JPH031127B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention provides an assembled mold in which an optical film body and first and second molds are assembled into a gasket, and after the assembled mold is brought into a tilted or vertical state, the tilted The resin monomer is injected from the injection port provided at the upper end or the vertical upper end, and at this time, the air in the cavities formed on both sides of the optical film body is sequentially discharged, and the liquid levels in both cavities are approximately aligned. To manufacture a high-quality composite lens with high efficiency and high yield without causing distortion in the optical film body 5 and with no fear of bubble entrapment, based on the principle that the optical film body 5 rises in a state of make it possible to
The present invention relates to a method for manufacturing a synthetic resin compound lens and a gasket for manufacturing the same.

(Prior art and its problems) In recent years, with the increasing demand for polarized lenses, we have focused on resin materials that are lightweight, have excellent impact resistance, and are highly productive, and have developed high-quality polarized lenses using these resin materials. Efforts have been made to manufacture these efficiently and with high yields, and recent examples include the manufacturing method disclosed in Japanese Patent Publication No. 59-36244 and the manufacturing method disclosed in Japanese Patent Application Laid-open No. 187819-1982. There are manufacturing methods, etc.

The former method, that is, the manufacturing method disclosed in Japanese Patent Publication No. 59-36244, will be explained based on FIG. A predetermined amount of resin monomer c is injected and filled, a polarizing film d is laminated on the top surface of the resin monomer c, a predetermined amount of resin monomer e is injected and filled onto the top of the polarizing film d, and then the upper mold f is gasketed. It is attached to the upper part of the lens a, and the desired polarized lens is manufactured by polymerizing and curing the resin monomer.

However, in the case of this manufacturing method,
As the applicant himself clearly states in the specification, when placing the polarizing film d on top of the resin monomer c, care must be taken not to trap air bubbles at the contact interface between the polarizing film d and the resin monomer c. There is a need,
Also, when injecting and filling the resin monomer e onto the polarizing film d, care must be taken not to trap air bubbles at the interface between the polarizing film d and the resin monomer e. Even when attaching to the gasket a, it was necessary to be careful not to trap air bubbles at the interface between the resin monomer e and the upper mold f. For this reason, in order to complete set g, each step must be performed extremely carefully, and almost all the work up to the set must be done by one worker. This made mass production of polarized lenses almost impossible due to poor work efficiency.

On the other hand, in the latter manufacturing method disclosed in JP-A-59-187819, as shown in FIG. 9, an upper mold i and a lower mold j are fixed above and below a cylindrical gasket h, and both molds i ,j
In between, a polarizing film m is placed on the projection l provided on the inner surface k of the gasket h so as to have a gap between it and the inner surface k of the gasket h, and the resin monomer is injected from the injection port n provided on the upper part of the gasket h. The desired polarized lens is manufactured by injecting and filling the resin monomer and polymerizing and curing the resin monomer.

However, in the case of this manufacturing method,
When injecting the resin monomer, it is necessary to supply the resin monomer onto the polarizing film m after the resin monomer is filled between the polarizing film m and the lower mold j. It is necessary to perform the injection extremely carefully so that the injection liquid flows down along the inner surface of the gasket h until the resin monomer is filled under the polarizing film m, and as a result, productivity is reduced. Moreover, air bubbles are easily trapped between the polarizing film m and the lower mold j, and the polarizing film m is easily deformed, so the optical quality of the obtained polarized lens tends to be uneven, and the product yield is reduced. It also had the disadvantage of being bad.

The inventor of the present invention focused on the fact that the problems in each of the above-mentioned embodiments are caused by performing each step with the mold in a horizontal state, and as a result of extensive research, the inventor found that After the assembled mold is placed in an inclined or vertical position, resin monomer is injected from the injection port provided at the inclined upper end portion or vertical upper end portion, and at this time, the air in the cavity formed on both sides of the optical film body is If the liquid levels in both chambers rise while being sequentially discharged, even if the chamber formed between both molds is divided into two by an optical film, They thought that it would be possible to completely fill the resin monomer without entrapping air bubbles, and as a result of further research, they arrived at the present invention.

(Means for Solving the Problems) A method for manufacturing a synthetic resin compound lens according to the present invention (hereinafter referred to as a manufacturing method) is a method for manufacturing a composite lens made of synthetic resin according to the present invention. Between the pieces 16 and 17, an optical film body 5 such as a polarizing film body
The first mold 2 and the second mold 3 are tightly fixed to the gasket 1 on both sides of the optical film body 5 by sandwiching the peripheral edge of the first mold 2.
A first cavity 21 is formed between the mold 3 and the optical film body 5, and a second cavity 22 is formed between the second mold 3 and the optical film body 5.
The mold 26 assembled in this way is placed in an inclined or vertical state, and the inclined upper end portion of the peripheral wall 23 of the gasket 1 is connected to at least one of the first cavity 21 and the second cavity 22. Alternatively, the resin monomer is injected from the injection port 25 provided at the vertical upper end portion, and during the injection,
The resin is passed through the communication groove 20 formed by recessing the inner circumferential protruding surface portion 13 of the gasket 1 so that the first and second chambers 21 and 22 are in communication at the inclined lower end portion or the vertical lower end portion. The monomer flows from one cavity into the other cavity, and as the resin monomer is injected, the air in the cavity communicating with the injection port 25 flows into the injection port 2.
The air in the cavity which is directly discharged from the gasket 1 and which does not communicate with the inlet part 25 flows through the inner periphery of the gasket 1 so that the first and second cavities 21 and 22 are in communication with each other at the inclined upper end portion or the vertical upper end portion. Projection part 13
The resin monomer is discharged from the injection port 25 through the communication groove 19 formed by recessing the chamber, or is discharged from the exhaust port provided so as to communicate with the empty chamber. 1. After filling the second cavities 21 and 22, the resin monomer is polymerized and cured, and then the first and second molds 2 and 3 and the gasket 1 are removed to produce a polarized lens. It is characterized by

Further, one of the gaskets 1 according to the present invention has a flexible cylindrical shape formed using a synthetic resin material, etc., and has a first mold 2 on the inner periphery on both sides of the opening.
and step portions 11 and 12 that can come into contact with the peripheral portions 9 and 10 of the second mold 3, and both step portions 11,
On the inner circumferential protruding surface portion 13 between 12 and 12, there are clamping pieces 16 and 1 that clamp the peripheral portion 15 of the optical film body 5 such as a polarizing film body.
7 is provided protrudingly, and the peripheral wall 23 has a first cavity formed between the first mold 2 and the optical film body 5 when the optical film body 5 and both molds 2 and 3 are attached. A resin monomer injection port 25 is provided so as to communicate with the second cavity 22 formed between the second mold 3 and the optical film body 5, and a portion on the side of the injection port 25 and substantially opposite thereto. A communication groove 1 that communicates the first and second empty chambers 21 and 22
9 and 20 are formed by recessing the inner circumferential protruding surface portion 13.

In addition to the gasket 1 according to the present invention, it has a flexible cylindrical shape made of a synthetic resin material, etc., and has a first mold 2 on the inner periphery on both sides of the opening.
and step portions 11 and 12 that can come into contact with the peripheral portions 9 and 10 of the second mold 3, and both step portions 11,
The inner circumferential protruding surface portion 13 that protrudes inward between the peripheral wall 23 is provided with holding pieces 16 and 17 that hold the peripheral edge portion 15 of the optical film body 5 such as a polarizing film body.
includes an optical film body 5 and first and second molds 2 and 3.
When the first mold 2 and optical film body 5 are attached,
A resin monomer injection port 25 communicates with both the first cavity 21 formed between the second mold 3 and the optical film body 5 and the second cavity 22 formed between the second mold 3 and the optical film body 5. A communication groove 20 that communicates the first and second chambers 21 and 22 is formed in a portion substantially facing the injection port 25 by recessing the inner peripheral protrusion 13. It is characterized by

(Example) Examples of the manufacturing method and gasket according to the present invention will be described below based on the drawings.

1 to 3 illustrate a gasket 1 used when carrying out the manufacturing method of the present invention, and on both sides of the opening, as shown in FIG. 3, a first mold 2 and a second mold 3 are installed. An optical film body (polarizing film body 5a in this embodiment) 5 is attached between both molds 2 and 3 prior to attachment of the first and second molds. Here, the first mold 2 and the second mold 3 are formed as, for example, glass molds that respectively form a concave spherical surface and a convex spherical surface of the intended polarizing lens 6 (shown in FIG. 4). The optical film body (polarizing film body 5a) 5 is made of a film-like or relatively thick sheet-like material, and is formed into a spherical shape corresponding to the concave spherical surface or convex spherical surface of the polarizing lens to be manufactured, In this example,
It has an outer diameter approximately equal to the inner diameter of the inner circumferential protruding surface portion 13 of the gasket 1. Further, an adhesive coating treatment is applied to enhance adhesion with a resin monomer 29 to be described later.

The gasket 1 has a flexible cylindrical shape made of a synthetic resin material or the like, and has peripheral portions 9 of the first mold 2 and the second mold 3 on the inner periphery on both sides of the opening. , 10 are provided around the periphery. Both steps 1
Between 1 and 12 is an inner circumferential protrusion 13 that protrudes inward.
is formed on the inner peripheral protrusion 13, and a second
Along the peripheral edge of the mold attachment step 12, clamping pieces 16 and 17 that clamp the peripheral edge 15 of the polarizing film 5a so that the polarizing film 5a does not rotate during injection and filling of the resin monomer are inwardly inserted. It is preferable that the holding piece 17 on the step portion 11 side protrudes slightly from the inner circumferential protruding surface portion 13 in order to facilitate attachment of the polarizing film 5a. Further, communication grooves 19 and 20 are recessed in opposing parts of the inner circumferential protruding surface part 13 so as to cross the inner circumferential protruding surface part 13, and as a result, as shown in FIG. , 3 formed between the first mold 2 and the polarizing film body 5a and the second mold 3.
and the polarizing film body 5a.
2 are in communication with each other through the communication grooves 19 and 20. Further, the peripheral wall 23 is provided with a resin monomer injection port 25 that opens near the step 11 at the bottom of one of the communication grooves (for example, the communication groove 19).

Next, a compound lens (polarized lens in this example) is manufactured using the gasket 1, the first and second molds 2 and 3, and the optical film body (polarized film body 5a in this example) 5. The method for doing this will be explained with reference to FIG. 3 as follows.

That is, first, the polarizing film 5 is held between the clamping pieces 16 and 17 provided on the inner peripheral protrusion 13 of the gasket 1.
After teaching the first mold 2 and the second mold 3 not to rotate during injection and filling of the resin monomer, the first mold 2 and the second mold 3 are fitted with the gasket 1 so that the peripheral portions 9 and 10 thereof are in contact with the stepped portions 11 and 12. The first mold 2 is tightly fixed to the inner circumference on both sides of the opening.
A first cavity 21 is formed between the mold 3 and the polarizing film 5a, and a second cavity 22 is formed between the second mold 3 and the polarizing film 5a. An assembly mold 26 is constructed in which the gap corresponds to the thickness of the intended lens. In this embodiment, the polarizing film body 5a is held between the holding pieces 16 and 17 so that the direction of its polarization axis coincides with a straight line connecting the opposing communication grooves 19 and 20. In addition, in FIG. 3, 27 is a clamping means.

Next, the assembly mold 26 assembled in this way is inserted into the injection port 2 provided in the gasket 1.
5 is located at the upper end and the first cavity 21 is on the top, and from the injection port 25, for example, along the spherical surface of the first mold 2 located on the upper side, Inject resin monomer 29.
As the resin monomer, it is possible to use well-known ones conventionally employed for manufacturing synthetic resin lenses, such as methyl methacrylate, trimethylolpropane triacrylate, dianoethyl methacrylate, and diethylene glycol bisallyl carbonate. It may be a homopolymer or a copolymer using each of these alone, or a prepolymer that has been partially polymerized to the extent that it does not cause trouble in injection and filling operations.

When injecting and filling the resin monomer 29, as described above, the first cavity 21 and the second cavity 22 are provided facing the communication groove 19 on the injection port 25 side. Since the communication groove 20 at the lower end of the slope provides communication, the resin monomer 29 injected into the first cavity 21 flows into the second cavity 22 through the lower communication groove 20. It was decided that
Therefore, the liquid level 30 in the first cavity 21 and the liquid level 31 in the second cavity 22 rise while being substantially coincident with each other. Since the assembly mold 26 is in an inclined state, as the resin monomer 29 is injected, the air in the first cavity 21 communicating with the injection port 25 naturally flows into the injection port 25 as shown by the arrow F1. The air in the second cavity 22 which is directly discharged from the inlet and which does not communicate directly with the inlet section 25 is directed by the arrow F2.
As shown, the injection port 2 passes through the upper communication groove 19.
5, the first and second empty chambers 21,
The resin monomer 29 is completely filled in the resin monomer 22 without any air bubbles being trapped therein.

In this way, after the resin monomer 29 is filled into the first and second empty chambers 21 and 22, the injection port 25
is sealed with a stopper (not shown), the resin monomer 29 is heated and polymerized in this state, and then released from each mold 2, 3 and gasket 1 to form the desired compound lens (in this example, polarized light lens) will be obtained.

FIG. 4 shows a polarized lens 6 obtained by such a manufacturing method, and a portion of the gasket 1 corresponding to both communicating grooves 19 and 20 has the communicating groove 1.
Projections 32 and 33 are formed that match the shapes of 9 and 20, and these projections 32 and 33 can serve as indicators for determining the polarization axis. That is, in the case of the polarized lens 6, the straight line connecting both the protrusions 32 and 33 clearly indicates the polarization axis. This is because, as mentioned above, the polarizing film body 5
a indicates the communication grooves 19 and 2 whose polarization axes are opposite to each other;
Holding pieces 16, 17 so that they match the straight line connecting 0.
In addition, the resin monomer is injected into the
This is because it is clamped so that it does not rotate during filling.

FIG. 5 shows another configuration of the gasket 1 along with its use condition, and the difference from the configuration of the gasket described above is that the injection port 25 is connected to the first cavity 21 and the second cavity 22. The point is that it was set up so that it communicates with both. Note that the air in the first empty chamber 21 and the air in the second empty chamber 22 are discharged as indicated by arrows F3 and F4 in the figure.

In the present invention, the optical film body 5 refers to a light-transmitting film body such as a polarizing film body, a light control film body, a light control/polarization film body, etc., and a compound lens including the optical film body is a completed lens. It may be a semi-finished lens. Although the gasket 1 is preferably cylindrical, it can have any cross-sectional shape such as rectangular, square, or oval, and the clamping pieces 16 and 17 provided on the gasket 1 are The holding pieces are not limited to the annular shape shown, but may be formed as opposing projecting pieces, or may be held in a staggered manner. The state in which the peripheral edge of the optical film body 5 is clamped by the clamping pieces is not limited to the clamping state in which the optical film body 5 cannot rotate when the resin monomer is injected, but the peripheral edge of the optical film body 5 is clamped by the clamping pieces. In consideration of workability, etc., the clamping may be somewhat loose. Furthermore, the clamping pieces 16,1
The protruding portion 7 corresponds to the inner peripheral protruding surface portion 13 of the gasket 1.
It may be set at any part of both step portions 11 and 12,
As shown in the embodiment, it is not limited to the area near the concave surface of the lens. Furthermore, in the gasket according to the present invention, when the inlet portion 25 is communicated with one of the first cavity 21 or the second cavity 22, the air in the cavity that does not communicate with the inlet portion 25 is
As shown in the embodiment, the communication groove 19
In addition to being discharged from the injection port 25 through the inlet 25, the gas may be discharged from an exhaust port (not shown) provided in the peripheral wall 23 so as to communicate with the second cavity 22. On the other hand, when the inlet portion 25 is provided so as to communicate with both the first cavity 21 and the second cavity 22, the communication groove is formed at the inclined lower end portion (when the assembly mold 26 is in an inclined state). ),
Alternatively, it may be provided only at the vertical lower end portion (when the assembly mold 26 is in the vertical state).
In this case, as shown in FIG. 6, it is preferable to provide small holes (notches or the like) 34 and 35, which serve as indicators for determining the polarization axis, in opposing parts. Furthermore, in the present invention, "the communication groove 20 is provided in a portion of the gasket 1 on the side of the injection port 25 that is substantially opposite to the communication groove 19" means that the communication groove 20 is provided in a portion of the gasket 1 on the side of the injection port 25 that is opposite to the communication groove 19. In addition to providing the groove 20, if the injected resin monomer flows from the injection side cavity to the other cavity without any hindrance (that is, without causing distortion or the like to the optical film body 5), This means that the communication groove 20 may be provided at a portion slightly distant from the opposing portion as shown in FIG.
Furthermore, the term "the communicating groove 20 is provided in a portion of the gasket 1 substantially facing the injection port 25" as used in the present invention should be understood in the same manner. Further down the communication groove 20
The number of communication grooves 19, 2 may be plural.
The width of 0 is determined by the air discharge condition in the empty chamber and the communication groove 20.
It is set to an appropriate value in consideration of the inflow state of the resin monomer through the pipe, etc.

(Effects of the Invention) As described above, according to the method of manufacturing a synthetic resin composite lens of the present invention and the gasket for manufacturing the same, after the assembled mold including the optical film body is brought into the inclined or vertical position, the inclined upper end portion or The resin monomer is injected from the injection port provided at the vertical upper end, and at this time, the air inside the cavities formed on both sides of the optical film body is sequentially discharged, and the liquid level rises with almost the same level. Unlike the conventional case where the resin monomer is injected and filled with the mold held horizontally, the air in the cavity is naturally created at the inclined upper end portion or the vertical upper end portion as the resin monomer is injected. The first,
Since the liquid level in the second cavity rises substantially in unison, there is no possibility that excessive force will be applied to the optical film body, causing distortion, etc., and a compound lens of excellent quality can be manufactured at a high yield. Can be done. Moreover, since the air in the chamber can be automatically exhausted in this way, there is no need to be as careful when injecting the resin monomer as in the case of conventional manufacturing methods. This makes it possible to mass-produce compound lenses with significant improvements.

[Brief explanation of the drawing]

Fig. 1 is a perspective view illustrating the gasket of the present invention, Fig. 2 is a partial perspective view thereof, Fig. 3 is a sectional view showing the injection state of resin monomer into the assembly mold, and Fig. 4 is a manufactured composite. FIG. 5 is a perspective view illustrating a lens; FIG. 5 is a cross-sectional view showing another example of the gasket together with its usage state and the state in which resin monomer is injected into the assembly mold; FIG. 6 is a perspective view illustrating an optical film body; FIG. 7 is a front view showing another example of the gasket, and FIGS. 8 and 9 are explanatory diagrams for explaining a conventional method of manufacturing a compound lens. 1... Gasket, 2... First mold, 3
...Second mold, 5...Optical film body, 11,1
2... Step portion, 13... Inner peripheral protrusion, 16, 17...
...Holding piece, 19, 20...Communication groove, 21...First
vacant room, 22... second vacant room, 23... surrounding wall, 2
5... Inlet part, 26... Assembly mold.

Claims (1)

[Claims] 1. Between opposing clamping pieces 16 and 17 provided on the inner circumferential protruding surface portion 13 of the cylindrical gasket 1,
sandwiching the peripheral edge of the optical film body 5 such as a polarizing film body,
A first mold 2 and a second mold 3 are tightly fixed to the gasket 1 on both sides of the optical film body 5, and a first cavity 21 is formed between the first mold 2 and the optical film body 5. Also, the second mold 3 and the optical film body 5
A second cavity 22 is formed between the mold 26 and the mold 26 assembled in this way is placed in an inclined or vertical position and communicates with at least one of the first cavity 21 and the second cavity 22. As shown in FIG. , 22 are in communication with each other.
0 so that the resin monomer flows from one cavity into the other cavity, and as the resin monomer is injected, the air in the cavity communicating with the injection port 25 is directly discharged from the injection port 25. The air in the cavity that does not communicate with the inlet portion 25 flows through the inner circumferential protruding surface 13 of the gasket 1 so that the first and second cavities 21 and 22 are in communication at the inclined upper end portion or the vertical upper end portion. The resin monomer is discharged from the injection port 25 through the communication groove 19 formed by recessing, or is discharged from the exhaust port provided so as to communicate with the empty chamber. After filling the second empty chambers 21 and 22, the resin monomer is polymerized and cured, and then the first and second molds 2 and 3 and the gasket 1 are removed to produce a polarized lens. A method for manufacturing a synthetic resin compound lens featuring features. 2 It has a flexible cylindrical shape formed using a synthetic resin material, etc., and has a first tube on the inner periphery on both sides of the opening.
forming step portions 11 and 12 that can come into contact with the peripheral portions 9 and 10 of the mold 2 and the second mold 3;
The inner circumferential protruding surface portion 13 that protrudes inward between the two step portions 11 and 12 is provided with protruding holding pieces 16 and 17 that sandwich the peripheral portion 15 of the optical film body 5 such as a polarizing film body, and the peripheral wall 23 includes a first cavity 21 formed between the first mold 2 and the optical film body 5 when the optical film body 5 and the first and second molds 2 and 3 are attached, or Second mold 3 and optical film body 5
An injection port 25 for the resin monomer is provided so as to communicate with the second cavity 22 formed between the injection port 25 and a portion substantially opposite to the injection port 25.
A gasket for manufacturing a composite lens made of synthetic resin, characterized in that communication grooves 19 and 20 that communicate the first and second chambers 21 and 22 are formed by recessing the inner peripheral protrusion 13. . 3 It has a flexible cylindrical shape formed using a synthetic resin material, etc., and has a first tube on the inner periphery on both sides of the opening.
forming step portions 11 and 12 that can come into contact with the peripheral portions 9 and 10 of the mold 2 and the second mold 3;
The inner circumferential protruding surface portion 13 that protrudes inward between the two step portions 11 and 12 has holding pieces 16 and 17 protruding from the peripheral portion 15 for holding the peripheral portion 15 of the optical film body 5 such as a polarizing film body. 23 includes a first cavity 21 and a first cavity formed between the first mold 2 and the optical film body 5 when the optical film body 5 and the first and second molds 2 and 3 are attached. A resin monomer injection port 25 is provided so as to communicate with both of the second cavity 22 formed between the second mold 3 and the optical film body 5. A gasket for manufacturing a composite lens made of synthetic resin, characterized in that a communication groove 20 that communicates the first and second chambers 21 and 22 is formed by recessing an inner peripheral protrusion 13.