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Precision composite article

A composite and semi-solid technology, applied in the direction of synthetic resin layered products, layered products, instruments, etc., can solve problems such as difficult liquid handling and gasket sealing, high shrinkage barriers, etc.

Inactive Publication Date: 2007-05-23
ZMS LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0014] Unfortunately, attempts to cast optical components onto chip surfaces have been hampered by the high shrinkage associated with curing these curable liquid resins, not to mention difficulties with the required liquid handling and gasket sealing

Method used

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Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0100] Embodiment 1. Experimental procedure

[0101] Inactive polymers are added to vials pre-filled with small amounts of the intended reactive plasticizer. Gently heat with stirring to homogenize the mixture. The resulting semi-solid material was visually observed and the optical clarity at various temperatures was recorded. Complete clarity indicates that the components are miscible. Faint haze indicates partial miscibility, while opacity equates to incompatibility (light scattering due to phase separation). A number of pairs of inactive polymer-reactive plasticizers have thus been investigated.

Embodiment 2

[0103] Example 2. Kraton-based systems

[0104] The following polymers were studied using the procedure described in Example 1. The accompanying table summarizes the polymer characteristics.

[0105] Krayton species

Composition (%)

illustrate

G 1652

SEBS (S: 29 / EB: 71)

linear, low molecular weight

G 1650

SEBS (S: 29 / EB: 71)

Linear, medium Mw

G 1657

SEBS (S: 13 / EB: 87)

linear

G 1102

SBS (S: 28 / EB: 72)

Linear, medium Mw

D 4141

SBS (S: 31 / EB: 69)

linear

D 4240p

(SB) n (S:44 / B:56)

branching

D 1116

(SB) n (S:21 / B:79)

branching

D 1107

SIS (S: 14 / L: 86)

linear

[0106] S = styrene, EB = ethylene butylene, B = butadiene, I = isoprene

[0107] Hexanediol diacrylate solvates all Kraton samples well except G 1650 which is partially miscible. Photomer 4200 solvates D1102, D1107, D4141, D4240p, and G1657 at elev...

Embodiment 3

[0109] Example 3. SBS system rich in styrene

[0110] Kraton D1401P is a styrene-rich linear SBS triblock copolymer. Reactive plasticizers capable of solvating Kraton D1401P include: vinyl benzoate; tetrahydrofurfuryl acrylate; benzyl (meth)acrylate; isobornyl (meth)acrylate; butyl acrylate; Octyl Acrylate; Isodecyl Acrylate; Butylene Glycol Diacrylate; Hexylene Glycol Diacrylate; Ethoxylated Bisphenol A Diacrylate; and Trimethylolpropane Triacrylate. Sulfur-containing monomers such as phenylthioethylacrylate and others also solvate SBS-based polymers well. One advantage of sulfur-containing monomers is that their addition can increase the Abbe number of the cured resin.

[0111] In order to obtain a thermodynamically compatible system comprising a styrene-rich SBS triblock copolymer, Kraton D1401 P can be replaced by other SBS copolymers such as those available from Phillips Chemical Company (K-resins), BASF (Styrolux), Fina Chemicals ( Finaclear), and those of Asahi Chemi...

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Abstract

The invention is directed to a method for making composite articles, including optical lenses, which includes the steps of obtaining a substrate; placing a semi-solid-like polymerizable composition in contact with at least one of the front or back surface of the substrate; compressing or heating the resulting semi-solid / substrate sandwich between two mold halves, where the mold contacting the semi-solid polymerizable material has a desired surface geometry; and exposing the semi-solid / substrate sandwich to a source of polymerizing energy. The resulting composite article has the desirable characteristics of the substrate but is also easily fabricated as a result of the semi-solid molding process. Also included within the present invention is a composite article comprising a substrate portion and at least one layer of a cured resin bonded to the substrate portion, the cured resin comprising an interpenetrating crosslinked polymer network of reactive plasticizer within a dead polymer. In one embodiment, the reactive plasticizer polymer network is further crosslinked to the dead polymer. The composite article exhibits dimensional stability and high-fidelity replication of an internal mold cavity.

Description

field of invention [0001] This invention is in the fields of polymerization and molding. More particularly, it relates to a process for rapidly and inexpensively producing optical quality lenses or other clear lenses on an underlying substrate. It also concerns optimal materials of construction and resulting composite structures. Background of the invention [0002] Ophthalmic lenses correct vision by altering the focal length of light rays entering the wearer's pupil. If the patient is short-sighted or far-sighted, this can be corrected fairly simply by using a single vision lens in which the outer and inner surfaces of the lens are spherical but have different radii of curvature. The complexity increases if the patient has astigmatism in one or both eyes. In this case, the back surface of the lens becomes toroidal by creating two different radii on the same surface. In order to properly correct for astigmatism, the rotational position of the annular surface must be fix...

Claims

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Application Information

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Patent Type & Authority Patents(China)
IPC IPC(8): G02B1/04B32B27/00G02C7/00G02C7/02G02C7/10
CPCY10T428/31935G02B1/041Y10T428/31855Y10T428/31909G02B1/04B32B27/00Y10T428/31645Y10T428/31616
Inventor D·S·索尼M·R·休斯敦
Owner ZMS LLC