Method for producing spectacle lens

Abstract

The present disclosure addresses the problem of providing a method for producing a spectacle lens, wherein the method makes it possible to produce a spectacle lens capable of maintaining surface hydrophilic properties over a long period of time. A method for producing a spectacle lens according to the present disclosure comprises a step for bringing into contact a laminate including a spectacle lens base material and an antireflective film having an SiO2 layer on the outermost surface thereof with an alkaline solution having a pH of more than 7.0 but less than 9.8.

Description

Eyeglass lens manufacturing method

[0001] The present disclosure relates to a method for manufacturing eyeglass lenses.

[0002] In Patent Document 1, SiO ２ The method for manufacturing an eyeglass lens having an anti-fogging layer formed on a lens substrate on which an inorganic anti-reflection film having a layer of the above-mentioned formula is formed is as follows: ２ A method is disclosed in which the layer is treated with a strongly basic processing solution containing an inorganic alkali.

[0003] JP 2012-194359 A

[0004] The present disclosure relates to a spectacle lens substrate and a glass substrate having SiO ２ The present invention relates to a method for manufacturing a spectacle lens, the method comprising the step of contacting a laminate including an anti-reflection film having a layer of the formula (I) with an alkaline solution having a pH greater than 7.0 and less than 9.8.

[0005] The present disclosure will be described in detail below. According to the method for manufacturing an eyeglass lens of the present disclosure, it is possible to manufacture an eyeglass lens that can maintain the hydrophilicity of the anti-reflection coating for a long period of time. The following description of the constituent elements may be based on representative embodiments of the present disclosure, but the present disclosure is not limited to such embodiments.

[0006] In this specification, a numerical range expressed using "to" means a range that includes the numerical values ​​written before and after "to" as the lower and upper limits. Furthermore, in this specification, when two or more types of a certain component are present, the "content" of that component means the total content of those two or more components. In this specification, in a numerical range described in stages, the upper or lower limit value described in a certain numerical range may be replaced with the upper or lower limit value of another numerical range described in stages. Furthermore, in a numerical range described in this specification, the upper or lower limit value described in a certain numerical range may be replaced with a value shown in the Examples. In this specification, a combination of two or more preferred embodiments is a more preferred embodiment.

[0007] [Method for manufacturing eyeglass lenses] The method for manufacturing eyeglass lenses according to the present disclosure is a method for manufacturing eyeglass lenses by forming an eyeglass lens substrate and a SiO ２The method includes a step of contacting a laminate including an anti-reflective coating having the layer of the formula (1) with an alkaline solution having a pH of more than 7.0 and less than 9.8.

[0008] [Laminate] <Eyeglass Lens Substrate> The laminate has an eyeglass lens substrate. Materials constituting the eyeglass lens substrate include organic materials and inorganic materials, with organic materials being preferred. Examples of organic materials include acrylic ester resins, methacrylic ester resins, thiourethane resins, allyl resins, episulfide resins, polycarbonates, urethane resins, polyesters, polystyrene, polyethersulfone, poly4-methylpentene-1, and diethylene glycol bisallyl carbonate resins (CR-39), with thiourethane resins, episulfide resins, and diethylene glycol bisallyl carbonate resins being preferred.

[0009] The thiourethane resin is a resin obtained by polymerizing a polyisocyanate compound and a polythiol compound. Preferred polyisocyanate compounds include m-xylylene diisocyanate, a mixture of 2,5-bis(isocyanatomethyl)-bicyclo[2,2,1]heptane and 2,6-bis(isocyanatomethyl)-bicyclo[2,2,1]heptane, isophorone diisocyanate, hexamethylene diisocyanate, and tolylene diisocyanate. Preferred polythiol compounds include pentaerythritol tetrakis(3-mercaptopropionate), 1,2-bis[(2-mercaptoethyl)thio]-3-mercaptopropane, or 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. The episulfide resin is a resin obtained by ring-opening polymerization of a monomer having an episulfide group (epithio group) or a mixed monomer containing such a monomer. Preferred episulfide group-containing monomers are bis(2,3-epithiopropyl)sulfide or bis(2,3-epithiopropyl)disulfide.

[0010] Examples of spectacle lens substrates include finished lenses in which the convex and concave surfaces are optically finished and molded to match the desired diopter, semi-finished lenses in which only the convex surface is finished as an optical surface (for example, a spherical surface, a rotationally symmetric aspherical surface, and a progressive surface), and semi-finished lenses in which the concave surface is processed and polished to match the wearer's prescription.

[0011] From the viewpoint of ease of handling, the thickness of the spectacle lens substrate is preferably 0.8 to 30.0 mm, more preferably 1.0 to 10.0 mm. The refractive index of the spectacle lens substrate is preferably 1.50 or more, more preferably 1.60 to 1.80, and even more preferably 1.60 to 1.74.

[0012] <Anti-reflection film> The laminate has an SiO ２ The anti-reflection coating has a layer of SiO ２ The laminate having the layer is treated with an alkaline solution having a predetermined pH, which will be described later, to form a layer of SiO ２ It is presumed that the surface of the layer is etched, forming a fine uneven structure and increasing the surface area, and as a result, the hydrophilicity can be maintained for a long period of time. ２ That is, the outermost surface of one of the main surfaces of the laminate is made of SiO ２ The outermost surface of the other main surface may be a layer of SiO ２ and a layer of SiO ２ The anti-reflection film may be a layer other than SiO. ２ The antireflection film may have either a single layer structure or a multilayer structure, and from the viewpoint of antireflection properties, a multilayer structure is preferred. The antireflection film is also preferably an inorganic antireflection film made of an inorganic compound. A multilayer antireflection film preferably has a structure in which low refractive index layers and high refractive index layers are alternately laminated. The low refractive index layers of the multilayer structure are preferably made of SiO ２Examples of materials constituting the high refractive index layer include oxides of metals selected from titanium, zirconium, aluminum, niobium, tantalum, and lanthanum (e.g., zirconium oxide, titanium oxide, tantalum oxide, and indium tin oxide).

[0013] Examples of methods for forming the anti-reflection film include dry methods such as vacuum deposition, sputtering, ion plating, ion beam assisted deposition, and CVD.

[0014] The thickness of the antireflection film is preferably from 100 to 10,000 nm, more preferably from 300 to 700 nm.

[0015] <Other Layers> The laminate may have layers other than the above-mentioned spectacle lens substrate and anti-reflection film. Examples of the other layers include a primer layer and a hard coat layer.

[0016] (Primer layer) The laminate may have a primer layer. The primer layer is preferably disposed between the eyeglass lens substrate and the hard coat layer described below. In this case, adhesion between the eyeglass lens substrate and the hard coat layer is likely to be improved, and the impact resistance of the eyeglass lens can be improved.

[0017] The primer layer preferably contains a resin. The resin may be in particulate form. Examples of the resin include urethane resin, epoxy resin, phenol resin, polyimide, polyester, bismaleimide resin, and polyolefin, with urethane resin being preferred. The primer layer may contain an additive such as a surfactant.

[0018] Examples of methods for forming a primer layer include a method in which a primer layer-forming composition containing a resin is applied to a desired member to form a coating film, and the coating film is subjected to a curing treatment (e.g., drying treatment) as necessary to form a primer layer. In other words, the primer layer is preferably a layer obtained by applying a primer layer-forming composition to a desired member to form a coating film, and then curing the coating film. Examples of methods for applying the primer layer-forming composition include a dipping coating method, a spin coating method, a spray coating method, an inkjet coating method, and a flow coating method.

[0019] The thickness of the primer layer is preferably 0.3 to 2.0 μm.

[0020] (Hard Coat Layer) The laminate may have a hard coat layer. The hard coat layer is preferably disposed on the primer layer, and more preferably disposed between the primer layer and the anti-reflection film. When the laminate has a hard coat layer, the scratch resistance of the eyeglass lens can be improved. The hard coat layer preferably exhibits a hardness of H or higher in pencil hardness according to JIS K5600. As the hard coat layer, a known hard coat layer can be used, and examples thereof include an organic hard coat layer, an inorganic hard coat layer, and an organic-inorganic hybrid hard coat layer. For example, in the field of eyeglass lenses, an organic-inorganic hybrid hard coat layer is commonly used.

[0021] As a method for forming a hard coat layer, for example, a method can be mentioned in which a composition for forming a hard coat layer is applied to a desired member to form a coating film, and the coating film is subjected to a curing treatment (for example, a light irradiation treatment and a drying treatment) as necessary to form a hard coat layer.In other words, the hard coat layer is preferably a layer obtained by applying a composition for forming a hard coat layer to a desired member to form a coating film, and then curing the coating film.As a method for applying a composition for forming a hard coat layer to a substrate, for example, a method can be mentioned in which the above-mentioned composition for forming a primer layer is applied.

[0022] The thickness of the hard coat layer is preferably from 1 to 20 μm, more preferably from 2 to 18 μm.

[0023] [Alkaline Solution] The alkaline solution used in the contacting step has a pH of more than 7.0 and less than 9.8. The pH of the alkaline solution is preferably more than 7.0 and not more than 8.6, more preferably more than 7.0 and not more than 8.2. The pH can be measured by the glass electrode method defined in JIS Z8802. The pH refers to the value at the temperature when the alkaline solution is brought into contact with the laminate.

[0024] <Alkali Source> The alkaline solution contains an alkali source. The alkali source may be either an inorganic alkali source or an organic alkali source, with inorganic alkali sources being preferred. Examples of inorganic alkali sources include hydrogen carbonates, carbonates, hydrogen phosphates, dihydrogen phosphates, borates, and ammonia. Examples of the salts include alkali metal salts such as sodium salts and potassium salts, alkaline earth metal salts such as calcium salts and magnesium salts, and ammonium salts. Alkali metal salts are preferred, and sodium salts are more preferred. The inorganic alkali source preferably contains at least one selected from the group consisting of hydrogen carbonates, hydrogen phosphates, and dihydrogen phosphates. Examples of the organic alkali source include amine compounds and salts thereof, such as trishydroxymethylaminomethane, 2-[4-(2-hydroxyethyl)-1-piperazinyl]ethanesulfonic acid, and 2-amino-2-methyl-1,3-propanediol. Examples of the salts include hydroxide salts, halide salts, and acetate salts.

[0025] The alkali source may be used alone or in combination of two or more. The concentration of the alkali source can be appropriately adjusted so that the pH of the alkaline solution falls within the above-mentioned range, but is preferably 0.01 to 3.0 mol / L, more preferably 0.05 to 1.0 mol / L.

[0026] <Solvent> Examples of the solvent contained in the alkaline solution include water and organic solvents. The solvent preferably contains water, and more preferably water. The organic solvent is preferably a water-miscible organic solvent that is miscible with water in any ratio at 25°C, and more preferably an alcohol. Examples of the alcohol include alkyl alcohols such as methanol, ethanol, propanol, isopropanol, butanol, isobutanol, hexanol, and octanol; aromatic alcohols such as phenol, cresol, benzyl alcohol, and phenethyl alcohol; alicyclic alcohols such as cyclohexanol; glycols such as ethylene glycol, propylene glycol, 1,3-butanediol, 1,4-butanediol, diethylene glycol, dipropylene glycol, and triethylene glycol; alkylene glycol monoalkyl ethers; polyalkylene glycols; and polyalkylene glycol monoalkyl ethers. One type of solvent may be used alone, or two or more types may be used in combination.

[0027] The alkaline solution may contain components other than the alkali source and the solvent, such as acidic compounds such as organic acids and their salts, surfactants, preservatives, rust inhibitors, antifoaming agents, and antioxidants.

[0028] The alkaline solution may be a buffer solution exhibiting the above-mentioned pH. Known buffer solutions can be used as the buffer solution. In terms of ease of preparation, preferred are phosphate buffer solutions (containing at least one of sodium dihydrogen phosphate and disodium hydrogen phosphate as an alkaline source), carbonate-bicarbonate buffer solutions (containing at least one of sodium bicarbonate and sodium carbonate as an alkaline source), borate buffer solutions (containing sodium borate as an alkaline source), Tris buffer solutions (containing trishydroxymethylaminomethane as an alkaline source), HEPES buffer solutions (containing 2-[4-(2-hydroxyethyl)-1-piperazinyl]ethanesulfonic acid as an alkaline source), and GTA buffer solutions (containing trishydroxymethylaminomethane and 2-amino-2-methyl-1,3-propanediol as alkaline sources, and further containing 3,3-dimethylglutaric acid), and more preferred are phosphate buffer solutions.

[0029] [Contacting Step] The method for manufacturing a spectacle lens according to the present disclosure includes a step (contacting step) of bringing the laminate into contact with the alkaline solution. As the contacting method, known methods can be used, such as an immersion method, an immersion and shaking method, and a spraying method. The contacting step is carried out by contacting the SiO present on the outermost surface of the anti-reflection film with the alkaline solution. ２ The contacting step is carried out so that the layer is brought into contact with the alkaline solution. The contacting step may be carried out only once or may be carried out two or more times. When the contacting step is carried out two or more times, the same method may be repeated or different methods may be combined.

[0030] The temperature of the alkaline solution during the contact step is preferably 10° C. or higher but lower than 60° C., more preferably 10° C. or higher but lower than 40° C., and even more preferably 20° C. or higher but lower than 30° C. If the temperature is equal to or higher than the lower limit temperature, the treatment time can be shortened, and if the temperature is equal to or lower than the upper limit temperature, it is more preferable in that cracks in the antireflective film can be further suppressed.

[0031] The contact time in the contact step can be adjusted as appropriate depending on the pH, temperature, etc., but is preferably 48 to 144 hours, and more preferably 72 to 96 hours. When the contact time is equal to or greater than the lower limit, the hydrophilicity of the resulting eyeglass lens is superior, and when the contact time is equal to or less than the upper limit, cracks in the antireflection film can be further suppressed, which is preferable.

[0032] [Other Steps] The method for manufacturing a spectacle lens according to the present disclosure may include steps other than the contacting step described above.

[0033] The method may include a step of cleaning the outermost surface of the laminate prior to the contacting step, such as plasma dry cleaning, ozone treatment, or ultrasonic cleaning.

[0034] A rinsing step may be included after the contacting step. The rinsing treatment carried out in the rinsing step can remove excess alkaline solution from the surface of the laminate. A known rinsing method can be used, for example, a method of contacting the laminate with a rinse liquid. The contacting method can be the above-mentioned method of contacting the laminate with an alkaline solution. Examples of the rinsing liquid include water, organic solvents, and mixed solvents thereof. Examples of the organic solvent that can be used include the above-mentioned alcohols and acetone.

[0035] After the contacting step and / or the rinsing step, a drying treatment may be carried out as necessary. Examples of the drying method include spin drying, flowing a dry gas over the workpiece, heating, Marangoni drying, Rotagoni drying, isopropanol drying, and any combination thereof.

[0036] The method for manufacturing a spectacle lens according to the present disclosure may include, after the contact step described above, a step of forming another layer on the anti-reflection film (e.g., a water-repellent layer or a hydrophilic layer, and an intermediate layer between these and the anti-reflection film).

[0037] [Eyeglass Lens] The eyeglass lens obtained by the method of the present disclosure comprises an eyeglass lens substrate and a SiO 2 film on the outermost surface (the outermost surface opposite to the eyeglass lens substrate) treated with the alkaline solution described above. ２ The anti-reflection coating has a layer of SiO treated with the above-mentioned alkaline solution. ２ The surface of this layer can maintain its hydrophilicity for a long period of time and has excellent anti-fogging properties, making it suitable for use as an eyeglass lens.

[0038] The present disclosure will be explained in more detail below using examples, but the present disclosure is not limited to these examples in any way.

[0039] Example 1 Preparation of Alkaline Solution 21 g of sodium hydrogen carbonate was dissolved in 500 ml of deionized water to prepare a 0.5 mol / L alkaline solution.

[0040] [Manufacturing of eyeglass lenses] As a laminate, an anti-reflection coated lens (Nikon-Essilor, trade name ECC, with the top coat layer removed (a lens with no top coat layer attached from the beginning)) was prepared, which had been cleaned with a plasma dry cleaner (Yamato Scientific PDC210, 400W, treatment time 30 seconds). The outermost surface of the anti-reflection coated lens had a SiO ２ 500 ml of the prepared alkaline solution was placed in a lidded polypropylene container, and the laminate was placed therein and completely immersed. The container was then closed with a lid and left to stand at 25°C for 91 hours. The immersed lens was then washed with tap water, rinsed with deionized water, and dried with an air gun to obtain the spectacle lens of Example 1.

[0041] [Examples 2 to 3 and Comparative Examples 2 to 3] Spectacle lenses of Examples 2 to 3 and Comparative Examples 2 to 3 were obtained in the same manner as Example 1, except that the alkali source, concentration, liquid temperature, and immersion time were changed to those shown in Table 1. In Examples 2 to 3, a phosphate buffer solution of pH 7.6 or pH 8.0 purchased from Fujifilm Wako Pure Chemical Industries was used as is. The alkaline solution of Comparative Example 2 was prepared using commercially available sodium sesquicarbonate. In Comparative Example 3, deionized water was used as is without adding an alkali source.

[0042] Comparative Example 1 A laminate prepared in the same manner as in Example 1 was used in the test described below without contacting it with an alkaline solution.

[0043] The composition of the alkaline solution and the treatment conditions are shown in Table 1. The pH values ​​in the table are those at the liquid temperatures shown in the table below.

[0044]

[0045] [Evaluation] (Appearance) The appearance of the anti-reflective coating of the produced eyeglass lenses was compared with that before contact with the alkaline solution and evaluated visually as follows: No change in appearance: No alteration of the anti-reflective coating was observed. Slight change in appearance: The alteration of the anti-reflective coating was slight enough to pose no practical problem. Crack: Linear cracks were observed in the anti-reflective coating. Point-like defects: Circular corrosion was observed in the anti-reflective coating.

[0046] (Water Contact Angle) The anti-reflection coating surface of the prepared eyeglass lens was wiped with a Kimwipe soaked in acetone and then dried with an air gun, and the water contact angle of the central portion at room temperature (25°C) was measured using a contact angle meter (DM500, manufactured by Kyowa Interface Science Co., Ltd.). When the hydrophilicity was so high that the contact angle could not be measured from the tangent line, it was recorded as <5°. Measurements were conducted twice, immediately after preparation of the example lens and after storage at room temperature for 3 days. In practice, it is preferable that the contact angle be low (<5°) even after storage for 3 days.

[0047] [Results] The evaluation results are shown in Table 2.

[0048]

[0049] As shown in Table 2, the eyeglass lenses manufactured by the eyeglass lens manufacturing method of the present disclosure exhibited high hydrophilicity both immediately after treatment and three days later, confirming that hydrophilicity can be maintained for a long period of time. A comparison of Examples 1 to 3 confirmed that the appearance of the anti-reflective coating was superior when an alkaline solution with a pH greater than 7.0 and equal to or less than 8.2 was used. In contrast, the eyeglass lenses of Comparative Example 1, which was not contacted with an alkaline solution, and Comparative Examples 2 and 3, which were contacted with a solution with a pH of 7.0 or less or 9.8 or more, initially exhibited hydrophilicity, but the hydrophilicity decreased after being left for a long period of time.

Claims

1. Glasses lens substrate and SiO on the outermost surface ２ 1. A method for manufacturing a spectacle lens, comprising the step of contacting a laminate including an anti-reflection film having a layer of the formula (I) with an alkaline solution having a pH greater than 7.0 and less than 9.

8.

2. The method for manufacturing eyeglass lenses according to claim 1, wherein the temperature of the alkaline solution is 10°C or higher and lower than 60°C.

3. The method for manufacturing eyeglass lenses according to claim 1 or 2, wherein the alkaline solution contains an inorganic alkaline source.

4. The method for manufacturing a spectacle lens according to claim 3, wherein the inorganic alkali source comprises at least one selected from the group consisting of hydrogen carbonate, dihydrogen phosphate, and hydrogen phosphate.

5. The method for manufacturing eyeglass lenses according to any one of claims 1 to 4, wherein the pH of the alkaline solution is greater than 7.0 and not greater than 8.2.

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