Polymerizable Composition for Optical Material
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Solution Overview
Problem
Existing methods for manufacturing optical materials through thermally curing polymerizable compositions often result in striae defects, which can lead to product abandonment and inefficiencies, especially in thick shapes, and underwater polymerization requires expensive facilities with decreased production efficiency.
Innovation Solution
A polymerizable composition incorporating specific compounds such as ester and ether compounds, polyiso(thio)cyanate compounds, and (poly)alkylene glycol components, which are blended to reduce striae formation during polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If curing is carried out slowly over a long period of time to suppress striae, then striae are suppressed, but production efficiency decreases
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the polymerizable composition. Specifically, it controls the polymerizable compound content at 5-50 wt%, hydroxyl compound content at 0.1-10 wt%, and water content at 0.1-5 wt%. These parameter adjustments enable the composition to cure without forming striae while maintaining reasonable production efficiency, resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
The patent creates a composite polymerizable composition by combining multiple components with specific functions: polymerizable compounds (for base material formation), hydroxyl compounds (for striae suppression), and controlled water content (for heat management). This composite approach allows the system to achieve both striae-free curing and acceptable production efficiency simultaneously.
2Manufacturing precision
If underwater polymerization is performed to increase heat conduction and suppress striae, then striae are suppressed, but expensive facilities are required and production efficiency decreases
Solution Approach 1:
The patent replaces the expensive and complex underwater polymerization facility with a simple, disposable chemical additive approach. By incorporating hydroxyl compounds and controlling water content in the composition itself, the patent achieves enhanced heat conduction and striae suppression without requiring specialized underwater processing equipment, thus eliminating facility complexity while maintaining manufacturing precision.
Solution Approach 2:
The patent substitutes the mechanical/physical system of underwater polymerization with a chemical system. Instead of using water as a heat transfer medium in a complex facility, the patent uses chemically active hydroxyl compounds and controlled water content within the composition to manage heat conduction internally, replacing the need for external mechanical heat management systems.
3Manufacturing precision
If monomer composition is thickened by preliminary reaction to suppress striae, then striae are suppressed, but additional process steps are required increasing manufacturing complexity
Solution Approach 1:
The patent merges the striae suppression function directly into the base polymerizable composition formulation. By incorporating hydroxyl compounds and optimized water content into the original composition (rather than requiring a separate thickening step), the patent combines multiple functions into a single formulation, eliminating additional process steps while maintaining striae suppression capability.
4Shape
If molding is performed in thick shapes, then product functionality is achieved, but striae are very likely to occur
Solution Approach 1:
The patent applies parameter changes by optimizing the chemical composition to accommodate thick shapes. Specifically, it adjusts polymerizable compound content (5-50 wt%), hydroxyl compound content (0.1-10 wt%), and water content (0.1-5 wt%) to enable proper curing in thick sections without generating striae, thus resolving the contradiction between achieving functional thick shapes and maintaining manufacturing precision.
Solution Approach 2:
The patent applies local quality by having the hydroxyl compounds and water distributed throughout the polymerizable composition at controlled concentrations. This creates local heat management and polymerization control within thick sections, preventing striae formation in areas where thick shapes are required, thus enabling both thick shape capability and striae-free manufacturing.
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 proposed composition effectively minimizes striae formation, extends the pot life of the polymerizable mixture, and enhances the quality and yield of optical materials like plastic lenses with improved optical properties.
Implementation Method 1
thermally curing a polymerizable composition
Implementation Method 2
cast polymerization of monomers
Implementation Method 3
underwater polymerization or the like may be performed to increase the heat conduction
Data Source
AI summary
A polymerizable composition for an optical material according to the present invention includes one or two or more compounds selected from the group consisting of component (A) : an ester compound having a specific structure and component (B): an ether compound having a specific structure, and a polymerizable compound.