Polythiourethane Lens Composition for Impact and Alkali Resistance
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Solution Overview
Problem
Existing polyurethane-based lenses face challenges in achieving high impact resistance while maintaining excellent alkali resistance and appearance, especially when a primer layer is not disposed between the base layer and the hard coat or antireflection coat layers, and they require complex manufacturing processes.
Innovation Solution
A polymerizable composition comprising specific isocyanate compounds with cyclic structures, aliphatic isocyanate compounds, and thiol compounds, which allows for the production of lenses with improved impact resistance, optical characteristics, heat resistance, and alkali resistance without the need for a primer layer, using a simpler manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polyurethane-based lens includes a hard coat layer and an antireflection coat layer to improve surface properties, then optical characteristics and hardness are improved, but impact resistance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the base layer by specifying particular ratios of isocyanate compounds (aromatic 10-70 wt%, aliphatic 30-90 wt%) and thiol compounds (5-50 wt%), creating a polythiourethane composition that inherently provides both surface durability and impact resistance without requiring additional protective layers
Solution Approach 2:
The patent creates a composite material system by combining multiple isocyanate compounds (aromatic and aliphatic) with thiol compounds to form a polythiourethane base layer that integrates the functions of both structural strength and surface protection, eliminating the need for separate hard coat and antireflection layers
2Reliability
If a primer layer is disposed between the base layer and the hard coat layer to improve adhesion, then coating stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts and eliminates the primer layer from the multi-layer coating structure by formulating the base layer composition (with specific isocyanate and thiol ratios) to provide inherent adhesion properties, thereby simplifying the manufacturing process while maintaining coating stability
Solution Approach 2:
The base layer composition is designed to perform multiple functions simultaneously: it provides structural support, ensures adhesion to subsequent layers, and delivers impact resistance, eliminating the need for a separate primer layer that would otherwise be required for adhesion purposes
3Reliability
If polyurethane-based materials are used to achieve high impact resistance, then impact resistance is improved, but manufacturing complexity increases due to prepolymerization requirements
Solution Approach 1:
The patent extracts and eliminates the complex prepolymerization step from the manufacturing process by using a direct polymerization approach where isocyanate compounds and thiol compounds are combined in specific ratios to form the polythiourethane base layer in a single step, simplifying production while maintaining high impact resistance
Solution Approach 2:
The patent changes the manufacturing approach by adjusting the composition parameters (isocyanate to thiol ratios, specific compound selections) to enable direct polymerization without requiring pre-formed polyurethane prepolymer, thereby simplifying the manufacturing process while achieving the desired impact resistance
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 polymerizable composition effectively enhances the impact resistance and alkali resistance of the lenses, maintaining excellent optical characteristics and handling properties, and simplifies the manufacturing process by eliminating the requirement for a primer layer.
Implementation Method 1
a polymerizable composition including: at least one isocyanate compound (A) having a cyclic structure... an aliphatic isocyanate compound (B)... and a thiol compound (C)
Data Source
AI summary
The polymerizable composition of the present invention includes at least one isocyanate compound (A) having a cyclic structure, selected from compounds represented by the following Formulae (1), (2), and (3), and aliphatic isocyanate compound (B) having 4 to 11 carbon atoms, and a thiol compound (C).