JP2010201621A - Method of manufacturing plastic lens, and the plastic lens - Google Patents

Abstract

Provided is a method for manufacturing a plastic lens having excellent optical characteristics at low cost without requiring a complicated process or a special apparatus.
A method of manufacturing a plastic lens includes a step of preparing an open mold 1 including a cavity portion 1a having a curved shape, and filling the cavity portion 1a with a liquid photocurable or thermosetting resin; b ) A step of forming a resin molded body 5 having a transfer surface on which the curved surface shape is transferred by curing the resin; c) a step of preparing a plate-like substrate 11; and d) a photocurable or thermosetting resin. The plate-like base material 11 and the resin molded body are cured by bonding the plate-like base material 11 and the open surface of the resin molded body 5 with the adhesive resin layer 15 containing the resin interposed therebetween. And 5) forming a plastic lens, and e) releasing the plastic lens from the open mold 1.
[Selection] Figure 4

Description

  The present invention relates to a method of manufacturing a plastic lens and a plastic lens manufactured by this method.

  Conventionally, a plastic lens is used as an optical component in, for example, a small camera module for a portable device, a compact digital camera, and a laser pickup module for a CD or DVD. As a method for molding a plastic lens, for example, a thermoplastic resin is melted at a high temperature and filled into a mold, a mold is formed by filling a thermosetting resin into a heated mold, or a monomer of a reactive curable resin is used. There are known a method of molding by filling a mold and irradiating an electromagnetic wave such as UV, and a method of applying a photo-curable resin on a pre-formed lens and molding it into a desired shape. However, in these molding methods, a desired shape cannot be obtained due to volume shrinkage due to cooling or solidification due to reaction, or refractive index distribution or birefringence occurs due to the stress accompanying shrinkage, resulting in a decrease in optical performance. There was a problem that. The following proposals have been made for such problems.

  In Patent Document 1, a method is provided in which an opening is provided in addition to a transfer surface for transferring a mirror surface in an injection mold, a pressure difference is created in the opening by applying air pressure, and a sink is formed there, thereby preventing the transfer surface from sinking. Has been proposed.

  Moreover, in patent document 2, after filling resin in a metal mold | die, the slidable cavity piece provided in the metal mold | die was forcedly moved at the time of cooling, and it moved away from resin, and between resin and a cavity piece | blade. There has been proposed a method for preventing the transfer surface from sinking by defining a space to cause sinking on the resin surface.

  In Patent Document 3, the molten resin is filled in the cavity of the mold and cooled, and after the resin is solidified, the same molten resin heated to the softening temperature or higher is filled in the cavity to solidify first. There has been proposed a method for eliminating sink marks and warpage caused by shrinkage of the resin.

  Moreover, in patent document 4, in the metal mold | die provided with the heating mechanism and the cooling mechanism inside, the filled resin is cooled first, and after that, it heats more than a softening temperature with a heating mechanism, and recompresses with a movable piece. A method of performing molding with high accuracy has been proposed.

  The above Patent Documents 1 to 4 are examples of molding using a thermoplastic resin, but the following proposals have been made regarding molding using a thermosetting resin or a UV curable resin.

  In Patent Document 5, in order to prevent sink marks due to curing shrinkage when molding a lens, a method of manufacturing a molded article free from sink marks by heating and curing in a state covered with a thin piece material such as a resin film. Has been proposed.

  In Patent Document 6, a liquid active energy ray-curable resin is supplied to the surface of a lens substrate that forms an aspherical surface, and is clamped with an aspherical die, and then cured by irradiation with active energy rays. It has been proposed that by repeating the process from the opening to the mold opening, the cured and shrunk volume can be compensated and a highly accurate molded product can be manufactured.

  The methods of Patent Documents 1 to 4 require a surface for making sinks in addition to the transfer surface, and there is a problem that the method cannot be applied unless the shape allows sinks to be formed at a site where light does not pass. For example, when molding an optical component such as a lens, sink marks cannot be formed in the central portion of the lens through which light passes. Further, as in Patent Document 4, when recompression is performed at a temperature higher than the softening point of the resin, there is a possibility that stress is generated again depending on the shape. Such a problem may occur not only in a thermoplastic resin but also in a thermosetting resin or a UV curable resin. Moreover, in the example of patent document 5, there exists a possibility that the shrinkage stress at the time of hardening may remain in the lens which is a molded article, and optical characteristics may be deteriorated by covering with a thin piece material. In addition, as in Patent Document 3 and Patent Document 6, there is a problem that the method of supplementing the resin has multiple processes, which increases the cost accordingly.

Japanese Patent No. 3034721 Japanese Patent No. 3512595 JP-A-1-160621 JP 61-182918 A JP 2006-7765 A JP-A-1-171932

  An object of the present invention is to provide a method for producing a plastic lens having excellent optical characteristics at a low cost without requiring a complicated process or a special apparatus.

In order to solve the above problems, a method for producing a plastic lens according to the present invention includes:
a) preparing an open mold having a cavity portion having a curved shape, and filling the cavity portion with a liquid photocurable or thermosetting resin;
b) curing the resin to form a resin molded body having a transfer surface to which the curved surface shape of the cavity portion is transferred and an open surface not restrained by the open mold;
c) preparing a plate-like substrate;
d) After interposing an adhesive resin layer containing a photocurable or thermosetting resin between the plate-like substrate and the open surface of the resin molded body, the adhesive resin layer is cured. Forming a plastic lens by fusing and integrating the plate-like base material and the resin molded body,
e) releasing the plastic lens from the open mold;
It has.

  In the method for producing a plastic lens according to the present invention, after the steps a to e are performed to form the resin molded body on one side of the plate-like base material, the plate a base is further performed by performing the steps a to e. It is preferable to further form a resin molding on the opposite surface of the material.

  In the method for producing a plastic lens according to the present invention, it is preferable that the step d is simultaneously performed on both surfaces of the plate-like substrate.

  In the plastic lens manufacturing method according to the present invention, the viscosity of the resin at the time of filling in the step a is within a range of 3000 Pa · s or less at a temperature of 100 ° C. or less, and the adhesive resin before curing in the step d The viscosity of the layer is preferably in the range of 0.1 Pa · s to 5000 Pa · s at a temperature of 100 ° C. or lower.

  The plastic lens which concerns on this invention is manufactured by the manufacturing method of the said plastic lens.

  According to the method for producing a plastic lens of the present invention, an open mold is filled with a resin and cured, and after actively forming sink marks on the open surface, a plate-like substrate is formed on the open surface via an adhesive resin layer. The plastic lens with excellent optical characteristics can be manufactured by eliminating the sink marks formed on the open surface by bonding and integrating them. In the prior art, in order to obtain an optically curved surface, it was necessary to create a sink at a portion where the light beam does not pass. However, in the method of the present invention, a sink is formed on the open surface, while maintaining the molding accuracy of the transfer surface. Is eliminated by fusion with the adhesive resin layer. Therefore, it is possible to make a sink mark regardless of whether it is a light passing surface, and the degree of freedom in product design is great, and the structure of the mold can be greatly simplified. Thus, in the method of the present invention, the structure is simplified by including a step of actively creating a sink on a surface other than the transfer surface and a step of eliminating the sink regardless of whether or not it is a light passage portion. It is possible to use a simple open mold, a mold of a complicated mechanism is not required, a process is simple, and a plastic lens having excellent optical characteristics can be manufactured at a low cost.

It is drawing explaining the process a in the 1st Embodiment of this invention. It is drawing explaining the process b in the 1st Embodiment of this invention. It is drawing explaining formation of the process c and the adhesive resin layer in the 1st Embodiment of this invention. It is drawing explaining the process d in the 1st Embodiment of this invention. It is drawing explaining the process e in the 1st Embodiment of this invention. It is drawing explaining the example which formed the resin molding on both surfaces of the plastic lens. It is drawing explaining the process f in the 1st Embodiment of this invention. It is sectional drawing which shows the structure of the plastic lens manufactured by this invention method. It is drawing explaining formation of the adhesive resin layer in the 2nd Embodiment of this invention. It is drawing explaining the process d in the 3rd Embodiment of this invention.

Embodiments of the present invention will be described with reference to the drawings.
[First Embodiment]
The manufacturing method of the plastic lens of this Embodiment is implemented by performing the following process a to the process e and the process f as needed, for example. Hereinafter, details of each process will be described.

Step a:
First, as shown to Fig.1 (a), the open mold | type 1 is prepared. The open die 1 has a mirror-polished cavity 1a having a curved shape corresponding to the convex curved surface of a plastic lens to be molded. As the material of the open mold 1, for example, metal, ceramics, quartz or the like can be used. The cavity portion 1a may be subjected to a surface treatment for enhancing the peelability as necessary.

  Then, as shown in FIG. 1B, the cavity portion 1 a of the open mold 1 is filled with a photocurable or thermosetting liquid resin 3. Although the filling method of the liquid resin 3 is not ask | required, what is necessary is just to pour in the cavity part 1a using the nozzle 10, for example. Examples of the photocurable resin include an ultraviolet curable epoxy resin, an ultraviolet curable silicone resin, an ultraviolet curable acrylic resin, and an ultraviolet curable vinyl resin. Examples of the thermosetting resin include a thermosetting epoxy resin, a thermosetting silicone resin, a thermosetting acrylic resin, and a thermosetting vinyl resin.

  In step a, the liquid resin 3 needs to have sufficient fluidity and spread in the cavity portion 1a of the open mold 1 without a gap. From such a viewpoint, the viscosity of the liquid resin 3 is preferably adjusted to be 3000 Pa · s or less at a temperature of 100 ° C. or less (for example, 40 ° C. or more and 100 ° C. or less), and is 300 Pa · s or less. It is more preferable to adjust so as to be within the range. When the viscosity of the liquid resin 3 is greater than 3000 Pa · s at a temperature of 100 ° C. or less, the shape transfer of the cavity portion 1a may be insufficient. The viscosity of the liquid resin 3 can be adjusted by the type and concentration of the solvent. In addition, there is no restriction | limiting in particular as a solvent of the liquid resin 3, However, As a preferable solvent, ethyl acetate, toluene, methyl ethyl ketone, tetrahydrofuran etc. can be mentioned, for example. In addition, reactive diluents such as low molecular vinyl monomers such as acrylic acid, methacrylic acid, methyl methacrylate, and vinyl acetate, and silicone monomers can also be used.

Step b:
Next, as shown in FIG. 2 (a), the liquid resin 3 filled in the cavity 1a of the open mold 1 is cured by irradiating with ultraviolet rays from an ultraviolet light source 20 (in the case of an ultraviolet curable resin), and resin molding is performed. The body 5 is molded. The resin molded body 5 is substantially hemispherical or fan-shaped in cross section, and has a convex curved surface 5a that is a transfer surface onto which the shape of the cavity portion 1a of the open mold 1 is transferred. When the liquid resin 3 is cured, the resin to be cured is restrained by the cavity portion 1a at the portion in contact with the cavity portion 1a of the open mold 1, so that the shape of the cavity portion 1a is precisely transferred and the convex curved surface 5a. Is formed. On the other hand, the open surface 5b which is the surface opposite to the convex curved surface 5a (back side) of the resin molded body 5 is a free surface which is not restrained by the open mold 1 at the time of curing. Arise. In the method of the present invention, by using the open mold 1 and actively forming sink marks 7 on the open surface 5b, distortion due to shrinkage during curing is absorbed by the open surface 5b, and sink marks on the convex surface 5a on the opposite side are absorbed. Generation | occurrence | production was prevented and it comprised so that the shaping | molding precision of the convex curve 5a might be maintained. That is, in the prior art, in order to obtain an optically curved surface of a plastic lens, it is necessary to make sink marks 7 in a portion where light rays do not pass. However, in the method of the present invention, sink marks 7 are positively formed on the open surface 5b. Thus, the forming accuracy of the convex curved surface 5a can be maintained. Since the sink marks 7 on the open surface 5b can be eliminated in a later process, it is possible to make the sink marks 7 regardless of whether or not it is a light passing surface, and the degree of freedom in product design is great. The structure of the open mold 1 can be greatly simplified.

  When the liquid resin 3 is a thermosetting resin in the step b, it can be cured by performing a heat treatment with a heating lamp 30 as shown in FIG. 2B, for example.

Step c:
In step c, a plate-like substrate 11 is prepared. As shown in FIG. 3A, the plate-like substrate 11 is a flat base having a plane substantially orthogonal to the optical axis direction of the lens, and the material thereof is the same as that of glass or liquid resin 3, for example. It is preferable to use a cured resin material. In the present embodiment, the adhesive resin 13 is applied to at least one surface of the plate-like base material 11 and is spread so as to have a uniform film thickness, thereby bonding as shown in FIG. A resin layer 15 is formed. As the adhesive resin 13, a liquid photocurable or thermosetting resin similar to the liquid resin 3 can be used. As the solvent for spreading the adhesive resin 13, the same solvent as the liquid resin 3 can be used.

  The method for applying the adhesive resin 13 to the plate-like substrate 11 is not particularly limited. In FIG. 3A, the applicator 40 is exemplified, but for example, a method such as die coating, dripping, spin coating or the like. Can be done. The thickness of the adhesive resin layer 15 formed on at least one surface of the plate-like substrate 11 is such that sink marks 7 present on the open surface 5b disappear when the adhesive resin layer 15 is bonded to the open surface 5b of the resin molded body 5 in step d described later. Although it will not be restrict | limited especially if it is the thickness which can be made to be, For example, it is preferable to set it as the range of 0.02 mm-1.0 mm.

Step d:
In step d, the adhesive resin layer 15 is interposed therebetween, the plate-like base material 11 and the open surface 5b of the resin molded body 5 are aligned, and then the adhesive resin layer 15 is cured to cure the plate-like base material 11. And the resin molded body 5 are integrated to form a plastic lens. First, as shown in FIG. 4A, the adhesive resin layer 15 of the plate-like substrate 11 and the open surface 5b of the resin molded body 5 cured in the cavity portion 1a of the open mold 1 face each other. Align and abut. At this time, it is preferable to soften the adhesive resin layer 15 by heating the adhesive resin layer 15 to a temperature within a range of 40 ° C. to 150 ° C., for example, using a heating lamp 30 or the like. In this case, it is preferable to adjust the viscosity of the adhesive resin layer 15 to be within a range of 0.1 Pa · s to 5000 Pa · s at a temperature of 100 ° C. or lower (for example, 40 ° C. or higher and 100 ° C. or lower). It is more preferable to adjust so that it may be in the range of 10 Pa · s to 3000 Pa · s. If the viscosity of the adhesive resin layer 15 is less than 0.1 Pa · s at a temperature of 100 ° C. or lower, problems such as dripping may occur. If it exceeds 5000 Pa · s, the adhesive resin layer 15 is bonded to the open surface 5b of the resin molded body 5. There is a possibility that the adhesiveness at the time of making it become insufficient. By joining the open surface 5b of the resin molded body 5 with the adhesive resin layer 15 sufficiently softened, the sink marks 7 formed on the open surface 5b are eliminated by the fusion with the adhesive resin layer 15. Optical characteristics sufficient as a lens can be obtained.

  When a thixotropic material that generates fluidity due to stress is used as the resin material constituting the adhesive resin layer 15, the sink marks 7 can be sufficiently eliminated only by the pressure at the time of pressure bonding, not by heating.

  Then, as shown in FIG. 4B, the adhesive resin layer 15 is cured by irradiating ultraviolet rays from the ultraviolet light source 20 (in the case of an ultraviolet curable resin), preferably while being pressurized at a predetermined pressure, to form a plate shape. The base material 11 and the resin molded body 5 are integrated. The pressure at this time is preferably within a range of 0.01 MPa to 10 MPa. In addition, as long as the adhesive resin layer 15 before curing is in a sufficiently softened state, pressurization is not necessarily required, and for example, bonding by only the weight of the plate-like substrate 11 is possible.

  In the case where the adhesive resin layer 15 is made of a thermosetting resin, as shown in FIG. 4C, the adhesive resin layer 15 may be cured by performing a heat treatment with a heating lamp 30.

The step d is preferably performed in a vacuum state in a vacuum chamber (not shown) in order to prevent air bubbles from being mixed into the joint portion between the adhesive resin layer 15 and the resin molded body 5. In this case, it is preferable to carry out on the pressure conditions of 10 < ^-1 > Pa to 10 < ^-6 > Pa, for example.

Step e:
Next, as shown in FIG. 5, the plastic lens 9 is released from the open mold 1. The plastic lens 9 manufactured in this way can be used as an optical product as it is. However, if necessary, the plastic lens 9 can also be used on the side of the plate-like substrate 11 where the resin molded body 5 is not bonded. You may form another resin molding 5 by performing process a-process e. In this way, as shown in FIG. 6, it is possible to manufacture a double-sided convex type plastic lens 9 a in which the resin molded body 5 is formed on both sides of the plate-like substrate 11.

Step f:
In the method of the present invention, as a preferred embodiment, a step of adjusting the viscosity of the adhesive resin layer 15 formed on the plate-like substrate 11 can be provided as a step f after the step c and before the step d. In step f, the viscosity of the adhesive resin layer 15 is adjusted to be higher than that in step c. In step f, it is preferable to adjust the viscosity of the adhesive resin layer 15 within a range of 0.1 Pa · s to 5000 Pa · s, for example, at a temperature of 100 ° C. or lower (for example, 40 ° C. or higher and 100 ° C. or lower). -It is more preferable to adjust in the range of s to 3000 Pa · s. If the viscosity of the adhesive resin layer 15 is less than 0.1 Pa · s at a temperature of 100 ° C. or lower, problems such as dripping may occur. If it exceeds 5000 Pa · s, it is difficult to soften the adhesive resin layer 15 in step d. Therefore, there is a possibility that the adhesiveness at the time of pressure bonding with the open surface 5b of the resin molded body 5 is insufficient.

  As an example of the method of adjusting the viscosity of the adhesive resin layer 15 within the above range in the step f, the photocurable resin or thermosetting resin constituting the adhesive resin layer 15 is made into a semi-cured state (so-called B stage). Can be mentioned. In this case, as shown in FIG. 7 (a), for example, the ultraviolet light source 20 is irradiated with ultraviolet rays, or as shown in FIG. It is possible to make the photo-curable or thermosetting resin constituting 15 into a semi-cured state.

  Further, as another example of the method of adjusting the viscosity of the adhesive resin layer 15 in the step f, the viscosity can be adjusted within the above range by the solvent concentration in the adhesive resin layer 15. For example, by drying the adhesive resin layer 15, it becomes possible to increase the viscosity as compared with the step c.

  Furthermore, it is also possible to adjust the adhesive resin layer 15 to a desired viscosity by previously blending a gelling agent with the adhesive resin 13 applied to the plate-like substrate 11.

  By adjusting the viscosity of the adhesive resin layer 15 to the above range in the step f, dripping in the step d can be prevented and the handling property is improved, and the bonding to the resin molded body 5 in the step d is performed. It becomes easy to manage the degree of reviscosity adjustment (softening in this case) by heating and / or pressurization of the adhesive resin layer 15 at the time.

FIG. 8 is an enlarged cross-sectional view of the plastic lens 9 manufactured by the steps a to e (including the step f as necessary). The plastic lens 9 is a hybrid lens including the plate-like base material 11, the adhesive resin cured layer 17 obtained by curing the adhesive resin layer 15, and the resin molded body 5 through the above steps. Here, if the refractive index of the plate-shaped substrates 11 _{D A,} the refractive index of the adhesive resin cured layer 17 _{D B,} the refractive index of the resin molding 5 was _{D C,} and _{D A} and _{D B} and _{D C} there may be all different values, the optical properties of the plastic lens 9, it is preferable that at least D _B and D _C is the same, that all the D _a and D _B and D _C is the same value ,desirable. The same applies to the plastic lens 9a shown in FIG.

  The thickness of the thickest part (central part) of one resin molded body 5 on one side of the convex plastic lenses 9 and 9a is the total thickness of the plate-like base material 11, the adhesive resin cured layer 17 and the resin molded body 5. It can be in the range of 3% to 96%. In general, as the thickness of the molded body increases, sink marks are more likely to occur during curing molding. Therefore, the conventional hybrid lens generally has a structure in which, for example, a very thin aspheric plastic layer is formed on the surface of a spherical glass, but the method of the present invention can completely eliminate sink marks 7 during the process. Therefore, the thickness ratio of the resin molded body 5 can be freely adjusted, and for example, it can be easily expanded to the upper limit of the above range. In the method of the present invention, the resin molded body 5 that occupies all or most of the curved surface portion of the lens can be formed by a simple process, and a flat plate-like substrate 11 that is easy to mass-process is used as the base of the lens. It is possible, and is excellent in industrial property and mass productivity.

  As described above, according to the method of the present invention, since sink marks 7 can be made at the center of the lens, which is the passage of light, there is a great degree of freedom in product design. Further, since the open mold 1 can be used, a complicated mechanism mold is not required, and the process is simple. Therefore, there is a merit that the plastic lenses 9, 9a having excellent optical characteristics can be manufactured at low cost, and the industrial value is high.

  In the present embodiment, step a and step b and step c (and optional step f) may be performed in parallel, or step c (and step b) prior to step a and step b. f) may be performed.

  Moreover, after forming the adhesive resin layer 15 on both surfaces of the plate-like base material 11 in the step c and performing the step f on the adhesive resin layers 15 on both sides as necessary, the step d and the step e are performed on the plate-like base material. 11 may be performed simultaneously on both sides.

[Second Embodiment]
Next, a second embodiment of the present invention will be described. Since the plastic lens manufacturing method according to the present embodiment is carried out in substantially the same process procedure as in the first embodiment, the following description will focus on differences from the first embodiment. .

  First, in the present embodiment, step a and step b are performed in the same manner as in the first embodiment. Next, in step c, a plate-like substrate 11 is prepared. Here, in 1st Embodiment, although the adhesive resin layer 15 was formed in the single side | surface of the plate-shaped base material 11, it is not the plate-shaped base material 11 but the open surface 5b of the resin molding 5 in this Embodiment. A step of forming the adhesive resin layer 15 by applying the adhesive resin 13 is provided. That is, as shown in FIG. 9A, the adhesive resin 13 is applied to the open surface 5 b of the resin molded body 5 using the applicator 40 and spread so as to have a uniform film thickness. As the adhesive resin 13, the same resin as in the first embodiment can be used. Further, the method of applying the adhesive resin 13 to the open surface 5b of the resin molded body 5 is not particularly limited, and can be performed by various methods as in the first embodiment. Then, as shown in FIG. 9B, the adhesive resin layer 15 is formed on the open surface 5 b of the resin molded body 5. The thickness of the adhesive resin layer 15 is not particularly limited as long as it can eliminate sink marks 7 present on the open surface 5b, as in the first embodiment. It is preferable to be within the range of 0 mm.

  The subsequent steps d and e are performed in the same manner as in the first embodiment except that the adhesive resin layer 15 is formed on the resin molded body 5 side in the step d, whereby the plastic lenses 9 and 9a are processed. Can be manufactured. Moreover, the process similar to the process f can be performed about the adhesive resin layer 15 on the resin molding 5 as needed.

  In the present embodiment, since the adhesive resin layer 15 is formed on the open surface 5b of the resin molded body 5, it is not necessary to form the adhesive resin layer 15 on the plate-like base material 11 side, but the first embodiment Similarly to the form, the adhesive resin layer 15 can be formed on the plate-like substrate 11 side.

  Other configurations and effects in the present embodiment are the same as those in the first embodiment.

[Third Embodiment]
Next, a third embodiment of the present invention will be described. Since the plastic lens manufacturing method according to the present embodiment is carried out in substantially the same process procedure as in the first embodiment, the following description will focus on differences from the first embodiment. .

  First, in the present embodiment, step a and step b are performed in the same manner as in the first embodiment. Next, in step c, a plate-like substrate 11 is prepared. Here, in the first embodiment, the adhesive resin layer 15 is formed on one surface of the plate-like base material 11, but in this embodiment, for example, photocuring or thermosetting is performed separately from the plate-like base material 11. An adhesive resin film 15a containing a hydrophilic resin is prepared. The adhesive resin film 15a is preferably made of, for example, a resin in a B-stage state, but an uncured resin film may be prepared and a step for making a B-stage state may be separately provided.

  Then, in the next step d, as shown in FIG. 10A, the adhesive resin film 15 a as the adhesive resin layer is joined between the resin molded body 5 and the plate-like substrate 11. . At this time, for example, the adhesive resin film 15a is heated to a temperature in the range of, for example, 40 ° C. to 150 ° C. using the heating lamp 30 or the like, and the viscosity of the adhesive resin film 15a is changed to the adhesive resin in step d of the first embodiment. It is preferable to adjust to the same range as the layer 15. And as shown in FIG.10 (b), preferably the adhesive resin film 15a is hardened by ultraviolet irradiation or heat processing, pressurizing with predetermined pressure, and the plate-shaped base material 11 and the resin molding 5 are integrated. Let The conditions at this time can be implemented in the same manner as in the first embodiment. In FIGS. 10A and 10B, the ultraviolet light source 20 and the heating lamp 30 are not shown.

  Next, the plastic lens 9 and 9a can be manufactured by performing the process e similarly to 1st Embodiment.

  In the present embodiment, the adhesive resin film 15a is used. However, as in the first embodiment, the adhesive resin layer 15 can be separately formed on the plate-like substrate 11 side. Similarly to the second embodiment, it is possible to separately form the adhesive resin layer 15 on the open surface 5 b of the resin molded body 5.

  In this Embodiment, the application | coating process of the adhesive resin 13 can be skipped by using the adhesive resin film 15a. Therefore, there is no fear of dripping in the coating process, and it is not necessary to adjust the thickness of the coating film. Further, by adjusting the thickness of the adhesive resin film 15a, there is an advantage that the thickness of the adhesive resin cured layer 17 can be freely adjusted. The thickness of the adhesive resin film 15a used in the present embodiment is not particularly limited as long as it is a thickness that can eliminate sink marks 7 present on the open surface 5b, as in the first embodiment. For example, it is preferable to be within a range of 0.02 mm to 1.0 mm.

  Other configurations and effects in the present embodiment are the same as those in the first and second embodiments.

  Although the embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications can be made. For example, in the above embodiment, the present invention has been described by taking a convex lens having a convex curved surface 5a as an example. However, the method of the present invention can also be applied to molding a concave lens or a meniscus lens.

  DESCRIPTION OF SYMBOLS 1 ... Open type, 1a ... Cavity part, 3 ... Liquid resin, 5 ... Resin molded object, 5a ... Convex curved surface, 5b ... Open surface, 11 ... Plate-shaped base material, 13 ... Adhesive resin, 15 ... Adhesive resin layer, 15a ... Adhesive resin film, 17 ... Adhesive resin cured layer, 20 ... Ultraviolet light source, 30 ... Heating lamp, 40 ... Applicator

Claims (5)

A method of manufacturing a plastic lens,
a) preparing an open mold having a cavity portion having a curved shape, and filling the cavity portion with a liquid photocurable or thermosetting resin;
b) curing the resin to form a resin molded body having a transfer surface to which the curved surface shape of the cavity portion is transferred and an open surface not restrained by the open mold;
c) preparing a plate-like substrate;
d) After interposing an adhesive resin layer containing a photocurable or thermosetting resin between the plate-like substrate and the open surface of the resin molded body, the adhesive resin layer is cured. Forming the plastic lens by integrating the plate-like substrate and the resin molded body by,
e) releasing the plastic lens from the open mold;
A method of manufacturing a plastic lens comprising:   After the steps a to e are performed to form the resin molded body on one side of the plate-like substrate, the resin is further applied to the surface on the opposite side of the plate-like substrate by further performing the steps a to e. The method for producing a plastic lens according to claim 1, wherein a molded body is formed.   The method for producing a plastic lens according to claim 1, wherein the step d is simultaneously performed on both surfaces of the plate-like substrate.   The viscosity of the resin at the time of filling in the step a is within a range of 3000 Pa · s or less at a temperature of 100 ° C. or less, and the viscosity of the adhesive resin layer before curing in the step d is 0.1 Pa at a temperature of 100 ° C. or less. The method for producing a plastic lens according to any one of claims 1 to 3, wherein the plastic lens has a range of s to 5000 Pa · s.   The plastic lens manufactured by the method of any one of Claims 1-4.

Images