellent component vaporizes from the vapor deposition source 2B can be made different, and the period during which the metal component vaporizes from the vapor deposition source 2A and the period during which the metal component vaporizes from the vapor deposition source 2B can be made different. Therefore, the bias in the distribution of the water-repellent component and the metal component in the formed water-repellent layer can be reduced.

[0042] However, Specific Examples 1 to 3 are illustrative, and the present invention is not limited to such illustrations.

[0043] The maximum temperature reached during the temperature increase in the temperature profile may be determined according to the type of the vapor deposition material. For example, it can be 100°C or higher and 750°C or lower, but it is not limited to this range.

[0044] The film thickness of the water-repellent layer thus formed can be, for example, 30 nm or less, 25 nm or less, 20 nm or less, or 15 nm or less. The film thickness of the water-repellent layer can be, for example, 5 nm or more or 10 nm or more. Also, on the surface of the water-repellent layer, the contact angle with respect to water can be, for example, 100° or more and 120° or less. The water-repellent layer can be provided, for example, as the outermost layer on one or both sides of the spectacle lens.

[0045] <Example of the layer structure of a spectacle lens> In the above manufacturing method, the water-repellent layer can be provided directly on the surface of the lens substrate or indirectly via another layer.

[0046] FIG. 5 is a schematic cross-sectional view showing an example of the layer structure of a spectacle lens manufactured by the above manufacturing method. The spectacle lens 1 shown in FIG. 5 has a hard coat layer 12 on one surface 11a (for example, the object side surface) of the lens substrate 11, and a multilayer film 13 thereon. The multilayer film 13 is an alternately laminated film of a low refractive index layer 13L and a high refractive index layer 13H. A water-repellent layer 14 is provided on the surface of the multilayer film. For the water-repellent layer 14, reference can be made to the previous description.

[0047] (Lens substrate) The lens substrate of the spectacle lens can be a plastic lens substrate or a glass lens substrate. The glass lens substrate can be, for example, a lens substrate made of inorganic glass. From the viewpoints of being lightweight, difficult to break, and easy to handle, a plastic lens substrate is preferred as the lens substrate. Examples of the plastic lens substrate include styrene resins such as (meth)acrylic resins, polycarbonate resins, allyl resins, allyl carbonate resins such as diethylene glycol bisallyl carbonate resin (CR-39), vinyl resins, polyester resins, polyether resins, urethane resins obtained by reacting an isocyanate compound with a hydroxy compound such as diethylene glycol, thiourethane resins obtained by reacting an isocyanate compound with a polythiol compound, and cured products of curable compositions containing a (thio)epoxy compound having one or more disulfide bonds in the molecule (generally called transparent resins). As the lens substrate, an undyed one (colorless lens) or a dyed one (dyed lens) may be used. The refractive index of the lens substrate can be, for example, about 1.60 to 1.75. However, the refractive index of the lens substrate is not limited to the above range and may be above or below the above range within the above range. In the present invention and this specification, the refractive index refers to the refractive index with respect to light having a wavelength of 500 nm. Further, the lens substrate may be a lens having a refractive power (so-called powered lens) or a lens having no refractive power (so-called non-powered lens).

[0048] The spectacle lens can be various lenses such as a single-focus lens, a multi-focus lens, and a progressive power lens. The type of the lens is determined by the surface shapes of both surfaces of the lens substrate. Also, the surface of the lens substrate may be any of a convex surface, a concave surface, and a flat surface. In a normal lens substrate and spectacle lens, the surface on the object side is convex and the surface on the eyeball side is concave. However, the present invention is not limited thereto.

[0049] (Multilayer film) As one form of the multilayer film, an inorganic layer can be mentioned. In the present invention and this specification, the "inorganic layer" is a layer containing an inorganic substance, preferably a layer mainly composed of an inorganic substance. Here, the main component is the component that occupies the most in the layer, and usually occupies about 50% by mass to 100% by mass, and further about 90% by mass to 100% by mass of the mass of the layer. The same applies to the main components described later. The inorganic layer can be a layer directly laminated on the surface of the lens substrate, or can be a layer indirectly laminated on the surface of the lens substrate via one or more other layers. Examples of the above other layers include one or more known layers such as a cured layer of a curable composition generally called a hard coat layer and a primer layer provided for improving adhesion. The types and film thicknesses of these layers are not particularly limited and can be determined according to the functions and optical properties desired for the spectacle lens.

[0050] When the multilayer film is an inorganic layer, that is, an inorganic multilayer film, a water-repellent layer can be provided on the uppermost inorganic layer (that is, the inorganic layer at the position farthest from the lens substrate). Examples of such an inorganic multilayer film include a multilayer film containing at least one high refractive index layer and at least one low refractive index layer. Such a multilayer film can be an antireflection film having the property of preventing reflection of light of a specific wavelength or light in a specific wavelength range, or a reflection film having the property of reflecting light of a specific wavelength or light in a specific wavelength range. In the present invention and this specification, the "high" and "low" regarding "high refractive index" and "low refractive index" are relative notations. That is, the high refractive index layer refers to a layer having a higher refractive index than the low refractive index layer contained in the same multilayer film. In other words, the low refractive index layer refers to a layer having a lower refractive index than the high refractive index layer contained in the same multilayer film. The refractive index of the high refractive index material constituting the high refractive index layer is, for example, 1.60 or more (for example, in the range of 1.60 to 2.40), and the refractive index of the low refractive index material constituting the low refractive index layer can be, for example, 1.59 or less (for example, in the range of 1.37 to 1.59). However, as described above, since the notations "high" and "low" regarding the high refractive index and the low refractive index are relative, the refractive indices of the high refractive index material and the low refractive index material are not limited to the above ranges.

[0051] Specifically, examples of the high refractive index material for forming the high refractive index layer include one or more mixtures of oxides selected from the group consisting of zirconium oxide (e.g., ZrO2), tantalum oxide (e.g., Ta2O5), titanium oxide (e.g., TiO2), aluminum oxide (e.g., Al2O3), yttrium oxide (e.g., Y2O3), hafnium oxide (e.g., HfO2), and niobium oxide (e.g., Nb2O5). On the other hand, examples of the low refractive index material for forming the low refractive index layer include one or more mixtures of oxides or fluorides selected from the group consisting of silicon oxide (e.g., SiO2), magnesium fluoride (e.g., MgF2), and barium fluoride (e.g., BaF2). In the above examples, for convenience, the oxides and fluorides are shown in stoichiometric compositions, but those in which oxygen or fluorine is deficient or excessive from the stoichiometric composition can also be used as the high refractive index material or the low refractive index material.

[0052] Preferably, the high refractive index layer is a film mainly composed of a high refractive index material, and the low refractive index layer is a film mainly composed of a low refractive index material. Such a film (e.g., a vapor deposition film) can be formed by performing film formation using a film-forming material (e.g., a vapor deposition material) mainly composed of the high refractive index material or the low refractive index material. The film and the film-forming material may inevitably contain impurities, and may also contain other components, for example, other inorganic substances or known additive components that play a role in assisting film formation, as long as the functions of the main components are not impaired. Film formation can be performed by a known film formation method. From the viewpoint of ease of film formation, it is preferably performed by vapor deposition, and more preferably by vacuum vapor deposition. The antireflection film can be, for example, a multilayer film in which a high refractive index layer and a low refractive index layer are alternately laminated in a total of 3 to 10 layers. The film thickness of the high refractive index layer and the film thickness of the low refractive index layer can be determined according to the layer structure. Specifically, the combination of the layers included in the multilayer film and the film thickness of each layer can be determined by optical design simulation by a known method based on the refractive index of the film-forming material for forming the high refractive index layer and the low refractive index layer, and the desired reflection characteristics and transmission characteristics brought to the spectacle lens by providing the multilayer film. In addition, the multilayer film may contain one or more layers of a vapor deposition film of a conductive oxide (conductive oxide layer), preferably a vapor deposition film of a conductive oxide formed by vapor deposition using a vapor deposition material mainly composed of a conductive oxide, at an arbitrary position. The film thickness of each layer of the high refractive index layer and the low refractive index layer included in the multilayer film can be, for example, 3 to 500 nm, and the total thickness of the multilayer film can be, for example, 100 to 900 nm. The film thickness in the present invention and this specification is the physical film thickness.

[0053] In one form, the spectacle lens manufactured by the above manufacturing method can have a water-repellent layer on the surface of the inorganic layer. For example, the water-repellent layer can be a layer directly laminated on the surface of the multilayer film, or can be a layer indirectly laminated on the surface of the multilayer film via one or more other layers. For other layers, reference can be made to the previous description.

[0054] The water-repellent layer can be formed on at least one surface of the lens substrate, or can also be formed on both surfaces. For example, the water-repellent layer body can be located on the object side of the spectacle lens, the water-repellent layer can be located on the eyeball side of the spectacle lens, and the water-repellent layer can also be located on both the object side and the eyeball side of the spectacle lens. When the water-repellent layers are located on both sides of the spectacle lens, the water-repellent layer on the object side and the water-repellent layer on the eyeball side can be the same water-repellent layer or different water-repellent layers. In the present invention and this specification, the "eyeball side" refers to the surface side located on the eyeball side when the spectacle equipped with the spectacle lens is worn by the wearer. The "object side" refers to the opposite surface side, that is, the surface side located on the object side when the spectacle equipped with the spectacle lens is worn by the wearer.

[0055] By incorporating the spectacle lens manufactured by the above manufacturing method into a frame, a spectacle equipped with the above spectacle lens can be produced. For the spectacle, regarding the configuration such as the frame, known techniques can be applied.

Example

[0056] Hereinafter, the present invention will be further described with reference to examples. However, the present invention is not limited to the embodiments shown in the examples.

[0057] Hereinafter, the SiO2 layer is a vapor deposition film formed by using silicon oxide as a vapor deposition material, and the ZrO2 layer is a vapor deposition film formed by using zirconium oxide as a vapor deposition material. Each vapor deposition material consists of only the described oxide except for unavoidably mixed impurities.

[0058] [Example 1] <Fabrication of a lens substrate with a hard coat layer> A hard coat liquid containing inorganic oxide particles and a silicon compound was spin-coated on the entire surface (convex surface) of the object side of a plastic lens substrate manufactured from a monomer for spectacle lenses (MR8 manufactured by Mitsui Chemicals, Inc.), and heat-cured in a heating furnace at an internal temperature of 100°C for 60 minutes to form a single-layer hard coat layer with a film thickness of 3 μm.

[0059] <Fabrication of Multilayer Anti-Reflection Film> Next, the lens substrate on which the hard coat layer was formed was placed in a vacuum deposition apparatus, and a multilayer anti-reflection film with a total of 7 layers of "SiO2 layer / ZrO2 layer / SiO2 layer / ZrO2 layer / SiO2 layer / ZrO2 layer / SiO2 layer" (total thickness: about 400 - 600 nm) was formed on the entire surface of the hard coat layer by vacuum deposition. The notation " / " indicates that the part described on the left of " / " and the part described on the right are directly laminated. This point is the same in the following descriptions. Thus, an eyeglass lens having a layer structure of "lens substrate / hard coat layer / multilayer anti-reflection film (inorganic layer)" was fabricated.

[0060] <Film Formation of Water-Repellent Layer> (Fabrication of Evaporation Source) As a solution of the water-repellent component, a water-repellent agent manufactured by Shin-Etsu Silicone Co., Ltd. (product name: KY-130, containing a fluorine-containing organosilane compound) was used. As a solution of the metal component, an aqueous dispersion containing silver particles with a particle size of 2 - 5 nm at a concentration of 5000 ppm was prepared. As a carrier for the evaporation source, a disk-shaped sintered filter with a diameter of 18 mm (material: SUS) was used, and two evaporation sources were fabricated by the following method. The carrier injected with the amount of the water-repellent component solution shown in Table 1 was subjected to a drying treatment in a drying furnace with an internal temperature of 50°C for 1 hour to fabricate the first evaporation source. The carrier injected with the amount of the metal component solution shown in Table 1 was subjected to a drying treatment in a drying furnace with an internal temperature of 50°C for 1 hour to fabricate the second evaporation source.

[0061] (Film Formation of Water-Repellent Layer by Heat Evaporation Method) As shown in FIG. 1, a spectacle lens on which the multilayer antireflection film was formed and the evaporation source were arranged in a vacuum chamber of a vacuum evaporation apparatus. As the evaporation source 2A, a first evaporation source in which a fluorine-containing organic silane compound, which is a water-repellent component, is supported on a carrier was arranged, and as the evaporation source 2B, a second evaporation source in which silver particles, which are metal components, are supported on a carrier was arranged. Each evaporation source was placed on a molybdenum boat (not shown in FIG. 1) and arranged in the vacuum chamber. The pressure in the vacuum chamber was set to 2×10 -2 Pa or less, and the heaters 3A and 3B (both are halogen heaters) were heated according to the temperature profile of Specific Example 1 in FIG. 2. Specifically, in the temperature profile of the heater 3A, the temperature was raised to 400°C over 6 minutes, and then raised from 400°C to 650°C over 1 minute and 30 seconds. In the temperature profile of the heater 3B, the temperature was raised to 630°C over 3 minutes and 30 seconds, and then raised from 630°C to 650°C over 4 minutes. By heating in this way, the water-repellent component and the metal component can be heated and vaporized, and a vapor deposition film in which the water-repellent component and the metal component are deposited can be formed on the surface of the multilayer antireflection film. As described above, a water-repellent layer with a film thickness of 10 to 20 nm containing a water-repellent component and a metal component was formed on the surface of the multilayer antireflection film.

[0062] Through the above steps, a spectacle lens of Example 1 having a layer structure of "lens substrate / hard coat layer / multilayer antireflection film (inorganic layer) / water-repellent layer" was produced.

[0063] [Example 2] A spectacle lens of Example 2 was produced by the method described for Example 1, except that the injection amount of the solution of the metal component (silver particles) onto the carrier in the production of the second evaporation source was changed to the value shown in Table 1.

[0064] [Comparative Example 1] A spectacle lens of Comparative Example 1 was produced by the method described for Example 1, except that only one evaporation source was used and the heating of this evaporation source was carried out according to the temperature profile of the heater 3A in Example 1. The evaporation source was produced by the following method. The same materials as those in Example 1 were used as the carrier, the solution of the metal component, and the solution of the water-repellent component. After injecting the solution of the metal component in the amount shown in Table 1 into the carrier, it was dried in a drying oven at an internal temperature of 50°C for 1 hour, and then after injecting the solution of the water-repellent component in the amount shown in Table 1, it was dried in a drying oven at an internal temperature of 50°C for 1 hour to produce the evaporation source.

[0065] For each of the spectacle lenses of the examples and comparative examples, the antibacterial test and the measurement of the contact angle of the spectacle lenses without the friction wear treatment (initial) and with the friction wear treatment were carried out by the following methods. The friction wear treatment was carried out by the following method. As a friction wear member obtained by wrapping a lens wiping paper (Dasper manufactured by Otsu Sangyo Co., Ltd.) around a rubber eraser cut into a size of 19 mm × 24 mm, it was attached to a reciprocating friction wear tester (Tribogear 30S manufactured by Yamato Scientific Co., Ltd.). The water-repellent layer surface of the spectacle lens was rubbed back and forth 1000 times or 5000 times with the friction wear member under a load of 2 kg.

[0066] [Antibacterial test] The antibacterial test was carried out in accordance with JIS Z 2801:2012. In the antibacterial test of each spectacle lens of the examples and comparative examples, a spectacle lens produced in the same manner as each example or comparative example except that the water-repellent layer was not formed was used as a reference sample. After putting a test piece of 50 mm × 50 mm (a test piece cut out from each spectacle lens of the examples and comparative examples and its reference sample) into a sterilized petri dish, 0.4 mL of a bacterial solution containing 1.0×10 5 ~4.0×10 5 test bacteria (Escherichia coli) was dropped onto the central part of the test piece and covered with a polyethylene film cut into 40 mm × 40 mm. After culturing this petri dish at a relative humidity of 90% or more for 24 hours, the viable cell count per 1 cm 2 was measured, and the following antibacterial activity value was calculated. Antibacterial activity value = Ut - At ≧ 2.0 Ut: Average value of the logarithmic values of the viable cell count per 1 cm 2 after 24-hour culture of the unprocessed test piece (reference sample) At: Logarithmic mean value of viable cell count per 1 cm after 24-hour culture of antibacterial processed test piece (sample of example or comparative example) 2 Average value of logarithmic value of viable cell count per area The SIAA (Antibacterial Products Technical Council) stipulates that a product has antibacterial effect when its antibacterial activity value is 2 or more. Therefore, for each of the spectacle lenses of Example 1, Example 2 and Comparative Example 1, antibacterial property was judged according to the following criteria based on the value of the antibacterial activity value obtained above. OK: Antibacterial activity value is 2.0 or more NG: Antibacterial activity value is less than 2.0

[0067] [Measurement of contact angle] Using a CA-D type manufactured by Kyowa Interface Science Co., Ltd. as a contact angle meter, a water droplet with a diameter of 2 mm was formed at the tip of the needle in a measurement environment with an ambient temperature of 25 °C, and this was brought into contact with the uppermost part of the convex surface of the water-repellent layer of the spectacle lens to form a liquid droplet. The angle between the liquid droplet and the surface generated at this time was measured and taken as the static contact angle. The measurement of the contact angle was performed within 10 seconds after bringing the water droplet into contact with the spectacle lens in order to minimize the measurement error due to the evaporation of water. The static contact angle θ is obtained by the following formula, where r is the radius of the water droplet (the radius of the part where the water droplet is in contact with the spectacle lens surface) and h is the height of the water droplet. θ = 2 × tan− 1 (h / r)

[0068]

Table 1

[0069] The spectacle lenses of Example 1 and Example 2 are spectacle lenses on which a water-repellent layer is formed by a heat evaporation deposition method by heating a plurality of evaporation sources with different temperature profiles. On the other hand, the spectacle lens of Comparative Example 1 is a spectacle lens on which a water-repellent layer is formed using a single evaporation source. From the results shown in Table 1, it can be confirmed that the spectacle lenses of Example 1 and Example 2 exhibit antibacterial properties exerted by the metal component both initially and after the friction and wear treatment, and that the spectacle lenses of Example 1 and Example 2 have a larger contact angle value and are also superior in water repellency compared to the spectacle lenses of Comparative Example 1 both initially and after the friction and wear treatment.

[0070] Regarding each of the spectacle lenses of Example 1 and Example 2, when the antibacterial test was carried out by the method described above using Staphylococcus aureus as the test bacterium, the evaluation results were "OK" in all cases of initially, after 1000 times of friction and wear treatment, and after 5000 times of friction and wear test.

[0071] Finally, the above aspects are summarized.

[0072] According to one aspect, there is provided a method for manufacturing a spectacle lens, wherein the spectacle lens has a water-repellent layer, and forming the water-repellent layer by a heat vapor deposition method, and the film formation by the heat vapor deposition method includes heating a plurality of vapor deposition sources with different temperature profiles, and the plurality of vapor deposition sources include at least one vapor deposition source containing a water-repellent component and at least one vapor deposition source containing a metal component.

[0073] According to the above manufacturing method, it is possible to produce a spectacle lens that can exhibit water repellency and the performance exerted by the metal component contained in the water-repellent layer, and that is also excellent in the durability of those performances.

[0074] In one form, the metal component can include a silver-containing component.

[0075] In one form, the silver-containing component can be silver particles.

[0076] In one form, the water-repellent component can be a fluorine-containing component.

[0077] In one form, the fluorine-containing component can be a fluorine-containing organosilane compound.

[0078] In one form, in the different temperature profiles, one or more heating parameters selected from the group consisting of a heating rate, a heating start time, and a heating end time may be different.

[0079] In one form, the plurality of evaporation sources can include an evaporation source containing only one of the metal component and the water-repellent component.

[0080] In one form, the plurality of evaporation sources can include an evaporation source containing only the metal component among the metal component and the water-repellent component, and an evaporation source containing only the water-repellent component among the metal component and the water-repellent component.

[0081] Each of the various aspects and forms described in this specification can be combined in any combination of two or more.

[0082] The embodiments disclosed this time should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is shown not by the above description but by the claims, and it is intended that all modifications within the meaning and scope equivalent to the claims are included.

Industrial Applicability

[0083] One aspect of the present invention is useful in the fields of manufacturing spectacle lenses and spectacles.

Claims

Claim 1 A method for manufacturing a spectacle lens, wherein the spectacle lens has a water-repellent layer, and the method includes forming the water-repellent layer by a heat deposition method, wherein the formation of the film by the heat deposition method includes heating a deposition source A containing a silver-containing component and a fluorine-containing water-repellent component with a heater A, and heating a deposition source B containing a silver-containing component and a fluorine-containing water-repellent component with a heater B, and a method for manufacturing a spectacle lens, wherein the heating start time and the heating rate of the heater A are different from the heating start time and the heating rate of the heater B. Claim 2 The method for manufacturing a spectacle lens according to claim 1, wherein the silver-containing component is silver particles. Claim 3 The method for manufacturing a spectacle lens according to claim 1 or 2, wherein the fluorine-containing component is a fluorine-containing organosilane compound.

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