Phosphorus-Based Mold Release Agent Synthesis

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Solution Overview

Problem

The preparation process of phosphate ester-based mold release agents is complex and generates byproducts, leading to poor appearance and increased production costs in plastic lenses.

Innovation Solution

A polymerizable composition comprising a thiol compound, an isocyanate compound, and a phosphorus-based mold releasing agent, where the phosphorus-based mold releasing agent includes a first compound with one hydroxyl group and a second compound with two hydroxy groups, reacting with water or alcohol to simplify the process without byproduct generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If phosphate ester-based mold release agent is prepared by reacting phosphoryl halide with monoalcohol in solvent using amine catalyst, then mold release function is achieved, but byproducts (HCl, HBr, gas, salt) are generated making the process complex and difficult to control

Engineering Contradiction:

Improvepreparation process simplicityVSAvoidbyproduct generation

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful byproduct generation into a beneficial feature by using phosphorous pentoxide as a starting material that reacts with water and alcohol to form phosphoric acid and phosphate ester without generating harmful byproducts. This transformation turns the previously harmful byproduct-generating process into a clean synthesis method.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the chemical parameters of the reaction system by using phosphorous pentoxide instead of phosphoryl halide, and by adjusting the reaction conditions (using water and alcohol as reactants instead of requiring catalytic amine and solvent). This parameter change eliminates byproduct generation while maintaining the mold release function.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If byproducts are removed by washing and filtration steps, then purity is improved, but production time increases and wastewater is generated

Engineering Contradiction:

Improveproduct purityVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent eliminates the need for time-consuming washing and filtration steps by designing a synthesis method that does not generate harmful byproducts in the first place. The reaction of phosphorous pentoxide with water and alcohol produces only phosphoric acid and phosphate ester, which can be directly obtained without purification steps.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent extracts and removes the harmful byproducts from the process entirely by changing the reaction pathway. Instead of generating byproducts that require removal, the new method uses phosphorous pentoxide as a starting material that transforms directly into the desired phosphate ester product through reaction with water and alcohol.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If phosphate ester-based compound is used as mold release agent, then resin release from mold is achieved, but appearance of lens deteriorates due to byproducts

Engineering Contradiction:

Improvemold release performanceVSAvoidappearance quality

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of byproducts on lens appearance into a beneficial outcome by using a synthesis method that produces no harmful byproducts. The reaction of phosphorous pentoxide with water and alcohol yields only phosphoric acid and phosphate ester, ensuring that the lens appearance remains flawless while maintaining effective mold release performance.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The simplified process allows for easier production of phosphorus-based mold releasing agents that enhance the appearance and optical characteristics of plastic lenses by preventing byproduct-related defects and reducing environmental impact and production costs.

Implementation Method 1

reacting phosphorous pentoxide with a monoalcohol and/or water to form a phosphoric acid and a phosphate ester

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS11248011B2Phosphorus-based releasing agent, optical polymerizable composition comprising same and preparation thereof

Publication Date: 2022.02.15 SK PUCORE CO LTD

AI summary

Embodiments relate to a polymerizable composition comprising a phosphorus-based mold releasing agent for an optical use whose preparation process is improved, and a process for preparing the phosphorus-based mold releasing agent. The phosphorus-based mold releasing agents can be prepared more easily and conveniently by using phosphorous pentoxide, which can easily react with a monoalcohol and/or water at room temperature in the absence of a catalyst or a solvent. In addition, byproducts are not generated during the reaction. Thus, when a lens is produced by using the mold release agent obtained therefrom, it is possible to prevent a defective appearance of the lens that may be caused by byproducts, thereby further enhancing the appearance properties thereof. Further, since separate steps for removing byproducts, specifically, such steps as washing and filtration, are not required, wastewater is not generated. Thus, it is not only environmentally friendly, but the production cost can also be reduced as the process is simple.