Source: http://www.patentgenius.com/patent/7439278.html
Timestamp: 2018-06-24 13:12:58
Document Index: 586730311

Matched Legal Cases: ['art 5', 'art 5', 'art 5', 'art 5', 'art 5', 'art 8', 'art 8', 'art 5']

Curable adhesive composition and its use in the optical field - Patent # 7439278 - PatentGenius
7439278 Curable adhesive composition and its use in the optical field
Inventor: Jallouli
Application: 10/838,840
Inventors: Jallouli; Aref (Largo, FL)
U.S. Class: 522/103; 156/228; 156/275.5; 156/74; 156/99; 427/508; 427/516; 427/517; 428/413; 522/100; 522/113; 522/114; 522/121; 522/134; 522/135; 522/137; 522/144; 522/172; 522/181; 522/182
Field Of Search: 522/100; 522/181; 522/172; 522/182; 522/130; 522/103; 522/134; 522/135; 522/137; 522/113; 522/114; 522/121; 522/120; 522/144; 427/508; 427/516; 427/517; 428/413; 156/228; 156/99; 156/74; 156/275.5
International Class: C08F 2/50; B29C 65/14; B32B 27/30; B29C 65/00; B32B 27/00; G02B 1/00; G02B 1/04
Foreign Patent Documents: 2792010; WO 99/29494; WO 03/004255; WO 03/040461
Abstract: The invention concerns a photocurable adhesive composition comprising, based on total weight of photopolymerizable monomers and/or oligomers of the composition: (A1) 20 to 80 wt % of at least one diacrylate monomer or oligomer thereof (A1); (A2) 80 to 20 wt % of at least one dimethacrylate monomer or oligomer thereof; (B) 0 to 50 wt %, of at least one copolymerizable monomer different from components (A1) and (A2); with the proviso that the composition is free from any thio(meth)acrylate (--SCOCR'.dbd.CH.sub.2, with R'.dbd.H or CH.sub.3) monomer or oligomer thereof.
1. A curable adhesive composition comprising, based on the total weight of the polymerizable monomers and/or oligomers of the composition: (A1) 20 to 80 wt % of atleast one diacrylate monomer or oligomer thereof, (A2) 80 to 20 wt % of at least one polyalkoxylated bisphenol dimethacrylate or oligomer thereof; (B) 0 to 50 wt % of at least one copolymerizable monomer different from components (A1) and (A2); withthe proviso that the composition is free from any thio(meth)acrylate (--SCOCR'.dbd.CH.sub.2, with R'.dbd.H or CH.sub.3) monomer or oligomer thereof.
3. The curable composition of claim 1, wherein the polyalkoxylated bisphenol dimethacrylate has the following formula: ##STR00008## in which R is H or a C.sub.1-C.sub.4 alkyl radical and m+n.gtoreq.0.
4. The curable composition of claim 3, wherein m+n.gtoreq.2.
12. The curable composition of claim 1, wherein said at least one diacrylate monomer (A1) has a calculated solubility parameter ranging from 8 to 12 (cal/cm.sup.3).sup.1/2.
13. The curable composition of claim 1, wherein said at least one diacrylate monomer (A1) has a calculated solubility parameter ranging from 8.5 to 11.5 (cal/cm.sup.3).sup.1/2.
15. The curable composition of claim 1, wherein said at least one diacrylate monomer (A1) has a molecular weight .ltoreq.350.
18. The curable composition of claim 1, further comprising at least one photoinitiator.
19. The curable composition of claim 18, wherein the photoinitiator represents 0.1 to 5 parts by weight for 100 parts by weight of the polymerizable monomers and/or oligomers.
20. The curable composition of claim 1, wherein, after curing, the composition has a refractive index n.sub.D.sup.25 of 1.53 to 1.65.
21. A process for transferring a coating from a support onto a surface of a polymer material substrate comprising: providing a polymer material substrate having at least one main surface; providing a support having an internal surface bearinga coating and an external surface; depositing on the main surface of the substrate or on the coating a pre-measured amount of a curable adhesive composition comprising, based on the total weight of polymerizable monomer and/or oligomers of thecomposition: (A1) 20 to 80 wt % of at least one diacrylate monomer or oligomer thereof, (A2) 80 to 20 wt % of at least one polyalkoxylated bisphenol dimethacrylate or oligomer thereof; (B) 0 to 50 wt % of at least one copolymerizable monomer differentfrom components (A1) and (A2); with the proviso that the composition is free from any thio(meth)acrylate (--SCOCR'.dbd.CH.sub.2, with R'.dbd.H or CH.sub.3) monomer or oligomer thereof; moving relatively to each other the substrate and the support toeither bring the coating into contact with the curable composition or bring the curable composition into contact with the main surface of the substrate; applying a sufficient pressure onto the external surface of the support so that the thickness of afinal layer, once the curable composition has cured is less than 100 .mu.m; curing the layer of the composition to form a final cured layer; and withdrawing the support to recover a substrate with the coating adhered onto its main surface.
22. The process of claim 21, wherein the substrate polymer material is a thermoplastic material.
23. The process of claim 21, wherein the thermoplastic material of the substrate is polycarbonate.
24. The process of claim 21, wherein the curable composition comprises 20 to 71 wt % of component (A1) and 29 to 80 wt % of component (A2).
25. The process of claim 21, wherein the curable composition comprises 28 to 71 wt % of component (A1) and above 29 to 72 wt % of component (A2).
26. The process of claim 21, wherein the curable composition comprises 28 to 42 wt % of component (A1) and 58 to 72 wt % of component (A2).
27. The process of claim 21, wherein the curable composition comprises 30 wt % or less of component (B).
28. The process of claim 21, wherein the curable composition comprises 20 wt % or less of component (B).
29. The process of claim 21, wherein the curable composition comprises 10 wt % or less of component (B).
30. The process of claim 21, wherein the curable composition comprises 0% of component (B).
31. The process of claim 21, wherein said at least one diacrylate monomer (A1) has a calculated solubility parameter ranging from 8 to 12 (cal/cm.sup.3).sup.1/2.
32. The process of claim 21, wherein said at least one diacrylate monomer (A1) has a calculated solubility parameter ranging from 8.5 to 11.5 (cal/cm.sup.3).sup.1/2.
33. The process of claim 21, wherein said at least one diacrylate monomer (A1) has a molecular weight <500.
34. The process of claim 21, wherein said at least one diacrylate monomer (A)1 has a molecular weight .ltoreq.350.
35. The process of claim 21, wherein said at least one monomer (A1) is a low refractive index monomer.
36. The process of claim 21, wherein said diacrylate monomer (A1) is a non-aromatic diacrylate monomer.
37. The process of claim 21, wherein the at least one polyalkoxylated bisphenol dimethacrylate monomer (A2) is an ethoxylated bisphenol-A monomer.
38. The process of claim 21, wherein the curable composition is a photocurable composition further comprising at least one photoinitiator.
39. The process of claim 38, wherein the photoinitiator represents 0.1 to 5 parts by weight for 100 parts by weight of the photopolymerizable monomers.
40. The process of claim 21, wherein the substrate is a lens blank, and the main surface is a geometrically defined surface of the lens blank.
41. The process of claim 21, wherein the substrate is a tinted substrate.
42. The process of claim 41, wherein the support is made of polycarbonate.
43. The process of claim 21, wherein the support is a flexible support part having an internal surface conformable to a geometrically defined surface of the lens blank when brought into contact therewith.
44. The process of claim 43, wherein the support has a thickness of 0.3 to 1 mm.
45. The process of claim 42, wherein the flexible support is urged against the lens blank by means of an inflatable membrane.
46. The process of claim 21, wherein the support is made of polycarbonate.
47. The process of claim 21, wherein the thickness of the final cured layer is less than 80 .mu.m.
48. The process of claim 21, wherein the thickness of the final cured layer is less than 50 .mu.m.
49. The process of claim 21, wherein the final cured layer has a refractive index n.sub.D.sup.25 of 1.53 to 1.65.
50. The process of claim 21, wherein the exerted pressure ranges from 5 to 50 Psi (0.35 to 3.5 kjf/cm.sup.3).
51. The process of claim 21, wherein the coating comprises a hydrophobic top coat, an anti-reflective coating layer, an anti-abrasion coating layer, an impact resistant coating layer, a photochromic coating layer, a dying coating layer, apolarized coating layer, a printed layer or a stack of two or more of these coating layers.
52. The process of claim 51, wherein the coating has a thickness of 50 .mu.m or less.
53. The process of claim 21, wherein the coating consists of a hydrophobic top coating, an anti-reflective coating layer, an anti-abrasion coating layer and an impact resistant coating layer.
54. The process of claim 21, wherein said at least one main surface of the substrate is a surface of a tinted coating formed on the substrate.
55. The process of claim 21, wherein the substrate is a semi-finished lens having one face already provided with a coating.
56. The process of claim 55, wherein the face already provided with a coating is the front face of the lens and the geometrically defined surface onto which the coating is transferred is the back surface of the lens.
57. The process of claim 21, wherein the support is made of a thermoplastic material.
58. The process of claim 56, wherein the substrate is made by injection molding.
59. An overmolding process comprising: providing a polymer material substrate having at least one main surface; providing a mold part having an internal surface and an external surface; depositing on the main surface of the substrate or onthe internal surface of the mold part a pre-measured amount of a curable adhesive composition comprising, based on the total weight of the polymerizable monomers and/or oligomers of the composition: (A1) 20 to 80 wt % of at least one diacrylate monomeror oligomer thereof; (A2) 80 to 20 wt % of at least one polyalkoxylated bisphenol dimethacrylate or oligomer thereof; (B) 0 to 50 wt % of at least one copolymerizable monomer different from components (A1) and (A2); with the proviso that thecomposition is free from any thio(meth)acrylate (--SCOCR'502 CH.sub.2, with R'.dbd.H or CH.sub.3) monomer or oligomer thereof; moving relatively to each other the substrate and the mold part to either bring the internal surface of the mold part or themain surface of the substrate in contact with the curable composition; applying a sufficient pressure onto the external surface of the mold part to uniformly spread the curable composition and form a uniform layer, which, when cured, has a thickness ofat least 200 .mu.m; curing the layer of the composition to form a final cured layer; and withdrawing the mold parts to recover the substrate overmolded with a cured layer of the curable composition.
60. The overmolding process of claim 59, wherein the polymer material of the substrate is a thermoplastic material.
61. The overmolding process of claim 59, wherein a coating to be transferred is applied to the internal surface of the mold part before depositing the curable composition.
62. A process for transferring a coating from a support onto a surface of a polymer material substrate comprising: providing a polymer material substrate having at least one main surface; providing a support having an internal surface bearinga coating and an external surface; depositing on the main surface of the substrate or on the coating a pre-measured amount of a curable adhesive composition comprising, based on the total weight of polymerizable monomer and/or oligomers of thecomposition: (A1) 20 to 80 wt % of at least one diacrylate monomer or oligomer thereof (A2) 80 to 20 wt % of at least one polyalkoxylated bisphenol dimethacrylate or oligomer thereof; (B) 0 to 50 wt % of at least one copolymerizable monomer differentfrom components (A1) and (A2); with the proviso that the composition is free from any thio(meth)acrylate (--SCOCR'.dbd.CH.sub.2, with R'.dbd.H or CH.sub.3) monomer or oligomer thereof; moving relatively to each other the substrate and the support toeither bring the coating into contact with the curable composition or bring the curable composition into contact with the main surface of the substrate; applying a sufficient pressure onto the external surface of the support so that the thickness of afinal layer, once the curable composition has cured is less than 100 .mu.m; curing the layer of the composition to form a final cured layer; and withdrawing the support to recover a substrate with the coating adhered onto its main surface, wherein thesupport is a flexible support part having a thickness of 0.3 to 1 mm and having an internal surface conformable to a geometrically defined surface of the lens blank when brought into contact therewith.
63. A process for transferring a coating from a support onto a surface of a polymer material substrate comprising: providing a polymer material substrate having at least one main surface; providing a support having an internal surface bearinga coating and an external surface; depositing on the main surface of the substrate or on the coating a pre-measured amount of a curable adhesive composition comprising, based on the total weight of polymerizable monomer and/or oligomers of thecomposition: (A1) 20 to 80 wt % of at least one diacrylate monomer or oligomer thereof; (A2) 80 to 20 wt % of at least one polyalkoxylated bisphenol dimethacrylate or oligomer thereof; (B) 0 to 50 wt % of at least one copolymerizable monomer differentfrom components (A1) and (A2); with the proviso that the composition is free from any thio(meth)acrylate (--SCOCR'.dbd.CH.sub.2, with R'.dbd.H or CH.sub.3) monomer or oligomer thereof; moving relatively to each other the substrate and the support toeither bring the coating into contact with the curable composition or bring the curable composition into contact with the main surface of the substrate; applying a sufficient pressure onto the external surface of the support so that the thickness of afinal layer, once the curable composition has cured is less than 80 .mu.m; curing the layer of the composition to form a final cured layer; and withdrawing the support to recover a substrate with the coating adhered onto its main surface.
64. The process of claim 63, wherein the thickness of the final cured layer is less than 50 .mu.m.
65. A process for transferring a coating from a support onto a surface of a polymer material substrate comprising: providing a polymer material substrate having at least one main surface; providing a support having an internal surface bearinga coating and an external surface; depositing on the main surface of the substrate or on the coating a pre-measured amount of a curable adhesive composition comprising, based on the total weight of polymerizable monomer and/or oligomers of thecomposition: (A1) 20 to 80 wt % of at least one diacrylate monomer or oligomer thereof; (A2) 80 to 20 wt % of at least one polyalkoxylated bisphenol dimethacrylate or oligomer thereof; (B) 0 to 50 wt % of at least one copolymerizable monomer differentfrom components (A1) and (A2); with the proviso that the composition is free from any thio(meth)acrylate (--SCOCR'502 CH.sub.2, with R'502 H or CH.sub.3) monomer or oligomer thereof; moving relatively to each other the substrate and the support toeither bring the coating into contact with the curable composition or bring the curable composition into contact with the main surface of the substrate; applying a sufficient pressure onto the external surface of the support so that the thickness of afinal layer, once the curable composition has cured is less than 100 .mu.m, wherein the exerted pressure ranges from 5 to 50 Psi (0.35 to 3.5 kjf/cm.sup.3); curing the layer of the composition to form a final cured layer; and withdrawing the support torecover a substrate with the coating adhered onto its main surface.
66. A process for transferring a coating from a support onto a surface of a polymer material substrate comprising: providing a polymer material substrate having at least one main surface; providing a support having an internal surface bearinga coating and an external surface; depositing on the main surface of the substrate or on the coating a pre-measured amount of a curable adhesive composition comprising, based on the total weight of polymerizable monomer and/or oligomers of thecomposition: (A1) 20 to 80 wt % of at least one diacrylate monomer or oligomer thereof; (A2) 80 to 20 wt % of at least one polyalkoxylated bisphenol dimethacrylate or oligomer thereof; (B) 0 to 50 wt % of at least one copolymerizable monomer differentfrom components (A1) and (A2); with the proviso that the composition is free from any thio(meth)acrylate (--SCOCR'.dbd.CH.sub.2, with R'.dbd.H or CH.sub.3) monomer or oligomer thereof; moving relatively to each other the substrate and the support toeither bring the coating into contact with the curable composition or bring the curable composition into contact with the main surface of the substrate; applying a sufficient pressure onto the external surface of the support so that the thickness of afinal layer, once the curable composition has cured is less than 100 .mu.m; curing the layer of the composition to form a final cured layer; and withdrawing the support to recover a substrate with the coating adhered onto its main surface, wherein thecoating has a thickness of 50 .mu.m or less and comprises a hydrophobic top coat, an anti-reflective coating layer, an anti-abrasion coating layer, an impact resistant coating layer, a photochromic coating layer, a dying coating layer, a polarizedcoating layer, a printed layer or a stack of two or more of these coating layers.
67. The curable composition of claim 1, wherein monomer (A1) is diethyleneglycol diacrylate, triethyleneglycol diacrylate, tetraethyleneglycol diacrylate, neopentylglycoldiacrylate or 1,6-hexanediol diacrylate.
68. The process of claim 21, wherein monomer (A1) is diethyleneglycol diacrylate, triethyleneglycol diacrylate, tetraethyleneglycol diacrylate, neopentyiglycoldiacrylate or 1,6-hexanediol diacrylate.
69. The overmolding process of claim 59, wherein the overmolded cured layer of the curable composition has a thickness of at least 500 .mu.m.
70. A process for making laminated thermoplastic articles comprising depositing a pre-measured amount of a curable adhesive composition on a main surface of a first part made of polymer material, bringing into contact the deposited curablecomposition with a main surface of a second part made of a polymer material, pressing the first and second parts against each other to uniformly spread the curable composition to form a uniform thin layer, and photocuring the thin layer to obtain alaminated article, wherein the photocurable composition comprises, based on the total weight of the polymerizable monomers and/or oligomers of the composition: (A1) 20 to 80 wt % of at least one diacrylate monomer or oligomer thereof; (A2) 80 to 20 wt %of at least one polyalkoxylated bisphenol dimethacrylate or oligomer thereof; (B) 0 to 50 wt % of at least one copolymerizable monomer different from components (A1) and (A2); with the proviso that the composition is free from any thio(meth)acrylate(--SCOCR'.dbd.CH.sub.2, with R'.dbd.H or CH.sub.3) monomer or oligomer thereof.
71. The process of claim 70, wherein the polymer materials of first and second parts are thermoplastic materials.
72. The process of claim 70, wherein the article is an ophthalmic lens.
US 2003/0017340 describes one process or method for transferring a coating from at least one mold part onto at least a geometrically defined surface of a lens blank which comprises: providing a lens blank having at least one geometrically definedsurface; providing a support or mold part having an internal surface bearing a coating and an external surface; depositing on said geometrically defined surface of said lens blank or on said coating a pre-measured amount of a curable adhesivecomposition; moving relatively to each other the lens blank and the support to either bring the coating into contact with curable adhesive composition or bring the curable adhesive composition into contact with the geometrically defined surface of thelens blank; applying a sufficient pressure onto the external surface of the support so that the thickness of a final adhesive layer once the curable composition cured is less than 100 micrometers; curing the layer of adhesive composition; and withdrawingthe support or mold part to recover the lens blank with the coating adhered onto the geometrically defined surface of said lens blank.
The curable adhesive composition not only must allow a quick and safe transfer of the coating from the support onto the lens blank surface and a good adhesion of the coating onto the lens blank surface but also must not impair the optical andmechanical properties of the resulting ophthalmic lens, such as good adhesion, haze, no application stain and resistance to thermal cracking (critical temperature).
Application stain refers to the existence of an area of increased haze level, on the lens blank, coinciding with the initial adhesive composition application area. Application stain is particularly severe when using tinted lens blanks. The Hazemay be observed if the adhesive composition is allowed to sit on the lens blank surface for longer than 20 seconds before undergoing the surface transfer process.
Preferred compounds for the curable glue or adhesive are acrylate compounds such as polyethyleneglycol diacrylates, ethoxylated bisphenol-A diacrylate, various trifunctional acrylates such as (ethoxylated)trimethylolpropane triacrylate andtris(2-hydroxyethyl) isocyanurate triacrylate.
Thus, an object of the invention is to provide a photocurable adhesive composition which overcomes the drawbacks of the prior art curable adhesive compositions, in particular for use in a coating transfer process; a further object of theinvention is to provide a photocurable adhesive composition as above which not only results in a good adhesion of the coating or coating stack onto the substrate but also does not impair the optical and mechanical properties of the final product, such ashaze, application stain and resistance to thermal cracking, in particular when tinted substrates such as tinted lens blanks or lenses are used.
These and other objects which will become apparent in the following description are reached according to the invention by providing a curable adhesive composition, preferably a photocurable adhesive composition, comprising based on the totalweight of the polymerizable monomers and/or oligomers of the composition:
with the proviso that the composition is free from any thio(meth)acrylate (--SCOCR'.dbd.CH.sub.2, with R'.dbd.H or CH.sub.3) monomer or oligomer thereof.
In a preferred embodiment the curable, preferably photocurable, adhesive composition comprises: (A1) 20 to 71 wt % of at least one diacrylate monomer or oligomer thereof; and (A2) 80 to 29 wt % of at least one aromatic dimethacrylate monomer oroligomer thereof;
##STR00001## in wich R is H or a C.sub.1-C.sub.4 alkyl radical, preferably CH.sub.3 and m+n>0, preferably m+n.gtoreq.2, more preferably m+n.gtoreq.4; and
In a preferred embodiment, the diacrylate monomers (A1) have a calculated solubility parameter ranging from 8 to 12, preferably 8.5 to 11.5 (cal/cm.sup.3).sup.1/2.
Also, the preferred diacrylate monomers (A1) have a molecular weight less than 500, preferably .ltoreq.350.
The present invention also concerns a process or method for transferring a coating from a support onto a surface of a polymer material substrates, preferably a thermoplastic material substrate, comprising: providing a polymer material substrate,preferably a thermoplastic material substrate, having at least one main surface; providing a support having an internal surface bearing a coating and an external surface; depositing on said main surface of the substrate or on said coating a pre-measuredamount of a curable adhesive composition; moving relatively to each other the substrate and the support to either bring the coating into contact with the curable adhesive composition or bring the curable adhesive composition into contact with the mainsurface of the substrate; applying a sufficient pressure onto the external surface of the support so that the thickness of a final adhesive layer, once the curable composition has cured, is less than 100 .mu.m; curing the layer of adhesive composition;and withdrawing the support to recover a substrate with the coating adhered onto the main surface of the substrate, wherein the curable adhesive composition is a curable adhesive composition as defined above.
The present invention also concerns an overmolding process which comprises: providing a polymer material substrate, preferably a thermoplastic material substrate, having at least one main surface; providing a mold part having an internal surfaceand an external surface; depositing on said main surface of the substrate or on said internal surface of the mold part a pre-measured amount of a curable adhesive composition as disclosed above; moving relatively to each other the substrate and the moldpart to either bring the internal surface of the mold part or the main surface of the substrate in contact with the curable adhesive composition; applying a sufficient pressure onto the external surface of the mold part to uniformly spread the curableadhesive composition and form a uniform layer, once cured, having a thickness of at least 200 .mu.m; curing the layer of adhesive composition; and withdrawing the mold parts to recover the substrate overmolded with a cured layer of the curable adhesivecomposition.
The overmolded cured layer of adhesive composition has preferably a thickness of at least 500 .mu.m.
It is encompassed within the scope of the invention to use a support or mold part wherein the amount of curable adhesive composition has been predeposited. However, in the process of the invention, one prefers applying the adhesive compositionjust before moving the substrate and the mold towards each other.
The present invention further concerns a process for making laminated polymer articles, preferably thermoplastic articles, such as laminated ophthalmic lenses, which comprises depositing a pre-measured amount of a curable, preferably aphotocurable, adhesive composition on a main surface of a first part made of polymer material, bringing into contact the deposited curable adhesive composition with a main surface of a second part made of a polymer material, preferably a thermoplasticmaterial, pressing the first and second parts against each other to uniformly spread the curable adhesive composition to form a uniform thin layer and curing, preferably photocuring, the thin layer to obtain a laminated article, wherein the curableadhesive composition is as defined above.
The adhesive composition of the invention can be deposited on a naked substrate, i.e. a substrate free of any coating on its main surfaces, or on an already coated substrate. In particular, the adhesive composition of the invention isparticularly suitable for the transfer of coatings on organic glass substrate in which a dye or pigment has been superficially diffused or which have been previously coated with a tintable material such as an acrylic material and in which a dye orpigment has been diffused (typically by dipping the coated substrate in a dying bath).
The first component (A1) of the curable, preferably photocurable, adhesive composition of the invention consists of at least one diacrylate monomer or oligomer thereof. Preferably, diacrylate monomers (A1) have a solubility parameter rangingfrom 8 to 12 (cal/cm.sup.3).sup.1/2, more preferably from 8.5 to 11.5 (cal/cm.sup.3).sup.1/2 and a molecular weight of less than 500, preferably of 350 or less and typically between 200 and 300, most preferably between 200 and 275.
The solubility parameters of the diacrylate monomers (A1) are calculated using the group distribution method, using in the calculation the group values as determined by Hoy (Hoy's group contribution values can be found in Band Up J, and E. H.Immerget, ed S. Polymer Handbook 3.sup.rd ed. John Wiley and Sons, New York 1989) [pages 524-525).
By low refractive index acrylate monomers it is meant acrylate monomers which by homopolymerisation result in homopolymers having refractive indices, n.sub.D.sup.25, ranging from 1.47 to 1.53.
TABLE-US-00001 Calculated Solubility Molecular parameters (cal/cm.sup.3).sup.1/2 weight Diethyleneglycoldiacrylate 9.44 214 Triethyleneglycoldiacrylate 9.40 258 Tetraethyleneglycoldiacrylate 9.46 302 Neopentylglycoldiacrylate 8.56 2121,6-hexanedioldiacrylate 8.84 226
##STR00002## in which m+n>0, preferably m+n.gtoreq.2, and more preferably m+n.gtoreq.4. Generally, m+n ranges from 2 to 10, preferably from 2 to 8, more preferably from 3 to 5.
Among the preferred ethoxylated bisphenol-A dimethacrylate monomers, there may be cited ethoxylated (2) bisphenol-A dimethacrylate m+n=2, ethoxylated (4) bisphenol-A dimethacrylate (m+n=4), ethoxylated (8) bisphenol-A dimethacrylate (m+n=8) andethoxylated (10) bisphenol-A dimethacrylate (m+n=10).
Optional component (B) may be any copolymerizable monomer other than components (A1) and (A2) with the exclusion of any thio(meth)acrylate monomer, i.e. monomers comprising at least one --SCOCR'.dbd.CH.sub.2 (R'.dbd.H or CH.sub.3) functionnality.
Among the preferred component (B) there may be cited mono(meth)acrylate monomers and poly(meth)acrylate monomers other than the monomers (A1) and (A2) such as tetrahydrofurfurylacrylate and poly(alkylene glycol) mono acrylate, olefinic compounds,in particular aromatic olefinic compounds such as divinylbenzene or styrene.
As the photopolymerization initiator, any widely known compound can be used without limitation that is added for photopolymerizing the polymerizable monomers and/or oligomers. Among the photopolymerization initiators that can be suitably used inthe present invention, there may be cited benzophenone compounds, acetophenone compounds, .alpha.-dicarbonyl compounds, acylphosphine oxide compounds, bisacylphosphine oxide compounds and mixtures thereof.
##STR00003## wherein R.sup.3 is an alkyl group or a hydrogen atom and R.sup.4 and R.sup.5 are alkyl groups which together may form a cyclohexane ring,
##STR00004## wherein R.sup.6 is the same or different and is a methyl group, a methoxy group or a chlorine atom, e is 2 or 3, and R.sup.7 is a phenyl group or methoxy group,
1) 1-Phenyl-2-hydroxy-2-methylpropane-1-one, 2) 1-Hydroxycyclohexylphenyl ketone, and 3) 1-(4-Isopropylphenyl)-2-hydroxy-2-methylpropane-1-one. .alpha.-Dicarbonyl Compounds: 1) 1,2-Diphenylethanedione, and 2) Methylphenylglyoxylate. Acylphosphine Oxide Photopolymerization Initiators: 1) 2,6-Dimethylbenzoyidiphenylphosphine oxide, 2) 2,4,6-Trimethylbenzoyldiphenylphosphine oxide, 3) Methyl 2,4,6-trimethylbenzoyldiphenylphosphinate ester, 4) 2,6-Dichlorobenzoyldiphenylphosphine oxide,and 5) 2,6-Dimethoxybenzoyidiphenylphosphine oxide. Bisacylphosphine Oxide Photopolymerization Initiators: 1) Bis(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentylphosphine oxide.
The preferred photocurable adhesive compositions of the invention have, after curing, a high refractive index n.sub.D.sup.25, ranging from 1.53 to 1.65, preferably 1.53 to 1.57, typically 1.54 to 1.55 and a glass transition temperature Tg ofpreferably at least 50.degree. C., more preferably at least 60.degree. C. and better at least 70.degree. C., and even better at least 80.degree. C.
The curable, preferably photocurable, adhesive composition is appropriate for use in coating transfer processes, lamination and over molding processes, using naked or coated substrate such as organic glass substrates, in particular thermoplasticsubstrates and preferably PC substrates. The composition of the invention is particularly suitable for use with tinted substrates in order to avoid application stain. It is particularly useful for making ophthalmic lenses and other optical articles.
Use of the curable composition of the invention will now be described as applied to a coating transfer process for making coated substrates such as ophthalmic lenses. It shall be understood that the photocurable adhesive composition of theinvention may be used in any coating transfer method and not solely in the process described below.
Computes the efficient value for the amplitudes of the surfaces (RMS). This parameter is included in the EUR 15178 EN report (Commission of the European Communities) Stout et al. 1993: The development of methods for the characterization ofroughness in three dimensions.
The measurement condition was under 2 .mu.m tip 1 mg force 10 scans 500 .mu.m long 2000 data points.
Among the organic glass substrates suitable for the present invention, there may be cited substrates obtained by polymerization of alkyl(meth)acrylates, in particular C.sub.1-C.sub.4 alkyl(meth)acrylates such as methyl(meth)acrylate andethyl(meth)acrylate, allylic compounds such as allyl carbonates of, linear or branched, aliphatic or aromatic polyols, thio(meth)acrylates, thiourethans, aromatic polyalkoxylated(meth)acrylates such as polyethoxylated aromatic dimethacrylates, inparticular polyethoxylated bisphenolates dimethacrylates and polycarbonates (PC).
Among the preferred substrates, there may be cited the substrates resulting from the polymerization of polyolalkylcarbonates, in particular polyolallylcarbonates, such as ethyleneglycol bisallylcarbonate, diethyleneglycol bis(allylcarbonate),diethyleneglycol bis(2-methylcarbonate), etyleneglycol bis(2-chloroallylcarbonate), triethyleneglycol bis(allylcarbonate), 1,3-propanediol bis(allylcarbonate), propyleneglycol bis(2-ethylallylcarbonate), 1,3-butanediol bis(allylcarbonate), 1,4-butanediolbis(2-bromo allylcarbonate), dipropyleneglycol bis(allylcarbonate), trimethyleneglycol bis(2-ethylallylcarbonate), pentamethyleneglycol bis(allylcarbonate), dipropylene bisphenol-A bis(allylcarbonate) and polycarbonates, in particular bisphenol-Apolycarbonates.
In a preferred embodiment, the substrate is a tinted substrate, i.e. a substrate in which at least one dye or pigment has been superficially diffused in the substrate itself or a substrate at least a main surface of which has been coated with alayer of a tintable material such as an acrylic material and in which a dye or pigment has been diffused (generally through diffusing in a dying bath). Such a tinting process is known in the art and is disclosed in particular in International PatentApplication n.sup.o WO 03/040461. Typically, the dying bath comprises water, at least one dye or pigment, a carrier and optionally a surfactant.
The dying process can also be performed on a substrate which has been pretreated by UV irradiation as disclosed in French Patent Application n.sup.o 9904409.
Briefly stated, this dying process comprises irradiating the substrate, in particular a PC substrate, with UV irradiation to realize within the substrate a superficially photodegraded layer of at least 1 .mu.m thickness and contacting thephotodegraded layer with a coloring agent to diffuse the coloring agent to a depth of at least 1 .mu.m within the photodegraded layer.
The UV light has a wavelength spectrum during irradiation such that at least 50% of the irradiation energy is provided by irradiation of wavelength .ltoreq.320 mm. Preferably, the irradiation energy of UV light .ltoreq.320 mm is 2.4 to 48J/cm.sup.2, more preferably 10 to 30 J/cm.sup.2 and the irradiation energy of UV light >320 mm is 0.9 J/cm.sup.2 to 15 J/cm.sup.2, preferably 2 J/cm.sup.2 to 8 J/cm.sup.2.
Nevertheless, the pressure exerted on the external surface of the support is preferably substantially maintained at least up to the gelling of the adhesive composition. Maintaining the pressure can be effected through the use of an inflatablemembrane placed on the external surface of the support.
Preferably, the applied pressure ranges from 5 to 50 Psi (0.35 to 3.5 kgf/cm.sup.2), and more specifically 0.3 to 3 kgf/cm.sup.2.
Most preferred range is 5 to 20 Psi (0.35 to 1.40 kgf/cm.sup.2).
Using the above described process, coatings may be transferred successively or simultaneously to both front and rear geometrically defined surfaces of the lens blank. The transfer of the coatings may also be performed only to one side of thelens blank, preferably to the back side (or rear side).
The coating support or carrier may simply be a thin supporting film made of an appropriate material such as a plastic material, for example a polycarbonate film. The coating support is preferably a mold part made of any appropriate material,preferably made of a plastic material especially a thermoplastic material and in particular of polycarbonate.
The working surface of the mold part may have a relief organized according to a pattern, in other words, may be microstructured and may confer to the final lens an optical surface having the properties imparted by the microstructure (for exampleantireflective properties).
The support, typically a mold part, may be rigid or flexible, but is preferably flexible. Using rigid mold parts necessitates to have a large number of mold parts each comprising a geometrically defined surface whose geometry is adapted to aspecific geometry of the geometrically defined surface of a lens blank. In order to avoid the necessity of having such a huge number of different mold parts, the mold part is preferably a flexible mold part, in particular a flexible mold part made of aplastic material such as polycarbonate. When using this flexible mold part it is only necessary to provide the mold part with a surface the geometry of which conforms to the general shape of the optical surface of the lens blanks onto which the coatingis to be transferred, either a concave or convex shape, but it is not necessary that this surface strictly corresponds to the geometry of the lens blank surface to be coated. Thus, the same mold part can be used for transferring coatings onto lensblanks having surfaces of different specific geometries. Generally, the flexible mold part has two parallel main surfaces and consequently has an even thickness.
In this patent application, when one refers to the base curvature of the mold part, one means the base curvature of the working surface of the mold part, that is to say the surface which bears the coatings to be transferred to the lens or lensblank.
In this application, the base curvature has the following definition: For a spheric surface, having a radius of curvature R, Base curvature (or base)=530/R (R in mm); such kind of definition is quite classical in the art For a toric surface,there are two radii of curvature and one calculates, according to the above formula, two base curvatures BR, Br with BR<Br.
For a coating transfer to a spherical back side of a lens or lens blank, in order to avoid distortions, in particular when using a flexible mold part, the base curvature (BC) of the flexible mold part (front side) must be slightly higher than thebase curvature (BL) of the geometrically defined surface of the lens or the lens blank on which the coating is to be transferred. However, BC shall not be too high in order to avoid cracking of the coating during the transfer process or an optical poweroutside tolerance of the Optical Laboratory Standard Z80.1 after the transfer.
Typically, for a spheric lens or lens blank, base curvature BL of the lens or lens blank and base curvature BC of the flexible mold part shall satisfy the relationship: 0<BC-BL<1.5 Preferably 0.2<BC-BL<1
For a coating transfer to a toric back side of a lens or a lens blank (cylindric lens or lens blank), having two principal meridians, of radii R and r with R>r, it is possible to calculate two base curvatures BLR and BLr correspondingrespectively to radii R and r defining the toric surface.
Base curvatures of the lens BLR and BLr and the base curvature of the flexible mold part shall satisfy the following relationship: BLR<BLr a) if BLr-BLR.ltoreq.3.5 0<BC-BLR<3} |BC-BLr|<1} preferably 0.2<BC-BLR<2.5}|BC-BLr|<0.5} b) if BLr-BLR>3.5 BLR<BC<BLr
Preferably, when moving relatively to each other the mold part and the blank, the contact between coating(s) and curable adhesive composition or between adhesive composition and lens blank geometrically defined surface occurs respectively in thecenter area of the coated mold part or in the center area of the lens blank geometrically defined surface.
In particular in the case of a flexible mold part, the convex front face of the mold part may have a shorter radius of curvature than the concave surface of the blank to be coated. Thus, pressure is applied at the center and the mold part isthen deformed to conform to the blank surface. The glue layer is formed starting from the center of the blank, which avoids entrapping air bubbles within the final cured adhesive composition layer. The same will be true using the concave surface of amold part of longer radius of curvature than a convex blank surface to be coated.
The inflatable membrane can be made of any elastomeric material which can be sufficiently deformed by pressurization with appropriate fluid for urging the flexible mold part against the lens or lens blank in conformity with the surface geometryof the lens or the lens blank.
The pressure applied to the mold part by the inflatable membrane will preferably range from 30 kPa to 150 kPa and will depend on the lens or lens blank and flexible mold part sizes and curvatures. Of course, the pressure needs to be maintainedonto the flexible mold part and the lens or lens blank until the glue or adhesive is sufficiently cured so that enough adhesion of the coating to the lens or lens blank is obtained.
The lens blank can also be a semi-finished lens wherein one face of the lens, preferably the front face of the lens has previously been treated with an appropriate coating (anti-reflective, hard coat, etc . . . ) and the remaining face,preferably the rear face, of the lens is coated using the transfer process of the invention. The lens blank can be a polarized lens.
Referring now to the drawings and in particular to FIGS. 1A to 1C, a lens blank 1 having a concave surface 2 is placed on a supporting element 3 with its concave surface 2 facing upwardly. A pre-measured drop of a UV curable adhesive composition4 according to the invention is then deposited onto the surface 2 of the lens blank 1. A flexible mould part 5 having a convex optical surface, which has been previously coated with a prescribed coating 6, is placed onto a supporting element 7 with itssurface bearing the optical coating facing downwardly.
Deposition of coating 6 on the surface of the flexible mold part 5 can be done through any usual deposition process employed in the optical field, such as vacuum deposition, spin coating, brush coating, dip coating etc. . . . Of course, thedeposition process will depend on the nature of the coating layer or layers deposited on the surface of the flexible mold part 5.
Thereafter the supporting elements 3, 7 are moved relatively to each other to bring into contact coating 6 and UV curable adhesive composition drop 4 and a pressure is exerted to the external surface of the mold part opposite to the coating insuch a manner that the UV curable adhesive composition drop will spread on the surface 2 of the lens blank 1 and on the coating 6. However, the exerted pressure shall only be sufficient for spreading the drop of adhesive composition in order to obtainthe required thickness for the final cured film (generally 100 .mu.m or less) but insufficient to impart any deformation to the lens blank 1.
As shown in FIG. 1B, the assembly formed by the lens blank 1, the adhesive composition film 4, the coating 6 and the mold part 5 is then placed into a device for UV curing the adhesive composition film 4. After UV curing of the film 4, the moldpart 5 is withdrawn and a blank 1 having a coating 6 adhered onto its concave surface 2 is recovered as shown in FIG. 1C.
As shown in FIG. 2A, a flexible mould part 8, for example a mould part made of polycarbonate having a thickness of 1 mm, whose concave surface has been previously coated with an optical coating 9 is placed onto a supporting element 3. Apre-measured drop 10 of a UV curable adhesive composition is then deposited onto coating 9. A lens blank 1 is then placed on mold part 8 with its convex surface 2' in contact with glue drop 10. A pre-measured UV curable adhesive composition drop isthen deposited on concave surface 2 of lens blank 1. A flexible mold part 5, for example a polycarbonate mold part of 1 mm thickness, whose convex surface has been previously coated with an optical coating 6 is placed on a supporting element 7. Supporting elements 3, 7 are then moved relatively to each other to bring coating 6 into contact with adhesive composition drop 4 and a pressure is exerted on at least the external surface of one of the mold part to spread the adhesive composition drops4 and 10 to form films. As indicated previously, the pressure exerted must only be sufficient to spread the adhesive composition drops and form films of required thickness after curing but insufficient to create any deformation in the lens blank 1.
FIGS. 3A and 3B are schematic views of a third embodiment of the process of the invention in which the transfer of the coating is performed using a flexible mold part or carrier which is urged against the lens blank surface using an inflatablemembrane.
Referring to FIG. 3A, a lens blank 1, is placed in a lens blank support with its geometrically defined surface 1a facing outwardly.
A drop of photocurable adhesive composition 3 is deposited at the center of the geometrically defined surface 1a of the lens blank 1.
A thin flexible carrier 4, for example a spheric carrier, having a transferable coating 5 deposited on one of its faces, is placed on the adhesive composition drop 3 so that the transferable coating 5 is in contact with the adhesive drop 3. Thebase curvature of the flexible carrier 4 is slightly higher than the base curvature of the geometrically defined surface 1a of a lens blank 1.
The inflatable membrane apparatus 10 comprises a fluid accumulator 11, for example an air accumulator provided with fluid port 12, for example an air port connected to a pressurized fluid source (not represented) for introducing pressurized fluidwithin the accumulator and also evacuating pressurized fluid from the accumulator. the upper face of the accumulator 10 comprises a light transparent portion 13, for example a UV transparent quartz glass portion, whereas the lower face of theaccumulator 10 comprises a transparent inflatable membrane 14 in register with the transparent quartz glass 13.
As shown in FIG. 3A, the apparatus 10 further comprises a guiding means 15 for laterally guiding the inflatable membrane 14 during inflatation thereof. More specifically, this guiding means comprises a trunconical part or funnel 15 projectingoutwardly form the lower face of the accumulator 10 and whose greater base is obturated by the inflatable membrane and whose smaller base is a circular opening having a diameter at least equal to the base diameter of the flexible carrier 4 but preferablyslightly larger (up to 5 mm larger . . . ).
Typically, the funnel height will range from 10 to 50 mm, preferably 10 to 25 mm, and will have a taper of 10 to 90.degree., preferably 30 to 50.degree..
Generally, the assembly comprising the lens blank holder 2, the lens blank 1, the adhesive composition drop 3 and the flexible carrier 4 is placed so that the rim of the flexible carrier 4 be within the plan of the rim of the smaller base openingof funnel 15 or separated therefrom by a distance up to 50 mm, preferably up to 20 mm.
As shown in FIG. 3B, a pressurized fluid, such as pressurized air, is introduced into the accumulator 11 from an external source (not represented) through entrance 12. The pressure increase within the accumulator, inflates the inflatablemembrane 14 uniformly urges the flexible carrier against the lens blank 1, while uniformly spreading the adhesive 3.
After completion of the curing step, the lens blank 1 is disassembled from the holder 2 and the flexible carrier 4 is removed to recover a lens blank 1 whose geometrically defined surface 1a bears the transferred coating 5.
The membrane guiding means (funnel) is very important to let the membrane expand in good shape and direction for applying an even pressure on the flexible carrier through the lens blank without any extra pressure on the carrier and lens blankedges.
As previously mentioned, the thickness of the final adhesive composition layer after curing is less than 100 .mu.m preferably less than 80 .mu.m, most preferably less than 50 .mu.m and usually 1 to 30 .mu.m.
However, even if they are not preferred, substrates made of thermosetting (cross linked) materials such as diethyleneglycol bis allylcarbonate polymer (CR39.RTM.PPG), polyurethane, polythiourethane, episulfide high index material can be used.
Preferably, the substrate has a very high refractive index, i.e. a refractive index, n.sub.D.sup.25, of 1.56 or more, typically from 1.56 to 1.74 and preferably from 1.57 to 1.59.
The transferred coating may comprise any coating layer or stack of coating layers classically used in the optical field, such as a hydrophobic top coat, an anti-reflective coating layer, an anti-abrasion coating layer, an impact resistant coatinglayer, a polarized coating layer, a photochromic coating layer, an optical-electronical coating, an electric-photochromic coating, a dying coating layer, a printed layer such as a logo or a stack of two or more of these coating layers.
According to a preferred embodiment of the invention, it is transferred to the geometrically defined surface of the lens blank a stack comprising: optionally, a hydrophobic top coat; an antireflective stack, generally comprising inorganicmaterial such as metal oxide or silica; an anti abrasion (hard) coat, preferably comprising a hydrolyzate of one or more epoxysilane (s) and optionally one ore more inorganic filler(s) such as colloidal silica; optionally, an impact resistant primer,preferably a polyurethane latex or an acrylic latex; each of the layers of the stack being deposited onto the support in the above recited order.
The method of the invention is particularly interesting for transferring the whole stack comprising "top coat, antireflective coat, hard coat and primer coat".
Typically, the total thickness of the coating to be transferred is 1 to 500 .mu.m, but is preferably less than 50 .mu.m, more preferably less than 20 micrometers, or even better 10 .mu.m or less.
TABLE-US-00002 Component Parts by weight PETA LQ (acrylic ester of pentaerythritol) 5.00 Dowanol PnP 5.00 Dowanol PM 5.00 n-propanol 5.00 1360 (Silicone Hexa-acrylate, Radcure) 0.10 Coat-O-Sil 3503 (reactive flow additive) 0.06 Photoinitiator0.20
The PC carrier is cleaned using soapy water and dried with compressed air. The carrier convex surface is then coated with the above protecting coating composition via spin coating with application speed of 600 rpm for 3 seconds and dry speed of1200 rpm for 6 seconds. The coating is cured using Fusion System H+ bulb at a rate of 1.524 m/minute (5 feet per minute).
1. The carrier having the protective coating already applied on the surface, is loaded into a standard box coater and the chamber is pumped to a high vacuum level. 2. Hydrophobic coating (Chemical=Shin Etsu KP801M) is deposited onto thesurface of the carrier using a thermal evaporation technique, to a thickness in the range of 2-15 nm. 3. The dielectric multilayer AR coating, consisting of a stack of sublayers of high and low index materials is then deposited, in reverse of thenormal order. Details of this deposition are as such:
TABLE-US-00003 SiO.sub.2 103-162 nm ZrO.sub.2 124-190 nm SiO.sub.2 19-37 nm ZrO.sub.2 37-74 nm
B/ At the completion of the deposition of the four-layer anti-reflection stack, a thin layer of SiO.sub.2, comprising of a physical thickness of 1-50 nm, is deposited. This layer is to promote adhesion between the oxide anti-reflection stack anda lacquer hard-coating which will be deposited on the coated mold at a later time.
TABLE-US-00004 Component Parts by weight Glymo 21.42 0.1 N HCl 4.89 Colloidal silica 30.50 Methanol 29.90 Diacetone alcohol 3.24 Aluminium acetylacetonate 0.45 Coupling agent 9.00 Surfactant FC-430 (3 M company) 0.60
TABLE-US-00005 Component Parts by weight Polyurethane latex W-234 35.0 Deionized water 50.0 2-Butoxy ethanol 15.0 Coupling agent 5.00
The PC carrier after deposition of protecting coating and AR coating in Steps 1 and 2 is then spin coated by HC solution at 600 rpm/1200 rpm, and precured 10 minutes at 80.degree. C., and again spin coated by latex primer solution at the samespeed and postcured for 1 hour at 80.degree. C.
TABLE-US-00006 Component Parts by weight GLYMO 10 (Glycidoxypropyltrimethoxysilane) Acryloxypropyltrimethoxysilane 10 0.1 N HCl 0.5 Aluminum acetylacetonate 0.5 Diacetone alcohol 1.0
Testing and Inspection Procedures Adhesion is measured using the cross-hatch adhesion test according to ISTM 02010, using 3M SCOTCH.RTM. n.sup.o 600 transparent tape. 25 squares are formed.
TABLE-US-00007 Adhesion score Squares removed Area % left intact 0 0 100 1 <1 96 2 1 to 4 96-84 3 >4 to 9 83-64 4 >9 to 16 63-36 5 >16 <36
Resistance to thermal cracking is determined by the measure of the critical temperature (Tc) according to ISTM method n.sup.o 02032.
The critical temperature Tc of an anti-reflective treated lens is that temperature at which crazing (fine cracking) of the anti-reflective treatment is first noted by visual inspection. Lenses are placed in a temperature controlled oven(50.degree. C. to start) for one hour, then removed and quickly examined for crazing. If no crazing is noted, the lenses are then placed in an oven, 10.degree. C. higher in temperature than the previous oven. The process is repeated until crazing isnoted, or the lens survives 100.degree. C.
If crazing is found on a lens immediately after removal from the oven, but is not visible 24 hours later (kept at room temperature), the reported critical temperature is modified with a "+" suffix.
A coated lens is considered as resistant to thermal cracking if Tc>60.degree. C., preferably Tc.gtoreq.65.degree. C. However, a coated lens having a Tc.gtoreq.50.degree. C. is considered acceptable. Haze and application stain levels werevisually determined using a standard R17 application lamp with Vita-Life 15 Watt fluorescent bulb and then a mini-spot 41601 lamp manufactured by OSRAM.
TABLE-US-00008 0 none 1 light 2 medium 3 intense
In some cases, haze has also been determined using Hazeguard.RTM. apparatus.
Clear (uncolored) PC lenses (5.0 back curve, -2.00 dioptries) are washed with soap and water, and rinsed with deionized water prior to drying with compressed air. Then, they are blown with anti-static air and placed in the lens holder of aninflatable membrane apparatus. Drops of adhesive composition (previously filtered through a 0.45 .mu.m syringe filter) are applied on the back side of the lenses: one drop in the center, and 4 drops equally distant from the first drop, on the corners ofa 1.6 cm.sup.2 square.
A HMC coating as previously disclosed is provided on a 6.1 front curve of a surfaced PC carrier (examples 1 to 3 and C1) or a thermoformed carrier 5.5 curve and 0.47 mm center thickness (examples 4 to 6 and C2) and the HMC coating is transferredonto the back surfaces of the lenses using the BST process of the present invention. The inflatable membrane apparatus is a manual apparatus or an automated apparatus and transfer parameters are as follows:
TABLE-US-00009 Manual apparatus Distance between stage and 31 mm membrane ring: Membrane pressure (pressure 12 psi (0.827 bar) applied by the membrane on the mold): UV irradiation: UV lamp Dymax 5000-EC flood UV light with D-bulb partn.degree.38560, intensity 135 mW/cm.sup.2 Exposure (curing) time: 30 seconds Total BST process time: 65 seconds Automated apparatus Distance between stage and 27.5 mm membrane ring: Membrane pressure: 12 psi (0.827 bar) UV irradiation: UV lamp Xenon(890-1886)B 4.2'' spiral lamp (ozone free) pulsed UV (100 PPS), intensity 1188 mW/cm.sup.2 Inflation time: 21-23 seconds Deflation time: 3 seconds Exposure (curing) time: 25 seconds Total BST process time: 120 seconds
TABLE-US-00010 TABLE 1 EXAMPLE 1 2 3 4 5 6 C1 7 C2 Composition Formulation wt % Diethyleneglycoldiacrylate 48.1 38.0 28.1 39.83 49.67 60.05 17.9 69.64 78.- 30 (SR 230) 4EO Bisphenol-A 48.9 59.0 68.9 57.13 47.33 36.91 79.0 27.29 18.77dimethacrylate (CD 540) IRGACURE .RTM. 819 3.0 3.0 3.0 3.04 3.0 3.03 3.0 3.07 2.93 Properties Refractive index of 1.5000 1.5065 1.5145 -- -- -- 1.5220 -- -- adhesive at 25.degree. C. before cure HMC transfer Yes Yes Yes Yes Yes Yes Yes Yes Yes Visualhaze 0 0 0 0 0 0 0 1 2 Hazeguard -- -- -- 0 0.04 0.07 -- 0.15 0.38 Application stain 0 0 0 0 0 0 0 1 2 Adhesion 0 0 0 0 0 0 5 0 0 Tc (.degree. C.) 50 50 50 70 60 70 50 70 70
These examples show that for surfaced carriers the binary compositions of the invention are fully satisfactory for use in BST process and that compositions containing more than 80 wt % of component (A1) are not satisfactory regarding applicationstain and haze and compositions containing less than 20 wt % of (A1) are not satisfactory regarding adhesion.
TABLE-US-00011 TABLE 2 EXAMPLE 8 9 10 11 12 13 C3 Composition Formulation wt % Blue tinted Green tinted Blue and green tinted lenses Diethyleneglycoldiacrylate (SR 230) 28.1 38.0 48.1 30.35 34.88 39.79 24.3 4EO Bisphenol-A dimethacrylate (CD540) 68.9 59.0 48.9 66.69 62.01 57.15 29.1 Bis(methacryloylthioethyl)sulfide -- -- -- -- -- -- 43.7 IRGACURE .RTM. 819 3.0 3.0 3.0 2.96 3.11 3.06 2.9 Application stain 0 1 2 0 0-1 1 3
The results show that the composition of the invention are superior regarding application stain to ternary compositions containing a thiomethacrylate constituent when used with tinted lenses, and in particular for compositions according to theinvention containing 28 to 42 parts by weight of component (A1) and 72 to 58 parts by weight of component (A2).
Clear PC lenses are coated with HMC coating using BST process as disclosed in examples 1 to 7, with the following modifications: lenses are clear PC lenses (5.1 back curve-2.00 dioptries) carrier is a PC thermoformed carrier (5.5 back curve) 0.47mm center thickness Inflatable membrane apparatus is an automated apparatus
TABLE-US-00012 TABLE 3 EXAMPLE 14 15 16 Composition Formulation wt % Diethyleneglycoldiacrylate (SR 230) 30.35 34.88 39.79 4EO Bisphenol-A dimethacrylate (CD 540) 66.69 62.01 57.15 IRGACURE .RTM. 819 2.96 3.11 3.06 Properties HMC transfer YesYes Yes Visual haze 0 0 0 Application stain 0 0 0 Adhesion <1 <1 0 Tc (.degree. C.) 50-70 50 50-60
Examples 1 to 7 are repeated using thermoformed 5.5 back curve carriers, 5.1 back curve, -2.00 dioptries lenses and the composition formulations set forth in Table 5. The properties of the lenses are also given in table 5.
TABLE-US-00013 TABLE 4 EXAMPLE 17 18 19 Composition Formulation wt % Diethyleneglycoldiacrylate (SR 230) 27.9 27.74 27.86 4EO Bisphenol-A dimethacrylate (CD 540) 45.62 22.86 45.89 Tris(2-hydroxylethyl) isocyanurate 23.48 46.3 -- triacrylate(SR368D) Ditrimethylopropane tetra acrylate (SR355) -- -- 23.26 IRGACURE .RTM. 819 3 3.09 2.99 Properties HMC transfer Yes Yes Yes Visual haze 0 0 0 Application stain 0 0 0 Adhesion 0 0 0 Tc (.degree. C.) 60 60 60
HMC coating transfer is made on 5.1 back curve PC lenses, 02.00 power, using injection molded PC carriers, 5.5 base curve, 0.56 mm center thickness and automated apparatus using the compositions of Table 5. The properties of the resulting coatedlenses are also given in Table 5.
TABLE-US-00014 TABLE 5 EXAMPLE 20 21 22 23 24 25 Diethylene glycol 35.0 48.3 67.2 35.1 49.2 67.8 diacrylate SR 230 (%) 4EO Bisphenol-A 62.0 48.7 29.8 0.0 0.0 0.0 dimethacrylate CD 540 (%) 8EO Bispheol-A 0.0 0.0 0.0 61.9 47.7 29.2 dimethacrylateCD 542 (%) Irgacure .RTM. 819 (%) 3.0 3.0 3.0 3.0 3.1 3.0 Lens after BST Good Good Good Good Good Good HMC Transfer Yes Yes Yes Yes Yes Yes Visual haze 0 0 0 0 0 0 Application stain 0 0 0 0 0 1 Adhesion 0 0 0 0 0 0 Critical temperature (.degree. C.) 5050 50 50 50 50
TABLE-US-00015 TABLE 6 Company Product Cure Comments X-htch Adhesion Haze Application stain Tc (.degree. c.) Dymax OP-4-20628 CST 0 YES YES NT Corporation OP-42B IST/EC 4-5 NO 0 NT X-301-44-2 EC 1 NO 0 NT X-415-102-A IST/EC 5 n/a n/a NTX-410-96-1 IST/EC 0 NO 0 50 OP-4-20632 NO TRANSFER 5 n/a n/a NT OP-40 #54194 CST 5 n/a n/a NT 3-20256 #72521 CST 0 YES yes NT X-372-45-1 #00327 CST 0 NO ? 50 X-372-45-1 #03191 CST 0 NO no? 50 1128M #28542-26083 CST 5 YES yes NT 1181-M #28542-27047 IST 0YES yes NT 1186-M #28542-27887 EC 5 YES 0 NT 1191-M #28542-23578 EC 0 NO 0 NT 1-20560 #28542-25319 EC 0 YES 0 NT OP-54 NO TRANSFER 5 n/a n/a NT OP-30 EC 1-2 YES 0 NT OP-61-LS CURED OPAQUE n/a n/a n/a NT OP-21 EC+ 0 NO 0 NT OP-29V EC+ 5 n/a n/a NT OP-29VEC+ 1-2 NO 0 NT Norland NOA 61 IST/EC 5 n/a n/a NT Optical NOA 65 IST/EC 5 n/a n/a NT Adhesives NOA 68 IST/EC 5 n/a n/a NT NOA 81 IST/EC 5 n/a n/a NT NOA 83H e.c. 5 n/a n/a NT Loctite 3104-23694 CST 0 YES yes NT 3105-23695 CST 0 NO 0 50 3494 IST 0 NO 050 FT-01616 (X-245622) IST 0 NO 0 50 Epoxy EPO-TEK OG144 CST 5 n/a n/a NT Technology, INC. EPO-TEK OG142-13 IST/EC 5 n/a n/a NT Summers Type SK-9 Lens Bond CST 5 n/a n/a NT Optical Type J-91 Lens Bond IST 5 n/a n/a NT S. C. Radco 222A CST 5 n/a n/a NTCyberlife 4436 CST/EC 2-3 NO 0 NT NT = not tested due to earlier failure Cure comments abbreviations CST Complete stack transfer IST Incomplete stack transfer EC Edge cracks during BST process EC+ Extensive edge cracking n/a non applicable
The following example will show, step by step, how the solubility parameter for neopentylglycol diacrylate was calculated. The solubility parameter calculation is based on the technique of group contribution, which assumes that each functionalgroup in a molecule contributes additively to a thermodynamic property. Hoy's group contribution values are derived from vapor pressure measurements.
The energy of vaporization is given by: .DELTA.E.sup.v=.SIGMA..sub.jn.sub.j.DELTA.e.sub.j where n.sub.j is the number of groups of type j in the molecule, and .DELTA.e.sub.j is the energy of vaporization contribution for group j.
Hoy's (and others) group contribution values are reported as molar attraction constants (F), which are related to the energy of vaporization in the following way: F.sub.j= {square root over (.DELTA.E.sup.v.sub.i,jV.sub.i,j)}
where V.sub.i is the molar volume of the molecule.
The solubility parameter (.delta.) for a molecule is related to the molar attraction constants in the following way:
.delta..DELTA..times..times..times..SIGMA..times..rho..times..SIGMA..times- . ##EQU00002##
where .rho..sub.ij is the density of the molecule, and M.sub.i is the molecular weight.
The molecule is deconstructed into the different functional groups which are listed by Hoy. FIG. 1 shows a ball-and-stick drawing of neopentylglycol diacrylate. The different functional groups have been numbered, with multiple occurrences ofthe same functional group being given the same number.
TABLE-US-00016 TABLE 7 Group # of contr. Total group Group n.sup.o Group Type occurrences Value contr. Value 1 Unsat. .dbd.CH.sub.2 2 259 518 2 Unsat. .dbd.CH-- 2 249 498 3 Carboxylic --COO-- 2 688 1376 4 Sat. --CH.sub.2-- 2 269 538 5 Sat..dbd.C.dbd. 1 65 65 6 Methyl --CH.sub.3 2 303 606
Density of neopentylglycol diacrylates=1.031, and the molecular weight is 212 (Sartomer Co. Data). (518+498+1376+65+606)=3601 (3601*1.031/212=17.51 (MPa).sup.1/2*{(cal/cm.sup.3).sup.1/2/2.046 (MPa).sup.1/2}=8.56 (cal/cm.sup.3).sup.1/2.
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