Method for manufacturing vision lens, combined mold and myopia lens

Abstract

A method for manufacturing a vision lens, a combined mold (60) and a myopia lens. A plastic mold is manufactured by vacuum molding by means of a metal mold (50), and the plastic mold is used as the combined mold (60) for preparing a vision lens; in addition, the plastic mold further transmits a microstructure received from the metal mold (50) to the vision lens by means of a casting molding method, wherein the vision lens is a lens made of polyurethane, acrylic acid and a photocurable resin. By means of the process, the plastic mold can be obtained at low cost, and good dimensional stability is kept at a set temperature, such that the precision of the stability of the microstructure is guaranteed; and in addition, the smoothness and roughness requirements of manufacturing the lens can be met.

Description

Method for manufacturing eye lens, combined mold and myopia lens Technical Field

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

[0002] In traditional ophthalmic lens production, tempered glass molds are the primary mold type widely used. These molds are highly favored for their exceptional properties, including superior impact resistance, excellent thermal stability, and extremely low mold scrap rates. These qualities enable tempered glass molds to withstand the various mechanical stresses and high temperatures encountered during eyewear manufacturing, ensuring their longevity and stability. High impact resistance is a key characteristic of tempered glass molds, enabling them to withstand the pressure and forces of the manufacturing process. This strength not only helps maintain the integrity of the mold, preventing breakage during operation, but also ensures that the mold retains its shape and dimensions over time, thus maintaining the consistency and precision of the finished eyewear lens. Excellent thermal stability is another factor contributing to the popularity of tempered glass molds. During the thermal processing of ophthalmic lenses, molds must withstand high temperatures, and the excellent thermal stability of tempered glass molds ensures their stability and durability under these conditions. This is crucial for processes such as high-temperature grinding in eyewear manufacturing.

[0003] As new vision-correcting lenses emerge in the ophthalmic field, the eyewear manufacturing industry is facing increasingly personalized and innovative production requirements. These new lenses are required not only to provide traditional vision correction functions but also to incorporate sophisticated and complex microstructures on the lens surface to achieve more precise vision control. These microstructures can be designed in a variety of shapes and arrangements to provide more customized vision solutions, such as reducing glare, improving contrast, or preventing the transmission of specific wavelengths of light.

[0004] However, existing tempered glass molds are struggling to meet this trend. First, their high cost is a limiting factor, especially when mass production is required to meet market demand. Second, microstructure consistency is difficult to ensure, which can lead to inconsistent lens quality and affect the user experience. Most importantly, their non-reworkable nature makes tempered glass molds incapable of adapting to these new requirements. Once the mold is manufactured, it cannot be modified to meet different design requirements, making it inflexible in the face of rapidly evolving market demands.

[0005] Summary of the Invention

[0006] In order to solve the above technical problems, the embodiments of the present invention hope to provide a method for manufacturing eye vision lenses, a combination mold and a myopia lens. The above method can accurately make the mold at low cost. In addition, it can also accurately realize the vision prevention and control microstructure on the surface of polyurethane, acrylic or photocurable resin lenses.

[0007] The technical solution of the present invention is achieved as follows:

[0008] In a first aspect, the present invention provides a method for manufacturing an ophthalmic lens, the method comprising:

[0009] A first mold is manufactured using a metal mold by vacuum molding, wherein the first mold has a shaping end face, and the shaping end face receives the uneven microstructure from the metal mold; the first mold and the second mold define a casting cavity for casting the eyeglass lens through a seal, wherein the shaping end face is located in the casting cavity; a thermosetting resin or a photocurable resin is poured into the casting cavity to form the eyeglass lens, wherein the microstructure is integrally formed on the eyeglass lens.

[0010] Specifically, the "manufacturing the first mold by vacuum molding using a metal mold" specifically includes the following steps: placing a metal lower mold having an arc-shaped groove into the bottom opening of a cylindrical mold, and placing a plastic preform used to manufacture the first mold on the arc-shaped groove, wherein the shape of the plastic preform is close to the shape of the final product; placing a metal upper mold into the top opening of the cylindrical mold, wherein the end of the metal upper mold facing the metal lower mold has an arc-shaped boss, the arc-shaped boss is processed with a microstructure by super-finishing, and the arc-shaped boss and the arc-shaped groove correspond to hold the plastic preform; placing the metal mold consisting of the metal upper mold, the metal lower mold and the cylindrical mold into a vacuum environment; a driving device drives the metal upper mold and the metal lower mold to move closer, and the plastic preform is squeezed and extended into the space between the arc-shaped boss and the arc-shaped groove to form the first mold, wherein the side of the plastic preform facing the arc-shaped boss is the shaping end face, and the shaping end face is integrally formed with a microstructure.

[0011] Preferably, the “manufacturing the first mold by vacuum molding using a metal mold” further comprises: coating the shaping end surface.

[0012] Specifically, the "first mold and the second mold define a casting cavity for casting the eyewear lens through a seal" specifically includes the following steps: a gap is maintained between the first mold and the second mold, wherein the shaping end face is configured to face the second end face of the second mold; the seal is fixed to the outer diameter surfaces of the first mold and the second mold at the same time, so that the casting cavity is formed between the first mold and the second mold.

[0013] Specifically, the "pouring of thermosetting resin or photocurable resin into the casting cavity to form the eyeglass lens" specifically includes the following steps: pouring thermosetting resin or photocurable resin into the casting cavity; placing the mold for manufacturing the eyeglass lens at the curing temperature required for the eyeglass lens for curing; and waiting for the resin to cool and fix into shape, taking the eyeglass lens out of the casting cavity.

[0014] In a second aspect, the present invention also provides a combination mold for manufacturing eye lenses, wherein the combination mold is configured to replicate an uneven microstructure onto the surface of a resin lens by casting, and the combination mold comprises: a first mold, wherein the first mold is made by vacuum molding using a metal mold, the first mold having a shaping end face, the shaping end face having an uneven microstructure, wherein the roughness of the shaping end face is less than 10 nm; a second mold, wherein the second mold has a second end face; and a seal, wherein the seal is detachably fixed to the outer diameter surfaces of the first mold and the second mold, wherein the shaping end face, the second end face and the inner surface of the seal constitute a casting cavity that can be sealed.

[0015] Preferably, the combined mold is configured to grow one or more dense films on the entire or partial surface of the casting cavity.

[0016] Preferably, the combined mold is made of a material with a glass transition temperature greater than 180°C.

[0017] In a third aspect, the present invention further provides a myopia lens, which is manufactured by the method described in the first aspect.

[0018] Preferably, the myopia lens is made of polyurethane series, acrylic or light-curing resin material.

[0019] The present invention utilizes a metal mold to form a plastic mold through vacuum molding. The metal mold has a precise microstructure. The plastic mold is then used as a composite mold for manufacturing ophthalmic lenses. The microstructure is transferred to the ophthalmic lenses by casting within the composite mold. The ophthalmic lenses are made from polyurethane, acrylic, and photocurable resins. This process enables low-cost mass production of plastic molds, achieving good dimensional stability at a given temperature, thereby ensuring stable microstructure accuracy. Furthermore, it can meet the finish and roughness requirements for the lenses. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG1 is a schematic flow chart of a method for manufacturing an eyeglass lens according to an embodiment of the present invention;

[0021] FIG2 is a schematic diagram of a process for manufacturing a first mold by vacuum molding using a metal mold in a method for manufacturing an eyewear lens according to an embodiment of the present invention;

[0022] FIG3 is a schematic diagram of a process of forming a casting cavity for casting the eyeglass lens by defining a first mold and a second mold through a seal in a method for manufacturing an eyeglass lens according to an embodiment of the present invention;

[0023] FIG4 is a schematic diagram of a process for pouring a thermosetting resin or a light-curing resin into the pouring cavity to form the eyeglass lens in a method for manufacturing the eyeglass lens according to an embodiment of the present invention;

[0024] FIG5 is a schematic structural diagram of a metal mold used in a method for manufacturing an eyeglass lens according to an embodiment of the present invention;

[0025] FIG6 is a schematic structural diagram of a combined mold for manufacturing eyeglass lenses according to an embodiment of the present invention. DETAILED DESCRIPTION

[0026] The technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present invention.

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Generally, the components of the embodiments of the present application described and shown in the drawings herein can be arranged and designed in various different configurations.

[0028] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application as claimed, but merely represents selected embodiments of the present application. It should be noted that, unless there is a conflict, the various features of the embodiments of the present application may be combined with each other, and the combined embodiments are still within the scope of protection of the present application.

[0029] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0030] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "inner," "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the product of this application is typically placed when in use. These terms are intended solely to facilitate the description of this application and to simplify the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," "third," etc., are used solely to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0031] It should also be noted that, in the description of this application, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to direct connections, indirect connections through an intermediate medium, or internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0032] In the existing technology, in view of the shortcomings of glass molds, in order to produce vision control lenses, major lens manufacturers have had to turn to injection metal molds to produce injection-molded or light-cured vision control lenses. However, in the field of optical resin lenses, the materials that can be used to make lenses through the injection molding process are quite limited, mainly concentrated in acrylic and PC. At the same time, the degree of the lenses made by light-curing lenses varies greatly due to the problem of material shrinkage stability. The current vision control lenses are mainly dominated by PC injection-molded lenses and light-curing resins, which makes it difficult to give full play to the industry's existing huge casting production capacity and severely limits the diversity of the lens' refractive index. This situation not only affects the diversity of lens products, but also fails to meet consumers' urgent demand for a variety of vision control lens products.

[0033] Therefore, in the current technology, a common method is to use metal molds to manufacture molds through injection molding, and use these molds to manufacture vision prevention and control lenses. The process steps of using injection molding equipment to manufacture molds include: raw material preparation, heating and melting, injection, cooling, mold opening and post-processing. First, it is necessary to prepare the raw materials, put the plastic granular raw materials into the melting cavity, and heat the plastic raw materials to a molten state through the heating system to form a melt; inject the melt into the cavity of the metal mold through the injection module. Once the melt is filled, the mold will begin to cool, so that the plastic cools and solidifies. The cooling time will vary depending on the thickness and size of the target product; when the plastic is completely cooled, open the metal mold to obtain a molded mold.

[0034] Molds with microstructures can be prepared through the above-mentioned process flow. However, when using the equipment currently used for injection molding to manufacture molds for the production of vision control lenses, especially when the vision control lenses are made of polyurethane, acrylic or light-curing resin materials, it is often difficult to reach the set manufacturing temperature. In other words, the equipment used to melt the raw materials is not able to heat the raw materials to the molten state required for injection fluidity. In addition, the viscosity of the plastic in the molten state is high, and the airflow resistance inside the entire injection system is large, resulting in poor fluidity of the molten plastic entering the cavity of the metal mold by injection, and the final mold will have defects such as air marks, bubbles, and deformation. These defects may lead to poor lens quality and reduced finished product output when the vision control lenses are subsequently manufactured in a high-temperature production environment.

[0035] In addition, when obtaining the microstructure on the metal mold, the molten plastic needs to flow fully inside the cavity to fill the entire cavity, and the liquid in the cavity is squeezed against each other to ensure that the gaps in the microstructure are filled. However, in this process, the accurate shape of the microstructure is often not obtained, resulting in air pockets and poor appearance in the connection parts of the microstructure. The resulting trapped air phenomenon makes the smoothness and roughness of the microstructure on the mold unable to meet the strict requirements of the US military standard MIL13830 20 / 10. Given that the roughness and microstructure accuracy of the plastic mold obtained in the step of using a metal mold to manufacture a plastic mold do not meet the standards and cannot meet the process standards for the subsequent manufacture of myopia lenses, it is difficult to achieve full-scale mass production of myopia lens technology through the above process.

[0036] In order to solve the above technical problems, referring to FIG1 , which shows a flow chart of a method for manufacturing an ophthalmic lens according to an embodiment of the present invention, the method comprises:

[0037] S101. Use a metal mold to manufacture a first mold by vacuum molding, wherein the first mold has a shaping end surface, and the shaping end surface receives the uneven microstructure from the metal mold.

[0038] Based on the above disclosed content of the present invention, the first mold is used as the main mold for manufacturing eye vision lenses. The first mold has a shaping end face, and an uneven microstructure is prepared on the shaping end face. With the rise of new vision control lenses in the field of ophthalmology, it is necessary to implant microstructures of different shapes on the surface of the lens to achieve the purpose of vision control. The shaping end face can ensure that the first mold meets the production requirements of eye vision lenses. It should be noted that the microstructure can cover the entire area of ​​the shaping end face, and can also exist on a part of the shaping end face according to needs.

[0039] Based on the above disclosure, the present invention further discloses a method for preparing the first mold using a vacuum molding process. Specifically, referring to FIG. 2 , the process includes the following steps:

[0040] S201. Place a metal lower mold with an arc-shaped groove into the bottom opening of a cylindrical mold, and place a plastic preform used to manufacture the first mold on the arc-shaped groove, wherein the shape of the plastic preform is close to the shape of the final product; S202. Place a metal upper mold into the top opening of the cylindrical mold, wherein the end of the metal upper mold facing the metal lower mold has an arc-shaped boss, and the arc-shaped boss is processed with a microstructure by super-finishing, and the arc-shaped boss and the arc-shaped groove correspondingly hold the plastic preform.

[0041] In the present invention, a metal mold is used to prepare a first mold. See Figure 5, which shows a structural schematic diagram of a metal mold 50. The metal mold 50 includes a metal lower mold 52, a metal upper mold 51 and a sleeve 53, wherein the metal upper mold 51 and the metal lower mold 52 are respectively assembled in the upper opening and the lower opening of the sleeve 53, and a gap space is left between the metal upper mold 51 and the metal lower mold 52, and the gap space is used to form a molding cavity of the first metal mold 50.

[0042] Specifically, the metal upper mold 51 has an arc-shaped boss, and correspondingly, the metal lower mold 52 has an arc-shaped groove. When the metal upper mold 51 and the metal lower mold 52 are assembled in the sleeve 53, the arc-shaped boss is aligned with the arc-shaped groove and the above-mentioned molding cavity is formed therebetween. The surface of the arc-shaped boss is manufactured with a microstructure that meets the process requirements through ultra-precision machining. The microstructure can be a special structure such as a point-shaped, ring-shaped, point / ring-shaped, hexagonal shape, etc. In the specific preparation process, the plastic preform M used to prepare the first metal mold 50 is heated to a processable state, such as a viscous flow state or a highly elastic state, and is placed in the arc-shaped groove. The metal upper mold 51 moves downward along the inner wall of the sleeve 53 close to the metal lower mold 52, so that the arc-shaped boss enters the arc-shaped groove. In this case, the arc-shaped boss and the arc-shaped groove hold the plastic preform M in the form of extrusion. In another embodiment of the present invention, the metal upper mold 51 has an arc-shaped recessed groove, and the metal lower mold 52 has an arc-shaped protruding platform, and a space for accommodating the plastic preform M can be formed therebetween. Similarly, when the metal upper mold 51 and the metal lower mold 52 are close to each other, the plastic preform M is squeezed to form a first mold. In this case, the microstructure is adaptively arranged on the arc-shaped protruding platform of the metal lower mold 52.

[0043] S203, placing the metal mold consisting of the metal upper mold, the metal lower mold and the cylindrical mold into a vacuum environment; S204, a driving device drives the metal upper mold and the metal lower mold to move closer together, and the plastic preform is squeezed and extends in the space between the arc-shaped boss and the arc-shaped groove to form the first mold, wherein the side of the plastic preform facing the arc-shaped boss is the shaping end face, and the shaping end face is integrally formed with a microstructure.

[0044] In the process disclosed in the present invention, the assembled metal mold needs to be placed in a vacuum environment. By creating a vacuum environment, bubbles in the plastic preform can be effectively expelled. In addition, since microstructures need to be formed on the surface of the plastic preform, in a vacuum environment, a plastic preform in a processable state, such as a viscous flow state or a highly elastic state, can more easily fill the gaps between the microstructures. By eliminating air resistance, the plastic preform in a viscous flow state can more evenly reach every gap and detail of the microstructure, ensuring that the first mold accurately obtains the microstructure from the metal mold. In addition, the vacuum environment can better control the curing process of the material. In a vacuum environment, the material may have a longer curing time, which makes the manufacturing process more controllable. The metal upper mold is driven by a motor or other existing technical means to approach the metal lower mold, while squeezing the plastic preform, causing the plastic preform to extend within the molding cavity. During the extension process, the plastic preform fills all gaps and details of the microstructure, and the shape of the microstructure is inherited by the first mold, wherein the surface of the first mold having the microstructure is the shaping end surface of the first mold. In another embodiment of the present invention, to further ensure the accuracy of the microstructure, when machining the microstructure on the curved boss surface of the metal upper mold, high-precision testing equipment is used to measure the microstructure of the curved boss surface, and the results are compared with the original design drawing to ensure the machining accuracy of the microstructure on the curved boss surface. In addition, after the first mold is manufactured using the metal mold, the same high-precision testing equipment is used again to measure the microstructure of the finalized end surface, and the results are compared with the original design drawing to ensure the machining accuracy of the microstructure of the finalized end surface.

[0045] In another embodiment of the present invention, after a first mold is formed using a metal mold, the molded end face is coated. The molded end face is formed with a microstructure, which is used to form microstructures on the surface of the lens during the lens production process. In other words, the molded end face is the working surface for lens production. Coating the molded end face with at least one pre-set film layer by chemical or physical growth can improve the performance of the lens product or the process flow. For example, a waterproof layer, an anti-fouling layer, or an anti-sticking layer can be coated on the molded end face. For example, silicon oxide, titanium oxide, magnesium fluoride, and a waterproof layer can be coated on the molded end face by chemical or physical methods; or, Au, Ag, Sn, etc. can be coated on the molded end face to improve the adhesion of the resin lens to the mold. When the pre-set film layer is multi-layered, the multi-layer film layer can include different types of film layers, and the multi-layer film layers can be deposited sequentially in a stacked manner. It should be noted that the pre-set film layer can remain on the first mold during the lens demolding process to improve the demolding process, or can directly adhere to the lens product after the lens is demolded to improve lens quality.

[0046] After the above-mentioned first mold is made by a metal mold, an embodiment of the present invention provides a method for manufacturing an eyeglass lens, which also includes: S102, the first mold and the second mold define a casting cavity for casting the eyeglass lens through a seal, wherein the shaping end face is located in the casting cavity, and after the first mold is made by the above-mentioned process, the second mold is used to cooperate with the first mold to form a plastic mold for preparing the eyeglass lens. Specifically, the first mold and the second mold form a cavity for casting, and since the microstructure is formed on the shaping end face of the first mold, the shaping end face of the first mold constitutes the inner surface, so that the microstructure is transferred to the surface of the eyeglass lens during the casting process of preparing the eyeglass lens.

[0047] Specifically, in the process of defining a casting cavity for casting the eyeglass lens by the first mold and the second mold through the seal, referring to FIG3 , which shows a schematic flow diagram of the first mold and the second mold defining the casting cavity, the process specifically includes the following steps:

[0048] S401. A gap is maintained between the first mold and the second mold, wherein the shaping end face is configured to face the second end face of the second mold; S402. The sealing member is fixed to the outer diameter surfaces of the first mold and the second mold at the same time, so that the casting cavity is formed between the first mold and the second mold.

[0049] After obtaining the first mold through the metal mold, the first mold is used as the main mold for preparing the vision lens. The shaping end face of the first mold has a microstructure, and the second mold is used to cooperate with the first mold to form a casting cavity for preparing the vision lens. The second mold has a second end face, and the second end face is preferably a smooth plane. The shaping end face and the second end face are arranged opposite to each other, and a gap is left in the middle for forming a casting cavity. The seal fixes the first mold and the second mold through a circumferential structure, and the inner surface of the seal surrounds the above gap to form a casting cavity. Specifically, the inner surface of the seal, the shaping end face and the second end face surround a sealable cavity. It should be noted that the above cavity must have an opening for pouring the raw materials for preparing the vision lens. The opening is closable and is preferably arranged above or on the side of the cavity.

[0050] It should be noted that the preparation process of the second mold can be the same as or different from the preparation process of the first mold. Preferably, the preparation process of the second mold is the same as the preparation process of the first mold.

[0051] The embodiment of the present invention further includes step S103 , pouring a thermosetting resin or a light-curing resin into the pouring cavity to form the eyeglass lens, wherein the microstructure is integrally formed on the eyeglass lens.

[0052] After the first mold and the second mold are combined to form a combined mold for manufacturing eyeglass lenses, that is, after the first mold, the second mold, and the sealant form a casting cavity, the raw materials for manufacturing the eyeglass lenses are poured into the casting cavity, wherein thermosetting resin or photocurable resin is used as the raw materials for manufacturing the eyeglass lenses. Preferably, the eyeglass lenses can be produced by casting using polyurethane series (MR7, MR8, MR10, MR174) or acrylic or photocurable resin lenses. The process of manufacturing the eyeglass lenses specifically includes the following steps, as shown in FIG4 , which shows a schematic flow chart of manufacturing the eyeglass lenses using the combined mold:

[0053] S501. Pour a thermosetting resin or a photocurable resin into the pouring cavity; S502. Place a mold for manufacturing the eyeglass lens at the curing temperature required for the eyeglass lens for curing; S503. After the resin is cooled and fixed into shape, remove the eyeglass lens from the pouring cavity.

[0054] Based on the above disclosure, the plastic mold prepared by the above process can maintain good strength and dimensional stability at high temperatures. Preferably, the raw material of the plastic mold is selected from a material with a Tg (glass transition temperature) greater than 180°C. This selection of raw materials can maintain good dimensional stability of the plastic mold during the curing process of the ophthalmic lens. For example, when preparing ophthalmic lenses made of polyurethane (MR series), acrylic, and light-curing resins, this material selection can ensure that the plastic raw material maintains good dimensional stability at around 150°C, ensuring that the required curing temperature of 130°C can be achieved.

[0055] According to the method for manufacturing ophthalmic lenses disclosed in the above-mentioned embodiment of the present invention, a plastic mold is used instead of a glass mold. During the preparation stage, a metal mold is used to prepare the plastic mold so that the surface of the plastic mold has an uneven microstructure. By preparing the lens using the above-mentioned plastic mold, an ophthalmic lens with a microstructure on the surface can be obtained. The plastic mold is obtained by a vacuum molding process, which can improve the strength and precision of the microstructure on the surface of the plastic mold. In addition to the microstructure, the preparation process of the present invention can improve the roughness and surface finish of the plastic mold surface, thereby improving the quality of the plastic mold and further improving the quality of the ophthalmic lens. At the same time, the large-scale mass production of plastic molds can be achieved through the above-mentioned vacuum molding preparation process. In addition, by limiting the raw materials for preparing the plastic preform, it is possible to achieve good dimensional stability of the plastic mold at high temperatures, thereby ensuring the structural strength of the plastic mold during the curing period of the ophthalmic lens, so that the ophthalmic lens obtains a high precision microstructure from the surface of the plastic mold.

[0056] Based on the above disclosure, an embodiment of the present invention further discloses a combination mold for manufacturing ophthalmic lenses. The combination mold is used in the above-mentioned method for manufacturing ophthalmic lenses. Referring to FIG6 , there is shown a schematic structural diagram of the combination mold 60. The combination mold 60 is roughly lens-shaped and includes a first mold 61 and a second mold 62 corresponding to each other, and a seal 63 surrounding the outer diameter surfaces of the first mold 61 and the second mold 62. The first mold 61 has a shaping end face A, the surface of which has an uneven microstructure. The second mold 62 has a second end face B corresponding to the shaping end face A at one end. The first mold 61 is made by vacuum molding using a metal mold. The preparation process of the first mold 61 is the same as the manufacturing process disclosed in the method for manufacturing ophthalmic lenses disclosed in the present invention, and will not be repeated here.

[0057] Referring to FIG. 6 , the seal 63 extends completely along the circumference of the structure, allowing it to surround the outer circumferences of the first mold 61 and the second mold 62. Alternatively, the first mold 61 and the second mold 62 are respectively placed within the cylindrical inner diameter of the cylindrical seal 63, while the shaping end face A and the second end face B are arranged opposite each other, thereby forming a gap between the first mold 61 and the second mold 62, forming a casting cavity P. The first mold 61, the second mold 62, and the seal 63 form a sealed casting cavity P, which is used to produce eyeglass lenses by casting. It should be noted that the shaping end face A is preferably configured as an inwardly concave surface with a curvature, while the corresponding second end face B is configured as an outwardly protruding surface with the same or different curvature as the shaping end face A. The combination mold 60 is used in the method for manufacturing eye vision lenses disclosed in the above-mentioned present invention. Therefore, the process flow and usage method of using the combination mold 60 to prepare eye vision lenses refer to the above-mentioned method for manufacturing eye vision lenses. The above method can reduce the roughness of the forming end surface of the first mold. In the present invention, the roughness of the forming end surface A of the first mold 61 in the combination mold 60 is less than 10nm.

[0058] Preferably, in order to ensure that the combination mold 60 can maintain good strength and dimensional stability at high temperatures, the raw materials for preparing the combination mold are selected from materials with a Tg (glass transition temperature) greater than 180°C. The above-mentioned limitation on the raw materials can ensure that the combination mold 60 has good dimensional stability below 150°C, meeting the curing temperature requirement of 130°C for eye lenses.

[0059] Preferably, the combined mold 60 is configured to grow one or more layers of dense film on all or part of the surface of the casting cavity P. The molding end face A is formed with a microstructure, which is used to form a microstructure on the surface of the lens during the lens manufacturing process. That is, the molding end face A is the working surface for lens manufacturing. Coating the molding end face A with at least one pre-set film layer by chemical or physical growth methods can improve the performance of the lens product or the process flow. For example, coating the molding end face with a waterproof layer, an anti-fouling layer, or an anti-sticking layer can be performed. For example, silicon oxide, titanium oxide, magnesium fluoride, and a waterproof layer can be chemically or physically coated on the molding end face A; alternatively, Au, Ag, Sn, etc. can be coated on the molding end face A to improve the adhesion of the resin lens to the mold. When the pre-film layer is multi-layered, the multi-layer film can include different types of film layers, and the multi-layer film layers can be deposited sequentially in a stacked manner. It should be noted that the above-mentioned preset film layer can remain on the first mold 61 during the lens demolding process to improve the demolding process, or can be directly adhered to the lens product as the lens is demolded to improve the quality of the lens.

[0060] Based on the above method for manufacturing an eye lens, the present invention further discloses a myopia lens, which is manufactured according to the above method for manufacturing an eye lens. Preferably, the myopia lens is made of polyurethane (MR series), acrylic, and light-curable resin.

[0061] It should be noted that the technical solutions described in the embodiments of the present invention can be arbitrarily combined without conflict.

[0062] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

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

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

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

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

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

205. Coating the shaping end face.

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

401. A gap is maintained between the first mold and the second mold, wherein the shaping end face is arranged to face a second end face of the second mold; 402. The seal is fixed to the outer diameter surfaces of both the first mold and the second mold simultaneously, so as to form the pouring cavity between the first mold and the second mold.

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

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

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

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

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

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

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

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