Method for producing spectacle lens

Abstract

Provided is a method for manufacturing a spectacle lens 10, the method comprising: a cured film formation step for forming, on a lens substrate 1, a cured film having a height difference of 3.0 μm or less in a normal direction of the outermost surface of the cured film; a polishing step for polishing the outermost surface of the cured film; and a separate film formation step for forming another film so as to be in contact with the outermost surface of the cured film after the polishing step. A function as a functional region 12 is expressed by the surface shape of the lens substrate 1 and the refractive indices of the lens substrate 1 and the cured film so as to exhibit target defocus power. The present invention also provides a technology related to said method.

Description

Method for manufacturing spectacle lens

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

[0002] As a spectacle lens that suppresses the progression of refractive errors such as myopia, there is known a lens in which a plurality of island-shaped regions having a positive refractive power relative to a prescribed refractive power are formed on the lens (see, for example, Patent Document 1).

[0003] According to the spectacle lens having this configuration, among light beams incident from the object-side surface and exiting from the eyeball-side surface, a light beam that passes through a region other than the region having a positive refractive power focuses on the retina of a wearer, while a light beam that passes through a portion of the region having the positive refractive power focuses at a position closer to the front than the retina, thereby suppressing the progression of myopia.

[0004] Patent Document 2 employs a technique in which the outermost surface of a spectacle lens is made smooth, and instead, an interface portion is provided inside the spectacle lens, and a convex portion or a concave portion is provided on the interface portion. In this technique, defocus power is provided by utilizing the shape of the convex portion or the concave portion on the interface portion and the difference in refractive index between two types of surface base materials that sandwich the interface portion (

[0007] of Patent Document 2). This technique is also referred to as "embedded type" in the present specification.

[0005] Paragraph

[0091] of Patent Document 2 describes that: even if a convex portion or a concave portion is completely covered, the outermost surface of the covering member may still have a shape that attenuates the convex portion or the concave portion; and it is necessary to form a hard coat layer thick enough to prevent the influence of the convex portion or the concave portion from appearing on the outermost surface of the spectacle lens.

[0006] On the other hand, paragraphs

[0092] and

[0093] of Patent Document 2 describe that for thermosetting resins conventionally used as hard coat layers for spectacle lenses, it is difficult to secure a thickness of 10 μm or more, and even if such a thickness can be secured, cracks or distortion may occur, which may affect the originally designed power distribution of the spectacle lens, and the same problem can also occur with photocurable resins.

[0007] In contrast, in the case of convex portions, the recesses between the convex portions, in the case of concave portions, the concave portions themselves, and preferably the base portion as well, the segment smoothing layer is filled to flatten the surface, and a hard coat layer with inherent scratch resistance is further coated on the segment smoothing layer as described in Patent Document 2

[0094]

[0097] .

[0008] The segment smoothing layer and its raw materials are disclosed in

[0097] of Patent Document 2 as follows: "It may be an ultraviolet (photo) curable resin having low hardness and high flexibility, or a high-concentration thermosetting resin. Furthermore, raw materials conventionally used as a primer layer may be used. In addition, raw materials conventionally used as a photochromic film may be used."

[0009] Furthermore, in order to smooth the outermost surface portion of the spectacle lens corresponding to the convex or concave portion, polishing may be performed on the hard coat layer, which is the covering member of Embodiment 1, for example, as described in

[0111] of Patent Document 2.

[0010] U.S. Patent Application Publication No. 2017 / 0131567, Brochure No. WO2021 / 059887

[0011] Through diligent research by the inventors, it has become clear that when the above-mentioned unevenness is large, the unevenness remains even after polishing the hard coat film as described in Patent Document 2.

[0012] At first glance, it might seem that only the convex parts of the uneven surface are selectively removed. However, in the polishing of eyeglass lenses, a flexible pad is used that conforms to the curved shape of the lens. When the pad is pressed against the hard coat film during polishing, it comes into contact not only with the convex parts but also with the concave parts. Therefore, although the convex parts are removed preferentially to some extent, the concave parts are also removed. As a result, if the unevenness is large, some unevenness will remain even after polishing.

[0013] The presence of irregularities on the outermost surface means that the shape of these irregularities affects the defocus power to be achieved. In such cases, it may not be possible to achieve the target defocus power. In this specification, "outermost surface" refers to the surface of the object furthest from the lens substrate.

[0014] Through diligent research by the inventors, the following findings were also obtained: When employing the segment smoothing layer described in Patent Document 2, it was found that there are areas for improvement in the adhesion between the segment smoothing layer and the film placed directly above it.

[0015] One embodiment of the present invention provides a technique that employs an embedded type to achieve the target defocus power while improving the adhesion between the cured film provided on the lens substrate and the film directly above it.

[0016] The inventors have found that if the degree of unevenness resulting from the difference in shape between the substrate base portion and the substrate deformation portion on the outermost surface of the resulting cured film is such that the height difference in the normal direction is 3.0 μm or less, then even if the cured film is polished after formation, an unevenness level that does not hinder the achievement of the target defocus power can be obtained.

[0017] Furthermore, this polishing process significantly reduces the degree of unevenness on the outermost surface of the cured film, while increasing the surface roughness on the nano-order at the outermost surface of the cured film. By forming another film in contact with this outermost surface, an anchoring effect occurs due to the surface roughness, improving the adhesion between the cured film and the other film.

[0018] Based on the above findings, one aspect of the present invention is as follows.

[0019] The first embodiment is a method for manufacturing an eyeglass lens comprising: a base region having a base region that causes a light beam incident from the object-side surface to be emitted from the eye-side surface, incident into the wearer's pupil, and focused on the retina to realize the wearer's prescribed refractive power; a plurality of non-base regions having a different refractive effect from the base region and being arranged alternately with the base region in a predetermined direction when the eyeglass lens is viewed in plan view, wherein the functional region causes a light beam incident from the object-side surface to be emitted from the eye-side surface, while at least one of the light beam focusing effect outside the retina and the contrast reduction effect on the retina by the non-base regions provides a myopia progression suppression effect or a hyperopia reduction effect; a lens substrate having an uneven surface due to comprising a base portion and a plurality of deformed portions of the substrate protruding or recessed from the base portion; and a hardened film that forms the base region by being provided on the base portion and forms the non-base regions by being provided on the plurality of deformed portions of the substrate, A method for manufacturing eyeglass lenses comprising the steps of forming a hardened film on a lens substrate, wherein the hardened film is formed in a state in which the height difference in the normal direction of the outermost surface of the hardened film is 3.0 μm or less; polishing the outermost surface of the hardened film; and forming another film so as to be in contact with the outermost surface of the hardened film after the polishing step, wherein the surface shape of the lens substrate, the refractive index of the lens substrate and the hardened film are used to make the functional region function and to produce the target defocus power.

[0020] A second embodiment is a method for manufacturing eyeglass lenses according to the first embodiment, wherein the height difference of the outermost surface of the hardened film after the polishing step is 0.2 μm or less.

[0021] A third aspect is a method for manufacturing spectacle lenses according to the first or second aspect, wherein the cured film is composed of multiple cured films laminated together, and the thickness of the cured film laminated furthest from the lens substrate is 3.0 μm or more.

[0022] A fourth embodiment is a method for manufacturing eyeglass lenses according to any one of the first to third embodiments, wherein the ratio of the thickness of the cured film constituting the base region to the height of the protrusion or depth of the recess from the base portion of the substrate in the deformed portion of the substrate is 4.0 or more.

[0023] The fifth aspect is a method for manufacturing spectacle lenses according to any one of the first to fourth aspects, wherein the deformed portion of the substrate protrudes or recedes by 4.5 μm or more from the base portion of the substrate.

[0024] The sixth aspect is a method for manufacturing eyeglass lenses according to any one of the first to fifth aspects, wherein the thickness of the cured film is 30 μm or more.

[0025] The seventh aspect is a method for manufacturing eyeglass lenses according to any one of the first to sixth aspects, wherein the hardened film forming step includes a cutting step of cutting the hardened film in a state where the height difference in the normal direction of the outermost surface exceeds 3.0 μm, thereby reducing the height difference in the normal direction of the outermost surface to 3.0 μm or less.

[0026] The eighth aspect is a method for manufacturing spectacle lenses according to any one of the first to seven aspects, wherein the cured film is composed of a plurality of laminated cured films, and the thickness of the cured film furthest from the lens substrate is 5.0 μm or more.

[0027] According to one embodiment of the present invention, it is possible to provide a technology that employs an embedded type to achieve the target defocusing power while improving the adhesion between the cured film provided on the lens substrate and the film directly above it.

[0028] Figure 1 is a schematic cross-sectional view of an eyeglass lens according to one embodiment of the present invention immediately after the formation of a cured film, showing how the cured film is applied in three layers to a lens substrate having a base portion and a protruding portion. The cured film shown in Figure 1 comprises, in order from the side closest to the lens substrate, a cured film C1 made of a resin material different from the lens substrate, a cured film C2 made of a resin material with a different composition from that of the cured film C1, and a cured film C3 made of a resin material with a different composition from that of the cured film C2. Figure 2 is a schematic cross-sectional view of an eyeglass lens according to one embodiment of the present invention immediately after the formation of a cured film, showing how the cured film is applied in three layers to a lens substrate having a base portion and a protruding portion. In Figure 2, the compositions of the cured films C1 and C2 are different, and at least one of their hardness and refractive index may be different. On the other hand, the compositions, hardness, and refractive index of the cured films C2 and C3 are the same. Figure 3 is a schematic plan view of the object-side surface of an eyeglass lens according to one embodiment of the present invention.

[0029] An embodiment of the present invention is described below. The following description is illustrative, and the present invention is not limited to the illustrated embodiment. For matters not described below, please refer to Patent Document 1.

[0030] The spectacle lenses described herein have an object-facing surface and an eye-facing surface. The "object-facing surface" is the surface that faces the object when the spectacle lenses are worn by the wearer, and the "eye-facing surface" is the opposite surface, that is, the surface that faces the eye when the spectacle lenses are worn by the wearer. This relationship also applies to the lens substrate that forms the basis of the spectacle lens. In other words, the lens substrate also has an object-facing surface and an eye-facing surface. In one embodiment of the present invention, the object-facing surface is convex, and the eye-facing surface is concave. In other words, the spectacle lens in one embodiment of the present invention is a meniscus lens.

[0031] In this specification, the horizontal direction when wearing eyeglass lenses is defined as the X direction, the vertical direction (up and down) as the Y direction, and the thickness direction of the eyeglass lenses, which is perpendicular to the X and Y directions, as the Z direction. The Z direction is also the optical axis direction of the eyeglass lenses. The lens origin, which is the origin of the eyeglass lenses, is the lens center. The lens center refers to at least one of the optical center, geometric center, or centering center (reference point) of the eyeglass lenses. In this specification, examples are given for cases where each center coincides.

[0032] To the wearer, the right is the +X direction, the left is the -X direction, upwards is the +Y direction, downwards is the -Y direction, the direction toward the object is the +Z direction, and the opposite direction (away from the wearer) is the -Z direction. These forward and backward directions relate to the light beam passing through the center of the pupil, and strictly speaking, the XY coordinates should also be considered when considering peripheral vision, but for the sake of explanation, they are defined as above in this specification.

[0033] In this specification, "planar view" refers to the view from the normal line to the eye point on the outer surface of the spectacle lens (the surface facing the object or the surface facing the eyeball), unless otherwise specified. The present invention will also be effective when the configuration is applied to a planar view from an arbitrary point on the lens, such as the normal line to the point being evaluated, instead of a planar view from the normal line to the eye point.

[0034] Furthermore, if the functional area is provided only on the outermost surface on the eyeball side, the view from the -Z direction to the +Z direction may be considered as a planar view. Hereafter, when discussing "positions" such as the eye point and geometric center in eyeglass lenses, unless otherwise specified, it refers to the position in a planar view.

[0035] In this specification, "~" refers to a value greater than or equal to a predetermined value and less than or equal to a predetermined value. In this specification, the last digit of a numerical value is basically the value obtained by rounding to the number of digits one less than the last digit. However, for example, in the case of the lower limit of 0.1, zeros may be added as appropriate (for example, one, two, or three), such as 0.1"00".

[0036] From now on, "applying a hardened film on..." and "applying and drying a chemical solution on..." will refer to applying a hardened film or applying and drying a chemical solution so that it is in direct contact with the object to be treated. Furthermore, "cover" will be used to encompass not only cases where there is direct contact with the object, but also cases where there is indirect contact (contact via another object (film)).

[0037] <Functional configuration assumed in an eyeglass lens according to one embodiment of the present invention> Figure 3 is a schematic plan view of the object-side surface of an eyeglass lens according to one embodiment of the present invention. As shown in Figure 3, the eyeglass lens 10 according to one embodiment of the present invention comprises a central clear region 11 and a functional region 12. The central clear region 11 is composed of the base region 13 described so far. The functional region 12 is composed of the base region 13 described so far and a non-base region 14. It is preferable that the eyeglass lens 10 according to one embodiment of the present invention comprises at least the central clear region 11.

[0038] The central clear region 11 is a portion having a smooth surface shape that can realize the wearer's prescribed refractive power from a geometrical optical standpoint, and is, for example, a portion that is transparent in the visible light wavelength range. The central clear region 11 corresponds to the first refractive region of Patent Document 1.

[0039] Furthermore, the central clear region 11 is a region that includes the center of the lens and / or the eye point, and is a region in which the light beam incident from the object-side surface is emitted from the eye-side surface, incident into the wearer's pupil, and focused onto the retina.

[0040] The "eye point" is, for example, the position through which the line of sight passes when facing directly frontward when the spectacle lens 10 is worn, and this example will be used hereinafter. The eye point may also be a position through which the line of sight passes when the wearer visually recognizes an object close to the wearer (so-called during near vision), that is, a near vision eye point. In one embodiment of the present invention, the case where the geometric center of the spectacle lens 10 before edging processing for framing into a frame coincides with the eye point, also coincides with the prism reference point, and also coincides with the lens center is exemplified. Hereinafter, the spectacle lens 10 before edging processing for framing into a frame is exemplified as the spectacle lens 10 according to one embodiment of the present invention, but the present invention is not limited to this aspect.

[0041] The position of the eye point can be specified by referring to a remark chart or a centration chart issued by a lens manufacturer.

[0042] Prescription power (spherical power, cylindrical power, astigmatism axis, etc.) can be achieved by the central clear region 11 of one embodiment of the present invention. This spherical power may be a power to be corrected when viewing from the front (the distance to an object is from infinity to about 1 m) (for example, it is a distance power, and distance power is exemplified hereinafter), or may be a power to be corrected when viewing at intermediate distance (1 m to 40 cm) or near vision (40 cm to 10 cm).

[0043] In addition, the central clear region 11 is not provided with a configuration intended to provide a myopia progression inhibitory effect or a hyperopia reduction effect (e.g., a convex region and / or a concave region, an embedded structure, etc.).

[0044] The central clear region 11 (and the base region 13 in the functional region 12, further the outer clear region 15) of one embodiment of the present invention may function as a so-called single-vision lens. Other than that, it may be, for example, a progressive multifocal lens.

[0045] Incidentally, the prescription data of the wearer information is described on the lens bag of the eyeglass lens 10. That is, if the lens bag is available, the eyeglass lens 10 can be identified as a product based on the prescription data of the wearer information. And the eyeglass lens 10 is normally provided as a set together with the lens bag. Therefore, the eyeglass lens 10 with an attached lens bag also reflects the technical idea of the present invention, and the same applies to the set of the lens bag and the eyeglass lens 10.

[0046] The central clear region 11 may be defined as a circle that does not include the non-base region 14, and the inside of the circle having the maximum diameter from the lens center may be defined as the central clear region 11. Further, the boundary with the outer clear region 15 in the functional region 12 may be defined as a circle that includes the non-base region 14, and the circle having the maximum diameter from the lens center may be defined as said boundary.

[0047] The functional region 12 is an annular region that has a portion with a refractive power different from the wearer's prescribed refractive power and is arranged to sandwich (or surround) the central clear region 11. In this embodiment, the functional region 12 has a plurality of non-base regions 14 (also called convex regions) arranged in an island-like manner (i.e., spaced apart from each other and not adjacent to each other) as portions with a refractive power different from the wearer's prescribed refractive power. The plurality of non-base regions 14 are, for example, arranged independently and discretely such that the center of each non-base region 14 is the vertex of an equilateral triangle. The arrangement of the non-base regions 14 is not particularly limited. In the functional region 12, the portion other than the non-base regions 14 is a base region 13 that performs the same function as the central clear region 11. In other words, the functional region 12 is a region having a base region 13 and a plurality of non-base regions 14. The functional region 12 is, for example, a region in which a light beam incident from the object-side surface is emitted from the eye-side surface, while at least a portion of the light beam incident in the wearer's pupil is not focused onto the retina. As a result, the spectacle lens 10 of this embodiment exhibits a myopia progression suppression effect. In this specification, "planar view" refers to the view from the normal of the eye point on the outer surface (object-side surface or eye-side surface) of the spectacle lens 10, unless otherwise specified. The present invention is also effective when the configuration is applied to a planar view from an arbitrary point on the lens, such as the normal of the point to be evaluated, instead of a planar view from the normal of the eye point. Furthermore, the myopia progression suppression effect or hyperopia progression suppression effect is achieved by the light-gathering effect of the non-base region 14 in the functional region 12 toward the outside of the retina and / or the contrast-reducing effect on the retina.

[0048] Multiple non-base regions 14 may be formed on at least one of the object-side surface or the eye-side surface of the spectacle lens 10. Alternatively, they may be formed to be embedded between the object-side surface and the eye-side surface (inside the lens). When they are formed to be embedded, it is difficult for a third party to identify the position of the non-base regions 14 using reflected light as a clue. While this offers superior aesthetics, it is inferior in terms of fitting and ease of manufacturing. Therefore, a mark to indicate the position and extent of the non-base regions 14 is useful. In this case, the mark is easier to see if it is on the lens surface, but it may also be formed to be embedded in the same way as the non-base regions 14 for the purpose of protecting the mark and suppressing excessive reflection. The configuration in that case will be described later. In this embodiment, an example is given in which multiple non-base regions 14 are provided only on the object-side surface of the spectacle lens 10. The surface shape of the non-base regions 14 is not particularly limited, but for example, it is spherical. It is preferable that the multiple non-base regions 14 within the functional region 12 satisfy either or both of the following (1) and (2). (1) In order for the lens as a whole to exert a sufficient myopia progression suppression effect, the functional area 12 occupies 20% or more of the total area. (2) In order for the light-gathering effect of each non-base area 14 to be fully exerted, the centers (or vertices) of each non-base area 14 are separated by 0.2 mm or more. In particular, if the non-base area 14 is spherical in shape, it is preferable that either or both of the following conditions (i) and (ii) are met: (i) The number of non-base areas 14 is 18 or more (ii) The number of non-base areas 14 is 5000 or less Furthermore, if the non-base areas 14 are arranged in a concentric circle pattern with respect to a point on the lens, it is preferable that either or both of the following conditions (iii) and (iv) are met: (iii) The number of non-base areas 14 is 2 or more rings (iv) The number of non-base areas 14 is 50 or less

[0049] The annular outer clear region 15 surrounding the functional region 12 on the outer edge of the spectacle lens 10 directs the light beam incident from the object-side surface to the eye-side surface, causing it to enter the wearer's pupil and converge on the retina. In other words, the functional region 12 is an annular region located between the outer clear region 15 and the central clear region 11.

[0050] The annular functional region 12 may be composed of a plurality of convex regions (i.e., non-base regions 14, also called defocus regions) on a base region 13 having the same shape as the central clear region 11 or the outer clear region 15, as shown in Patent Document 1.

[0051] The functional region 12, sandwiched between the outer clear region 15 and the central clear region 11, is composed of a non-base region 14 and a base region 13.

[0052] The base region 13 performs the same function as the central clear region 11 (and the outer clear region 15 described later). In one embodiment of the present invention, the region of the functional region 12 other than the base region 13 is the non-base region 14.

[0053] The non-base region 14 is a region that causes a light beam incident from the object-side surface to exit from the eye-side surface, while achieving a myopia progression suppression effect or a hyperopia progression suppression effect through at least one of the light beam focusing effect outside the retina and the contrast reduction effect on the retina. As for the specific form of the non-base region 14, there is no limitation to a convex region as in Patent Document 1, as long as the light beam that passes through the non-base region 14 and enters the wearer's pupil produces at least one of the light beam focusing effect outside the retina and the contrast reduction effect on the retina. On the other hand, it may of course be a convex or concave region.

[0054] The non-base region 14 may be a region that has the same refractive power as the base region 13 but with a different prism power. Even in that case, the non-base region 14 may produce at least one of the following effects: a light beam focusing effect outside the retina and a contrast reduction effect on the retina. For this reason, the non-base region 14 is specified as having a "different refractive effect than the base region 13".

[0055] For the sake of explanation, as one embodiment of the present invention, similar to Patent Document 1, a case is given in which myopia progression suppression effect is achieved and the non-base region 14 has a curved shape that protrudes toward the outside of the lens. Here, an example is given in which the non-base region 14 is a convex region, and an example is given in which both the base region 13 and the non-base region 14 within the functional region 12 are spherical in shape, and an example is given in which the convex region is provided only on the surface facing the object.

[0056] In this specification, "defocus power" may be any of the following, or equivalent: (1) The difference in transmitted refractive power between the base region 13 and the non-base region 14 (defocus region) under lens mounting or measurement system conditions. (2) The value obtained by multiplying the difference in curvature between the base region 13 and the non-base region 14 by the influence of refractive power and the influence of the angle of incidence. (3) An alternative value using the height of the non-base region relative to the base region 13 (especially the boundary between the non-base region 14 and the base region 13). (4) The difference between the point where the optical indicators (MTF, spot intensity, etc.) are best for the light beam passing through the base region 13 and the light beam passing through the non-base region 14, respectively. Furthermore, defocus power may be treated not only as the mean spherical power, but also as the power in a specific direction or the power in the direction of maximum or minimum.

[0057] In this specification, "refractive force" refers to the average refractive force, which is the average value of the refractive force in the direction in which the refractive force is minimum and the refractive force in the direction in which the refractive force is maximum (perpendicular to that direction).

[0058] The following embodiments are preferred for defining the shapes of the outer edge side of the functional region 12 (i.e., the shape of the functional region 123 side in the outer clear region 15 and the boundary between the two) and the inner edge side (i.e., the shape of the functional region 123 side in the central clear region 112 and the boundary between the two).

[0059] In a planar view, the boundary line between the functional region 12 and the outer clear region 15 may be defined as the envelope of a collection of circles (all with the same radius) with radius r1 [mm] (r1 is any value in the range of 1.5 or more and 2.5 or less, e.g., 2) that do not include other non-base regions 14 within the functional region 12 on the outer clear region 15 side (definition of the outer edge side of the functional region 12). Since the value 2 * r1 targets the pupil diameter, in this specification, each of these circles is also referred to as a clear pupil circle. Hereafter, the envelope will be used as an example, but the shape of the outer clear region 15 may be defined as a "collection of clear pupil circles" rather than the envelope of the collection of clear pupil circles. The shape of the central clear region 11 may also be defined as a collection of clear pupil circles. Furthermore, in the spectacle lens 10, the region other than the central clear region 11 and the outer clear region 15 may be defined as the functional region 12.

[0060] <Material configuration of an eyeglass lens according to one embodiment of the present invention> In addition to the functional configuration described above, the eyeglass lens 10 according to one embodiment of the present invention also has the following material configuration: - A lens substrate 1 having an uneven surface, comprising a substrate base portion 2 and a plurality of substrate deformation portions 3 that protrude or are recessed from the substrate base portion 2 - A cured film that forms the base region 13 by being provided on the substrate base portion 2 and forms the non-base region 14 by being provided on the plurality of substrate deformation portions 3

[0061] In this specification, the base portion 2 corresponds to the portion without minute protrusions in Patent Document 1. In this specification, the base portion 2 is the portion that can realize the wearer's prescribed power.

[0062] In this specification, the substrate deformation portion 3 is the base portion of the non-base portion in the functional region 12. In this specification, as mentioned above, the case in which the non-base region 14 is a convex region is given as an example. Therefore, the substrate deformation portion 3 may also be called the substrate protrusion portion 3.

[0063] The substrate protrusion 3 corresponds to the minute protrusion described in Patent Document 1. The spectacle lens 10 according to one embodiment of the present invention can suppress the progression of myopia. Consequently, the lens substrate 1 itself can suppress the progression of myopia. Similar to the minute protrusion described in Patent Document 1, the plurality of substrate protrusions 3 according to one embodiment of the present invention only need to be formed on at least one of the object-side surface and the eyeball-side surface of the lens substrate 1, and this situation is referred to as "protrusion from the substrate base portion 2 on the surface of the lens substrate 1". In this specification, the case in which the plurality of substrate protrusions 3 are provided only on the object-side surface of the lens substrate 1 is mainly illustrated.

[0064] Even if the deformed portion 3 of the substrate is recessed from the base portion 2 of the substrate, the contents of the protruding portion 3 of the substrate can still be applied by converting "protrusion" to "recess" and "convex" to "concave" in the protruding portion 3 of the substrate as described herein.

[0065] The cured film in this specification satisfies the following conditions: - It forms the base region 13 by being provided on the substrate base portion 2. - It forms the non-base region 14 by being provided on the plurality of substrate deformation portions 3.

[0066] In this specification, "cured film provided on the substrate base portion 2 and the substrate deformation portion 3" refers to a cured film provided in contact with (or directly on) the lens substrate 1, i.e., the substrate base portion 2 and the substrate deformation portion 3. However, the part in contact with the lens substrate 1 may be the cured film C1 of a multilayer cured film (each illustrated example is a preferred example), or it may be the lower cured film that is directly below the cured film C1, closest to the lens substrate 1, and in contact with the lens substrate 1.

[0067] In this specification, the lens substrate 1 is exemplified as a plastic lens substrate or the glass lens substrate itself. The materials and other properties of the lens substrate 1 and the cured film, as well as modified examples (in which at least a substrate deformation portion 3 is provided as a separate component with respect to the plastic lens substrate or glass lens substrate), will be illustrated in detail later.

[0068] <Eyeglass Lens According to One Embodiment of the Present Invention> The specific configuration of the method for manufacturing an eyeglass lens 10 according to one embodiment of the present invention is as follows. The contents described in this paragraph reflect the functional and material configurations that are prerequisites, as mentioned above. "A method for manufacturing an eyeglass lens comprising: a step of forming a hardened film on a lens substrate, wherein the hardened film is formed in a state in which the height difference in the normal direction of the outermost surface of the hardened film is 3.0 μm or less; a polishing step of polishing the outermost surface of the hardened film; and a separate film forming step of forming another film so as to be in contact with the outermost surface of the hardened film after the polishing step, wherein the surface shape of the lens substrate and the refractive index of the lens substrate and the hardened film cause the function as a functional region to be expressed and the target defocus power to be exerted."

[0069] In the cured film formation process, the cured film is formed in a state where the height difference in the normal direction of the outermost surface of the cured film is 3.0 μm or less. One method for producing a cured film having this height difference on the outermost surface is illustrated below.

[0070] <Method for producing a cured film (Part 1)> Figure 1 is a schematic cross-sectional view of an eyeglass lens 10 according to one embodiment of the present invention immediately after the formation of a cured film, showing how the cured film is applied in three layers to a lens substrate 1 provided with a substrate base portion 2 and a substrate protrusion portion 3. The reference numerals and names of the parts in the figure are as follows: Lens substrate 1, substrate base portion 2, substrate deformation portion 3 (substrate protrusion portion 3 as an example), cured film C1 to 3, degree of unevenness U1 to 3.

[0071] The cured film shown in Figure 1 comprises, in order from the side closest to the lens substrate 1, a cured film C1 made of a resin material different from the lens substrate 1, a cured film C2 made of a resin material provided on the cured film C1 and having a different composition from the cured film C1, and a cured film C3 made of a resin material provided on the cured film C2 and having a different composition from the cured film C2. Because of the different compositions, the hardness and refractive index of cured films C1 and C2 may differ. The same applies to cured films C2 and C3. The section on embodiments below mainly illustrates cases where the compositions of the films differ in this way.

[0072] The cured film shown in Figure 2 comprises, in order from the side closest to the lens substrate 1, a cured film C1 made of a resin material different from the lens substrate 1, a cured film C2 made of resin provided on the cured film C1 and having a different refractive index from the cured film C1, and a cured film C3 made of resin provided on the cured film C2 and having the same refractive index as the cured film C2. In Figure 2, the cured films C1 and C2 have different compositions and at least one of their hardness and refractive index may differ. On the other hand, the cured films C2 and C3 have the same composition, hardness, and refractive index. In one embodiment of the present invention, it is sufficient to satisfy at least one of the following. In this specification, this content is referred to as difference α. - At least one of the composition and hardness differs between the cured films C1 and C2. - At least one of the composition and hardness differs between the cured films C2 and C3. In the examples section below, we illustrate a case where the composition (and probably hardness) differs between cured films C1 and C2, and the composition (and probably hardness) differs between cured films C2 and C3, but the refractive index is the same for cured films C1 to C3.

[0073] Since a hardened film C3 is formed after a hardened film C2, an interface is inevitably formed between hardened films C2 and C3. For example, the interface between hardened films C2 and C3 can be visually observed in cross-section using an electron microscope, etc., as long as hardened film C3 is fabricated after hardened film C2. This interface is formed clearly enough to be confirmed in cross-section using an electron microscope, etc., even if adjacent hardened films have the same composition. The same applies to the interface between hardened films C1 and C2.

[0074] First, in one embodiment of the present invention, as shown in Figure 1, the cured film comprises, in order from the side closest to the lens substrate 1, a cured film C1 made of resin (preferably made of a different material from the lens substrate 1), a cured film C2 made of resin with a different composition from the cured film C1, and a cured film C3 made of resin with a different composition from the cured film C2. As long as this condition is met, there are no limitations on the composition of each cured film C1 to C3 (and consequently, the composition of the chemical solutions M1 to C3 that form the basis of each cured film C1 to C3).

[0075] In this specification, "resin-based" refers to resins used for forming films (e.g., hard coat films, protective films, primer films) on optical components (especially eyeglass lenses 10). Examples of such resins include carbon resins and / or silicone resins.

[0076] In one embodiment of the present invention, as shown in Figure 1, the composition of the cured films in contact with each other in the Z direction is made different. Specifically, at least one of the hardness and refractive index may be made different. By making the composition of the cured films in contact with each other different, even if a crack or strain occurs in the cured film C3, the propagation of the crack or strain is likely to stop before reaching the cured film C2 because the cured film C2 has a different composition from the cured film C3. Even if the propagation of the crack or strain occurs in the order of cured film C3 and C2, the propagation is likely to stop before reaching the cured film C1. As a result, the propagation of cracks or strain to the entire cured film can be suppressed.

[0077] The description in the previous paragraph indicates that even when the composition of each cured film is the same but the hardness differs, the same effect can be achieved, i.e., the propagation of cracks or strain throughout the entire cured film can be suppressed. One way to make the hardness of each cured film the same but the composition differs is to differ the conditions during film formation for each cured film. Specifically, this can be done by differentiating the film formation method (immersion, spin coating, etc.) and the various conditions of each film formation method (immersion time, withdrawal speed, spin coating rotation speed, drying time, etc.). Hardness can be quantified using one of the following methods, for example, indentation hardness (Rockwell, Vickers, Brinell, etc.), scratch hardness (pencil method), or rebound hardness (Shore). Alternatively, the plastic deformation resistance of the material can be measured using a Rockwell hardness tester (HRB, HRC) or a Shore hardness tester (durometer) to quantify the hardness.

[0078] Furthermore, the composition of each of the cured films C1 to C3 (and at least one of their hardness and refractive index, particularly hardness) may be different from one another, or, for example, the composition of two separated cured films C1 and C3 may be the same.

[0079] When the compositions of the cured films C1 to C3 differ from each other, as shown in Figure 1, the propagation of cracks or strain can be further suppressed if both the cured film C1 and the cured film C2, and the cured film C2 and the cured film C3, possess the difference α (particularly the difference in composition). Furthermore, when the difference α is a difference in composition, it indicates that there is an even greater variety of options.

[0080] The reason why the propagation of cracks or strains is suppressed due to differences in composition between adjacent cured films is explained below.

[0081] The different compositions result in differences in glass transition temperatures (Tg). Resins with a high Tg tend to be harder, which means they have less flexibility (e.g., plastic deformation, viscoelastic deformation, degree of energy absorption, etc., hereafter the same), making them more susceptible to cracking or strain. On the other hand, in cured films made from resins with a relatively low Tg, the resin tends to become rubbery, possessing flexibility, which suppresses the propagation of cracks or strain. In other words, this other cured film functions as a so-called toughening layer. This function arises from the different compositions of each cured film.

[0082] The functions described in the previous paragraph can be explained not only by the difference in Tg, but also by the difference in elastic modulus and the difference in elongation at break (%). Even if a crack or strain occurs in a hardened film with a high elastic modulus (high hardness), the tip of the crack will undergo plastic deformation, slow down and stop its propagation in the other hardened film with a relatively low elastic modulus (low hardness). This is also the reason why the propagation of the crack or strain is suppressed due to the difference in hardness between adjacent hardened films. Even if a crack or strain occurs in a hardened film with a small elongation at break, the tip of the crack will undergo plastic deformation, slow down and stop its propagation in the other hardened film with a relatively large elongation at break.

[0083] In light of the above, the term "different composition" in this specification may be rephrased as "at least one of the following (preferably all of them) is different: the difference in glass transition temperature, the difference in elastic modulus, or the difference in elongation at break (%)" or "at least one of the following (preferably all of them) is different: the difference in glass transition temperature, the difference in elastic modulus, or the difference in elongation at break (%) is different AND the composition is different."

[0084] Furthermore, the number of layers of cured films is not limited to three, but may be four, five, or more. Even in that case, the compositions of the cured films that are in contact with each other in the Z direction shall be different. For example, when the number of layers is five or more, the cured films have a multilayer structure (that is, each cured film covers both the substrate base portion and the substrate protrusion portion, or is directly on top of them), and include, in order from the side closest to the lens substrate 1, a cured film C1 made of a resin material different from the lens substrate 1, a cured film C2 made of a resin material with a different composition from the cured film C1, a cured film C3 made of a resin material with a different composition from the cured film C2, a cured film 4 made of a resin material with a different composition from the cured film C3, and a cured film 5 made of a resin material with a different composition from the cured film 4.

[0085] The hardened film that is laminated furthest from the lens substrate 1 may be denoted as Cn (where n is an integer of 3 or more). If hardened films C1 and C2 are included, they are denoted as Ck (where k is a natural number). In this specification, hardened films C1 to n are collectively referred to simply as "hardened film". The above n may also be used for the designation of the "degree of unevenness" below, and they may be expressed as U1 to n.

[0086] Furthermore, the spectacle lens 10 according to one embodiment of the present invention has the following configuration. When the cured film C1 is provided, the outermost surface of the cured film C1 has a degree of unevenness U1 resulting from the difference in shape between the substrate base portion 2 and the substrate deformation portion (substrate protrusion portion) 3. When the cured film C2 is provided, the outermost surface of the cured film C2 is also uneven, but has a degree of unevenness U2 that is closer to flat than the degree of unevenness U1. When the cured film C3 is provided, the outermost surface of the cured film C3 has a degree of unevenness U3 that is closer to flat than the degree of unevenness U2. Each degree of unevenness U1 to U3 is shown enclosed by a dashed line in Figure 1.

[0087] In this specification, "degree of unevenness" refers to the degree of variation in the Z coordinate value (also called sag value) of each cured film per unit of diameter in a plan view of the substrate protrusion 3 (XY plane, i.e., the X direction and / or Y direction). "Per unit of diameter" refers to the degree of variation in the Z coordinate value when, for example, 1 / 10 (or 1 / 5, 1 / 4, 1 / 2) of the diameter is used as the smallest unit in the X direction and / or Y direction. Hereafter, the same applies to the smallest unit in this specification.

[0088] Furthermore, the absolute value of the smallest unit in the X and / or Y directions may be set to any value between 0.1 and 1.0 mm, for example.

[0089] In at least one spectacle lens 10, which is a myopia progression suppression lens, the dimensions of the minute protrusions in a planar view are on the order of millimeters or sub-millimeters. For example, Patent Document 2 illustrates a circular convex region with a diameter d of about 0.8 to 2.0 mm.

[0090] In order to exclude microscopic (micron-order or submicron-order) irregularities such as surface roughness Ra from the degree of unevenness as defined herein, the minimum unit of the degree of unevenness in the XY plane is set as described in the paragraph above.

[0091] The functional definition of this degree of unevenness is the degree of unevenness U1, which is "resulting from the difference in shape between the base portion 2 and the deformed portion (protruding portion) 3 of the substrate," and further, the degree of unevenness U2, which is "closer to flat than the degree of unevenness U1," and the degree of unevenness U3, which is "closer to flat than the degree of unevenness U2."

[0092] As the sign of the numerical value indicating the degree of unevenness increases, specifically through multiple layers of the hardening film solution applied to the lens substrate 1, the degree of unevenness decreases and approaches perfect flatness. As a result, the above-mentioned problem (unevenness remaining even after polishing) can be solved.

[0093] Furthermore, in addition to the above-mentioned specifications for each cured film and each degree of unevenness, the eyeglass lens 10 according to one embodiment of the present invention has the following configuration. The surface shape of the lens substrate 1, the refractive index of the lens substrate 1, and the refractive index of the cured films C1 to C3 enable the functional region 12 to function and exert the target defocus power.

[0094] Furthermore, if the difference α relates to the composition and the refractive index differs between the cured films, the interface shape between the cured films will further enable the functional region 12 to function and exert the target defocus power.

[0095] In this specification, the "target defocus power" can be determined from the eyeglass lens 10 as a product. For example, in the case of the myopia progression suppression lens exemplified in one embodiment of the present invention, the amount of defocus power to be set is indicated on the lens bag or prescription, at least in China. The eyeglass lens 10 is usually accompanied by a lens bag or prescription. Therefore, the target defocus power can be determined from the eyeglass lens 10 as a product.

[0096] Furthermore, "target defocus power" includes cases where it perfectly matches the additional power stated on the lens bag or prescription that is necessary to achieve the myopia progression suppression effect or hyperopia reduction effect, as well as cases where it is within tolerance (e.g., ±0.5D) of said additional power.

[0097] This configuration allows each refractive index of the cured films C1 to C3 to contribute to the defocusing power. Unlike the raw materials for the segmented smoothing layer described in Patent Document 2, where the number of candidates is limited when achieving the target defocusing power, in this configuration, it is possible to form a multilayer cured film by combining the compositions of the raw materials (chemical solutions M1 to C) of the cured films C1 to C3 to contribute to the achievement of the target defocusing power, thus ensuring a wide variety of options.

[0098] The reason why the description states "interface shape between cured films having the aforementioned difference α (i.e., the surface shape on the side of cured film C1 away from the lens substrate 1, and / or the surface shape on the side of cured film C2 away from the lens substrate 1)" and does not specify the outermost surface shape of cured film C3 is that the outermost surface shape of cured film C3 may be almost perfectly flat. If the outermost surface shape of cured film C3 is almost perfectly flat, there will be no protrusions on the outermost surface, and therefore, defocus power derived from the shape cannot be expected. Taking this into consideration, the outermost surface shape of cured film C3 is not considered an essential element for the expression of its function as a functional region 12. On the other hand, even if the outermost surface shape of cured film C3 is almost perfectly flat, the refractive index of cured film C3 contributes to the defocus power, so the refractive index is described as "cured films C1-3".

[0099] The target defocus power may be equal to or different from the defocus power generated by the substrate protrusion 3.

[0100] In this specification, "flatness" (and by extension, "degree of unevenness") may be defined as follows:

[0101] In this specification, "flat" may, for example, refer to a state in which the surface irregularities are 0.2 μm or less (where zero irregularities is considered "perfectly flat"). "Surface irregularities" refers to the difference between the maximum and minimum deviation distances from the nearest-neighbor spherical surface at a diameter of 4 mm (4φ, assuming pupil diameter). "Nearest-neighbor spherical surface" refers to the spherical shape calculated by the least squares method from the measured values ​​(height distribution) of the surface within the 4φ range.

[0102] From the perspective of surface average power, "flat" may be defined as follows: "Flat" refers to a surface where the rate of change of the surface average power (unit: D) ​​in any direction at any position on the surface is 0.5 D / mm or less (preferably 0.4 D / mm or less). The surface average power is expressed by the following formula: Surface average power = Curved surface average curvature (unit: 1 / m) * (Refractive index of surface material - 1.0)

[0103] Furthermore, "flatness" can also be defined as follows: a state in which the difference between the minimum and maximum values ​​of the average surface power is smaller than the difference between the minimum and maximum values ​​of the transmittance (power added by the embedded segment (substrate deformation portion 3)) may be considered "flat".

[0104] One way to quantify the degree of unevenness is to use, for example, the standard deviation of the Z-coordinate value (sag value) of the surface on the side furthest from the lens substrate 1 for each cured film. As the sign of the cured film increases, the standard deviation of the Z-coordinate value (sag value) of the surface furthest from the lens substrate 1 approaches zero. To give a specific example, the standard deviation of the sag value of cured film C2 is closer to zero than that of cured film C1. Note that if it is perfectly flat, the standard deviation will be zero.

[0105] Furthermore, "flat" can also be defined as follows: that is, the height difference in the normal direction of the outermost surface of the hardened film Cn (where n is an integer of 3 or more) that is laminated furthest from the lens substrate 1 may be 0.5 μm or less (preferably 0.2 μm or less).

[0106] In addition to the definition in the paragraph above, "flat" may also be defined as a relative value. For example, a surface may be considered "flat" if the height difference in the normal direction of the outermost surface, as described in the paragraph above, is 1 / 5 or less of the protrusion distance of the substrate protrusion 3. The intention of this relative specification is that if the protrusion distance of the substrate protrusion 3 is small, even if a film is formed on the substrate protrusion 3, the degree of unevenness on the outermost surface of the film will naturally be small, and the significance of the height difference specification as an absolute value described in the paragraph above will be diminished. By superimposing the specification in this paragraph, the degree of reduction in the degree of unevenness compared to the protrusion distance of the substrate protrusion 3 can be shown. Furthermore, a surface may be considered "semi-flat" if the height difference in the normal direction of the outermost surface, as described in the paragraph above, exceeds 1 / 5 and is 3 / 5 or less of the protrusion distance of the substrate protrusion 3. To reiterate, it is preferable for the height difference in the normal direction of the outermost surface, as described in the paragraph above, to be semi-flat or flat in order to achieve the target defocus power. In this specification, unless otherwise specified, the definitions given in the preceding paragraph and this paragraph are used as examples.

[0107] In this specification, "approaching flatness" means that the degree of unevenness approaches zero. Even in the "flat" state as defined above, it is entirely possible that the degree of unevenness may approach zero further. For example, even if the outermost surface of the cured film C2 is in the "flat" state as defined above, the outermost surface of the cured film C3 may approach zero further. The outermost surface of the cured film C1 may be quasi-flat (the definition is given herein) or have a greater degree of unevenness than quasi-flat. The outermost surface of the cured film C2 may be quasi-flat, flat, or have a greater degree of unevenness than quasi-flat.

[0108] Furthermore, in both the central clear region 11 and the outer clear region 15, it is preferable that the outermost surface of the side of the spectacle lens 10 on which the base material deformation portion 3 is provided (the object-side surface, preferably both sides) is flat.

[0109] The method for manufacturing an eyeglass lens 10 according to one embodiment of the present invention described above mainly comprises the following steps: "A step of forming a hardened film C1 by applying and drying a resin-based chemical solution M1 so as to cover the lens substrate 1, thereby forming a hardened film C1 whose outermost surface has a degree of unevenness U1 resulting from the difference in shape between the substrate base portion 2 and the substrate deformation portion 3; A step of forming a hardened film C2 by applying and drying a resin-based chemical solution M2 (preferably with a different composition from the chemical solution M1) to the hardened film C1, thereby forming a hardened film C2 whose outermost surface has a degree of unevenness U2 that is closer to flatter than the degree of unevenness U1; A step of forming a hardened film C3 by applying and drying a resin-based chemical solution M3 (preferably with a different composition from the chemical solution M2) to the hardened film C2, thereby forming a hardened film C3 whose outermost surface has a degree of unevenness U3 that is closer to flatter than the degree of unevenness U2." In other words, the formation of the cured film is carried out at least three times, in the steps of forming cured film C1, forming cured film C2, and forming cured film C3, and then the chemical solutions M1 to M3 are applied in layers.

[0110] Furthermore, the specific manufacturing process for the eyeglass lens 10 after the above design has been carried out may be carried out using known methods. For example, the following process may be adopted: "A method for manufacturing an eyeglass lens 10 comprising: a polishing step of polishing the outermost surface of the hardened film Cn; and a separate film forming step of forming another film (anti-reflective film, water-repellent film, etc.) in contact with the outermost surface of the hardened film after the polishing step."

[0111] To ensure that the hardened film Cn remains intact when polishing the outermost surface of the hardened film Cn, the thickness of the hardened film Cn may be 3.0 μm or more.

[0112] The term "flat" as described above refers to the state in which the hardened films C1 to C3 are stacked and have not been polished. On the other hand, "flat" may also refer to the state after the polishing process, as in the manufacturing method described below, or it may refer to the state after the cutting process described later has been performed before the polishing process.

[0113] <Method for preparing a cured film (part 2)> Note that even after applying multiple coats of the above chemical solutions M1 to M3, the outermost surface of the cured film C3 (or more broadly, the cured film Cn) may not be flat, or even semi-flat.

[0114] In this specification, "flat" refers to a state in which the above-mentioned height difference is 0.5 μm or less, or 0.2 μm or less. In this specification, "semi-flat" refers to a state in which the above-mentioned height difference is greater than 0.5 μm and 3.0 μm or less, preferably 2.0 μm or less, 1.5 μm or less, 1.2 μm or less, or 1.0 μm or less.

[0115] Related to the above issues, if the surface is in a semi-flat state, as shown in the examples below, even if the degree of unevenness is somewhat large, it can be flattened by polishing. Naturally, if polishing is performed from a flat state, it can be flattened. In other words, it is preferable that the outermost surface of the hardened film Cn (where n is an integer of 3 or more, for example n=3) that is laminated furthest from the lens substrate 1 is in a semi-flat or flat state.

[0116] A cutting process may be performed on the outermost surface even if it is not quasi-flat (i.e., has a high degree of unevenness). The specific configuration is as follows: "The hardened film formation process includes a cutting step in which the hardened film is cut when the height difference in the normal direction of the outermost surface exceeds 3.0 μm, and the height difference in the normal direction of the outermost surface is reduced to 3.0 μm or less (preferably 2.0 μm or less, 1.5 μm or less, 1.2 μm or less, 1.0 μm or less, or 0.5 μm or less)." Or, "The hardened film formation process includes a cutting step in which the hardened film is cut when the height difference in the normal direction of the outermost surface exceeds 0.5 μm (or exceeds 0.2 μm), and the height difference in the normal direction of the outermost surface is reduced to 0.5 μm or less (or 0.2 μm or less)."

[0117] In order to ensure that the hardened film Cn remains intact when the outermost surface of the hardened film Cn is cut (and subsequently polished), the thickness of the hardened film Cn (the hardened film furthest from the lens substrate 1) may be 5.0 μm or more.

[0118] After the above cutting process, it is preferable to reduce the height difference in the normal direction of the outermost surface of the hardened film C3 to 0.5 μm or less, or 0.2 μm or less, by the above polishing process as described above.

[0119] <Effects of one embodiment of the present invention> According to one embodiment of the present invention (for example, the method for producing a cured film (parts 1 and 2)), the degree of unevenness caused by the shape difference between the substrate base portion 2 and the substrate deformation portion 3 on the outermost surface of the obtained cured film can be reduced to a state where the height difference in the normal direction is 3.0 μm or less. Therefore, even if polishing is performed after the cured film is formed, a degree of unevenness can be obtained that does not hinder the achievement of the target defocus power.

[0120] Furthermore, by polishing the outermost surface in this state, the degree of unevenness on the outermost surface of the hardened film becomes very small, while the surface roughness on the nano-order increases on the outermost surface of the hardened film. By forming another film in contact with this outermost surface, an anchoring effect occurs due to the surface roughness, improving the adhesion between the hardened film and the other film.

[0121] <Further Specific Examples, Preferred Examples and Modifications of the Eyeglass Lens 10> Preferred examples and modifications of the eyeglass lens 10 in one embodiment of the present invention are described below.

[0122] If the primary focus is on the advantage of using an embedded type to achieve the target defocusing power while ensuring a wide variety of applicable materials, then it is preferable to first obtain the defocusing power from the refractive index difference between the substrate and the cured film C1. On the other hand, regarding the shape of the interfaces between cured films C1 and C2, and between cured films C2 and C3, when the refractive index difference is the primary focus, it is preferable to make the interface shape such that it does not generate excessive defocusing power. The following preferred example is based on this technical idea: "The refractive index difference between the cured film C1 and the substrate is 0.05 or more (preferably 0.08 or more), the refractive index difference between the cured film C1 and the cured film C2 is 0.02 or less (preferably 0.01 or less), and the refractive index difference between the cured film C2 and the cured film C3 is 0.02 or less (preferably 0.01 or less)."

[0123] Even if excessive defocusing power is generated due to the shape of the interfaces between hardened films C1 and C2, and between hardened films C2 and C3, the refractive index of each hardened film can be set so that this defocusing power is canceled out. The ability to use such flexible combinations of refractive indices is a major advantage of the present invention. The specific configuration for achieving this cancellation is as follows: "The refractive index of hardened film C2 is greater than the refractive index of hardened film C1 and less than the refractive index of hardened film C3, or the refractive index of hardened film C2 is less than the refractive index of hardened film C1 and greater than the refractive index of hardened film C3."

[0124] In the deformed portion of the substrate 3, the ratio of the thickness of the cured film constituting the base region 13 to the protrusion height or recess depth from the substrate base portion 2 is preferably 4.0 (or 4.5, 5.0, 8.0, 10) or more. This provision indicates that the cured film (combined cured films C1 to n) is provided to a sufficient thickness relative to the Z-direction dimension of the deformed portion of the substrate 3, and the degree of unevenness can be sufficiently reduced to approach (almost) zero. There is no upper limit to this ratio, but for example, 100 is given.

[0125] The deformed portion 3 of the substrate may protrude or recess by 4.5 μm or more from the substrate base portion 2. As long as the invention is limited to the content described in Patent Document 2, the greater the degree of protrusion or recession of the deformed portion 3 of the substrate, the greater the thickness of the cured film required to fill the protrusion or recession. In that case, problems such as cracks or distortion as described in Patent Document 2 may occur. On the other hand, by adopting the features of the embodiment of the present invention described so far (in particular by adopting a configuration involving three or more layers of cured film), the above problem can be solved even if the deformed portion 3 of the substrate protrudes or recesses by 4.5 μm or more from the substrate base portion 2.

[0126] However, one embodiment of the present invention is not limited to the deformed portion 3 of the substrate protruding or recessing from the substrate base portion 2 by 4.5 μm or more, as shown in the section on embodiments listed later. Instead of 4.5 μm or more, values ​​of 0.5 μm or more, 0.8 μm or more, 1.0 μm or more, 1.2 μm or more, 1.5 μm or more, or 2.0 μm or more may be used. There is no upper limit to the protrusion or recession, but it may be a value in the range of 10 to 100 μm, for example.

[0127] For example, the thickness of the cured film may be 30 μm or more. There are no limitations on the thickness of each cured film C1 to n. As an example of the thickness, the thickness of each cured film may be increased as the sign of the cured film increases. For example, it is preferable that the thickness of cured film C2 is greater than that of cured film C1, and the thickness of cured film C3 is greater than that of cured film C2.

[0128] Within the cured film, the cured film C1 is most susceptible to the shape of the substrate protrusion 3 at its outermost surface. Therefore, the cured film C1 experiences relatively large stresses compared to other cured films. The greater the thickness of the cured film C1, the greater this effect becomes. For this reason, it is preferable to keep the thickness of the cured film C1 relatively small.

[0129] The cured film C2 is subjected to relatively large stresses, second only to the cured film C1, compared to the cured films C3 and later. Therefore, it is preferable to make the thickness of the cured film C2 larger than that of the cured film C1, but relatively smaller than that of the cured films C3 and later.

[0130] The thickness of the cured film C2 may be 3 to 10 times the thickness of the cured film C1, or the thickness of the cured film C3 may be 1.5 to 5 times the thickness of the cured film C2. There is no upper limit to the thickness of the cured film, but it may be a value within the range of 100 to 1000 μm, for example.

[0131] Regarding the thickness of each cured film C1 to C3, the thickness of cured film C2 may be greater than or equal to the thickness of cured film C1, the thickness of cured film C3 may be greater than or equal to the thickness of cured film C2, and the thickness of cured film C3 may be greater than the thickness of cured film C1. In the provisions of this paragraph, for example, the thicknesses of cured films C2 and C3 may be equal, but the thickness of cured film C3, which is closer to the outermost surface, is greater than that of cured film C1. This provision also solves the above-mentioned stress problem.

[0132] The cured films C1 and C2 do not need to satisfy the "flat" condition described above. However, the cured film C3 may be made to satisfy the "flat" condition. Alternatively, the cured film C1 may not satisfy the "flat" condition, while the cured films C2 and C3 may satisfy the "flat" condition.

[0133] Furthermore, the following preferred examples may be adopted to make it difficult for cracks or strains in the directly above cured film to propagate to the cured film below. The thickness of the cured film C1 (e.g., primer film) is preferably greater than 0.5 μm. Other preferred examples are as follows: The thickness of the cured film C1 is preferably 1 (or 2) to 30 μm. The thickness of the cured film C2 is preferably 3 (or 5) to 50 μm. The thickness of the cured film C3 is preferably 5 (or 10) to 50 μm.

[0134] The height difference of the substrate deformation portion 3 on the surface of each cured film may be defined as follows: The value of (height difference in the normal direction to the outermost surface of the cured film Ck (where k is an integer between 1 and 3)) / (height difference in the normal direction to the outermost surface of the cured film Ck-1 (if k-1 is zero, the lower cured film relative to the substrate deformation portion 3 or cured film C1)) may be 0.25 or more and less than 1 (or 1 or less, or 0.95 or less). This provision suppresses the abrupt change in the height difference as it approaches the outermost surface. As a result, the occurrence of cracks or distortion can be suppressed. The provisions of this paragraph may also be applied to all of the cured films. However, if, for example, 10 layers of cured films are provided, the height difference ratio between the outermost layer and the layer directly below it may be 1. It is preferable to take this into account and satisfy the following provisions. The value of (height difference in the normal direction of the outermost surface of the hardened film Ck (where k is a natural number (or an integer of 4 or more in some cases))) / (height difference in the normal direction of the outermost surface of the hardened film Ck-1 (if k-1 is zero, the lower hardened film relative to the deformed substrate portion 3 or hardened film C1)) is 0.25 or more and 1 or less (or 0.95 or less). Not all hardened films, but each hardened film Ck that is laminated furthest from the lens substrate and whose height difference in the normal direction of the outermost surface of the hardened film Ck (where k is a natural number) is 3 / 5 (or 1 / 2, 1 / 5) or less of the protrusion height or recess depth from the substrate base portion in the deformed substrate portion may satisfy the following provisions. The value of (height difference in the normal direction of the outermost surface of the hardened film Ck (where k is an integer of 2 or more)) / (height difference in the normal direction of the outermost surface of the hardened film Ck-1) is 0.25 or more and less than 1 (or 0.95 or less). For the hardened film C1 that is directly affected by the stress due to the height difference of the deformed part of the substrate 3, the following may be specified: The value of (height difference in the normal direction of the outermost surface of the hardened film C1) / (height difference in the normal direction of the outermost surface of the deformed part of the substrate 3) may be 0.80 or more and less than 1 (or 0.95 or less).

[0135] Furthermore, the cured film may have a lower cured film (not shown) on the side closest to the lens substrate 1. This lower cured film is one or more cured films located below the cured film C1. Preferably, the portion of the lower cured film that contacts the lens substrate 1 has a different composition from the lens substrate 1. The cured film C1 may be provided directly on the lens substrate 1, or it may be provided indirectly on the lens substrate 1 via the lower cured film. To encompass these cases, the expression "covers" is used with respect to the cured film C1.

[0136] When the cured film includes an underside cured film, it is preferable that no cracks or distortions occur in the underside cured film, and it is preferable that the following conditions are met: The value of (height difference in the normal direction of the outermost surface of the underside cured film) / (height difference in the normal direction of the outermost surface of the deformed portion 3 of the substrate) is 0.25 (or 0.80) or more and less than 1 (or 0.95 or less). If the presence of the underside cured film is taken into consideration, it is further preferable that the following conditions are met: The value of (height difference in the normal direction of the outermost surface of each cured film Ck (k is a natural number (or an integer of 4 or more in some cases)) / (height difference in the normal direction of the outermost surface of cured film Ck-1 (if k-1 is zero, the underside cured film)) is 0.25 or more and 1 or less (or 0.95 or less).

[0137] Furthermore, in terms of achieving the effects of the present invention, whether or not the lower cured film is present, as long as the difference α exists, the propagation of cracks or strain can be suppressed, thus solving problem 2. Also, the fact that the cured film employs a multilayer structure remains unchanged, and the variations are more abundant compared to when using a segment smoothing agent, thus solving problem 1. And, the degree of unevenness is reduced by the cured film C1 on the lower cured film, the cured film C2 on the cured film C1, and the cured film C3 on the cured film C2, thus solving problem 3.

[0138] An eyeglass lens 10 according to one embodiment of the present invention is a myopia progression suppression lens, similar to the eyeglass lens 10 described in Patent Document 1. However, the eyeglass lens 10 according to one embodiment of the present invention is not limited to this. For example, the eyeglass lens 10 according to one embodiment of the present invention may also be a hyperopia progression suppression lens. Myopia progression suppression and hyperopia progression suppression are collectively referred to as refractive error progression suppression.

[0139] Patent Document 2 describes that by changing minute protrusions to concave areas, an eyeglass lens 10 that provides a hyperopia reduction function can be obtained. The fact that changing convex to concave areas converts the myopia progression suppression function described so far into a hyperopia reduction function is also applicable to the content described herein. In that case, the non-base region 14 is exemplified as having a curved shape that is concave toward the inside of the lens.

[0140] In this specification, "concave" and "recessed" in relation to the eyeglass lens 10 for reducing farsightedness refer to a concave state relative to the surrounding area (e.g., base portion 2) of the object in question (e.g., base recess). In other words, "concave" and "recessed" in relation to the eyeglass lens 10 for reducing farsightedness naturally include cases where it is absolutely concave, as well as cases where it is absolutely convex.

[0141] Examples of a surface that is relatively concave and absolutely convex include the following: For example, in the lens substrate 1, there is a portion that protrudes outward from the object-side surface while having a curvature smaller than the macroscopic curve of the object-side surface (for example, a portion that is flatter than the substrate base portion 2). Strictly speaking, such a portion is absolutely convex because the object-side surface is convex. On the other hand, it is concave compared to the substrate base portion 2.

[0142] Various configurations can be adopted for the arrangement of the non-base region 14 within the functional region 12.

[0143] For example, as described in Patent Document 1, non-base regions 14, which are roughly circular in shape when viewed from above, may be arranged in an island-like manner (i.e., spaced apart from each other and not adjacent to each other) at equal intervals in the circumferential and radial directions around the central part of the spectacle lens 10. One example of the arrangement of the non-base regions 14 in plan view is to arrange them discretely and independently so that the center of each convex region becomes the vertex of an equilateral triangle (the center of each non-base region 14 is located at the vertex of a honeycomb structure). In this case, the spacing between the non-base regions 14 may be 0.7 to 2.0 mm. The number of non-base regions 14 may be 100 to 100,000. Note that the shape of the non-base regions 14 in plan view is not limited to circles, but may also be elliptical, polygonal, etc.

[0144] The diameter of each non-base region 14 in plan view is preferably about 0.6 to 2.0 mm. The surface area of ​​each is preferably 0.50 to 3.14 mm. ２ It may be to a certain extent. The radius of curvature of the convex non-base region 14 is spherical, with a radius of curvature of 50 to 250 mm, preferably about 86 mm.

[0145] There are no specific numerical limits on the defocus power in each non-base region 14, but for example, the minimum value of the defocus power produced by the non-base region 14 on the spectacle lens 10 is preferably in the range of 0.50 to 4.50 D, and the maximum value is preferably in the range of 3.00 to 10.00 D. The difference between the maximum and minimum values ​​is preferably in the range of 1.00 to 5.00 D.

[0146] In a plan view, the non-base regions 14 may be arranged in a honeycomb pattern, a circumferential pattern, or a spiral pattern. These arrangements may be combined in any way. Furthermore, an embodiment of the present invention includes a configuration in which several non-base regions 14 are linked together like beads. If the direction of linking is circumferential, the technical idea of ​​the present invention can be applied if, when viewed radially, the base regions 13 and non-base regions 14 are arranged alternately and repeatedly.

[0147] The functional area 12 is preferably contained within a circle centered on the eye point and having a diameter of one of the values ​​between 15.00 and 40.00 mm.

[0148] There are no limitations on the size and shape of the central clear area 11; its shape can be circular, rectangular, elliptical, etc. One guideline for the lower limit of the size of the central clear area 11 is that it should be large enough to encompass a circle with a diameter of 6.00 mm centered on the eye point. One guideline for the upper limit of the size of the central clear area 11 is that it should be large enough to fit within a circle with a diameter of 13.00 mm centered on the eye point.

[0149] Furthermore, in the functional region 12, the area of ​​the non-base region 14, which has a configuration that suppresses myopia progression or reduces hyperopia, in plan view may be defined as 20% or more and 80% or less of the total functional region 12.

[0150] The shape of the functional region 12 is not limited and may be ring-shaped in plan view. The ring may be circular, rectangular, elliptical, or a combination thereof on the inside (i.e., the boundary between the central clear region 11 and the functional region 12) and / or on the outside (i.e., the boundary between the outer clear region 15 and the functional region 12).

[0151] The eyeglass lens 10 in one embodiment of the present invention may be an eyeglass lens 10 after it has been fitted into a frame, and a part of the functional region 12 of the eyeglass lens 10 may be in contact with the outer edge of the eyeglass lens 10, while the other part of the functional region 12 may be in contact with the outer clear region 15. The expression "outer clear region 15 surrounding the functional region 12" includes this case. Furthermore, it is not prohibited to provide a non-base region 14 on the outer edge side of the outer clear region 15.

[0152] However, considering the need to easily obtain good visibility in the peripheral field of view, it is preferable that there are no structures (e.g., non-base region 14, convex region and / or concave region, embedded structure, etc.) between the outer edge of the spectacle lens 10 and the functional region 12 that are intended to provide a myopia progression suppression effect or a hyperopia reduction effect. In other words, it is preferable that the entire area between the outer edge of the spectacle lens 10 and the functional region 12 is the outer clear region 15.

[0153] The lens substrate 1 is formed from a thermosetting resin material such as thiourethane, allyl, acrylic, or epithio. However, other resin materials that can obtain the desired refractive index may be selected as the resin material constituting the lens substrate 1. Alternatively, the lens substrate 1 may be made of inorganic glass instead of a resin material.

[0154] Each cured film is formed using, for example, a thermoplastic resin or a UV-curable resin. Each cured film can be formed by immersing the lens substrate 1 in a chemical solution (e.g., hard coat solution) that serves as the raw material for each cured film, or by using a spin coating method, an inkjet method, or the like. By coating the lens with such a cured film, the durability of the spectacle lens 10 can be improved.

[0155] For the chemical agent M1 used as a raw material for cured film C1, a water-based polyurethane resin liquid is preferable. For the chemical agent M2 used as a raw material for cured film C2, a (meth)acrylate mixture is preferable. For the chemical agent M3 used as a raw material for cured film C3, a (meth)acrylate mixture is preferable.

[0156] Anti-reflective coatings include, for example, ZrO ２ MgF ２ Al ２ O ３ The anti-reflective coating is formed by depositing such an anti-reflective coating by vacuum deposition. By coating the lens with such an anti-reflective coating, the visibility of the image seen through the eyeglass lens 10 can be improved.

[0157] After each cured film has been formed, an anti-reflective film is further formed on the surface of the cured film Cn. The anti-reflective film can be formed by depositing the raw materials for the film by vacuum deposition. At the beginning of the formation of each cured film, a primer film may be formed on the lens substrate 1 as the cured film C1.

[0158] One or more additional films can be formed on top of the cured film Cn. Examples of such films include anti-reflective films, hydrophobic or hydrophilic anti-fouling films, and anti-fogging films. In this specification, these are collectively referred to as "coating films" or "additional films." Known techniques can be applied to the formation methods of these various films.

[0159] By manufacturing using this procedure, an eyeglass lens 10 is obtained having a plurality of non-base regions 14 on the object-side surface, including a base material deformation portion 3 that protrudes toward the object.

[0160] <Eyeglasses> The technical concept of the present invention is also reflected in eyeglasses in which the vicinity of the periphery of the eyeglass lens 10 is cut based on a predetermined frame shape and fitted into the frame. There are no limitations on the type or shape of the frame, and it may be full-rim, half-rim, under-rim, or rimless.

[0161] <Other> The technical scope of the present invention is not limited to the embodiments described above, and includes various modified and improved forms to the extent that specific effects can be obtained by the constituent elements of the invention or their combinations.

[0162] For example, the lens substrate 1 does not have to be the plastic lens substrate or the glass lens substrate itself. Specifically, a separate component comprising a substrate base portion 2 and a substrate deformation portion 3 may be provided on the plastic lens substrate or glass lens substrate and designated as the lens substrate 1, and this may be the target for hardening the film. Alternatively, only the substrate deformation portion (especially the substrate protrusion portion) 3 may be separately provided on the plastic lens substrate or glass lens substrate and designated as the lens substrate 1, and this may be the target for hardening the film. In any case, each time the hardened film is sequentially laminated, the uneven shape of the outermost surface is transferred in the lamination direction, but a substrate that has the substrate deformation portion (especially the substrate protrusion portion) 3 which is the source of that uneven shape may be considered as the lens substrate 1 in this specification. This lens substrate 1 may be called the primary structure. When the hardened film C1 is directly provided on the lens substrate 1, the hardened film C1 may be called the secondary structure, the hardened film C2 the tertiary structure, and the hardened film C3 the quaternary structure. When the lower curing film is directly applied to the lens substrate 1, the lower curing film may be referred to as a secondary structure, and the curing film C1 as a tertiary structure.

[0163] For example, the present invention is applicable not only to spectacle lenses 10 but also to other ophthalmic lenses (e.g., contact lenses, intraocular lenses (for phakic or aphakic patients)). The present invention is also applicable to ophthalmic lenses. In this specification, "spectacle lenses 10" includes ophthalmic lenses, but in a broader sense, it may be referred to as "optical components worn by humans."

[0164] In the above embodiment, as shown in Figure 1, the cured film consisted of a resin cured film C1, a resin cured film C2 with a different composition from the cured film C1, and a resin cured film C3 with a different composition from the cured film C2, in that order from the side closest to the lens substrate 1. On the other hand, as shown in the embodiments described later, the cured films C1 and C2 have different compositions, and the cured films C2 and C3 also have different compositions, while the refractive indices of the cured films C1 to C3 may be the same.

[0165] Even if the refractive indices of the hardened films C1 to C3 are the same, if the compositions of the hardened films C1 to C3 are different, the interfaces between each hardened film will make it easier to retain cracks or strain propagation.

[0166] Therefore, the effect of stopping the propagation of cracks or strain is sufficient even if the compositions of adjacent cured films are the same, as long as the difference α is secured. As a result, even in the example shown in Figure 2, where the compositions of cured films C2 and C3 are the same, the embedded type is used to achieve the target defocusing power, ensure a wide variety of applicable materials, and suppress the propagation of cracks or strain throughout the entire cured film.

[0167] Next, the present invention will be specifically described by showing examples. Of course, the present invention is not limited to the following examples. In each example, the process up to the cured film formation step is performed. In each example, the defocus power is obtained by chance, but it is clear that if this defocus power is set to the target defocus power from the beginning, the problem of achieving the target defocus power by employing an embedded type can be solved.

[0168] <Example 1> The following lens substrate 1 was fabricated. The prescription power was set to S (spherical power) 0.00D and C (astigmatism power) 0.00D. Diameter of lens substrate 1 in plan view: 100 mm Type of lens substrate 1: PC (polycarbonate) Refractive index of lens substrate 1: 1.589 Base curve of lens substrate 1: 0.00D (flat) Formation surface of substrate protrusion 3: Object-side surface Shape of substrate protrusion 3: Spherical Shape of substrate protrusion 3 in plan view: Perfect circle (diameter 1 mm) Height of substrate protrusion 3 from substrate base 2: 0.8 μm Arrangement of substrate protrusion 3 in plan view: Each substrate protrusion 3 is independently and discretely arranged so that its center becomes the vertex of an equilateral triangle (the center of each substrate protrusion 3 is located at the vertices of a honeycomb structure) Range in which substrate protrusion 3 is formed: Within a circle with a radius of 17 mm from the lens center Pitch between each substrate protrusion 3 (distance between the centers of substrate protrusion 3): 1.5 mm

[0169] A dipping method was used to form cured films on both sides (the entire top and bottom) of the lens substrate 1. The dipping and pulling directions were vertical.

[0170] The conditions for the dipping method for the cured film C1 and its raw material, chemical solution M1, are as follows: Type of chemical solution M1: A thermosetting coating agent that is a water-based polyurethane resin liquid Temperature of chemical solution M1: 10°C Viscosity of the coating solution: 10 mPa·s Boiling point of the solvent (methanol) of chemical solution M1: 64.7°C Immersion time: 3 minutes Withdrawal speed: 60 mm / min Drying method after withdrawal: Heating Drying temperature after withdrawal: 110°C Drying time after withdrawal: 90 minutes Film thickness of cured film C1: 3.0 μm

[0171] Tricyclodecanedimethanol dimethacrylate (100% by mass) (viscosity: 160 mPa·s) was used for the cured film C2 and its raw material, chemical solution M2. The cured film C2 was formed on the cured film C1 using a spin-coating method. The thickness of the cured film C2 was 10 μm. The conditions for its formation were as follows: Temperature of chemical solution M2: 10°C; Spin-coating rotation speed: 2000 rpm; Drying method after coating: UV curing.

[0172] The cured film C3 and its raw material, chemical solution M3, were a mixture of hydroxyl group-containing acrylate (10% by mass), Tosoh Corporation's Coronate 2715 (40% by mass), and 2-phenoxyethyl acrylate (50% by mass) (viscosity: 150 mPa·s). The cured film C3 was formed on the cured film C2 using a spin-coating method. The thickness of the cured film C3 was 30 μm. The conditions for its formation were as follows: Temperature of chemical solution M3: 10°C; Spin-coating rotation speed: 1000 rpm; Drying method after coating: UV curing.

[0173] The refractive indices of the cured films C1 to C3 were all 1.49. However, because the chemical solutions M1 to C3 are different, there is a difference in refractive index of approximately ±0.005 between each cured film. Therefore, strictly speaking, the refractive index differs between each cured film. However, from an optical standpoint for spectacle lenses, the effect of the third decimal place is negligible. For this reason, in this specification, the refractive indices of each cured film appearing in the examples section are treated as equivalent.

[0174] After depositing cured films C1 to C3, the degree of unevenness U3 of cured film C3 was investigated. As a result, the height difference in the normal direction of the outermost surface of cured film C3 was 0.26 μm. After depositing cured film C2, the degree of unevenness U2 of cured film C2 was investigated, and the height difference was 0.34 μm. After depositing cured film C1, the degree of unevenness U1 of cured film C1 was investigated, and the height difference was 0.7 μm.

[0175] <Example 2> An eyeglass lens 10 was manufactured in the same manner as in Example 1, except that the protrusion dimension of the substrate protrusion portion 3 was changed to 1.5 μm.

[0176] After depositing cured films C1 to C3, the degree of unevenness U3 of cured film C3 was investigated. As a result, the height difference in the normal direction of the outermost surface of cured film C3 was 0.9 μm. After depositing cured film C2, the degree of unevenness U2 of cured film C2 was investigated, and the height difference was 1.1 μm. After depositing cured film C1, the degree of unevenness U1 of cured film C1 was investigated, and the height difference was 1.4 μm.

[0177] <Example 3> An eyeglass lens 10 was manufactured in the same manner as in Example 1, except that the protrusion dimension of the substrate protrusion portion 3 was changed to 5.0 μm.

[0178] After depositing cured films C1 to C3, the degree of unevenness U3 of cured film C3 was investigated. As a result, the height difference in the normal direction of the outermost surface of cured film C3 was 1 μm. After depositing cured film C2, the degree of unevenness U2 of cured film C2 was investigated, and the height difference was 3.6 μm. After depositing cured film C1, the degree of unevenness U1 of cured film C1 was investigated, and the height difference was 4.2 μm.

[0179] <Summary of Examples 1-3> In each example, since the outermost surface is semi-flat or flat after film formation, even if the outermost surface is polished, the flat state can be maintained after polishing. As a result, in each example, even if polishing is performed after the hardened film is formed, a degree of unevenness that does not hinder the achievement of the target defocus power can be obtained. Furthermore, this polishing makes the degree of unevenness on the outermost surface of the hardened film very small, while increasing the nano-order surface roughness on the outermost surface of the hardened film. By forming another film in contact with this outermost surface, an anchoring effect on the film due to the surface roughness comes into play, improving the adhesion between the hardened film and the other film.

[0180] <Example 4> An eyeglass lens 10 was fabricated in the same manner as in Example 1, except that the protrusion dimension of the substrate protrusion 3 was changed to 5.0 μm and the thickness of the cured film C3 was changed to 10 μm.

[0181] After depositing cured films C1 to C3, the degree of unevenness U3 of cured film C3 was investigated. As a result, the height difference in the normal direction of the outermost surface of cured film C3 was 3 μm. After depositing cured film C2, the degree of unevenness U2 of cured film C2 was investigated, and the height difference was 3.6 μm. After depositing cured film C1, the degree of unevenness U1 of cured film C1 was investigated, and the height difference was 4.2 μm.

[0182] In Example 4, the degree of unevenness U3 is larger compared to the other examples described above, resulting in some difficulty in achieving flatness after polishing. On the other hand, even without the above cutting, the functional region 12 is able to function and exert the target defocus power after polishing, which is within the acceptable range according to the inventor's experience. Therefore, this example also belongs to one embodiment of the present invention. Furthermore, to be on the safe side, the above cutting described in <Method for producing a hardened film (part 2)> may be performed to make the degree of unevenness U3 semi-flat or flat.

[0183] <Example 5> Using the same lens substrate 1 as in Example 3, an eyeglass lens according to Example 5 was manufactured as follows.

[0184] (Formation of cured film C1) 305.0 g of methanol was mixed with 126 g of 4-hydroxy-4-methyl-2-pentanone (DAA) and 350.5 g of water. Then, 217.5 g of thermoplastic resin (Superflex 170, manufactured by Daiichi Kogyo Seiyaku Co., Ltd.) and 1.0 g of leveling agent (Y-7006, manufactured by Toray Dow Corning Co., Ltd.) were added, and the mixture was stirred at 20°C for 24 hours to obtain the primer solution as chemical solution M1.

[0185] The obtained primer solution was applied to a plastic lens substrate by the dipping method and dried and solidified at 100°C for 20 minutes to form a cured film C1 on both sides of the lens substrate. The thickness of the cured film C1 was 1.0 μm and the refractive index was 1.49. When the degree of unevenness U1 of the cured film C1 was investigated, the difference in height was found to be 4.5 μm.

[0186] (Formation of hardened film C2) 17 parts by mass of γ-glycidoxypropyltrimethoxysilane, 30 parts by mass of methanol, and 28 parts by mass of water-dispersed colloidal silica (solid content 40% by mass, average particle size 15 nm) were added to a glass container equipped with a magnetic stirrer and thoroughly mixed, and stirred at 5°C for 24 hours.

[0187] Next, 15 parts by mass of propylene glycol monomethyl ether, 0.05 parts by mass of a silicone-based surfactant, and 1.5 parts by mass of aluminum acetylacetonate as a curing agent were added, and after thorough stirring, the mixture was filtered to prepare a polymerizable composition for cured film C2 as chemical solution M2.

[0188] The polymerizable composition for the cured film C2 was coated onto the surface of the cured film C1 of the spectacle lens prepared as described above using a dip-coating method (pulling speed 20 cm / min). Subsequently, a cured film C2 (organosilicon-based cured layer) with a thickness of 3 μm and a refractive index of 1.49 was formed by heating and curing in a heat treatment furnace at a furnace temperature of 100°C for 60 minutes. When the degree of unevenness U2 of the cured film C2 was investigated, the difference in height was found to be 4.2 μm.

[0189] (Formation of cured film C3) Subsequently, a cured film C3 was formed on the convex surface (object-side surface) of the plastic lens substrate. Specifically, a water-based polyurethane resin liquid (polycarbonate polyol-based polyurethane emulsion; viscosity 100 CPS, solid content concentration 38% by mass) was used as the chemical solution M3. In an environment of 25°C and 50% relative humidity, it was applied to the surface of the cured film C2 of the spectacle lens prepared above by spin coating, and then allowed to air dry for 15 minutes to form a cured film C3 with a thickness of 10 μm and a refractive index of 1.49. When the degree of unevenness U3 of the cured film C3 was investigated, the difference in height was found to be 3.6 μm.

[0190] (Formation of cured film C4) A polymerizable composition for cured film C4 was prepared in a plastic container, consisting of 20 parts by mass of trimethylolpropane trimethacrylate, 35 parts by mass of BPE oligomer (2,2-bis(4-methacryloyloxypolyethoxyphenyl)propane), 10 parts by mass of EB6A (polyester oligomer hexaacrylate), 10 parts by mass of polyethylene glycol diacrylate with an average molecular weight of 532, and 10 parts by mass of glycidyl methacrylate.

[0191] To 100 parts by mass of the above polymerizable composition, a photoradical polymerization initiator (bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide (Omnirad819, manufactured by IGM Resin B.V.)), an antioxidant (bis[3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionic acid][ethylenebis(oxyethylene)]), and a light stabilizer (bis(1,2,2,6,6-pentamethyl-4-piperidyl) sebacate)) were mixed and thoroughly stirred to prepare a curable composition for thick film formation as chemical solution M4.

[0192] The chemical solution M4 prepared in this manner was applied to the above-mentioned cured film C3 by spin coating to form a coating layer. Ultraviolet light (wavelength 405 nm) was irradiated toward the surface of this coating layer in a nitrogen atmosphere (oxygen concentration 500 ppm or less) to cure the coating layer and form a cured film C4. The thickness of the formed layer was 35 μm and the refractive index was 1.49. When the degree of unevenness U4 of the cured film C4 was investigated, the difference in height was found to be 1.0 μm.

[0193] (Formation of cured film C5) In a plastic container, a (meth)acrylate having an oxyalkylene structure (NK Ester A-DPH-12E, manufactured by Shin Nakamura Chemical Industry Co., Ltd.) was mixed with a polymerization initiator (Omnirad 819, manufactured by IGM Resins B.V.) and a leveling agent (Dowsil L-7001, manufactured by Dow-Toray) and thoroughly stirred. In this way, a polymerizable composition for forming cured film C5 was prepared as chemical solution M5.

[0194] The chemical solution M5 prepared in this manner was applied to the above-mentioned cured film C4 by spin coating to form a coating layer. Ultraviolet light (wavelength 405 nm) was irradiated toward the surface of this coating layer in a nitrogen atmosphere (oxygen concentration 500 ppm or less) to cure the coating layer and form a cured film C5. The thickness of the formed protective layer, the cured film C5, was 15 μm, and the refractive index was 1.49. When the degree of unevenness U5 of the cured film C5 was investigated, the difference in height was found to be 0.5 μm.

[0195] (Formation of hardened film C6 and hardened film C7) In the same manner as hardened film C1, hardened film C6 was formed on hardened film C5. The thickness of hardened film C6 was 1.0 μm and the refractive index was 1.49. When the degree of unevenness U6 of hardened film C6 was investigated, the difference in height was found to be 0.17 μm. In the same manner as hardened film C1, hardened film C7 was formed on hardened film C6. The thickness of hardened film C7 was 3.0 μm and the refractive index was 1.49. When the degree of unevenness U7 of hardened film C6 was investigated, the difference in height was found to be 0.12 μm. These hardened films C6 and hardened film C7 were also sequentially formed on the eye-side surface of the spectacle lens.

[0196] In Example 5, since the outermost surface is semi-flat or flat after film formation, even if the outermost surface is polished, the flat state can be maintained after polishing. As a result, in Example 5, even if polishing is performed after the cured film is formed, a degree of unevenness that does not hinder the achievement of the target defocus power can be obtained. Furthermore, this polishing makes the degree of unevenness on the outermost surface of the cured film very small, while increasing the nano-order surface roughness on the outermost surface of the cured film. By forming another film in contact with this outermost surface, an anchoring effect on the film due to the surface roughness comes into play, improving the adhesion between the cured film and the other film.

[0197] Table 1 summarizes the film thickness and surface height difference of each cured film in Examples 1 to 4. Table 2 summarizes the film thickness and surface height difference of each cured film in Example 5.

[0198] 10 Eyeglass lens 11 Clear area on the center side 12 Functional area 13 Base area 14 Non-base area 15 Clear area on the outside 1 Lens substrate 2 Substrate base part 3 Substrate deformation part (substrate protrusion part) C1 Hardened film C1 C2 Hardened film C2 C3 Hardened film C3 U1 Degree of unevenness U1 U2 Degree of unevenness U2 U3 Degree of unevenness U3

Claims

1. A method for manufacturing an eyeglass lens comprising: a base region having a base region that causes a light beam incident from the object-side surface to be emitted from the eye-side surface, enters the wearer's pupil, and is focused onto the retina to achieve the wearer's prescribed refractive power; a plurality of non-base regions having a different refractive effect from the base region and being arranged alternately with the base region in a predetermined direction when the eyeglass lens is viewed in plan view; wherein the functional region causes a light beam incident from the object-side surface to be emitted from the eye-side surface, while at least one of the light beam focusing effect and contrast reduction effect on the retina by the non-base regions provides a myopia progression suppression effect or a hyperopia reduction effect; a lens substrate having an uneven surface due to comprising a base portion and a plurality of deformed portions of the substrate protruding or recessed from the base portion; and a hardened film that forms the base region by being provided on the base portion and forms the non-base regions by being provided on the plurality of deformed portions of the substrate; A method for manufacturing eyeglass lenses, comprising the steps of forming a cured film on a lens substrate, wherein the cured film is formed in a state in which the height difference in the normal direction of the outermost surface of the cured film is 3.0 μm or less; a polishing step of polishing the outermost surface of the cured film; and a separate film forming step of forming another film so as to be in contact with the outermost surface of the cured film after the polishing step, wherein the surface shape of the lens substrate, the refractive index of the lens substrate and the cured film cause the functional region to manifest and the target defocus power to be exerted.

2. The method for manufacturing eyeglass lenses according to claim 1, wherein the height difference of the outermost surface of the hardened film after the polishing step is 0.2 μm or less.

3. The method for manufacturing an eyeglass lens according to claim 1, wherein the cured film is composed of multiple cured films laminated together, and the thickness of the cured film laminated furthest from the lens substrate is 3.0 μm or more.

4. The method for manufacturing eyeglass lenses according to claim 1, wherein the ratio of the thickness of the cured film constituting the base region to the height of the protrusion or depth of the recess from the base portion of the substrate in the deformed portion of the substrate is 4.0 or more.

5. The method for manufacturing an eyeglass lens according to claim 1, wherein the deformed portion of the substrate protrudes or recedes by 4.5 μm or more from the base portion of the substrate.

6. The method for manufacturing eyeglass lenses according to claim 1, wherein the thickness of the cured film is 30 μm or more.

7. The method for manufacturing eyeglass lenses according to claim 1, wherein the hardened film forming step comprises a cutting step of cutting the hardened film in a state where the height difference in the normal direction of the outermost surface exceeds 3.0 μm, thereby reducing the height difference in the normal direction of the outermost surface to 3.0 μm or less.

8. The method for manufacturing an eyeglass lens according to claim 1, wherein the cured film is composed of multiple cured films laminated together, and the thickness of the cured film furthest from the lens substrate is 5.0 μm or more.

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