Non-corrective plastic spectacle lens

Abstract

The present invention provides a non-corrective spectacle lens which is a molded plastic lens used by a person having normal eyesight, or a polarizing lens constituted by the molded plastic lens and a polarizing film integrally superposed on the molded plastic lens. In order to moderately reduce the movement of the muscle necessary for focus adjustment, the non-corrective spectacle lens has a spherical power S within the range of −1.0 D≤S<−0.1 D, where D is diopter as a unit of the spherical power S.

Claims

1. A method for manufacturing a molded plastic spectacle lens, the method comprising: liquid-tightly combining a mold having a concave spherical surface, and a mold having a convex spherical surface through a ring-shaped gasket such that the concave spherical surface and the convex spherical surface are opposed to each other, so as to define a cavity between the opposed concave and convex spherical surfaces; preforming and inserting a polarizing element into the cavity; and introducing a resin material for lens molding into the cavity to form the plastic lens by molding, such that the plastic lens has a laminated structure comprising a front plastic layer and a back plastic layer that sandwich the polarizing film from a front side and a back side of the polarizing film, respectively, wherein a front surface of the front plastic layer has a radius of curvature equal to a radius of curvature of the preformed polarizing film, and the concave spherical surface has a radius of curvature of 79.84R and the convex spherical surface has a radius of curvature larger than 66.533R and not larger than 76.769R such that the molded plastic spectacle lens has a spherical power S in a range of −1.0 D≤S<−0.1 D.

2. The method according to claim 1, wherein the resin material for lens molding comprises one or more resins for cast molding selected from the group consisting of diethylene glycol bis(allyl carbonate) resin, a polyurethane resin, a thiourethane resin, and an acrylic resin.

3. The method according to claim 1, wherein the resin material for lens molding comprises one or more resins for injection molding selected from the group consisting of a polyamide resin, a polycarbonate resin and an acrylic resin.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A is a sectional view of a polarizing lens for spectacles embodying the present invention.

(2) FIG. 1B is an enlarged view of the polarizing lens for spectacles embodying the present invention.

(3) FIG. 2 is a plan view of molds and a gasket combined together so as to be used for manufacturing the polarizing lens for spectacles embodying the present invention.

(4) FIG. 3 is a sectional view of the molds and the gasket combined together so as to be used for manufacturing the polarizing lens for spectacles embodying the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(5) FIG. 1A illustrates a molded plastic lens embodying the present invention which includes a polarizing film 1, and front and back plastic layers 2 and 3 integrally superposed, respectively, on the front and back surfaces of the polarizing film 1. This molded plastic lens is a non-corrective, polarizing spectacle lens having a spherical power S of −1.0 D≤S<−0.1 D and used for purposes other than hyperopia or presbyopia correction.

(6) In the embodiment, as illustrated in the enlarged view of FIG. 1B, the radius of curvature of the front surface of the lens, i.e., of the front surface of the front plastic layer 2 (this radius of curvature is known as the “base curve”) is equal to the curve (radius of curvature) of the polarizing film 1 after being preformed, so that the lens has a uniform polarizing performance in its entirety. Further, taking also into consideration the refractive index of the material forming the lens, the back surface of the back plastic layer 3 has a radius of curvature smaller than the radius of curvature of the imaginary surface indicated by the dashed line in FIG. 1B, which has the same radius of curvature as the front surface of the front plastic layer 2.

(7) If, for example, diethylene glycol bis(allyl carbonate) resin (trade name: CR39) is used as the resin material for the molded plastic lens having the spherical power of −1.0 D S S<−0.1 D, it is preferable that the radius of curvature of the front surface of the front plastic layer 2 (i.e., the base curve of the lens) is set at 79.84R, and the back surface of the back plastic layer 3 has a radius of curvature of more than 66.533R and 76.769R or less.

(8) The reason why the spherical power S is set within the range of −1.0 D≤S<0.0.1 D as mentioned above is because (i) lenses with a spherical power of less than −1.0 D are substantially no different from lenses for myopia correction, so that if a person with normal eyesight uses such lenses, they will impose a burden on the focus adjustment function, thus making it difficult to improve the person's eyesight, e.g., in an environment where illuminance is reduced; and (ii) lenses with a spherical power of −0.1 D or more are incapable of sufficiently assisting in the focus adjustment function while a person is feeling eye strain, e.g., in an environment where illuminance is reduced, thus making it impossible to reliably ensuring the effects of the present invention. In order to reliably ensure the effects of the present invention, the spherical power S is preferably within the range of −0.80 D<S<−0.25 D, more preferably within the range of −0.75 D<S<−0.20 D.

(9) The non-corrective plastic spectacle lens according to the present invention is incapable of correcting myopia or hyperopia, but is capable of correcting astigmatism as necessary. In this case, the numerical value range of the above spherical power is replaced by the spherical equivalent.

(10) The polarizing film 1 used in the embodiment is a transparent film having optical anisotropy, for example, a film of polyvinyl alcohol containing iodine or a dichroic dye, and uniaxially stretched to three to five times its original axial length so as to be molecularly oriented, or a film having properties similar to such a film.

(11) When manufacturing the polarizing lens, the polarizing film 1 is preformed into a curved shape, so that it is possible to easily form the plastic layers 2 and 3 into spherical shapes by integrally laminating the plastic layers 2 and 3 onto and along the curved polarizing film 1.

(12) The polarizing spectacle lens has a laminated structure in which, for example, the plastic layers 2 and 3 are superposed, respectively, on the front and back surfaces of the polarizing film 1 so that the polarizing film 1 is sandwiched between the plastic layers 2 and 3. In order to ensure necessary strength even when used as a non-prescription lens, the polarizing lens has, for example, a thickness of approximately 1 to 3 mm.

(13) The polarizing spectacle lens according to the present invention, which is characterized by its weak power, can be formed by molding in molds 4 and 5 with the polarizing film 1 inserted in the molds 4 and 5, or by integrally bonding the plastic layers 2 and 3 formed by cast molding beforehand to the polarizing film 1 through adhesive layers.

(14) As illustrated in FIGS. 2 and 3, in order to form the polarizing lens by cast molding after inserting the polarizing film 1, first, the edge of the polarizing film 1 preformed into a spherical shape is retained, by known means, on the inner peripheral surface of a ring-shaped gasket 6 having an inner diameter dimension corresponding to the diameter of the edge of the lens to be formed. Then, the molds 4 and 5, which comprise a pair of disc-shaped molds, are fitted to the inner peripheral surface portions of the ring-shaped gasket 6 at its respective ends. Then, the monomer of a resin material for forming the lens is introduced through pipe-shaped gates 7, after being mixed with a polymerization initiator or a hardening agent, into the cavity defined between the two molds. Then, the monomer is polymerized or hardened by, e.g., heating to form the plastic layers 2 and 3 and the polarizing film 1 into an integral body.

(15) The monomer as the resin material of the lens comprises, for example, a liquid resin material for cast molding, such as diethylene glycol bis(allyl carbonate) resin, a polyurethane resin, a thiourethane resin, or an acrylic resin. Such a liquid resin material is introduced into the cavity through the pipe-shaped gates 7, which communicate with the cavity, and comes into contact with the polarizing film 1, while being simultaneously polymerized or hardened, into transparent plastic layers forming an integral body with the polarizing film 1 sandwiched therebetween. Thereafter, by removing the gasket 6 and the molds 4 and 5, which have a concave inner surface 4a and a convex inner surface 5a, respectively, a polarizing spectacle lens is obtained which has radii of curvature defined by the concave and convex inner surfaces 4a and 5a.

(16) The resin material(s) for lens molding may comprise, instead of a resin (or resins) for cast molding as described above, one or more resin materials for injection molding selected from the group consisting of polyamide resins, polycarbonate resins and acrylic resins.

(17) Alternatively, the non-corrective plastic spectacle lens may be obtained by introducing a resin material for lens molding into the cavity, without inserting the polarizing film 1 as described above, so as to form a plastic lens without the polarizing film, and then integrally superposing, on the surface of the thus-formed plastic lens, a polarizing element comprising a printed layer formed by printing polarizing ink. Needless to say, it is also possible to prepare a normal non-corrective plastic spectacle lens, i.e., a lens having no polarizing properties, by omitting the polarizing film 1.

(18) The spectacle lens embodying the present invention may be subjected to post-treatment such as hard coat treatment. For example, the lens may be immersed in a solution containing a silicon compound to form a strengthening film thereon, thereby increasing the surface hardness. Also, the spectacle lens embodying the present invention may be subjected to post-treatment other than hard coat treatment, such as anti-fog treatment, anti-reflection treatment, chemical resistance treatment, antistatic treatment, or mirror treatment, thereby further improving the performance of the lens

EXAMPLES

Example 1

(19) A spectacle lens having a weak power was formed by cast molding using diethylene glycol bis(allyl carbonate) resin (CR39) in a pair of molds for forming spectacle lenses that were combined together such that their concave and convex spherical surfaces come into close contact with each other through a ring-shaped gasket. The concave spherical surface had a radius of curvature of 79.84R, while the convex spherical surface had a radius of curvature of 76.769R (i.e., had a smaller radius of curvature than the concave spherical surface). As a result thereof, the spectacle lens formed had a weak power of −0.25 D.

Example 2

(20) As in Example 1, a spectacle lens was formed by cast molding using diethylene glycol bis(allyl carbonate) resin (CR39) in a pair of molds for forming spectacle lenses that were combined together such that their concave and convex spherical surfaces come into close contact with each other through a ring-shaped gasket. The concave spherical surface had a radius of curvature of 79.84R, while the convex spherical surface had a radius of curvature of 73.77R (i.e., had a smaller radius of curvature than the concave spherical surface). As a result thereof, the spectacle lens formed had a weak power of −0.50 D.

Example 3

(21) As in Example 1, a spectacle lens was formed by cast molding using diethylene glycol bis(allyl carbonate) resin (CR39) in a pair of molds for forming spectacle lenses that were combined together such that their concave and convex surfaces come into close contact with each other through a ring-shaped gasket. The concave spherical surface had a radius of curvature of 79.84R, while the convex spherical surface had a radius of curvature of 71.285R (i.e., had a smaller radius of curvature than the concave spherical surface). As a result thereof, the spectacle lens formed had a weak power of −0.75 D.

Example 4

(22) As in Example 1, a spectacle lens was formed by cast molding using diethylene glycol bis(allyl carbonate) resin (CR39) in a pair of molds for forming spectacle lenses that were combined together such that their concave and convex spherical surfaces come into close contact with each other through a ring-shaped gasket. The concave spherical surface had a radius of curvature of 79.84R, while the convex spherical surface had a radius of curvature of 68.68R (i.e., had a smaller radius of curvature than the concave spherical surface. As a result thereof, the spectacle lens formed had a weak power of −1.00 D.

Comparative Example 1

(23) As in Example 1, a spectacle lens was formed by cast molding using diethylene glycol bis(allyl carbonate) resin (CR39) in a pair of molds for forming spectacle lenses that were combined together such that their concave and convex spherical surfaces come into close contact with each other through a ring-shaped gasket. The concave spherical surface had a radius of curvature of 79.84R, while the convex spherical surface had a radius of curvature of 66.533R (i.e., had a smaller radius of curvature than the concave spherical surface. As a result thereof, the spectacle lens formed was a lens for myopia correction having a power of −1.25 D.

Comparative Example 2

(24) As in Example 1, a spectacle lens was formed by cast molding using diethylene glycol bis(allyl carbonate) resin (CR39) in a pair of molds for forming spectacle lenses that were combined together such that their concave and convex spherical surfaces come into close contact with each other through a ring-shaped gasket. The concave spherical surface had a radius of curvature of 79.84R, while the convex spherical surface had a radius of curvature of 64.387R (i.e., had a smaller radius of curvature than the concave spherical surface. As a result thereof, the spectacle lens formed was a lens for myopia correction having a power of −1.50 D.

Examples 5 to 8

(25) Polarizing spectacle lenses having weak powers of −0.25 D, −0.50 D, −0.75 D and −1.00 D, respectively, were formed by cast molding in exactly the same manner as in Examples 1 to 4 except that the polarizing film 1 (as explained in the above embodiment) was inserted. Specifically, the polarizing film 1 was inserted, when, as in Examples 1 to 4, the pair of molds for forming spectacle lenses were combined together such that their concave and convex spherical surfaces come into close contact with each other through the ring-shaped gasket, and diethylene glycol bis(allyl carbonate) resin (CR39) as a molding material was introduced.

Comparative Examples 3 and 4

(26) Polarizing spectacle lenses for myopia correction having powers of −1.25 D and −1.50 D, respectively, were formed by cast molding in exactly the same manner as in Comparative Examples 1 and 2 except that the polarizing film 1 (as explained in the above embodiment) was inserted. Specifically, the polarizing film 1 was inserted, when, as in Comparative Examples 1 and 2, the pair of molds for forming spectacle lenses were combined together such that their concave and convex spherical surfaces come into close contact with each other through a ring-shaped gasket, and diethylene glycol bis(allyl carbonate) resin (CR39) as a molding material was introduced.

(27) Using the non-corrective plastic spectacle lenses according to the Examples 1 to 8; and the corrective plastic spectacle lenses according to Comparative Examples 1 to 4, i.e., lenses whose visible light transmittance is so low as to cause eyesight deterioration, as described below, an eyesight measuring test was conducted to confirm the effect of improving the eyesight by the individual lenses.

Eyesight Measuring Test

(28) A special spectacle frame for eyesight testing was prepared to which, for the purpose of mimicking a low illuminance environment (50-100 lux), colored or polarizing spectacle lenses can be fitted, together with transparent lenses having a predetermined power so as to be superposed on the transparent lenses; and the lenses according to each of the Examples and Comparative Examples were fitted to this spectacle frame together with the below-described colored spectacle lenses (CL) or polarizing spectacle lenses (PL) to measure the eyesight of each test subject having normal eyesight in an indoor environment (where the illuminance was about 500 lux).

(29) The above colored lenses (CL) and polarizing lenses (PL) were formed by adding, during cast molding, a blue dye to the resin for cast molding such that the visible light transmittance would be 13% (CL) and 12% (PL). The test subjects consisted of nine healthy adult males and females (ages 23 to 29) having normal unaided eyesight of 0.7 to 1.5 vision. The results of the eyesight measuring test are shown in Tables 1 and 2 below.

(30) The numbers in the brackets in Tables 1 and 2 indicate, in four stages, the evaluated values of the difference between eyesight A, which is the eyesight through only the colored lenses (CL) whose spherical power S is 0 (zero), and eyesight B, which is the eyesight through both of the lenses of each of the Examples and Comparative Examples, having the predetermined spherical power S, and the colored lenses (CL). Specifically, Evaluated value “3” means that the difference between eyesight A and eyesight B is 0.3 or more, and thus “very effective”; evaluated value “2” means that the difference between “A” and “B” is 0.2, and thus “moderately effective”, evaluated value “1” means that the difference between “A” and “B” is 0.1, and thus “slightly effective (i.e., the use of the lenses is still worthwhile)”; and evaluated value “O” means the difference between “A” and “B” is 0 or less, and thus “ineffective”. Tables 1 and 2 also show the average value of the evaluated values for each of Examples 1 to 8 and Comparative Examples 1 to 4.

(31) TABLE-US-00001 TABLE 1 Comparative Comparative Example 1 Example 2 Example 3 Example 4 Example 1 Example 2 Reference Example [S - 0.25 [S - 0.50 [S - 0.75 [S - 1.00 [S - 1.25 [S - 1.50 [Colored lens: lens] + CL lens] + CL lens] + CL lens] + CL lens] + CL lens] + CL Tested subjects CL(visible light Eyesight B Eyesight B Eyesight B Eyesight B Eyesight B Eyesight B Unaided transmittance 13%)] (and evalu- (and evalu- (and evalu- (and evalu- (and evalu- (and evalu- Gender Age eyesight Eyesight A ated value) ated value) ated value) ated value) ated value) ated value) Female 28 0.7 0.6 0.9 (3) 0.9 (3) 0.9 (3) 0.9 (3) 0.8 (2) 0.8 (2) Female 26 1.0 0.8 0.9 (2) 0.9 (2) 0.9 (2) 0.9 (1) 0.8 (1) 0.7 (0) Male 23 1.0 0.9 0.9 (1) 1.0 (2) 1.5 (3) 1.2 (3) 1.5 (3) 1.2 (3) Mate 31 1.2 0.9 1.0 (2) 1.2 (3) 1.2 (3) 1.0 (1) 1.0 (2) 1.0 (2) Female 28 1.5 1.2 1.2 (1) 1.0 (0) 1.0 (0) 1.2 (1) 1.2 (1) 1.0 (0) Female 27 1.0 0.9 1.2 (3) 1.2 (3) 1.0 (2) 1.2 (3) 1.0 (2) 1.0 (2) Male 26 1.2 1.0 1.2 (2) 1.2 (2) 1.2 (2) 1.2 (2) 1.2 (2) 1.2 (2) Male 29 1.2 1.2 1.2 (1) 1.2 (1) 1.2 (1) 1.0 (0) 1.0 (0) 1.0 (0) Mate 39 0.7 0.7 1.0 (3) 1.2 (3) 1.2 (3) 1.2 (3) 1.5 (3) 1.2 (3) Average value (of evaluated values) 2.0 2.1 2.1 1.9 1.8 1.6

(32) TABLE-US-00002 TABLE 2 Comparative Comparative Example 5 Example 6 Example 7 Examples 8 Example 3 Example 4 Reference Example [S - 0.25 [S - 0.50 [S - 0.75 [S - 1.00 [S - 1.25 [S - 1.50 [Polarizing lens: lens] + PL lens] + PL lens] + PL lens] + PL lens] + PL lens] + PL Test subjects PL(visible light Eyesight B Eyesight B Eyesight B Eyesight B Eyesight B Eyesight B Unaided transmittance 12%)] (and evalu- (and evalu- (and evalu- (and evalu- (and evalu- (and evalu- Gender Age eyesight Eyesight A ated value) ated value) ated value) ated value) ated value) ated value) Female 28 0.7 0.7 0.7 (1) 0.9 (3) 1.0 (3) 1.0 (3) 0.9 (2) 0.8 (2) Female 26 1.0 0.8 0.8 (2) 0.8 (1) 1.0 (2) 1.0 (2) 0.9 (2) 0.8 (1) Male 23 1.0 0.9 0.9 (2) 1.0 (2) 1.2 (3) 1.5 (3) 2.0 (3) 1.5 (3) Male 31 1.2 1.2 1.2 (0) 1.0 (0) 1.0 (0) 1.0 (0) 1.2 (1) 1.0 (0) Female 28 1.5 1.2 1.2 (1) 1.0 (0) 1.0 (0) 1.2 (1) 1.0 (0) 1.0 (0) Female 27 1.0 0.9 0.9 (3) 1.2 (3) 1.2 (3) 1.2 (3) 1.2 (3) 1.2 (3) Male 26 1.2 1.0 1.0 (2) 1.2 (2) 1.2 (2) 1.2 (2) 1.2 (2) 1.2 (2) Male 29 1.2 1.2 1.2 (1) 1.2 (1) 1.2 (1) 1.2 (1) 1.0 (0) 1.0 (0) Mate 39 0.7 0.6 0.8 (2) 1.0 (3) 1.2 (3) 1.2 (3) 1.2 (3) 1.2 (3) Average value (of evaluated values) 1.5 1.7 1.9 2.0 1.8 1.6

(33) As is apparent from the results shown in Tables 1 and 2, eyesight B of the test subjects through the lenses of each of Examples 1-8, which have a power within the predetermined range, i.e., −0.25 D, −0.50 D −0.75 D, or −1.00 D, was clearly better than eyesight A, i.e., the eyesight through only the colored lenses (CL) or polarizing lenses (PL). It also turned out that, especially by using, in an environment where illuminance is low, or together with colored lenses or polarizing lenses, molded plastic lenses having a spherical power S within the range of −1.0 D≤S<−0.1 D, eyesight improves.

(34) Eyesight B through the lenses of each of Examples 1, 2, 5 and 6, which has a relatively weak power, was also clearly better than eyesight A, and such an eyesight improvement effect increased as the power of the lenses used increased, but when the power was more than −1.0 D, the average value of the evaluated values decreased. In view of this tendency, it seems that, if the power of the lenses used is more than −1.0 D, in an environment where illuminance is low, the lenses still assist in the eye's focus adjustment function, but imposes a burden on the eye's focus adjustment function beyond this assistance

(35) When, in order to mimic an environment where illuminance is low, colored lenses (visible light transmittance 13%) or polarizing lenses (visible light transmittance 12%) were superposed on the lenses of each of Comparative Examples 1 to 4, which have a power outside the predetermined range, i.e., −1.25 D or −1.50 D, eyesight B did not improve as expected by the adjustment of the lens power, but rather deteriorated, due, for example, to the fatigue of the muscle involved in the eye's focus adjustment function.

(36) The results of the above eyesight measuring test show that, the spectacle lenses according to Examples 1 to 4, and the polarizing spectacle lenses according to Examples 5 to 8 can be used as non-corrective plastic spectacle lenses assisting in the eye's focus adjustment function in the state where muscle relating to the eye's focus adjustment function is likely to get tired in a reduced illuminance environment, thereby making a user's eye less likely to get tired and enabling the user to clearly see close objects and letters even in a reduced illuminance environment.

DESCRIPTION OF REFERENCE NUMERALS

(37) 1: polarizing film 2, 3: plastic layer 4, 5: mold 4a: concave inner surface 5a: convex inner surface 6: gasket 7: pipe-shaped gate