JP7776264B2 - Eyeglass lens manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing eyeglass lenses.

It is known to manufacture eyeglass lenses according to prescriptions using semi-finished lenses, where one surface is an optical surface and the other is a non-optical surface. For example, the non-optical surface of the semi-finished lens is processed using the geometric center as the reference point for single-vision lenses, or a point specified by a hidden mark as the reference point for progressive-power lenses. The frame shape is then laid out for the processed lens, and the lens is then shaped according to the laid-out frame shape. This results in a cut lens that can be fitted into a frame.

In recent years, spectacle lenses (hereinafter referred to as "EC lenses") equipped with electrochromic films whose color development and fading can be reversibly controlled by applying a voltage have become known (see, for example, Patent Document 1). In semi-finished lenses for this type of EC lens, an electrochromic film that resembles the frame shape is attached to the optical surface.

JP 2017-111389 A

For semi-finished lenses that are not intended for EC lenses, the frame layout position is determined after the non-optical surfaces have been processed. Therefore, during the non-optical surface processing stage, there is no need to precisely determine the eyepoint position relative to the frame shape layout position.

In contrast, with semi-finished lenses for EC lenses, the frame layout position is already determined before the non-optical surfaces are processed. Therefore, during the non-optical surface processing stage, the eyepoint position must be determined with high precision relative to the layout position of the frame shape. If an error occurs in the eyepoint position relative to the layout position of the frame shape as a result of processing the non-optical surfaces, for example, when shaping is performed to match this eyepoint, the shaping position will be misaligned with the position of the electrochromic film attached to the optical surface, resulting in part of the electrochromic film being cut off and the product being defective. Also, when shaping is performed to match the electrochromic film, the eyepoint position will not be as prescribed.

For semi-finished lenses for EC lenses, it is conceivable to process the non-optical surfaces based on points specified by the geometric center or hidden marks, as has been done conventionally. However, if these points are used as the reference points for processing, it is difficult to process the non-optical surfaces while strictly considering the layout position of the frame shape, making it difficult to determine the eyepoint position with high precision relative to the layout position of the frame shape.

In consideration of the above circumstances, the present invention aims to provide a method for manufacturing eyeglass lenses that can accurately determine the eyepoint position relative to the layout position of the frame shape when manufacturing eyeglass lenses using lenses whose frame layout position is predetermined before processing of non-optical surfaces, such as semi-finished lenses for EC lenses.

A method for manufacturing an eyeglass lens according to one embodiment of the present invention includes the steps of attaching a film having an electrochromic layer between a pair of electrode layers and patterned to a frame shape to a semi-finished lens, measuring the position of the film attached to the semi-finished lens, determining the positions of the at least three marks on the semi-finished lens based on the measured values of the positions of the film so that the center position of the frame shape can be identified based on the at least three marks, attaching the at least three marks to the respective positions on the semi-finished lens determined in the mark position determination step, calculating the shape of the non-optical surface of the semi-finished lens based on the center position when processing the non-optical surface according to a prescription, and processing the non-optical surface into the shape calculated in the calculation step based on the center position. The at least three marks include a pair of marks located on a first line passing through the center position when viewing the semi-finished lens from the optical axis direction, and one mark located on a second line perpendicular to the first line and passing through the center position.

In the above calculation step, the eye point position may be calculated taking into account the center position, and the shape of the non-optical surface may be calculated based on the calculated eye point position.

In the above marking step, at least three marks may be applied to the optical surface of the semi-finished lens.

The method for manufacturing a spectacle lens according to one embodiment of the present invention may further include an edging step in which the lens, whose non-optical surface has been processed in the surface shape processing step, is edged based on the center position.

In the above marking step, at least three marks may be applied to the portion to be cut in the shaping step.

A method for manufacturing a spectacle lens according to one embodiment of the present invention may further include a step of attaching a film having an electrochromic layer between a pair of electrode layers and shaped to the frame to the semi-finished lens.

The method for manufacturing eyeglass lenses according to one embodiment of the present invention may further include a step of marking the optical surface of the semi-finished lens with a mark that resembles the frame shape.

According to a method for manufacturing eyeglass lenses according to one embodiment of the present invention, when eyeglass lenses are manufactured using lenses whose frame layout position is predetermined before the processing of the non-optical surfaces, the eyepoint position can be determined with high precision relative to the frame shape layout position.

1 is a front view of a semi-finished lens according to an embodiment of the present invention. 1 is a side view of a semi-finished lens according to one embodiment of the present invention. FIG. 1 is a diagram showing the layout of a semi-finished lens according to an embodiment of the present invention. FIG. 10 is a front view of a semi-finished lens according to another embodiment of the present invention. FIG. 10 is a front view of a semi-finished lens according to another embodiment of the present invention. FIG. 10 is a front view of a semi-finished lens according to another embodiment of the present invention. FIG. 10 is a front view of a semi-finished lens according to another embodiment of the present invention. FIG. 10 is a front view of a semi-finished lens according to another embodiment of the present invention. FIG. 10 is a front view of a semi-finished lens according to another embodiment of the present invention. 1 is a block diagram showing a configuration of a manufacturing system according to an embodiment of the present invention. 1 is a flowchart illustrating a method for manufacturing a semi-finished lens according to an embodiment of the present invention. 7 is a flowchart showing a method for manufacturing prescription eyeglass lenses using semi-finished lenses manufactured according to the flowchart of FIG. 6. 10A and 10B are diagrams illustrating a method for calculating the position of an eye point relative to a reference position of a frame in an embodiment of the present invention. 10A and 10B are diagrams illustrating a method for calculating the position of an eye point relative to a reference position of a frame in an embodiment of the present invention.

A method for manufacturing eyeglass lenses according to one embodiment of the present invention will be described below with reference to the drawings. In this embodiment, a semi-finished lens for EC lenses and a manufacturing method for manufacturing eyeglass lenses using this semi-finished lens will be described as examples.

The semi-finished lenses and manufacturing methods to which the present invention can be applied are not limited to semi-finished lenses for EC lenses and manufacturing methods using such lenses. Other types of semi-finished lenses not intended for EC lenses, in which the frame layout position is predetermined before the processing of the non-optical surfaces, and manufacturing methods using such lenses, also fall within the scope of the present invention.

In this embodiment, a method for manufacturing an inside progressive power lens having a concave progressive refractive element is described using a semi-finished lens in which the convex surface (object side surface) is spherically finished to an optical surface and the concave surface (eyeball side surface) is a non-optical surface. However, the semi-finished lenses and manufacturing methods to which the present invention can be applied are not limited to this. For example, the present invention also includes a semi-finished lens in which the concave surface is an optical surface and spherical and the convex surface is a non-optical surface, and a method for manufacturing an outside progressive power lens using this lens in which the convex progressive refractive element is a convex progressive refractive element.

The present invention also encompasses semi-finished lenses in which progressive refractive elements in one of the vertical and horizontal directions are added to the optical surface, and a method for manufacturing a double-sided compound progressive-power lens using such lenses. In this case, by processing the non-optical surface and adding a progressive refractive element in the other of the vertical and horizontal directions, a progressive-power lens is obtained in which the progressive refractive elements in both the vertical and horizontal directions are distributed between the convex and concave surfaces.

The present invention also encompasses semi-finished lenses in which some of the progressive refractive elements are added to the optical surface, and a method for manufacturing a double-sided progressive-power lens using such semi-finished lenses. In this case, by processing the non-optical surface and adding the remaining progressive refractive elements, a progressive-power lens in which the progressive refractive elements are distributed between the convex and concave surfaces can be obtained.

Furthermore, in the present invention, the spectacle lenses manufactured using semi-finished lenses are not limited to progressive power lenses, but may also be other types of spectacle lenses, such as single-vision spherical lenses, single-vision aspherical lenses, and multifocal (e.g., bifocal) lenses other than progressive power lenses.

In addition, instead of semi-finished lenses, eyeglass lenses may be manufactured using lens blanks with non-optical surfaces on both sides, one of which is finished to an optical surface.

Figure 1 is a front view of a semi-finished lens 1 for an EC lens according to one embodiment of the present invention (a front view of the semi-finished lens 1 as seen from the optical axis direction AX). Figure 2 is a side view of the semi-finished lens 1.

As shown in Figure 1, the semi-finished lens 1 has an electrochromic film 20 attached to the optical surface of the semi-finished lens and a mark 30 attached thereto.

Hereinafter, for convenience, in order to distinguish between a semi-finished lens before the electrochromic film 20 and mark 30 are applied and a semi-finished lens after the electrochromic film 20 and mark 30 are applied, the former will be referred to as the "lens substrate 10" and the latter will be referred to as the "semi-finished lens 1."

The lens substrate 10 is made of a resin such as acrylic resin, thiourethane resin, thioepoxy resin, methacrylic resin, allyl resin, episulfide resin, or polycarbonate resin, and has a spherical shape with a convex surface 12 finished as an optical surface, and a concave surface 14 that is a non-optical surface. The lens substrate 10 may also be made of glass.

The electrochromic film 20 is a film in which an electrochromic layer is provided between a pair of electrode layers. The electrochromic layer includes, for example, a reduction layer that develops color in response to a reduction reaction, an oxidation layer that develops color in response to an oxidation reaction, and an electrolyte layer that is electronically insulating and ionically conductive. By applying a voltage between the pair of electrode layers, a reversible oxidation-reduction reaction occurs, causing the color of the electrochromic layer to change reversibly. The surface of the electrode layer is protected by a plastic or glass layer.

The electrochromic film 20 is shaped like the frame (hereinafter referred to as the "frame shape 20a") that will encase the final eyeglass lens. The electrochromic film 20 is attached to the convex surface 12 of the lens substrate 10, for example, with an adhesive.

In this embodiment, the electrochromic film 20 is attached to the convex surface 12 of the lens substrate 10, but the configuration of the present invention is not limited to this. The electrochromic film 20 may also be embedded within the lens substrate 10 by sheet insert molding.

In addition, in other types of semi-finished lenses that are not intended for EC lenses, for example, instead of the electrochromic film 20, a mark that resembles the frame shape 20a (in other words, the shape of the cut lens after edging) is applied to the convex surface 12 using a laser marker or stamping machine.

Furthermore, even in the case of a semi-finished lens 1 intended for an EC lens, instead of the electrochromic film 20, a mark in the shape of the frame 20a may be applied to the convex surface 12 using a laser marker or stamping machine. In this case, the electrochromic film 20 is attached to the convex surface 12 in a later process (e.g., after edging).

The mark 30 is a mark for identifying the reference position FC of the frame shape 20a formed by the electrochromic film 20. In this embodiment, this reference position FC is the center position (frame center) of the frame shape 20a.

The center position (reference position FC) of the frame shape 20a is the geometric center of the frame shape 20a and is different from the geometric center of the lens substrate 10. However, the reference position FC may be positioned at a position that coincides with the geometric center of the lens substrate 10.

The reference position FC is not limited to the geometric center of the frame shape 20a. In another embodiment, the reference position FC may be a position other than the geometric center of the frame shape 20a, such as the center of gravity of the frame shape 20a.

The upper diagram in Figure 3 shows a front view of a semi-finished lens 1 in which the reference position FC does not coincide with the geometric center GC of the lens substrate 10, and the lower diagram in Figure 3 shows a front view of a semi-finished lens 1 in which the reference position FC coincides with the geometric center GC of the lens substrate 10. For convenience, each of these diagrams also shows a circle C with a smaller diameter than the semi-finished lens 1 and centered on the geometric center GC of the lens substrate 10, shown by a dotted line.

As shown in the upper diagram of Figure 3, when the reference position FC and the geometric center GC of the lens substrate 10 do not coincide, part of the electrochromic film 20 extends outside the circle C. In contrast, as shown in the lower diagram of Figure 3, when the reference position FC and the geometric center GC of the lens substrate 10 coincide, the entire electrochromic film 20 fits within the circle C. As can be seen by comparing the upper and lower diagrams of Figure 3, by positioning the reference position FC at a position that coincides with the geometric center GC of the lens substrate 10, the diameter of the semi-finished lens 1 can be reduced to the diameter of the circle C. Reducing the diameter of the semi-finished lens 1 can reduce manufacturing costs.

As shown in FIG. 1, a total of four marks 30 are placed on the convex surface 12 of the lens substrate 10 in the region 12a outside the frame shape 20a (in other words, the portion that will be cut during edging). The four marks 30 are short line marks and are placed on the top, bottom, right, and left portions of the convex surface 12, respectively. When the semi-finished lens 1 is viewed in the optical axis direction AX (in other words, when the semi-finished lens 1 is viewed from the front), the reference position FC is located at the intersection of a straight line La (one of the first and second lines) connecting the line segments at the top and bottom, and a straight line Lb (the other of the first and second lines) connecting the line segments at the right and left and perpendicular to line La.

The mark 30 is applied to the convex surface 12 using, for example, a laser marker or stamping machine.

After attaching the electrochromic film 20 to the convex surface 12, the attachment position of the electrochromic film 20 is measured. The position of the mark 30 on the convex surface 12 is determined based on this measurement, and the mark 30 is then attached to the convex surface 12.

In addition, after the mark 30 is attached to the convex surface 12, the electrochromic film 20 may be attached to the convex surface 12 so that the geometric center of the frame shape 20a is aligned with the reference position FC indicated by the mark 30.

The mark 30 may be any mark that can objectively identify the reference position FC, and is not limited to the example shown in Figure 1. Figures 4A to 4F show front views of semi-finished lenses according to other embodiments.

As shown in FIG. 4A, a total of three marks 30 may be attached to the region 12a outside the frame shape 20a. In the example of FIG. 4A, the marks 30 include, in a front view of the semi-finished lens 1, a pair of marks 30a located on a line Lc (first line) passing through the reference position FC, and one mark 30b located on a line Ld (second line) perpendicular to the line Lc and passing through the reference position FC. The reference position FC is located at the intersection of the lines Lc and Ld. In other words, there must be at least three marks 30 so that the reference position FC can be objectively identified, and the number is not limited to four.

By changing the shapes of marks 30a and 30b, it becomes easier to determine the up-down direction of the semi-finished lens 1. In the example of Figure 4A, one mark 30b, which has a different shape from mark 30a, is attached to the top of the convex surface 12. The operator can determine the up-down direction of the semi-finished lens 1 by visually checking mark 30b.

The semi-finished lens 1 shown in Figure 4B differs from the example in Figure 4A in that the appearance (here, the shape) of the pair of left and right marks 30a located on the line Lc is different from that of the pair of marks 30a. By making the appearances of the pair of marks 30a different from each other, the operator can tell whether the semi-finished lens 1 corresponds to a right lens or a left lens.

In addition to the shape, the pair of marks 30a may also be different in color, size, etc. Furthermore, it may be possible to determine from the mark 30b alone whether the semi-finished lens 1 corresponds to a right or left lens. As an example, by making the mark 30b an arrow mark pointing toward the nose, it becomes possible to determine from the mark 30b alone.

As shown in FIG. 4C, the marks 30 include a pair of marks 30c located on line Lc and a pair of marks 30d located on line Ld when the semi-finished lens 1 is viewed from the front. The pair of marks 30c are, for example, arrow marks pointing toward the nose. By visually checking the pair of marks 30b, the operator can determine whether the semi-finished lens 1 corresponds to a right lens or a left lens.

One of the pair of marks 30d is an arrow mark pointing upward toward the lens, and the other of the pair of marks 30d is a short line mark. By visually checking the pair of marks 30b (or the direction of the arrow mark), the operator can determine the up-down direction of the semi-finished lens 1.

In this way, by carefully considering the position and appearance of the mark 30, even if the electrochromic film 20 has a shape that makes it difficult to determine its orientation (for example, a perfect circle), it is possible to prevent the operator from making mistakes when working with the semi-finished lens 1 in the up/down/left/right directions.

As shown in Figure 4D, three marks 30 may be attached at 120-degree intervals in the outer region 12a of the frame shape 20a. In the example of Figure 4D, the position where the extensions of the three marks 30 intersect is the reference position FC.

As shown in FIG. 4E, the mark 30 may be placed in an area inside the frame shape 20a. In other words, the mark 30 may be placed in an area other than the area 12a outside the frame shape 20a, as long as it can objectively identify the reference position FC.

As shown in Figure 4F, the mark 30 may be placed directly at the reference position FC. In other words, the mark 30 is not limited to one that indirectly indicates the reference position FC, but may also be one that directly indicates the reference position FC. When manufacturing progressive power lenses or lenses with astigmatic power, it is necessary to specify the axial direction of the lens. However, the mark 30 shown in Figure 4F does not allow the operator to grasp the axial direction of the lens. Therefore, in the example of Figure 4F, a separate mark indicating the axial direction of the lens may be placed.

In the examples of Figures 4E and 4F, a mark 30 remains on the cut lens after edging. Therefore, the mark 30 is lightly engraved on the convex surface 12, for example, in the same way as a hidden mark.

In the examples of Figures 4E and 4F, the mark 30 is attached to the convex surface 12, but the configuration of the present invention is not limited to this. The mark 30 may also be attached to the electrochromic film 20. In this case, the mark 30 may be attached to the electrochromic film 20 in advance before the electrochromic film 20 is attached to the convex surface 12, or may be attached to the electrochromic film 20 after the electrochromic film 20 is attached to the convex surface 12.

Figure 5 is a block diagram showing the configuration of a manufacturing system 100 according to one embodiment of the present invention. As shown in Figure 1, the manufacturing system 100 includes an eyeglass store 200 and a manufacturing factory 300.

The eyeglass store 200 orders eyeglass lenses according to the prescription for the customer (wearer). The manufacturing factory 300 receives the order from the eyeglass store 200 and manufactures the eyeglass lenses. Orders to the manufacturing factory 300 are placed via a predetermined network such as the Internet or via data transmission by fax, etc. Orderers may include ophthalmologists and general consumers.

A storefront computer 210 is installed in the eyeglass store 200. The storefront computer 210 is, for example, a tablet terminal, smartphone, desktop PC (Personal Computer), or notebook PC, and has software installed on it for placing orders for eyeglass lenses with the manufacturing factory 300. Eyeglass lenses can also be ordered online. In this case, there is no need to install the above software on the storefront computer 210. Lens data and frame data are input into the storefront computer 210 by eyeglass store staff or the wearer themselves using a mouse, keyboard, etc.

Lens data includes, for example, the wearer's prescription information (distance power, near power, add power, progressive zone length, base curve, spherical power, astigmatic power, astigmatic axis direction, prism power, prism base direction, interpupillary distance (PD), etc.), spectacle lens wearing conditions (distance eyepoint position, corneal vertex distance, anterior tilt angle, frame tilt angle), spectacle lens type (single-focus spherical, single-focus aspherical, multifocal (bifocal, progressive), coating (dyeing, hard coat, anti-reflective coating, UV protection, etc.)), layout data tailored to the wearer's needs, and whether or not the lens has photochromic or tinting functions.

The frame data includes shape data of the frame selected by the wearer. The frame data is managed, for example, by a barcode tag, and can be obtained by reading the barcode tag attached to the frame with a barcode reader. The frame shape data may also be obtained by a frame tracer installed at the eyeglass store 200.

The in-store computer 210 transmits the order data (lens data and frame data) to the manufacturing factory 300, for example, via the Internet.

A LAN (Local Area Network) centered around a host computer 310 has been constructed in the manufacturing factory 300. The host computer 310 is connected to a number of terminal devices, including a design computer 320, which constitutes the eyeglass lens manufacturing equipment.

The design computer 320 is, for example, a general-purpose PC, on which a program for designing eyeglass lenses is installed. Order data transmitted from the in-store computer 210 via the Internet is input to the host computer 310. The host computer 310 transmits the input order data to the design computer 320.

In order to improve productivity, the manufacturing factory 300 divides the entire production range of powers into multiple groups, and various lens substrates 10 (i.e., semi-finished lenses) with convex curve shapes (e.g., spherical shapes, aspherical shapes, etc.) and lens diameters that match the power range of each group are prepared in advance in preparation for orders for eyeglass lenses.

Figure 6 is a flowchart showing the manufacturing method for the semi-finished lens 1.

In this manufacturing method, first, the design computer 320 identifies the lens substrate 10 that is suitable for the wearer's prescription from among multiple types of lens substrates 10 with different powers and lens diameters based on the order data (step S101).

Next, the design computer 320 identifies a flat electrochromic film 20 having a shape corresponding to the frame specified in the order data (step S102).

The operator places the flat electrochromic film 20 identified in step S102 in a mold and forms it into a curved shape (step S103). As a specific example, a mold is selected to match the shape of the convex surface 12 of the lens substrate 10 identified in step S101, and the electrochromic film 20 is sandwiched between the convex and concave molds of the selected mold and heated at a predetermined temperature. This thermoforming results in a curved electrochromic film 20.

The curved electrochromic film 20 is aligned with the convex surface 12 of the lens substrate 10 and attached to the convex surface 12 with an adhesive (step S104). In other words, step S104 is a step in which the electrochromic film 20 (a film having an electrochromic layer between a pair of electrode layers and shaped like a frame) is attached to the semi-finished lens (lens substrate 10). Step S104 results in a lens substrate 10 with the electrochromic film 20 attached to the convex surface 12.

For example, when manufacturing semi-finished lenses of other shapes that are not intended for EC lenses, step S104 can be replaced with a step of marking the optical surface of the semi-finished lens with a mark that resembles the frame shape.

The attachment position of the electrochromic film 20 attached to the convex surface 12 is measured. The position of the mark 30 is determined based on this measurement (step S105). In other words, step S105 is a mark position determination step that determines the positions of at least three marks 30 on the semi-finished lens (lens substrate 10) so that the reference position FC can be identified based on at least three marks 30.

Four marks 30 are made on the convex surface 12 of the lens substrate 10, in the area 12a outside the frame shape 20a, using a laser marker or engraving machine (step S106). In other words, step S106 is a marking step in which at least three marks 30 are made at the respective positions on the semi-finished lens (lens substrate 10) determined in step S105. Through this step, the semi-finished lens 1 shown in Figures 1 and 2 is obtained.

When applying the mark 30 to the convex surface 12, a hidden mark or other necessary information (such as a quality assurance mark or identification symbol) may also be applied to the convex surface 12. In this case, manufacturing efficiency can be improved compared to applying the mark 30 and the hidden mark in separate processes.

Figure 7 is a flowchart showing a method for manufacturing prescription eyeglass lenses using the semi-finished lens 1 manufactured according to the flowchart of Figure 6.

Conventionally, the concave shape is calculated based on a point specified by a hidden mark (the geometric center in the case of a single-vision lens), and the concave surface is machined based on this point. However, even when the concave shape is calculated and machined based on this point, it is difficult to calculate and machine the concave shape while strictly considering the layout position of the electrochromic film 20 already attached to the convex surface 12, making it difficult to accurately determine the eyepoint position relative to the layout position of the electrochromic film 20. As a result, errors in the eyepoint position relative to the layout position of the electrochromic film 20 can cause problems during shaping, such as parts of the electrochromic film 20 being cut off or the eyepoint position not being as prescribed.

In the manufacturing method shown in the flowchart of Figure 7, the concave shape is calculated based on the reference position FC of the frame shape 20a formed by the electrochromic film 20, and the concave surface is machined based on the reference position FC. Because the concave shape is calculated and machined taking into account the layout position of the frame shape 20a, errors in the eyepoint position relative to this layout position are reduced, thereby preventing the occurrence of the above-mentioned problems.

First, as shown in Figure 7, the design computer 320 calculates the concave surface shape and the lens shape based on the reference position FC based on the order data (step S201). That is, step S201 is a calculation step in which the shape of the concave surface 14 of the semi-finished lens 1 is calculated based on the reference position FC when the concave surface 14 is processed according to the prescription.

Prior to the processing of step S201, frame shape data is acquired. The frame shape data may be known data, or may be data measured by the measuring device 330. In the former case, the design computer 320 stores various frame shape data in advance.

The following describes how to obtain shape data for a frame measured by the measuring device 330. When measuring the shape of a frame, the probe of the measuring device 330 is brought into contact with the bevel groove of the frame. The measuring device 330 rotates the probe around a predetermined point to detect the shape coordinate values (Rn, θn, Zn) (n = 1, 2, ..., N) of the bevel groove. The detected shape coordinate values (Rn, θn, Zn) are transferred to the design computer 320.

For example, based on the shape coordinate values (Rn, θn, Zn), the design computer 320 calculates the center position (a, b, c) of the virtual sphere, the radius value RB of the virtual sphere when the frame is assumed to be on the virtual sphere, the frame PD (Pupillary Distance), the frame nose width DBL, the frame flap angle, the forward tilt angle, etc.

In step S201, the concave shape is calculated based on the reference position FC, and therefore the eye point position is also calculated based on the reference position FC. The method for calculating the eye point position relative to the reference position FC will be explained using Figures 8 and 9. Figure 8 is a perspective view showing the relationship between each constant of the virtual sphere and the Cartesian coordinate values. Figure 9 is a perspective view of the left and right eyeglass lenses arranged based on the layout position of the frame shape 20a.

The shape coordinate values (Rn, θn, Zn) detected by the measuring device 330 are converted into frame shape coordinate values (Xn, Yn, Zn) (n = 1, 2, ..., N). Specifically, as shown in Figure 8, the Cartesian coordinate values (Xn, Yn) of the frame shape coordinate values (Xn, Yn, Zn) are obtained by converting the polar coordinate values (Rn, θn). Zn is calculated as the Z-axis coordinate value at (Xn, Yn) on the spherical surface. The Z-axis direction is the front direction of the frame.

In this calculation method, "frame coordinates" are defined, with the datum line, which is the horizontal reference axis of the glasses, as the X-axis, the vertical direction of the glasses as the Y-axis, and the front direction of the glasses as the Z-axis. Then, on these frame coordinates, two frame shape coordinate values (Xn, Yn, Zn) are defined, with the center positions of the left and right frames as the reference position FC.

Specifically, first, two frame shape coordinate values (Xn, Yn, Zn) are set so that the X coordinate values of the nose-most points P1 and P2 of each of the left and right frame shapes 20a are -HDBL and +HDBL, respectively. HDBL is the frame nose width DBL divided by 2.

Also, one frame shape coordinate value (Xn, Yn, Zn) (whose nasal-most X coordinate value is -HDBL) is rotated by the frame tilt angle around a line passing through point P1 and parallel to the Y axis, and the other frame shape coordinate value (Xn, Yn, Zn) (whose nasal-most X coordinate value is +HDBL) is rotated by the frame tilt angle around a line passing through point P2 and parallel to the Y axis. Furthermore, one frame shape coordinate value (Xn, Yn, Zn) may be rotated by the forward tilt angle around a line passing through point P1 and parallel to the X axis, and the other frame shape coordinate value (Xn, Yn, Zn) may be rotated by the forward tilt angle around a line passing through point P2 and parallel to the X axis.

In this way, the position and orientation of the eyeglass lens relative to the three-dimensional frame shape defined on the frame coordinates are identified by determining the eyepoint positions EP1 and EP2 and the normal directions NL1 and NL2 on the convex surface of the eyeglass lens at these eyepoint positions.

The eyepoint positions EP1 and EP2 are points on the convex surface of the spectacle lens that should be located at the center of the wearer's pupil when the eyeglasses are worn. Layout information for the eyepoint positions EP1 and EP2 is included in the lens data acquired by the eyeglass store 200, and includes the horizontal distance HPD from the center line of the wearer's nose to the center of the pupil, and the vertical distance EPHT from the datum line to the center of the wearer's pupil. Hereinafter, the horizontal and vertical distances of the spectacle lens for the right eye will be denoted by the symbols HPD _R and EPHT _R , respectively. The horizontal and vertical distances of the spectacle lens for the left eye will be denoted by the symbols HPD _L and EPHT _L , respectively.

Therefore, the X and Y coordinates of eyepoint position EP1 are determined to be (-HPD _R , EPHT _R ), and the X and Y coordinates of eyepoint position EP2 are determined to be (-HPD _L , EPHT _L ). The Z coordinate of eyepoint position EP1 is determined according to the bevel position (the position where the bevel is provided on the lens edge, for example, whether it is a convex or concave surface). The bevel position is included in lens data obtained, for example, by the optician's shop 200.

In this way, the eyepoint positions EP1 and EP2 relative to the reference position FC (i.e., the eyepoint positions relative to the layout position of the electrochromic film 20) are determined. The concave shape and spherical shape of the semi-finished lens 1 according to the prescription are calculated so that the eyepoints are laid out at the determined positions EP1 and EP2. That is, in step 201, the eyepoint positions EP1 and EP2 are calculated taking into account the reference position FC, and the shape of the concave surface 14 is calculated based on the calculated eyepoint positions EP1 and EP2. Note that the process of calculating the concave shape and spherical shape according to the prescription is well known, so a detailed explanation will be omitted here.

A block jig 342 is attached to the convex surface 12 of the semi-finished lens 1 via a low-melting-point alloy such as alloy (step S202). In other words, blocking is performed.

Specifically, in step S202, the semi-finished lens 1 is photographed by a camera device mounted on the lens blocker 340, and the photographed semi-finished lens 1 is displayed on the display of the lens blocker 340. A mark image is displayed on the display superimposed on the photographed image at a position determined in advance by calculation. The mark image is, for example, an image of a short line segment like the mark 30, and a total of four mark images are displayed at the top, bottom, right, and left of the screen.

The reference point used by the block jig 342 to hold the semi-finished lens 1 for concave machining and edging is called the machining origin. The operator fine-tunes the position of the semi-finished lens 1 while checking the four marks 30 and four mark images affixed to the semi-finished lens 1 displayed on the display, and blocks the semi-finished lens 1 at a position where each of the four marks 30 coincides with the corresponding mark image. This results in the semi-finished lens 1 being held by the block jig 342 so that the reference position FC becomes the machining origin.

The concave surface shape data calculated in step 201 is sent from the design computer 320 to the curve generator 350. Based on the concave surface shape data, the curve generator 350 grinds the concave surface 14 of the semi-finished lens 1 held in the block jig 342 to the concave surface shape calculated in step 201 (i.e., to obtain the shape and power according to the prescription) (step S203). In other words, step S204 is a surface shape processing step in which the concave surface 14 of the semi-finished lens 1 is processed into the shape calculated in step 201 based on the reference position FC.

In step 201, the concave shape is calculated taking into account the eyepoint position relative to the reference position FC, so the eyepoint position relative to the layout position of the frame shape is determined with high precision. Therefore, by performing concave machining using the reference position FC as the machining origin, the eyepoint position relative to the layout position of the frame shape can be determined with high precision.

To improve the gloss of the concave surface 14 and the adhesion of the coating agent, the concave surface 14 is polished by a polishing machine 360 (step S204). This forms the concave surface 14 as an optical surface that meets the prescription.

The low-melting-point alloy is melted in hot water, and the semi-finished lens 1 is removed from the block jig 342 (step S205). Next, the semi-finished lens 1 is cleaned in the cleaning machine 370 to remove dirt and foreign matter (step S206).

The coating device 380 applies a coating (e.g., hard coating or anti-reflection coating) to the convex surface 12 (and electrochromic film 20) and concave surface 14 of the semi-finished lens 1 (step S207).

Here, an electrochromic film 20 shaped like a frame 20a is attached to the semi-finished lens 1. This allows the operator to easily distinguish between the parts of the semi-finished lens 1 that will ultimately be used as a spectacle lens and the parts that will not.

For example, consider a case where there is a defect (such as a scratch or foreign matter mixed in during the coating process) in the area 12a outside the frame shape 20a. Because area 12a is the part that is cut during edging, this defect will not remain in the final eyeglass lens product. Therefore, even a semi-finished lens 1 with such a defect can be used as a non-defective product. This can improve yield.

The semi-finished lens 1 after the coating process is blocked in the same manner as in step S202 (step S208). Here, too, the semi-finished lens 1 is held by the blocking jig 342 so that the reference position FC becomes the processing origin.

The lens shape data calculated in step S201 is sent from the design computer 320 to the lens shaping machine 390. The lens shaping machine 390 shapes the semi-finished lens 1 based on the lens shape data (step S209). In other words, step S209 is an edging step in which the semi-finished lens 1, on which the concave surface 14 has been machined, is shaped based on the reference position FC.

In step 201, the edging shape is calculated based on the reference position FC of the frame shape 20a formed by the electrochromic film 20. This minimizes deviation between the edging position and the position of the electrochromic film 20. As a result, edging is performed without cutting the electrochromic film 20.

The above is a description of exemplary embodiments of the present invention. The embodiments of the present invention are not limited to those described above, and various modifications are possible within the scope of the technical concept of the present invention. For example, appropriate combinations of examples and modifications explicitly shown in the specification or obvious examples and modifications are also included in the embodiments of the present application.

In the above embodiment, the concave shape and spherical shape are calculated and processed based on the reference position FC. From the perspective of achieving the goal of calculating and processing these shapes based on the reference position FC, a semi-finished lens that does not have marks that resemble the electrochromic film 20 or frame shape 20a (specifically, a configuration in which the electrochromic film 20 is omitted from the semi-finished lens 1 shown in Figure 1) can also be said to fall within the scope of the present invention.

1: Semi-finished lens 10: Lens substrate 20: Electrochromic film 30: Mark 100: Manufacturing system 200: Optician 210: Storefront computer 300: Manufacturing plant 310: Host computer 320: Design computer 330: Measuring instrument 340: Lens blocker 342: Block jig 350: Curve generator 360: Polishing machine 370: Cleaning machine 380: Coating device 390: Edge shaping machine

Claims (5)

attaching a film having an electrochromic layer between a pair of electrode layers, the film conforming to the shape of the frame, to the semi-finished lens;
measuring the position of the film attached to the semi-finished lens;
a mark position determination step of determining the positions of the at least three marks on the semi-finished lens based on actual measured values of the position of the film so that the center position of the frame shape can be identified based on the at least three marks;
a marking step of marking each of the at least three marks at the respective positions on the semi-finished lens determined in the mark position determining step;
a calculation step of calculating a shape of a non-optical surface of the semi-finished lens based on the center position when the non-optical surface is processed according to a prescription;
a surface shape processing step of processing the non-optical surface into the shape calculated in the calculation step, based on the center position;
Including,
the at least three marks include, when the semi-finished lens is viewed from the optical axis direction, a pair of marks located on a first line passing through the center position, and one mark located on a second line perpendicular to the first line and passing through the center position;
A method for manufacturing eyeglass lenses. In the calculation step, an eye point position is calculated taking into consideration the center position, and the shape of the non-optical surface is calculated based on the calculated eye point position.
The method for manufacturing the eyeglass lens according to claim 1 . In the marking step, the at least three marks are applied to the optical surface of the semi-finished lens.
The method for manufacturing a spectacle lens according to claim 1 or 2. The method further includes a shaping step of shaping the lens whose non-optical surface has been processed in the surface shape processing step, with the center position as a reference.
The method for manufacturing the eyeglass lens according to any one of claims 1 to 3. In the marking step, the at least three marks are applied to the portion to be cut in the edging step.
The method for manufacturing a spectacle lens according to claim 4 .