IP Library Granted Patent US 7,981,506
Granted Patent B2
US 7,981,506 · App. 11/413,017 · Granted Jul 19, 2011

Plastic lens and method of manufacturing a plastic lens

Assignee: Seiko Epson Corporation
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Quick Facts
Patent No.
US 7,981,506
App. No.
11/413,017
Granted
Jul 19, 2011
Kind
B2
Abstract

The plastic lens has the hard coat layer on a plastic lens base material containing at least sulfur atom and the organic anti-reflection film on the hard coat layer and further has a primer layer between the plastic lens base material and the hard coat layer. The hard coat layer comprises metal oxide particulates at least containing titanium oxide with rutile-type crystal structure and an organic silicon compound expressed by general Formula: R1SiX13. The organic anti-reflection film comprises a coating composition at least containing an organic silicon compound expressed by general Formula: R2nR3 mSiX24-n-m and silica system particulates of 1 to 150 nm mean particle diameter and has a refractive index which is lower than that of that of the hard coat layer by 0.10 or more.

Claims (38)

1. A plastic lens comprising a plastic lens substrate and a hard coat layer on the plastic lens substrate, and an organic antireflection film on the hard coat layer,

the plastic lens substrate including at least a sulfur atom, wherein the plastic lens substrate comprises a thiourethane based resin and/or an episulfide based resin, and wherein the plastic lens substrate is tinted,

the hard coat layer being a coating film formed with a coating composition which includes at least the following Component A and Component B,

the organic antireflection film being a coating film which includes at least the following Component C and Component D, and has a refractive index that is lower than the refractive index of the hard coat layer by 0.10 or more, and

the plastic lens including a primer layer between the plastic lens substrate and the hard coat layer:

Component A: metal oxide fine particles including titanium oxide having a rutile crystal structure, wherein the titanium oxide is a composite oxide with tin oxide and silicon dioxide,

Component B: an organic silicon compound represented by the general formula: R 1 SiX 1 3 (wherein, R 1 represents an organic group having a polymerizable reactive group and having two or more carbon atoms; and X 1 represents a hydrolytic group),

Component C: an organic silicon compound represented by the general formula: R 2 n R 3 m SiX 2 4-n-m (wherein, R 2 represents an organic group having a polymerizable reactive group; R 3 represents a hydrocarbon group having 1 to 6 carbon atoms; X 2 represents a hydrolytic group; n represents 0 or 1; and m represents 0 or 1; and where n or m cannot be 0 at the same time), and

Component D: silica fine particles having a mean particle diameter of 1 to 150 nm and having voids inside thereof;

wherein the primer layer is a coating film formed with a coating composition including the following Component E and Component F:

Component E: an organic resin polymer having a polar group, and

Component F: metal oxide fine particles including titanium oxide, wherein the titanium oxide is a composite oxide with tin oxide and silicon dioxide.

2. The plastic lens according to claim 1 , wherein the Component E is a polyester resin.

3. The plastic lens according to claim 1 , wherein

the primer layer comprises metal oxide fine particles prepared by subjecting the surface of the Component F to a modifying treatment with an organic silicon compound having an epoxy group.

4. The plastic lens according to claim 1 , wherein the organic antireflection film comprises the top most layer of said plastic lens.

5. The plastic lens according to claim 4 , wherein the organic antireflection film has a top surface and a bottom surface.

6. The plastic lens according to claim 5 , wherein the bottom surface of the organic antireflection film directly contacts the hard coat layer.

7. The plastic lens according to claim 1 , wherein the layer directly contacting the hard coat layer is the bottom surface of the organic antireflection film.

8. The plastic lens according to claim 1 , wherein the silica fine particles have a mean particle diameter of 20 to 150 nm.

9. A method of manufacturing a plastic lens comprising:

obtaining a plastic lens substrate by cast polymerization of a polymerizable composition including a monomer having a sulfur atom in the molecule; wherein the plastic lens substrate comprises a thiourethane based resin and/or an episulfide based resin, and wherein the plastic lens substrate is tinted,

forming a primer layer on the plastic lens substrate;

forming a hard coat layer on the primer layer using a coating composition including at least the following Component A and Component B; and

forming on the hard coat layer an organic antireflective layer having a refractive index that is lower than the refractive index of the hard coat layer by 0.10 or more using a coating composition including at least the following Component C and Component D:

Component A: metal oxide fine particle including titanium oxide having a rutile crystal structure, wherein the titanium oxide is a composite oxide with tin oxide and silicon dioxide,

Component B: organic silicon compound represented by the general formula: R 1 SiX 1 3 (wherein, R 1 represents an organic group having a polymerizable reactive group and having two or more carbon atoms, X 1 represents a hydrolytic group),

Component C: organic silicon compound represented by the general formula: R 2 n R 3 m SiX 2 4-n-m (wherein, R 2 represents an organic group having a polymerizable reactive group; R 3 represents a hydrocarbon group having 1 to 6 carbon atoms; X 2 represents a hydrolytic group; n represents 0 or 1, and m represents 0 or 1; and where n or m cannot be 0 at the same time), and

Component D: silica fine particles having a mean particle diameter of 1 to 150 nm and having voids inside thereof;

wherein Component B an Component C are hydrolyzed,

wherein said primer layer is a coating film formed with a coating composition including the following Component E and Component F:

Component E: an organic resin polymer having a polar group, and

Component F: metal oxide fine particles including titanium oxide, wherein the titanium oxide is a composite oxide with tin oxide and silicon dioxide.

10. A method of manufacturing a plastic lens according to claim 9 , wherein the organic antireflection film comprises the top most layer of said plastic lens.

11. A method of manufacturing a plastic lens according to claim 10 , wherein the organic antireflection film has a top surface and a bottom surface.

12. A method of manufacturing a plastic lens according to claim 11 , wherein the bottom surface of the organic antireflection film directly contacts the hard coat layer.

13. A method of manufacturing a plastic lens according to claim 9 , wherein the layer directly contacting the hard coat layer is the bottom surface of the organic antireflection film.

14. The method according to claim 9 , wherein the silica fine particles have a mean particle diameter of 20 to 150 nm.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 18, 2013
From: SEIKO EPSON CORPORATION
To: HOYA LENS MANUFACTURING PHILIPPINES INC.
Reel/Frame 030822/0408 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 28, 2006
From: NAITO, SHUJI; KOMAI, HIDENORI; KINOSHITA, JUN; KUTSUKAKE, YUSUKE; TAKESHITA, KATSUYOSHI
To: SEIKO EPSON CORPORATION
Reel/Frame 017836/0682 →
Priority Claims (1)
JP 2005-131034 · Apr 28, 2005 · national
Continuity (1)
Related Publication 20060251884A1 · Nov 9, 2006