Method for producing antireflection film-coated plastic lens, and antireflection film-coated plastic lens

Abstract

The method produces a plastic lens with an antireflection film which have the advantages of good adhesion of the antireflection film to any type of hard coat film that underlies it and good abrasion resistance and provides a plastic lens with an antireflection film. The method includes the steps of applying water or an aqueous solution to a plastic lens with an organosilicon compound-containing hard coat film to form a liquid film of water or the aqueous solution on the surface of the hard coat film, then allowing ozone gas to contact with the liquid film to treat the surface of the hard coat film with the ozone gas, and thereafter forming an antireflection film on the surface of the hard coat film through vapor deposition.

What is claimed is:  
     
         1 . A method for producing a plastic lens with an antireflection film on a surface thereof, comprising: 
 applying water or an aqueous solution to a plastic lens having an organosilicon compound-containing hard coat film formed on a surface thereof to form a liquid film of water or the aqueous solution on the surface of the hard coat film,    allowing ozone gas to contact with the liquid film so as to treat the surface of the hard coat film with the ozone gas, and    forming the antireflection film on the ozone gas treated surface of the hard coat film by vapor deposition.    
     
     
         2 . The method for producing a plastic lens with an antireflection film of  claim 1 , comprising spraying the water or the aqueous solution on the hard coat-film to form the liquid film on the hard coat film.  
     
     
         3 . The method for producing a plastic lens with an antireflection film of  claim 1 , wherein the water or the aqueous solution further comprises ozone gas.  
     
     
         4 . The method for producing a plastic lens with an antireflection film of claims  1 ,  2  or  3 , wherein the aqueous solution contains a radical scavenger.  
     
     
         5 . The method for producing a plastic lens with an antireflection film of  claim 4 , wherein the radical scavenger is a hydrogen carbonate or a phosphate.  
     
     
         6 . The method for producing a plastic lens with an antireflection film of  claim 5 , wherein the aqueous solution contains the radical scavenger in an amount of 0.01 mols/liter or more based on the aqueous solution.  
     
     
         7 . The method for producing a plastic lens of  claim 1 , wherein the hard coat film contains metal oxide fine particles.  
     
     
         8 . The method for producing a plastic lens of  claim 7 , wherein the metal oxide fine particles comprise at least one type of particle selected from silicon oxide particles, titanium oxide particles and tin oxide particles.  
     
     
         9 . The method for producing a plastic lens of  claim 1 , wherein the plastic lens comprises at least one resin selected from the group consisting of a polythiourethane resin, an epithio group-containing resin and a diethylene glycol bisallylcarbonate-containing resin.  
     
     
         10 . The method for producing a plastic lens of 1, wherein the concentration of the ozone gas allowed to contact the liquid film on the hard coat film is 50 g/Nm 3  or more.  
     
     
         11 . The method for producing a plastic lens of  claim 1 , wherein the concentration of the ozone gas allowed to contact the liquid film on the hard coat film is 100 g/Nm 3  or more.  
     
     
         12 . The method for producing a plastic lens of  claim 1 , wherein the concentration of the ozone gas allowed to contact the liquid film on the hard coat film is 140 g/Nm 3  or more.  
     
     
         13 . The method for producing a plastic lens as claimed in  claim 1 ,  2 ,  3 ,  7 ,  8 ,  9 ,  10 ,  11  or  12 , wherein the time for contacting the ozone gas with the liquid film is between about 10 seconds and about 10 minutes.  
     
     
         14 . The method for producing a plastic lens as claimed in  claim 4 , wherein the time for contacting the ozone gas with the liquid film is between about 10 seconds and about 10 minutes.  
     
     
         15 . The method for producing a plastic lens as claimed in  claim 5 , wherein the time for contacting the ozone gas with the liquid film is between about 10 seconds and about 10 minutes.  
     
     
         16 . The method for producing a plastic lens as claimed in  claim 6 , wherein the time for contacting the ozone gas with the liquid film is between about 10 seconds and about 10 minutes.  
     
     
         17 . The method for producing a plastic lens as claimed in  claim 1 ,  2 ,  3 ,  7 ,  8 ,  9 ,  10 ,  11  or  12 , wherein the organosilicon compound used to form the hard coat film is at least one compound selected from compounds of general formula (I):  
       (R 1 ) a (R 3 ) b Si(OR 2 ) 4−(a+b)    (I)  wherein R 1  and R 3  each independently represent a monovalent hydrocarbon group having from 1 to 10 carbon atoms, with or without a functional group; R 2  represents an alkyl group having from 1 to 8 carbon atoms, an aryl group having from 6 to 10 carbon atoms, an aralkyl group having from 7 to 10 carbon atoms or an acyl group having from 1 to 8 carbon atoms; a and b each independently indicate 0 or 1;    and a plurality of the OR 2  groups may be the same or different from each other, and compounds of general formula (II):                          wherein R 4  and R 5  each independently represent a monovalent hydrocarbon group having from 1 to 5 carbon atoms, with or without a functional group; X 1  and X 2  each independently represent an alkyl group having from 1 to 4 carbon atoms or an acyl group having from 1 to 4 carbon atoms; Y represents a divalent hydrocarbon group having from 1 to 20 carbon atoms; x and y each independently indicate 0 or 1; a plurality of the X 1  groups may be the same or different from each other; and a plurality of the X 2  groups may be the same or different from each other,    and hydrolyzates of the compounds of formula (I) and formula (II).    
     
     
         18 . The method for producing a plastic lens as claimed in  claim 4 , wherein the organosilicon compound used to form the hard coat film is at least one compound selected from compounds of general formula (I):  
       (R 1 ) a (R 3 ) b Si(OR 2 ) 4−(a+b)    (I)  
       wherein R 1  and R 3  each independently represent a monovalent hydrocarbon group having from 1 to 10 carbon atoms, with or without a functional group; R 2  represents an alkyl group having from 1 to 8 carbon atoms, an aryl group having from 6 to 10 carbon atoms, an aralkyl group having from 7 to 10 carbon atoms or an acyl group having from 1 to 8 carbon atoms; a and b each independently indicate 0 or 1; 
 and a plurality of the OR 2  groups may be the same or different from each other,  
                     
 and compounds of general formula (II):  
 wherein R 4  and R 5  each independently represent a monovalent hydrocarbon group having from 1 to 5 carbon atoms, with or without a functional group; X 1  and X 2  each independently represent an alkyl group having from 1 to 4 carbon atoms or an acyl group having from 1 to 4 carbon atoms; Y represents a divalent hydrocarbon group having from 1 to 20 carbon atoms; x and y each independently indicate 0 or 1; a plurality of the X 1  groups may be the same or different from each other; and a plurality of the X 2  groups may be the same or different from each other, and hydrolyzates of the compounds of formula (I) and formula (II).  
 
     
     
         19 . A plastic lens with an antireflection film produced by the method of  claim 13 .  
     
     
         20 . A plastic lens with an antireflection film produced by the method of  claim 15.